Induction boiler with own hands - drawings

Heating boilers of induction type appeared on the market relatively recently, but already were able to compete with the usual electric appliances with a heating element. Other things being equal( sizes, power consumption), induction boilers are able to heat up the heating system much faster. In addition, they work in systems with coolant of low quality, do not require complex maintenance. Knowledge of electrical engineering and savvy make it possible to make an induction boiler independently. The topic of today's article: induction boiler by own hands - drawings, schemes and installation. .

to the contents ↑

Principle of operation

The action of the induction boiler is based on the ability of materials conducting electric current to heat from eddy currents. They are created from electromagnetic induction:

• As an induction source, an alternating current of high frequency is used, which passes through the primary winding of the heating device. It is made in the form of a coil.
• The heating element located inside the coil serves as a secondary short-circuited winding.
• In the heating element, the electromagnetic energy is converted into thermal energy.

Important! The appearance of eddy currents is possible even with an industrial frequency of 50 Hz. However, the efficiency of heating will be small. In addition, the device will be very noisy and vibrate during operation. As the frequency of the alternating current increases to 10 kHz or more, the heating amplifies, and noise and vibration, on the contrary, disappear.

to the contents ↑

How is the industrial induction boiler arranged?

It is necessary to have an idea about the arrangement of such equipment, otherwise it is not possible to make an induction boiler by oneself, draw up drawings and perform assembly of the unit. So:

• At the heart of the industrial induction boiler is a heat exchanger with a toroidal winding connected to a high-frequency converter.
• The current passing through the winding creates an alternating electric field that induces eddy currents passing through the heat exchanger.
• With the signal from the control panel, the inverter generates a current of the desired frequency.
• Modern boiler models are automated. This makes it possible not only to create the optimal mode of heating the coolant, but also to disconnect the device in the event of an accident.
• The heat transfer medium is located inside the heat exchanger. The eddy currents warm it up to a predetermined temperature. Due to the difference in the temperatures of the coolant at the inlet and outlet, it is continuously circulated. It does not even require a pump connection.

Important! Boilers of induction type can be used in systems with both natural and forced circulation.

• As the coolant, you can use oil, antifreeze or antifreeze. The quality of the coolant does not matter.
• Vibration of a system that a person does not feel prevents the precipitation of scale on the thermal circuit.
• As the outer shell is used a metal casing, which is equipped with electrical and thermal insulation.
• The configuration of the boiler can be any. Since the tank inside the boiler is missing, its dimensions are small, and the mass is not more than 50 kg.

Important! Do not turn on the induction boiler if the system is not filled with a coolant. This is fraught with overheating of the boiler and failure of its elements.

to content ↑

Advantages:

• High efficiency value( 95-98%).
• Large range of models of different capacities, rated for 220 or 380 volts.
• Rapid heating of the heating system.
• Possibility to work with different heat carriers.
• The tightness of the circuit through which the coolant passes. This completely eliminates leaks and malfunctions associated with them.
• Continuous work without the formation of scale. It is the scum that reduces over time the efficiency of the boilers equipped with electric heaters. For the same reason, the heaters overheat, and the device is out of order.
• Long service life( 25-30 years).

Important! There are disadvantages, among them - high cost. This is the incentive for the self-made induction boiler. Despite the complexity of induction processes, it is possible to create a device that is not inferior in performance to industrial designs.

to contents ↑

Boiler powered by

welding inverter This is a fairly simple design. The most complicated element of an induction boiler is a high-frequency converter. The inverter for a heating boiler can not be made by hand. Its role is well performed by a modern welding inverter that is capable of outputting an output signal whose frequency is from 20 to 50 kHz. In addition, for installation are needed:

• Copper wire in enamel insulation with a diameter of 1.0-1.5 mm.
• Insulated wire equipped with terminals to connect the winding to the inverter.
• Scraps of stainless steel wire with a diameter of 3-5 mm, length 50 mm.
• Fine mesh of stainless steel.
• A meter section of a polyethylene or polypropylene water pipe with a diameter of 50 mm and a wall thickness of 8.4 mm.
• Textolite for securing the winding.
• Epoxy for winding insulation.

Important! The housing of a homemade boiler can be a switch cabinet made of metal or plastic. In the cabinet you can install an inverter and a heating element.

Algorithm for installing an induction boiler with your own hands - drawings and assembly order:

1. Using epoxy adhesive, fix 4 textolite strips with a width of 8-10 mm on a piece of pipe. In this case, it is necessary to retreat from the ends of the pipe to 7-10 cm. Winding will be wound on these strips. To fix the outer turns, make grooves in the textolite.
2. Wind 50-100 turns of copper wire in insulation. The distance between the turns should be the same, about 0.3-0.6 mm.

Important! The number of turns depends on the resistivity of the wire and its diameter, as well as the output characteristics of the inverter.

1. When installing the boiler in a residential area, it is desirable to make a toroidal outer winding to reduce the external electromagnetic field. The toroidal winding has the same number of oppositely directed turns. There is a mutual compensation of electromagnetic flows( they pass exclusively along the inner contour).
2. Insert the steel mesh inside the pipe and tightly thread the pipe from the opposite end with pieces of stainless steel wire. Under the action of eddy currents, the metal will be heated.

Important! It is desirable to use stainless steel to avoid corrosion of the metal. But for lack of stainless steel, the usual wire-rod is also suitable.

1. Solder on both ends of a pipe section of a polypropylene adapter. Install the ball valves on them to block the circulation of water.
2. Install a pressure relief valve on the outlet upper adapter side. Isolate the winding with epoxy glue.

Important! When making epoxy glue, add 10-15% less hardener. The insulation will not be so fragile.

1. Using crimp terminals, secure insulated wires to the winding leads. It is necessary that the second end of the wire has terminals for connection to the inverter.

Important! The diameter of the wires should be selected in such a way that it will withstand the greatest output current of the inverter.

1. Fix the heat exchanger in a cabinet on brackets of heat-resistant material that does not conduct electrical current. A good option - textolite.
2. Connect the water heater to the system, fill it with a coolant.
3. Install the inverter at the bottom of the cabinet. Connect the terminals to it and plug it into the network. Start the boiler and set it to the optimum operating mode.

to the contents ↑

How to make an induction boiler by hand from induction tiles?

Disassemble the heating element and use a copper wire for winding onto the heat exchanger. Use the tile control unit to power the winding by setting the desired power on the control panel.

However, this method has a number of its drawbacks:

• The need for an independent calculation of the inductance of a newly wound coil. Not the fact that it coincides with the original value. The device may malfunction.
• Most induction cookers are equipped with the function of automatic shutdown after 2-3 hours of operation. This means that the boiler will shut off regularly.
• The thickness of the tiles, as a rule, does not exceed 2.5 kW.For this reason, using parts from the induction cooker, you can only produce a low-power boiler.

There is an easier way to use the induction cooker without having to dismantle it: install a hermetically sealed stainless steel tank with inlet and outlet nozzles on the tile and connect it to the heating system.

Having a certain knowledge in the field of electrical engineering, you can perform an induction heating boiler yourself. The scheme and installation are not particularly complicated.