Earlier this year I started buying parts to make a Powder Coating Oven.
I will try to post images later to help others make their own PCO controller …
The goal is to have a Portable Powder Coating Oven (PCO) with removable panels that can be configured into different shapes to allow for powder coating rectangular boxy shaped items as-well-as long thin items by heating the same volume of air with 2 heating elements. ( Total of 5170 watts )
Also a portable (Plug-in) PID Controller for the Powder Coating Oven … with the bonus that the PID Controller can also be used with my Beer Home Brewing Equipment and a future outdoor Meat Smoking Hut 🙂
For this Project my plan was to first draw in all the purchased parts and then start designing the rest of the items using SolidWorks CAD Software.
CLICK HERE to Learn more about Powder Coating
Attempted to order as many parts as possible off of AMAZON.com
As they arrived, I weighed the parts and drew them into SolidWorks …
SolidWorks allows me to make the CAD part’s weight, and center of gravity, the same as the real-world part, so completed Assemblies are the correct weight.
SolidWorks also allows users to make Photo-Realistic renderings of the parts for presenting a visual of how real-life item will appear when finished.
I decided to 3D-Print many of the parts for the Oven’s Control Box …
First designed the Powder Coating Oven’s Electronics box with SolidWorks …
( Click on any image to see a larger view of the photo )
One of the benefits of using a 3D-Printer is designing any shape needed without worry of ‘draft angles’ which are required to make plastic injection parts.
For example, I wanted to be able to switch out different size/models of square shaped PID Controllers & Digital Timers.
So I designed and 3D-Printed a mounting setup which allows ‘square’ controls to go in a ’round’ hole easily drilled with a 2.5″ hole saw using a drill press.
Also designed and drew up some Cord Stop Clamps ( .STL Files )
I like to show lots to dimensions in my drawings to prevent mistakes 🙂
Tested the 3D-Printed parts, and the purchased parts, within the sheet metal cutouts prior to welding & painting the Electronics Box.
The electrical Terminal blocks I bought didn’t work, so I designed some …
Uploaded the 3Dp .STL files to GrabCAD ~ Link: 3Dp Terminal Blocks
Didn’t have 1/8″ thick Copper so found some Aluminum angle in scrap bin …
Drilled and Tapped the Aluminum and then cut it to the correct size …
3D-Printed one for White wires, and another for Black wires, and the ABS 3D-Printing material acts as an insulator for the 120V electrical connections.
The Cover keeps the screws from falling out even if they become loose …
I will probably switch out the Aluminum with Copper flatbar when I get some.
A specific feature I wanted for this (PCO) Powder Coating Oven was the ablity to know the cost of the electricity used while Powder Coating parts.
The multi-meter comes with a ring which needs to go around the L2 electrical wire to know the Amps being used, so I designed and 3D-Printed a stand.
Below is a SolidWorks rendering showing the wiring and Amp Ring Stand.
The baylite Multi-Meter shows the Voltage, Current, Power, and Energy.
3D-Printed ABS material provides protection from other wiring in the box …
Tested each of the parts prior to mounting the in the electronics box ~ In the photo below I have the baylite meter setup to test 120v amperage; however, the meter is wired to 240V power in the Powder Coating Oven control box.
In future posts, after fully testing out the Powder Coating Oven, I will show the wiring in SolidWorks, which is easier to view than the real-life wiring because I will be able to hide, or make transparent, other items in the box to show specific wires going to specific items.
I have already uploaded many of the CAD parts to GrabCAD.com …
Tried to keep most of the items as Single part files; yet, still allow the parts to be adjustable, such as allowing switches to be viewed as ON or OFF.
Made the gap adjustable so the switch fits on other material thicknesses …
The LED Readout numbers can also be set for Tutorials & User Manuals …
I try to use metal from my scrap metal bin to make equipment for my shop and sometimes the metal is heavier than I would normally use.
For example, the sheet metal for this PCO (Powder Coating Oven) Control box is 0.135″ thick and I would probably normally use 0.075″ thick sheet metal.
After drilling & cutting all the holes, I welded the Control box sides together …
Since this unit is for my shop I painted the PCO Control box Flat Black …
The Top & Back plates bolt-on to make the inner Controls easier to wire …
After the paint cured I started adding the controls & switches …
Noticed I was one ON/OFF switch short … They came in a Pack of 5 … *sigh*
Back on AMAZON to order more … For some reason I thought there was 6 🤔
After tests realized I didn’t need the Air Cooling fan but added one anyway.
Everything on the PCO is powered from outlets & extension cords, because this is a portable Powder Coating Unit that can be taken to different locations.
This Electronics box can also control a Meat Smoker & a Home Brewing system.
( I wanted a multi-use Control Box for future projects ~ Whoo Hoo!! ) 😜
Front Blue LED lights-Up when the Blower Fan 120V outlet is switched ON.
Front Green LED Lights-Up when Oven Light 120V outlet is switched ON.
The Amber Light on the front lets users know 240V power is plugged into the Control box … When dealing with 240 Volts – Safety, Safety, Safety!! ⚡
In addition, the Amber LEDs on each side of the control box light-up when the Contactor Switch is providing 240V power to the 240V side outlets that are connected to the Powder Coating Oven’s Heating Elements.
The White LED Lights-Up when 120V Power is plugged into the Control box.
I’m having ‘Laser Etched’ Metal Labels made up to explain Control functions.
Additional Views of the Controls for the Powder Coating Oven …
That’s All for Now 😜
I found the eStop button and added it to the PCO Control Box design …
Made a temporary stand/mount for the PCO Electronics Control Box …
Already has the nickname of ‘Roo-Rat’ 😜
I uploaded my SolidWorks ‘Working CAD Files’ to GrabCAD for anyone that would like to see how I tested the wiring.
The wiring in the model is not complete, but it will show how I wired the Auber PID Temperature Control, as-well-as the Inkbird Timer Control and the Digital Amp/Volt Meter.
GrabCAD Link: https://grabcad.com/library/powder-coating-oven-wiring-1
The Powder Coating Over Controls I used were:
Auber SYL-2342 PID Temperature Control
( SYL-2342 version is for Contactors not SSRs )
INKBIRD IDT-E2RH Timer
Eaton C25BNF240A Compact Definite Purpose Contactor
Bayite AC 80-260V LCD Watt Multimeter Ammeter Voltmeter
AC Infinity AXIAL 8038 Muffin Cooling Fan, 115V AC
Erb44t10010 2,585 watt Heating Elements ( 2 )
If you have any wiring/control Questions send me a comment 🙂