DIY 1000w SON gearbox: Internals (reupload)

Re-upload. I had uploaded the wrong photo and the file replace button doesn't seem to be working for me. Sorry.

Decided to put together an enclosure for the 1000w SON gear that I've had floating about for the last 10 years.
I decided a proper Hylec DEDS0200 IP66 steel enclosure would be the best and I really went to town with the wiring.
I used proper class 5 tri-rated cable and each conductor that went into a screw terminal got a crimped skirted ferrule on it.
Each conductor that went into a spade or ring terminal was soldered as well as crimped with the ends heat shrinked over.

The gear itself is a Philips BSN 1000 L78 with an SN59 ignitor and two 50uf 250v PFC capacitors.
I think I might be pushing that IEC C13 outlet at bit as the current rating is right on the limit!

The barsteward weighs over 20kg!

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Filename:	387A1890.JPG
Album name:	FrontSideBus / Control gear
Filesize:	5755 KiB
Date added:	31 Jan, 2022
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FrontSideBus

[01 Feb, 2022 at 02:56 PM]

I just fired it up, almost completely silent during the run up and in operation. Just that lovely soft 50hz hum if you open it and put your ear close, not a rattle or high pitched but a proper deep hum that says this is the real stuff and means business.
I've had it going for an hour so far and even with the lid closed the ballast is only warm to touch. Internal wiring is stone cold but I think the test lead that I'm using to hook it up to an old Low bay fitting with the gear stripped out which I use as a test box could use upgrading. It has a CSA of only 1mm² and has got quite warm and flexible with a bit over 10 amps of current going through it!

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