Simple Dremel TRIAC Hack Repair

Dremel Repair

It’s a wonderful thing to see a clever hack repair instead of disposing of a product. The best repair approach is finding exact replacement components, but sometimes exact components can’t be sourced or cross-referenced. Other times the product isn’t worth the shipping cost for replacement parts or you just don’t have time to wait for parts. That’s when you need to really know how something works electronically so you can source suitable replacement components from your junk bin to complete the repair. This is exactly what [Daniel Jose Viana] did when his 110 volt Dremel tool popped its TRIAC after he plugged it into a 220 volt outlet.

[Daniel] knew how the TRIAC functioned in the circuit and also knew that a standard TRIAC of sufficient specifications could be used as a replacement even if it didn’t have the correct form factor to fit the PCB layout. For [Daniel’s] tool repair he had to think outside the box enough to realize he could use some jumper wires and snuggle a larger TIC206E TRIAC that wasn’t meant for the device but still applicable into the housing where there was enough free space. A little shrink-wrap and all was good again. Sure the fix was simple, but let’s not trivialize the knowledge he needed for this repair.

And if you’re wondering if it worked, he notes that he’s been using this tool for three years since the repair. We thank [Daniel] for sharing this tip and allowing us to add this to our tool belt of Dremel repair tricks.

Making a solid-state relay with I2C interface

As [Mic] often got requests to make high-power switching boards, he recently finally gave in and designed the one shown above based around a solid-state relay. Some of our readers that already play with mains power know that switching should normally occur when the voltage crosses zero volts. The ‘TRIAC BLOC’ is able to do so, which also allows mains frequency measurement. [Mic] then tuned to the internal oscillator of his ATtiny microcontroller with this 50Hz by adjusting its OSCCAL register value, so the switching command can be sent at the ideal moment. Zero crossing detection is implemented by feeding the mains into an AC optocoupler. [Mic] discovered that the optocoupler diodes are not identical, so he had to adjust his firmware to account for the time differences.

All the resources are available on github, we would be interested to hear your detailed analysis of the circuit implemented with the passives R3/C1/L1/R8/C3.

Precise temperature control of a coffee urn

coffee-urn-temperature-controller

Hackaday Alum [Nick Schulze] decided to help out a friend who needed a controller to hold water at a precise temperature. Coffee guzzling hackers of the world should rejoice, as [Nick] targeted a coffee urn as the vessel for the project. What he came up with was a couple of custom boards and a roll-your-own temperature probe which does a fantastic job of regulating the temperature of the liquid.

Needing to switch the mains going to the heating element he immediately thought of an AC chopper circuit based on a Triac. What didn’t come to mind immediately was the need to detect the zero crossing. In the image above you can see nearest the urn his high voltage board. Below that is the zero crossing detector circuit. For feedback he created his own temperature probe using a TC1047 temperature sensor. After soldering on a filtering cap and the leads he dipped it in JB Weld to make it water tight. If you’re using this for coffee may we recommend seeking out a food safe probe.

After successful testing he added a user interface and buttoned it up in the enclosure seen in the video below.

[Read more...]

Add a shutoff timer to your bathroom fan

Adding this board (translated) to your bathroom fan will turn it into a smart device. It’s designed to automatically shut off the fan after it’s had some time to clear humidity from the room. It replaces the wall switch which normally controls these fans by converting the fan connection to always be connected to mains.  The board draws constant power to keep the ATtiny13 running via a half-wave rectification circuit. A single LED that rises from the center of the PCB lights up to signal that the fan is in operation, but it is also used as a light sensor, similar to the LED communications hack from a couple of days ago. When the lights go on in the bathroom the microcontroller will turn on the exhaust fan via a Triac. It will remain on until the light level in the bathroom drops.

There’s an interesting timing algorithm that delays the fan startup, and varies the amount of time it will stay on in the dark depending on how long the bathroom lights were on. This way, a longer shower (which will build up more humidity) will cause the fan to remain on for the base of five minutes, plus one minute longer for every two minutes the bathroom was in use. Pretty smart, and quite useful if your bathroom sees high traffic from several family members.

Christmas light controller

We get a lot of tips about Christmas light controllers but rarely do they contain the kind of juicy detail that [Vince Cappellano] included with his setup. His video explaining the controller he built is embedded after the break and it’s not to be missed.

We think there’s a lot of good design invovled in this porject. First off, he’s got eight physical channels, each with optisolation and a triac for 256 levels of power control. But he was able to double the control to sixteen virtual channels if you’re using LED lighting. That’s because on those strings half of the LEDs are reverse biased compared to the rest. By adding sensing circuitry to the incoming AC, he can switch the triacs to only send positive or negative voltage through the LED strands, which produces the additional virtual channels. And did we mention that he did all this using wire wrapping and point-to-point soldering?

[Read more...]

Waking up with the (fake) sun

[Bogdan] has some trouble getting up in the morning. A blaring alarm will do the trick but that’s no way to start the day. To get him through the dark winter months he wanted to try a sunrise simulator. He patched into the alarm signal of his bedside clock, intercepting the command from the clock’s microprocessor and using it as an input for his own ATtiny13. From there, the tiny13 gradually brightens a 150W halogen lamp using a triac until his room is as bright as a July morning. A signal is then sent to the alarm clock’s audio amplifier to turn on the audible alarm. He’s got the system set for a 20-minute sunrise so it’s just a matter of programming his alarm 20-minutes early than the ‘I absolutely have to get out of bed now’ time.

10,000 watt fluorescent array

This is an array of flourescent tubes that form a display. The video above is just two modules of a ten module installation that [Valentin] and his team are showing at an exhibition in Berlin tomorrow. The connected modules form something of a scrolling 16-segment display (similar to the 17 segment display modules of the ninja party badges but much larger). They’re using triacs, optocouplers, DMX, and an Arduino to interface a computer with the 182 fluorescent tubes of the display. Check out a second video after the break to see (or be blinded by) all ten modules pulling 10,000 watts.

[Read more...]

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