Renewable Energy Questions/Discussion > Solar (heating or electric)

New Electric Booster Boiler

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eraser3000:
Will be 20KW using 20 - 1KW Elements
The reason for this is for finer control and less of a hit on inverters.
Its easier on inverters to PWM an SSR on a small element than it is on a larger one.

So Im going to use SSRs on all these elements and build a custom PID control to control them.

Elements are Tempco 1000w - 480volt single phase elements.  Threads are 1/2 NPT.

I started by taping a piece of string in a spiral around the piece of 6" tubing.

I then marked and drilled all of the holes progressing from 1/8" to 5/8".
Then I cut 1/2" heavy wall couplings and cut off a small portion with about 6 threads.
Then I TIG welded them on around the spiral.

bj:
  Nice work.  Tig is the best way on something like that.

eraser3000:
Thanks BJ, I really enjoy TIG welding can't say that about stick or MIG.

eraser3000:
I finally got around to the Plasma table and cut out the top and bottom.

I roughed a quick sketch in Fusion 360 and had some quick and dirty G-Code.


(Contour1)
N20 M36 T6
(Through cutting)

N25 G0 X4.37 Y-0.0722
(TURN ON CUTTING)
N30 M7
(POINT-PIERCE)
N35 G4 X5.
N40 G1 Y-0.4122 F40
N45 G3 X4.62 Y-0.6622 I0.25
N50 Y0.6578 J0.66
N55 Y-0.6622 J-0.66
N60 X4.87 Y-0.4122 J0.25
N65 G1 Y-0.0722
(TURN OFF CUTTING)
N70 M8
N75 G0 X0.3845 Y-2.3183
(TURN ON CUTTING)
N80 M7
etc.................


Here the top placed.


Then I cut and chamfered 1" heavy wall couplings.


Then I welded them inside and out.


And now lid is on, time for grinding and painting.

DJ:

So what is the setup of this going to be?
Are you going to use it like an instant on demand heater or have it going to a storage tank?
Are you going to run all 20 elements at once or modulate them depending on available power at the time?

With 20Kw available, the water even with 1" flow is sure going to get a decent heat rise in a single pass. 

I have been playing with a modified gas water heater. Took the gas ring out and fire it with a modified waste oil burner.  I can sink about 20Kw into that without too much inefficiency in flames blowing right out the top.  I'd like to get a 400L tank. That way I could fire the thing every 2-3 days and be able to drop more heat in as well.

I'm trying to work out more about the controllers you linked to. I still don't fully understand their capabilities as I know nothing about them but I'll keep researching. they would seem to be ideal for controlling something like a burner and having some safety devices built in as well.

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