[dingo bingo]

HI guys,

For the last 45 mins I have been relentlessly trying to wire up the 16A IEC connector that comes included with the Maxibright Compact 1000W ballast, as the standard 10A connector fitted to the reflector isn't up to the job apparently. There's a sticker on there that states the wiring must be undertaken by a fully qualified electrician - yeah right, I'm good but have no idea how I'd explain the 1000W HID ballast to a leccy. A sneaky way for them to void most warranty claims perhaps?

I'm fairly capable of basic electrics, have wired up plenty of fans, fan controllers and various other plugs and cables although this connector is from another planet! I can not for the life of me work out how to get it wired up securely, the cable keeps slipping out.

The first image is of both connectors, the standard 10A ready fitted to the reflector on the left and the new 16A on the right. The obvious difference being that the old has vertical pins and the new has horizontal pins. The second image is the inside of the new 16A plug and where the wiring shold be connected to.

I have tried securing the wiring directly under the screw and also between the metal pin and plastic base, both with absolutely no luck.

Am I making a stupid mistake? Is there anything to help? Please please please can someone enlighten me as to how this can be done.

Many thanks in advance, DB

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[roundsquare]

dingo bingo, on 27 March 2012 - 01:43 PM, said:

I have tried securing the wiring directly under the screw and also between the metal pin and plastic base, both with absolutely no luck.

Duuno why that'd be slipping out mate. Sounds wierd to me. the wire should go not just beneath the screw but also between the plate(that's beneath the screw) and the plastic of the actual plug case, as it were...

Since it's a 16A plug it maybe expecting thicker wire. You could strip back your wires a little more, revealing more of the copper, then fold it over a bit to sort of 'double-up' the copper wire, maybe then it'll grab better. That's all i can think of by looking at pics mate

atb

[Chairman O The Bored]

Evening DB,

I feel your pain! I must have gone through this dozens of times during my various moves and "upgrades"!

I never really liked them, invariably the cable is too fat to wire into the plug easily. I like to solder the end, which makes it even harder. Also there are a few different makes, some better put together than others, also i tape the plug and socket together once all done as they can't pull apart easily... but i also worry that it may arc and spark if they are just conected.

So i thought....why do i need to use this type of connector?? So i bought a rubber plug and socket and rewired my ballast and light:



No problems getting the wires in.

No taping together

And another fuse in the link....


chair....

[dingo bingo]

roundsquare, on 27 March 2012 - 03:42 PM, said:

dingo bingo, on 27 March 2012 - 01:43 PM, said:

I have tried securing the wiring directly under the screw and also between the metal pin and plastic base, both with absolutely no luck.

Duuno why that'd be slipping out mate. Sounds wierd to me. the wire should go not just beneath the screw but also between the plate(that's beneath the screw) and the plastic of the actual plug case, as it were...

Since it's a 16A plug it maybe expecting thicker wire. You could strip back your wires a little more, revealing more of the copper, then fold it over a bit to sort of 'double-up' the copper wire, maybe then it'll grab better. That's all i can think of by looking at pics mate

atb

I'll give folding it over a try mate, thanks for suggesting that!

Chairman O The Bored, on 27 March 2012 - 03:57 PM, said:

Evening DB,

I feel your pain! I must have gone through this dozens of times during my various moves and "upgrades"!

I never really liked them, invariably the cable is too fat to wire into the plug easily. I like to solder the end, which makes it even harder. Also there are a few different makes, some better put together than others, also i tape the plug and socket together once all done as they can't pull apart easily... but i also worry that it may arc and spark if they are just conected.

So i thought....why do i need to use this type of connector?? So i bought a rubber plug and socket and rewired my ballast and light:



No problems getting the wires in.

No taping together

And another fuse in the link....


chair....

Excellent idea pal! What Ampage does it need to rated at? Is 13A enough? Also, where's best to buy from - I've had a quick look on B&Q and Wickes and can only find the socket, no plug.

DB

[Chairman O The Bored]

Afternoon DB,

Strange, the plug should be the easiest to source??

Any standard place should sell, including wickes and b&q..also maplins, screwfix... try some of the specific electrical counters like CEF or CPC or alike. It's just a standard plug and socket, albeit a "tough" one. Should be about £1 - £1.50 each.

NOTE: I AM NOT AN ELECTRICIAN (i'm a chairman )

But like you i have no issues with swapping out simple stuff. I run a 600W and have a 5A fuse in the plug. I tried a 3A, but it blew (as i expected), maybe a sparky can chip in, but im pretty definate you will be more than fine with 13A. In fact, I would try a 5A first, then i would know i had the most appropriate fuse in.

Of course, im sure you understand this is a fuse just for the lamp. You still need to use a contactor and appropriate fuse in your ballast. I have a 5A in my ballast.

chair......

[dingo bingo]

Yeah can find plenty of 13A plugs, just no 16A like the ballast instructions suggest. 13A it is I guess!

Yeah I understand it's just for the lamp, not sure what fuse is in the ballast but got the contactor and timer set up and ready.

Thanks for your help Chairman!

[Themadhippy]

take the 3 screws out strip the wire,split the strands in 2 pass half round 1 side of the screw,other half around the other side and then twist em together tight,and put the screw back

This post has been edited by Themadhippy: 28 March 2012 - 07:09 PM

[dingo bingo]

I like the idea Themadhippy! As much as an extra fuse in the system via the plug and socket would be, I am very skint for now so will give that a go!!

On the subject - am I right in thinking that one 13a socket will comfortably power 2 x 1000Ws? I've just checked and each ballast is stated at 5a on the label but 10.3a on the box?? (and a 13a plug?) and the contactor I bought to run 2 x 1000Ws is rated at 10a so that's well under 13a.

E2A: I just remembered from somewhere; is the maximum power - 13a x 240v = 3120W?

This post has been edited by dingo bingo: 28 March 2012 - 07:40 PM

[Saddam]

I stripped back enough insulation to make a loop around the screw, after several attempts and some bad language I managed to get the screw and wire to tighten up. Don't use a different cable unless it's the same size core/power rating as the one you intend to replace.. which is pretty pointless as you'll have the same problem wiring it. If you use the wrong size/rated cable it could melt or catch fire... 16amps is fkn deadly... Just look how thick the copper core is and has to be to comply with EU safety legislation! Be patient and calm, use the cable and plug provided and eventually it'll fit. Good wire cutters help as does trimming back enough insulation to work on the copper.
Good luck m8

[dingo bingo]

I've just tried to get it sorted by looping the original wire around the plug's screw although one of the screws has snapped in half.

So, plan B - I will use the original cable from both the ballast and reflector although instead of an IEC connector I would like to replace it with a heavy duty/garden style 13a rubber plug and socket just like the Chairman suggested.

The question is - will the 13a plug, socket and fuse be sufficient or is a 16a required?

It makes sense that a 13a will do as that's the fuse in the ballast's plug althought reassurance from someone with much more electrical knowledge than me would be very much appreciated!

DB

[dingo bingo]

Can anybody shine a light on this please?

[lemonchronic]

If you calculate the load of your 1000w light like this:
Amps=Watts/volts which means in your situation, 1000w/240v=4.16A
The start up load is going to be higher but it isnt likely that it will exceed the 13A the plug is rated at.
As the chairman has already stated it will be fine, and a good idea aswell will be doing it myself when i upgrade ballasts/reflectors,
lemon

[Saddam]

Come on m8, 4 days to wire a plug? Wtffffff?

[Chairman O The Bored]

dingo bingo, on 31 March 2012 - 11:41 AM, said:

Can anybody shine a light on this please?

Evening DB,

How did you get on? All safe i hope...

chair...

[dingo bingo]

Luckily the house hasn't burnt down, yet - most likely to do with the fact that I haven't touched it yet.

It's a slow pace of life in the DB household! There's no rush needed though, this is for the second light which won't be used until flower. I'll get the plug and socket tomorrow on lunch break and will wire it all up in the evening - will let you all know how it goes!