Difference between revisions of "Projects:Table Saw Automatic Dust Collection"

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(made some updates to the language and expanded on the details for clarity, added wiring diagram)
 
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Table saws are messy, and they need dust collection. The problem is remembering to turn it on. There are various solutions out there on the web to automate your dust collector, but not too many specifically for using a 120V dust collector with a 220V saw. That is the goal of this project.  
Table saws are messy, and they need dust collection. The problem is remembering to turn it on. There are various solutions out there on the web to automate your dust collector, but not too many specifically for using a 120V dust collector with a 220V saw. The goal of this project is to create a solution and outline the method so it is easily understood and repeatable.  


It turns out there are tons of components out there for switching and sensing, and there happened to be just the right combination to make a pretty simple setup for this.
There are many of components out there for switching and sensing, and there happened to be just the right combination to make a pretty simple setup for this.






[[File:tablesawdustcollectorparts.jpg|500px|thumb]]
[[File:tablesawdustcollectorparts.jpg|thumb|500px|Parts and rough layout]]
Parts:
== Parts ==
*[https://www.amazon.com/gp/product/B00I9IFJOM Dwyer Miniature Current Switch, MCS-111050, Solid Core, .5 to 50 A Continuous] - $27.40
*[https://www.amazon.com/gp/product/B00I9IFJOM Dwyer Miniature Current Switch, MCS-111050, Solid Core, .5 to 50 A Continuous] - $27.40
*[https://www.amazon.com/gp/product/B001KGSJ74 Packard C230B 2 Pole 30 Amp Contactor, 120 Voltage Coil] - $10.79
*[https://www.amazon.com/gp/product/B001KGSJ74 Packard C230B 2 Pole 30 Amp Contactor, 120 Voltage Coil] - $10.79
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*2" Conduit clamps for mounting - $8
*2" Conduit clamps for mounting - $8


==How it works==


The '''Contactor''' is essentially a big relay. It takes a small voltage on one pair of terminals, this powers an electromagnet that draws a metal plate down, and that metal plate connects two other sets of terminals carrying much more power. In this case, this Contactor uses 120V at around .04 Amps to trigger the coil, and the main load can carry 120V up to 30 Amps.
The '''Contactor''' is essentially a big relay. It takes a small voltage on one pair of terminals, this powers an electromagnet that draws a metal plate down, and that metal plate connects two other sets of terminals carrying much more power. In this case, this Contactor uses 120V at around .04 Amps to trigger the coil, and the main load can carry 120V up to 30 Amps.




The '''Miniature Current Switch''', or '''Current Sensor''' as I'll call it, is also a relay but more special. Instead of connecting power to it by a pair of terminals, it receives power through induction. With a wire running through the hole in it, when that wire carries a lot of Amps it will induce a magnetic field inside the Current Sensor. This magnetic field is then turned back into a small amount of Amps that turns on a relay.
The '''Miniature Current Switch''', or '''Current Sensor''' as I'll call it, is also a relay but more special. Instead of connecting power to it by a pair of terminals, it receives power through a magnetic field. It is designed to have a wire looped through the center hole. When power runs through the wire, the loop will turn into an electromagnet and turn on the relay. Normally the field around a wire isn't magnetic enough to notice, but this device was made to be very sensitive so it can work with even weak magnetic fields.
 


Using the Current Sensor, we can sense when there is power traveling through the power cord to the Table Saw. The sensor will close a pair of contacts just like a relay, which we can use to switch something else on. That something else the Contactor, which we will connect our Dust Collector to.


So using the Current Switch, we can sense the table saw is drawing a lot of power (when the motor turns on) and make a connection to something else. That something else the Contactor, which we will connect our Dust Collector to.
This will be the sequence of events:
# The operator turns on the Table Saw using its power switch.
# The wire inside the Current Sensor creates an electromagnetic field and activates its relay.
# The relay in the Current Sensor connects power to the Contactor, which activates it.
# The power goes through the Contactor and into the Dust Collector.


The power switch on the Dust Collector itself will have to stay in the On position for this to work. The control box we are building will turn it on and off at the same time the operator turns on the Table Saw on and off.


The Wiring:
*show diagram
*The 220V is essentially just passed through the box, except one of the power lines goes through the hole in the Current Sensor.
*The 120V gets connected to a few places. The Hot line goes to one side of the relay on the Current Sensor and of the Contactor. The Neutral line goes to the outlet,


==The Wiring==
[[File:TableSawAutomaticDustCollection-WiringDiagram.png|450px|Wiring Diagram]]
*There are 120V and 220V male and female plugs that are used to make the external connections. Nothing is hard-wired to the box for ease of repair.
*220V lines are essentially passed through the box. One of the Hot lines must loop through the hole in the Current Sensor in order to create the magnetic field that activates it.
*120V - Hot side connects to 1 pole of the Contactor, and one of the screw terminals on the Current Sensor.
*120V - Neutral line goes to the output plug and one side of the coil on the Contactor.
*Ground - all ground connections are connected together.




Other/Similar solutions found online:
==Other/Similar solutions found online ==
*[https://sawmillcreek.org/showthread.php?159100-Turning-on-Dust-Collector-automatically Thread on Sawmillcreek.org about auto-switching dust collectors]
*[https://sawmillcreek.org/showthread.php?159100-Turning-on-Dust-Collector-automatically Thread on Sawmillcreek.org about auto-switching dust collectors]
*[http://lumberjocks.com/topics/46199 Thread on Lumberjocks.com]
*[http://lumberjocks.com/topics/46199 Thread on Lumberjocks.com]

Latest revision as of 11:44, 17 March 2025

Tablesaw.jpg Tablesawdustcollectorswitch.jpg


Table saws are messy, and they need dust collection. The problem is remembering to turn it on. There are various solutions out there on the web to automate your dust collector, but not too many specifically for using a 120V dust collector with a 220V saw. The goal of this project is to create a solution and outline the method so it is easily understood and repeatable.

There are many of components out there for switching and sensing, and there happened to be just the right combination to make a pretty simple setup for this.


Parts and rough layout

Parts


How it works

The Contactor is essentially a big relay. It takes a small voltage on one pair of terminals, this powers an electromagnet that draws a metal plate down, and that metal plate connects two other sets of terminals carrying much more power. In this case, this Contactor uses 120V at around .04 Amps to trigger the coil, and the main load can carry 120V up to 30 Amps.


The Miniature Current Switch, or Current Sensor as I'll call it, is also a relay but more special. Instead of connecting power to it by a pair of terminals, it receives power through a magnetic field. It is designed to have a wire looped through the center hole. When power runs through the wire, the loop will turn into an electromagnet and turn on the relay. Normally the field around a wire isn't magnetic enough to notice, but this device was made to be very sensitive so it can work with even weak magnetic fields.


Using the Current Sensor, we can sense when there is power traveling through the power cord to the Table Saw. The sensor will close a pair of contacts just like a relay, which we can use to switch something else on. That something else the Contactor, which we will connect our Dust Collector to.

This will be the sequence of events:

  1. The operator turns on the Table Saw using its power switch.
  2. The wire inside the Current Sensor creates an electromagnetic field and activates its relay.
  3. The relay in the Current Sensor connects power to the Contactor, which activates it.
  4. The power goes through the Contactor and into the Dust Collector.

The power switch on the Dust Collector itself will have to stay in the On position for this to work. The control box we are building will turn it on and off at the same time the operator turns on the Table Saw on and off.


The Wiring

Wiring Diagram

  • There are 120V and 220V male and female plugs that are used to make the external connections. Nothing is hard-wired to the box for ease of repair.
  • 220V lines are essentially passed through the box. One of the Hot lines must loop through the hole in the Current Sensor in order to create the magnetic field that activates it.
  • 120V - Hot side connects to 1 pole of the Contactor, and one of the screw terminals on the Current Sensor.
  • 120V - Neutral line goes to the output plug and one side of the coil on the Contactor.
  • Ground - all ground connections are connected together.


Other/Similar solutions found online

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