Making an ion boiler at home

Ion boiler Galan

For domestic use, boilers of the Galan brand are produced in the Hearth series, which has several models:

"Head2" - designed to heat a room no more than 80 m3. The power consumption of the unit is 2 kW. The boiler operates from 220 V. With normal thermal insulation of the room, the electricity consumption fluctuates within 0.5 kW / h. The recommended amount of coolant fluid varies between 20-40 liters.

"Head 3" - Can warm up a room with a volume of 120 m3. The boiler power is 3 kW. Energy is consumed within 0.75 kW/h. Liquids for heating the system need from 25 to 50 liters.

"Head 5" - used in rooms with a volume of not more than 180 m3. The boiler has a power of 5 kW. Consumes about 1.25 kWh. The displacement of the coolant varies between 30-60 liters.

"Ochag 6" - is able to warm up 200m3. The power consumption is 6 kW and the consumption is 1.5 kW/h. Recommended from 35 to 70 liters. coolant.

Only the specially developed Potok liquid, which prevents corrosion of pipes, can be poured into the Galan boiler system.

Combined device

The need for maximum reliability has led to the invention of the Archives combo flame relays, for example. The main difference from a conventional device is that the device uses two fundamentally different registration methods - ionization and optical.

As for the operation of the optical part, in this case it selects and amplifies an alternating signal that characterizes the ongoing combustion process. During the burning of the burner and pulsing, the data is recorded by the built-in photosensor. The fixed signal is transmitted to the microcontroller. The second sensor is of the ionization type, which can receive a signal only if there is a zone of electrical conductivity between the electrodes. This zone can exist only in the presence of a flame.

Thus, it turns out that the device operates in two different ways to control the flame.

A simple do-it-yourself ion boiler

Having become acquainted with the features and principle by which ion heating boilers operate, it is time to ask the question: how to assemble such equipment with your own hands? First you need to prepare the tool and materials:

• Steel pipe with a diameter of 5-10 cm
• Ground and neutral wire terminals
• electrodes
• wires
• Metal tee and coupling
• Tenacity and desire

Before you start putting everything together, there are three very important safety rules to remember:

• Only the phase is supplied to the electrode
• Only the neutral wire is supplied to the housing
• Reliable grounding is required

To assemble the ion electrode boiler, just follow the following instructions:

• First, a pipe 25-30 cm long is prepared, which will act as a hull
• Surfaces must be smooth and free of corrosion, notches from the ends are cleaned
• On the one hand, electrodes are installed by means of a tee
• A tee is also required to organize the outlet and inlet of the coolant
• On the second side, they make a connection to the heating main
• Install an insulating gasket between the electrode and the tee (heat-resistant plastic will do)

• To achieve tightness, threaded connections must be exactly matched to each other.
• To fix the zero terminal and grounding, 1-2 bolts are welded to the body

Putting everything together, you can embed the boiler into the heating system. Such home-made equipment is unlikely to be able to heat a private house, but for small utility areas or a garage it will be an ideal solution.You can close the installation with a decorative casing, while trying not to restrict free access to it.

Features of the installation of ion boilers

A prerequisite for the installation of ion heating boilers is the presence of a safety valve, a pressure gauge and an automatic air vent. The equipment must be placed in a vertical position (horizontal or at an angle are unacceptable). At the same time, about 1.5 m of supply pipes are not galvanized steel.

The zero terminal is usually located at the bottom of the boiler. A ground wire with a resistance of up to 4 ohms and a cross section of more than 4 mm is connected to it. You should not rely solely on RAM - it is not able to help with leakage currents. The resistance must also comply with the rules of the PUE.

If the heating system is brand new, there is no need to prepare the pipes - they must be clean inside. When the boiler crashes into an already operating line, flushing with inhibitors is mandatory. The markets offer a wide range of products for removing deposits, salts and scale. However, each manufacturer of electrode boilers indicates those that he considers the best for his equipment. Their opinion should be followed. Neglecting washing, it will not be possible to establish the exact ohmic resistance.

It is very important to choose heating radiators for the ion boiler. Models with a large internal volume will not work, since more than 10 liters of coolant will be required per 1 kW of power

The boiler will constantly work, wasting part of the electricity in vain. The ideal ratio of boiler power and the total volume of the heating system is 8 liters per 1 kW.

If we talk about materials, it is better to install modern aluminum and bimetallic radiators with minimal inertia. When choosing aluminum models, preference is given to primary type material (not remelted). Compared to the secondary, it contains fewer impurities, reducing the ohmic resistance.

Cast iron radiators are the least compatible with an ion boiler, as they are the most susceptible to pollution. If it is not possible to replace them, experts recommend observing several important conditions:

• The documents must indicate compliance with the European standard
• Mandatory installation of coarse filters and sludge traps
• Once again, the total volume of the coolant is produced and equipment suitable for power is selected

Device and specifications

The construction of an ion boiler is at first glance complex, but it is simple and not forced. Outwardly, it is a seamless steel pipe, which is covered with a polyamide electrical insulating layer. Manufacturers have tried to protect people as much as possible from electric shock and leakage of expensive energy.

In addition to the tubular body, the electrode boiler contains:

1. The working electrode, which is made of special alloys and is held by protected polyamide nuts (in models operating from a 3-phase network, three electrodes are provided at once)
2. Coolant inlet and outlet pipes
3. Ground terminals
4. Terminals supplying power to the housing
5. Rubber insulating pads

The shape of the outer casing of ion heating boilers is cylindrical. Most common household models meet the following characteristics:

• Length - up to 60 cm
• Diameter - up to 32 cm
• Weight - about 10-12 kg
• Equipment power - from 2 to 50 kW

For domestic needs, compact single-phase models with a power of not more than 6 kW are used. They are enough to fully provide heat for a cottage with an area of ​​80-150 square meters. For large industrial areas, 3-phase equipment is used. A 50 kW installation is capable of heating a room up to 1600 sq. m.

However, the electrode boiler works most efficiently in conjunction with control automation, which includes the following elements:

• Starter block
• Surge Protection
• control controller

Additionally, control GSM modules can be installed for remote activation or deactivation. Low inertia allows you to quickly respond to temperature fluctuations in the environment.

Due attention should be paid to the quality and temperature of the coolant. The optimal liquid in the heating system with an ion boiler is considered heated to 75 degrees

In this case, the power consumption will correspond to that specified in the documents. Otherwise, two situations are possible:

1. Temperatures below 75 degrees - electricity consumption decreases along with the efficiency of the installation
2. Temperatures above 75 degrees - electricity consumption will increase, however, the already high efficiency rates will remain at the same level

What is an overheat sensor

In addition to the draft sensor, there is also an overheat sensor. It is a device that prevents the water heated by the boiler from boiling, which occurs when the temperature rises above 100 degrees Celsius.

When triggered, such a device turns off the boiler. The overheating sensor works properly only when installed correctly. An increase in water temperature without this device would threaten the failure of the gas boiler.

The overheating sensor monitors the temperature rise in the heating circuit. It is installed at the outlet of the heat exchanger of the heating circuit. When the critical temperature is reached, it opens the contacts and turns off the boiler.

Reasons for triggering the overheat sensor:

• Such a device may work if the water in the column is too hot;
• In case of poor contact of the sensor;
• Due to its malfunction;
• If the sensor has poor contact with the pipe.

In order to make the heating sensor more sensitive, a heat-conducting paste is used. In case of overheating, the sensor blocks the operation of the boiler. Modern devices are able to indicate the breakdown code on the display.

Gas boiler does not work

Why does the gas heating boiler not turn off?

This happens if the following happens on gas heat generators such as Baxi (Baksi), Keber, Lemax, Mimax, Dani, Danko, Zhitomir, etc.:

• the temperature sensor at the inlet to the heating system or on the return line is faulty - the sensor does not work when the set temperature is reached and the device works without stopping.

  Inspect the mechanical connection of the wires, the presence of oxides on them, clean and restore the connection. If this does not work, check the sensors for a short circuit and open circuit, if a malfunction is detected, replace the sensor;

• low temperature in the heating return circuit, the delta of the temperature difference between the flow and return is not observed. This happens in double-circuit units Keber, Junkers, Ariston, AOGV, Navien, Rinai, when large heat losses occur in the heating circuit due to poor room insulation. Insulate windows, doors, floors and walls;
• the heat generator does not switch off automatically when the heating medium velocity is low. This happens when the circulation pump has insufficient speed and the coolant cools down while passing through the batteries. Switch the pump speed to high;
• an insufficient constant temperature for heating the coolant is set, the unit continues to operate, having reached the set temperature, since there is not enough heat to warm up the housing. Increase the heating value;
• the unit can work without rest when the burner is set incorrectly at minimum modulation, as a result of which the heat generator does not gain power. Make power settings according to the instructions for the device;
• an incorrectly installed heating system, clogging of the bypass can also cause the heat generator, having reached the set temperature, continues to heat the coolant. Replace the heating system, clean the bypass;
• the programmer on the room thermostat turned off, check the operation of the thermostat, replace it if it breaks;
• when the heat exchanger is clogged with scale, the unit may not turn off for a long time, since a large layer of scale prevents normal heating. Rinse the heat exchanger by removing it from the device;
• failure of the electronic control unit. Check if the connection of the contacts is broken. If the electronic device is defective, it must be replaced.

Should your unit turn off after checking and eliminating the identified causes described above - the article describes the main, common malfunctions. In addition to them, there may be others that only a specialist can determine.

Control methods

To date, a variety of sensors allows the use of various methods of control. For example, to control the process of burning fuels in liquid or gaseous state, direct and indirect control methods can be used. The first method includes methods such as ultrasonic or ionization. As for the second method, in this case, the flame relay-control sensors will control slightly different quantities - pressure, vacuum, etc. Based on the data received, the system will conclude whether the flame fits the specified criteria.

For example, in small-sized gas heaters, as well as in domestic-style heating boilers, devices are used that are based on a photoelectric, ionization or thermometric flame control method.

Mounting Features

To achieve the most efficient circulation of the coolant, it is necessary to properly install a non-volatile gas heating boiler. These rules apply to both single-circuit and dual-circuit systems.

Primary requirements:

• observance of a certain slope necessary for natural circulation;
• the use of large diameter pipes - they reduce resistance when moving the coolant;
• the presence of an expansion tank in the system, in which excess coolant will be collected.

Read more about storage tanks in the article Battery tank in the heating system

Therefore, it is best to involve specialists who are familiar with all the requirements to create a heating system. And this applies not only to laying pipes. The smoke exhaust system deserves no less attention. Errors during its installation can have quite unpleasant consequences.

Gas boiler chimney device

When inviting qualified workers to create a heating system, be sure to check whether they have permission to carry out these works. In addition, you should conclude an agreement with a detailed description of the services provided.

Electric ion boilers

Such boilers operate on the principle of heating water (coolant) by ionization. This process takes place as follows:

When the boiler is connected to the network, water molecules are divided into positive and negative ions, which oscillate between two electrodes (anode and cathode). During this process, heat energy is generated. It is immediately transferred to the coolant, which distributes it throughout the heating system.

Such units are used as an autonomous heating system. They differ from boilers with heating elements in small sizes, as well as an electrode block, which has high performance and efficiency. Salt is additionally added to the water, which plays the role of a heat carrier. This is necessary to increase the electrical resistance of water. To avoid metal corrosion or scale formation, instead of water, antifreeze is poured into the system, designed specifically for ion boilers.

Electrode boilers were originally used only for military purposes to heat submarines or warships.After that, having slightly changed the design, the developers began to produce boilers for domestic or industrial use.

For example, the Galan brand boiler is produced in accordance with all established standards of military equipment, as manufacturers specialize in the manufacture of devices for submarines and ships.

The principle of operation of the electrode boiler

In heating equipment of this type, water is heated due to ions moving between the electrodes. When the unit is turned on, the ionization of the coolant occurs, in which the molecules break up into ions: positive and negative. The formed ions are sent to the electrodes: negative and positive. This process is carried out with the release of heat, which is transferred to the coolant. Thus, there is a direct heating of the liquid without the participation of "intermediaries", which are the heating elements in traditional electric boilers.

Water, which plays the role of an element of an electrical circuit in heating units, needs special preparation to obtain the desired electrical resistance value. Preparation, as a rule, consists in adding table salt to the water.

The increase in power in ionic units occurs gradually. When the coolant is heated, its electrical resistance decreases, the current increases, the amount of heat increases.

It is possible to connect an electrode boiler in combination with other types of heating equipment: solid fuel or gas. If necessary, for an existing heating system, a parallel connection of two or more electrode units can be used.

Sensor, indicator of combustion, flame, fire, torch. Ignition, fuse, spark igniter. Scheme.

Flame presence indicator combined with a fuse on one electrode (10+)

Flame sensor and spark igniter on the same electrode

1

2

Table of contents :: SearchSafety equipment :: Help

For a gas burner, I needed a spark ignition system and a fire indicator. And I really wanted to use the same electrode placed in the flame for the operation of both devices.

When developing the scheme, the following difficulties arose. First, the gas burns without a serious glow. So it is not possible to use a photoresistor. I settled on using the effect of one-way conduction of the plasma (the torch of the burner is the real plasma). To determine the presence of this effect, and, accordingly, the presence of a flame, it is necessary to place an electrode in the fire. The electrode is also needed for the spark discharge of the fuse. There is a temptation to use the same electrode. But, secondly, the direct approach with switching one electrode from the spark transformer to the sensor does not work, since I failed to find a switch that can withstand several tens of kilovolts in the fuse mode without breaking them into the sensor.

So I had to take a somewhat roundabout route. I connect the fire sensor in series with the ignition coil. During the fuse, the sensor is short-circuited. After switching to monitoring mode, the NO contacts open. The flame control voltage is supplied to the electrode through the ignition coil. However, with its not very high inductance, it does not interfere with the passage of an electric current with a frequency of 50 Hz from the network.

Here is a selection of materials for you:

The practice of designing electronic circuits The art of designing devices. Element base. Typical schemes. Examples of finished devices. Detailed descriptions. Online calculation. Possibility to ask questions to authors

Burner control

The LAE 10, LFE10 devices have become fairly common burner flame control sensors. As for the first device, it is used in systems where liquid fuel is used. The second sensor is more versatile and can be used not only with liquid fuels, but also with gaseous ones.

Most often, both of these devices are used in systems such as a dual burner control system. It can be successfully applied in systems of liquid-fuel blown gas burners.

A distinctive feature of these devices is that they can be installed in any position, as well as attached directly to the burner itself, on the control panel or on the switchboard

When installing these devices, it is very important to properly lay the electrical cables so that the signal reaches the receiver without loss or distortion. To achieve this, it is necessary to lay the cables from this system separately from other electrical lines.

You also need to use a separate cable for these control sensors.

During the use of any thermal equipment that runs on natural fuel, one must always be firmly aware of the high risk of ignition or even explosion of this natural combustible substance.

Such trouble can occur in situations in which the fire or torches may go out for any reason. If the gas mixture continues to flow into the interior of the unit or the outer space around it, one spark of an open fire will be enough to cause a fire or even an explosion.

The most common cause of such cases is the separation of the flame with subsequent attenuation. This occurs when it is displaced from the outlet in the direction of the flow of the gas mixture. As a result, the firebox is filled with gas, which leads to popping or explosion. The reason for the separation is the excess of the flow rate of the mixture over the rate of spread of fire.

Boiler Galan is a product of conversion development

The heating unit "Galan" is produced according to the standards for military equipment, since this device is a conversion development of enterprises that produce devices for heating submarines and warships.

The electrode boiler "Galan" is a cylinder with a diameter of 60 mm and a length of 310 mm. The current is supplied to the unit using concentric tubular electrodes, then transferred to the coolant. The heated coolant circulates through pipes and radiators. In heating systems with Galan electrode devices, the circulation pump serves to accelerate the heating of the coolant, and then it can be turned off.

Advantages of the ion boiler brand "Galan":

• the presence of a built-in sensor for automatic heating control;
• high efficiency - up to 98%;
• low sensitivity to voltage drops;
• small power consumption;
• no need for approval for installation and use with boiler supervision;
• more compact than those of heating elements, dimensions;
• low cost - from 250-300 dollars.

For these units, a special antifreeze "Potok" was developed. Additives to this liquid slow down the formation of scale on the walls of the device and the corrosion processes of the metal.

When installing the electrical part of the heating circuit with your own hands, you must use the "Instruction" of the Glavgosenergonadzor on March 21, 1994 No. 42-6 / 8-ET.

Characteristics advantages and disadvantages

An ion-type electrode boiler is characterized not only by all the advantages of electric heating equipment, but also by its own features. In an extensive list, the most significant can be identified:

• The efficiency of installations tends to the absolute maximum - not less than 95%
• No pollutants or ion radiation harmful to humans are released into the environment
• High power in a relatively small body compared to other boilers
• It is possible to install several units at once to increase productivity, a separate installation of an ion-type boiler as an additional or backup heat source
• A small inertia makes it possible to quickly respond to changes in ambient temperature and fully automate the heating process through programmable automation
• No need for a chimney
• The equipment is not harmed by an insufficient amount of coolant inside the working tank
• Power surges do not affect heating performance and stability

You can find out how to choose an electric boiler for heating here.

Of course, ion boilers have numerous and very significant advantages. If you do not take into account the negative aspects that occur more often during the operation of the equipment, all the benefits are lost.

Among the negative aspects it is worth noting:

• For the operation of ion heating equipment, do not use direct current power supplies, which will cause liquid electrolysis
• It is necessary to constantly monitor the electrical conductivity of the liquid and take measures to regulate it.
• Care must be taken to ensure reliable grounding. If it breaks down, the risks of being electrocuted increase significantly.
• It is forbidden to use heated water in a single-circuit system for other needs.
• It is very difficult to organize efficient heating with natural circulation, the installation of a pump is obligatory
• The temperature of the liquid should not exceed 75 degrees, otherwise the consumption of electrical energy will increase sharply
• Electrodes wear out quickly and need to be replaced every 2-4 years

It is impossible to carry out repair and commissioning work without the involvement of an experienced craftsman

Read about other ways of electric heating at home, read here.

How does the draft sensor work in a gas boiler

Traction sensors can have a different structure. It depends on what type of boiler they are installed in.

At the moment there are two types of gas boilers. The first is a natural draft boiler, the second is forced draft.

Types of sensors in boilers of various types:

If you have a natural draft boiler, then you might notice that the combustion chamber is open there. The draft in such devices is equipped with the correct size of the chimney

The draft sensors in boilers with an open combustion chamber are made on the basis of a biometallic element. This device is a metal plate on which a contact is attached. It is installed in the gas path of the boiler and responds to temperature changes. With good draft, the temperature in the boiler remains quite low and the plate does not react in any way. If the draft becomes too low, the temperature inside the boiler will rise and the sensor metal will begin to expand. Upon reaching a certain temperature, the contact will lag behind and the gas valve will close. When the cause of the breakdown is eliminated, the gas valve will return to its normal position.
Those with forced draft boilers should have noticed that the combustion chamber in them is of a closed type. The thrust in such boilers is created by the operation of the fan. In such devices, a thrust sensor in the form of a pneumatic relay is installed. It monitors both the operation of the fan and the speed of the combustion products. Such a sensor is made in the form of a membrane that flexes under the influence of flue gases that occur during normal draft. If the flow becomes too weak, the diaphragm stops flexing, the contacts open and the gas valve closes.

Draft sensors ensure the normal operation of the boiler. In natural combustion boilers, with insufficient draft, symptoms of reverse draft may be observed. With such a problem, the products of combustion do not go out through the chimney, but return back to the apartment.

There are a number of reasons why the draft sensor may work. By eliminating them, you will ensure normal operation of the boiler.

Because of what the traction sensor may work:

• Due to clogging of the chimney;
• In case of incorrect calculation of the dimensions of the chimney or its incorrect installation.
• If the gas boiler itself was installed incorrectly;
• When a fan was installed in the forced draft boiler.

When the sensor is triggered, it is urgent to find and eliminate the cause of the breakdown. However, do not try to forcibly close the contacts, this can not only lead to the failure of the device, but is also dangerous for your life.

The gas sensor protects the boiler from damage. For better analysis, you can purchase an air gas analyzer, it will immediately report the problem, which will allow you to quickly fix it.

Overheating of the boiler threatens the entry of combustion products into the room. Which can have a negative impact on the health of you and your loved ones.