This article describes a simple and inexpensive inline power meter for use as a test instrument.
The box cutouts were done on a CNC router, but they could be done with hand tools.
Above, calcs of feeds and speeds for the CNC router. The box is actually ABS, but cutting speed for Polycarbonate is the same.
Above is the tool path for one side of the box. The cutouts suit the 7P-2 strain reliefs. The gcode is generated from a custom Python file using a custom library of common shapes that I use.
Above, the box cutouts were done on a CNC router.
Above, the tool path for the box bottom to receive the power meter module.
Power meter module
Above is the power meter module, about $23 on eBay. Using the current transformer seen, it is rated for up to 100A, but the cord set used is only good for 15A.
The module displays voltage, real power, current, power factor, accumulated energy (kWh), and frequency.
- power meter module;
- extension cord;
- 2x Heyco 7P-2 strain relief bushings;
- bootlace terminals, end splices; and
- self adhesive rubber feet.
I might mention that the closed end splices used are NOT the cheap Chinese knock offs with soft aluminium ferrules.
You will need to strip sufficient cable to be able to wire using the end splices.
Above, the power meter wired and ready to be fitted with the bottom lid.
Above, the completed power meter. The load is a 2kW induction motor at high load (hence the high PF).
Do not undertake this project unless you have the requisite competencies and experience.