Steam Engine Power controller assembly
...the dimmer switch comes with clear instructions
...you want to set it up as a:
SINGLE POLE APPLICATION
>My dimmer switch had two black (hot) wires coming out
of it and a green (ground) wire.
>My cord had a black (hot), a white (neutral) and a
green (ground) wire coming out of it.
>My outlet had a brass screw for the black (hot) wire,
an aluminum screw for the white (neutral) wire and a
green screw for the (ground) wire.
STEPS TO SUCCESS:
(A) I first made the holes in the box for the single
outlet (big one and two small ones for mounting
screws), a 1/4" hole in the face of box for the dimmer
knob's post and two small ones for mounting screws
...and lastly a 3/8" hole for the cord to come in the
box end opposite the outlet.
(B) I gave the box a coat of polyurethane on the
outside before mounting any of the electronics AND
glued a small wood block at each corner of the box
where it would meet the wood base (plaque)...it
allowed 1/8" gap all the way around for ventilation.
I am considering adding a few more vents after the
fact as it will get a little warm with extended use
(like an hour).
(C) I stripped back 1/2" of the wire covering from
each wire of the incoming cord...then ran cord thru
the box into the inside, pulling some slack thru to
make it easier to work for now. Remove the outermost
wire's plastic covering (ivory part on my wire)...for
about 4", giving yourself three 4 inch long wires
inside the box...plenty of room for this and makes it
easier to connect things up. I put a plastic cable
tie tightly on the outer wire cover inside the box at
a point that it would prevent the wire being pulled
out of the wood later, loosening connections...just
an easy safeguard to do.
(D) Connect the white (neutral) wire from cord
directly to the aluminum screw of the outlet
(E) Connect the green (ground) wire from cord AND the
green (ground) wire from dimmer BOTH to the green
(ground) screw on the outlet.
(F) Connect the black (hot) wire from cord to one of
the black (hot) wires of dimmer using wire nuts that
come with the dimmer...(I also add black plastic
electrician's tape over the wire nut as extra
insurance it won't come loose later).
(G) Connect the other black (hot) wire from the dimmer
to the brass (hot) screw of the outlet.
(H) Mount the outlet into the box first...attach two
screws thru box to hold it in place. Then mount
dimmer up thru it's dimmer knob hole and attach with
it's two screws thru box...slide dimmer knob on the
post sticking thru the center of the box. Lastly pull
most slack of the cord out of box til your cable tie
prevents any further.
(I) Mount the box to the wooden plaque with wood glue
or epoxy...being sure the little blocks of wood
installed earlier give you 1/8" or more of ventilation.
(J) Remove dimmer knob and give the whole box and base
another coat of polyurethane (try to keep it off the
outlet's plastic)...pop the dimmer knob back on and
you are in business!!!
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ONE more safety suggestion I use on all my old electric
engines. Since most do NOT have a grounded 3 prong
outlet, I made up a 2 foot piece of green wire with an
alligator clip on one end, prong to insert in a grounded
outlet on the other end. I clip oneend to a slightly
loosened firebox screw on my Jensensand underneath my
Empires. I run the other end to the ground (round hole)
of a 3 hole US 110 Volt AC outlet.