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Is It Safe to Hard-Wire an AC Input SSR for Automatic Shop-Vac Control in Garage?

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  • #1 21684080
    Dashiell Hall
    Anonymous  
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  • #2 21684081
    David Ashton
    Anonymous  
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  • #3 21684082
    Dashiell Hall
    Anonymous  
  • #4 21684083
    David Ashton
    Anonymous  
  • #5 21684084
    David Ashton
    Anonymous  
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  • #6 21684085
    Dashiell Hall
    Anonymous  
  • #7 21684086
    David Ashton
    Anonymous  
  • #8 21684087
    David Ashton
    Anonymous  
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  • #9 21684088
    Dashiell Hall
    Anonymous  
  • #10 21684089
    David Ashton
    Anonymous  
  • #11 21684090
    Dashiell Hall
    Anonymous  
  • #12 21684091
    Dashiell Hall
    Anonymous  
  • #13 21684092
    David Ashton
    Anonymous  

Topic summary

✨ The discussion addresses the safety and feasibility of hard-wiring an AC input solid state relay (SSR) to automatically control a shop vacuum in a garage when power tools are turned on. The original SSR (ThermoSense SSR-A1241, 41A) requires 240V control voltage and is not suitable for detecting current draw from tools to switch the vacuum. Instead, a current sensing relay or current sensor is recommended to detect when any tool is powered on by sensing live wire current. The current sensor outputs a low voltage proportional to current, requiring rectification, amplification, and a comparator circuit to drive the SSR input. Alternatively, a current sensing switch with a built-in relay output (rated 0.5A at 240VAC) can directly control the SSR without additional electronics. Looping the live wire through the sensor coil increases sensitivity by effectively doubling the sensed current. The shop vac is rated at 1250W, tools range from 300W to 1200W, and each tool is on a 13A fuse with a 16A circuit breaker protecting the circuit. The solution avoids voltage drop issues and ensures the vacuum only runs when a tool is active. The current sensing switch approach is cost-effective (~£20-£30) and practical for this application, though care must be taken to stay within sensor current ratings and ensure proper wiring with earth and isolators. The discussion includes links to suitable SSRs and current sensing switches and emphasizes the need for proper electrical safety and compliance with local regulations.

FAQ

TL;DR: Use a 0.2–30 A current‑sensing switch to trigger an AC‑input SSR so the shop‑vac starts with your tool; “you only need the live wire going through the hole.” [Elektroda, Anonymous, post #21684086]

Why it matters: This lets hobbyists auto‑start dust extraction safely without starving tools or violating circuit limits.

Quick Facts

Is it safe to hard‑wire an AC‑input SSR for automatic shop‑vac control?

Yes, when the SSR is triggered by a current‑sensing switch, not placed in series with tools. This avoids voltage drop and ensures only the vac is switched. Use proper enclosures, strain relief, and follow breaker and fuse ratings. Get an electrician to check it. [Elektroda, Anonymous, post #21684089]

Can I put an AC‑input SSR directly in series with my tools?

No. An AC‑input SSR expects a control voltage, not line current through the load path. In series, tools may not start, while only the vac triggers. Use a sensor that detects tool current and then drives the SSR. [Elektroda, Anonymous, post #21684083]

How should the current sensor be wired?

Route only the live conductor through the sensing window. Do not pass neutral through it. “You only need the live wire going through the hole.” Passing both live and neutral cancels the magnetic fields and prevents triggering. [Elektroda, Anonymous, post #21684086]

What ratings should I plan for?

Use a sensor adjustable from 0.2–30 A. A 0.5 A at 240 VAC sensor output equals 125 W, which cannot power a typical vac directly. Drive an SSR for the vac. Keep tools on 13 A fuses and a 16 A breaker as shown. [Elektroda, Anonymous, post #21684090]

Can the sensor switch the shop‑vac directly?

Only if the vac is ≤125 W, which is rare. A typical shop‑vac is about 1250 W. Use the sensor’s small output to feed the SSR input, and let the SSR switch mains to the vac. [Elektroda, Anonymous, post #21684089]

How do I increase sensitivity if light‑load tools don’t trigger the vac?

Loop the live conductor through the sensor twice. This doubles apparent current at the sensor, raising sensitivity. Note the trade‑off: a 30 A sensor with two loops behaves like 15 A max. Adjust threshold after looping. [Elektroda, Anonymous, post #21684089]

What’s a Solid State Relay (SSR)?

An SSR is an electronic switch that uses a small control signal to switch AC power without moving parts. Here, an AC‑input SSR receives line‑voltage control from the sensor and switches the vac’s mains line. Use proper heat dissipation and ratings. [Elektroda, Anonymous, post #21684083]

What’s a current‑sensing relay/switch?

It detects current flow in a conductor that passes through its sensing window. When tool current exceeds the adjustable threshold (e.g., 0.2–30 A), its output closes and can drive the SSR that powers the vacuum. [Elektroda, Anonymous, post #21684092]

Do I need a delay on start or stop?

No delay is required for basic operation. The thread setup turns the vac on when a tool draws current and off when it stops. You can add delays later with different modules if desired. [Elektroda, Anonymous, post #21684082]

What happens if I run both live and neutral through the sensor?

The magnetic fields cancel. The sensor sees nearly zero net current, so it never trips. This is a common failure case in first builds. Route only the live through the sensor window. [Elektroda, Anonymous, post #21684086]

Can I avoid using a DC power supply for control?

Yes. Use a current‑sensing switch with a built‑in AC‑rated output contact. That contact can feed an AC‑input SSR directly, eliminating a separate DC supply and comparator electronics. [Elektroda, Anonymous, post #21684089]

Is the approach compatible with high inrush tools?

Yes, because triggering is based on current draw exceeding a threshold. For very low‑idle or soft‑start tools, reduce the threshold or loop the live twice to ensure reliable starts. Verify against your 16 A breaker. [Elektroda, Anonymous, post #21684090]

How do I add a manual bypass to use the vac alone?

Place a changeover or separate switch to feed the vac directly, bypassing the SSR. Keep clear labeling and ensure the bypass still respects fuse and breaker ratings. Enclose all wiring. [Elektroda, Anonymous, post #21684082]

What brands or parts did the builders reference?

They discussed an AC‑input SSR, an adjustable 0.2–30 A current‑sensing switch, and standard UK 13 A fused plugs on a 16 A circuit. Any equivalent, correctly rated parts will work. [Elektroda, Anonymous, post #21684090]

Quick how‑to: how do I wire the auto‑start?

  1. Route only the live feed to your tool sockets through the current sensor window.
  2. Wire the sensor’s output to the AC‑input SSR control; wire the SSR output to the vac.
  3. Power a tool, adjust the sensor threshold, and test start/stop. [Elektroda, Anonymous, post #21684089]

Who should perform the final wiring and checks?

A qualified electrician should wire or verify the build. The project deals with lethal mains voltages. Enclosures, earthing, isolation, and breaker coordination must be correct before use. [Elektroda, Anonymous, post #21684089]
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