Design of ion heating boilers: principle of operation, diagrams, video reviews

Is it possible to economically heat a home with electricity? Many, without hesitation, will answer that no, remembering the most common heating device on heating elements - this is not true. Old military technologies, until recently inaccessible to ordinary citizens, are a reality.

Device for one and two phases We are talking about an ion boiler - an alternative heat source. Military technology developed back in the middle of the last century is now available to everyone.

History of appearance and principle of operation

It all started during the times of the USSR. The state, surrounded on all sides by potential military opponents, maintained a large navy. To provide life support for diesel submarines, enterprises of the USSR OK developed autonomous heating systems.

Such a submarine crew heating system had to meet such requirements as: simplicity, reliability, independence from exhaust, absence of moving parts and noise during operation, sufficient power in the harsh conditions of the Arctic Ocean, replaceable and accessible coolant.

The task was completed successfully and was used effectively until the collapse of the socialist state. In the 90s, the country's defense enterprises found themselves out of business. These are difficult times. To survive, consumers were presented with a civilian version of the electrode heater. Engineers D.N. Kunkov received a patent for this invention. and Ilyin A.P.

Difference from heating element

The principle of operation was elementary - the internal resistance of the coolant was used: instead of a metal heating element, salt water was used. Under the influence of electric current, the coolant molecules collide with each other and heat up, and the electrical energy is converted into thermal energy. For stable operation, an alternating current of 50-60 Hz (oscillation amplitude) is required, otherwise it starts to work like a battery.

Then a simple device was developed, with one electrode. A phase was connected to it, and a zero was connected to the metal body. The container contains coolant. For safety, the housing is grounded.

It turns out the following: a current with an amplitude of 50 Hz passes through salt water, which heats up in a short time; due to the temperature difference and the pressure created by the installation, the coolant circulates through a closed thermal system - it’s simple.

Diagram of a heating system for an ion boiler

The ion heating element must be turned on by special installation electrical personnel with a clearance group, since this is due to the electrical safety requirements of the equipment.

To carry out commissioning work, you can use the diagram provided by the manufacturer.

General connection diagram for an ion boiler

For installation you will need:

1. Ion boiler.
2. Ball shut-off valve for the possibility of closing the coolant in an emergency or changing the heating medium in the system.
3. Centrifugal electric pump for circulating coolant in the heating network.
4. Filter for cleaning the coolant from suspended substances.
5. A drain valve for draining water from the system is installed at the lowest point of the return pipeline.
6. Expansion tank to protect against network breaks due to thermal expansion of the coolant.
7. Control and protection unit.
8. Air intake.

For the normal functioning of an ion heating boiler, water of a strictly defined composition is required. If the boiler will be installed in an existing heating network, before the first start-up it will be necessary to replace the coolant and add a special inhibitor. The water itself must be distilled.

Do such boilers need to be grounded?

Production standards for the operation of an ion boiler unit require the mandatory installation of a grounding system that complies with the PUE, for the reason that in the event of a current leakage, this system cannot be protected using an RCD.

The grounding copper conductor must have a diameter of 4.0 to 6.0 mm, and the system resistance cannot exceed 4 ohms. The electrical wiring is connected to the “0” terminal located in the lower part of the boiler structure.

All accessible electrically conductive parts of the boiler unit and heating network are grounded, this can extend the service life of the heating source. Corrosive wear of the grounding system cannot exceed 50%.

The structure of the grounding system must not be painted or covered with dielectric coatings. A heating system equipped in accordance with the requirements of the PUE is a reliable and efficient source of thermal energy.

Characteristics: advantages and disadvantages

The design is simple and elementary, but has a number of unique properties:

• small installation dimensions, with significant equipment power;
• independently creates pressure in the system, which makes it possible to use it without injection pumps;
• completely anti-emergency system - overheating is not possible, operation stability does not depend on the coolant level;
• Convenience of temperature control - the automation will do everything itself: temperature sensors will work when needed;
• voltage drops in the power supply network do not affect the performance and safety of the system - it will produce less or more energy;
• the highest efficiency - the maximum of all existing heating devices;
• absence of radiation negative for life and health;
• easy to integrate into heating as an additional or backup source.

It might look like this.
To be objective, let's consider the disadvantages:

• operates only on alternating current, since direct current causes electrolysis;
• it is necessary to monitor the condition of the electrolyte (salt water) - distilled water is not acceptable, since it is a universal conductor, and requires a specific resistance for operation;
• in the absence of grounding, it is prohibited to operate the installation - it is dangerous to life;
• any resistance (resistor) decreases its nominal value as the temperature increases, and as a result, when heated to 75 ° C, the boiler significantly loses power, but the current increases;
• requires periodic cleaning of working elements, as losses begin to occur due to scale on the electrode(s);
• once every 2-3 years, replacement of the electrode(s) is required;
• with an extensive heating network, a pressure pump is required;
• insufficient water level in the heating system is critical, since water with salt impurities corrodes the metal;
• the complexity of physiological adjustment of water resistance - this is very difficult to do without a specialist;
• servicing the circuit requires special knowledge, skills, and special equipment.

"Galan" Geyser 15

A safe and productive single-circuit electrode boiler, which is often preferred by owners of country property. Equipment power 15 kW, suitable only for three-phase network. The maximum current for three phases is 22.7 A. The control is mechanical; the boiler is installed only on the floor. As an additional option, it is possible to connect external control.

"Galan" Geyser 15

It is bought due to the following advantages:

• Simplicity and ease of use - even a beginner can understand the device.
• light weight of the structure and compact dimensions - only 5.3 kg.
• large heating area - up to 180 sq.m.
• electronic automatic control - the presence of a control unit that allows you to create an interval for heating the coolant.
• ability to connect to a room temperature indicator.
• The average price of the device will be 7800-8000 rubles.

Device and technical characteristics

The considered operating principle of an electric boiler gives a first idea of ​​the design. Although this equipment is already about a hundred years old, the basic design has not changed. And externally, since the start of heating private residential buildings, it has remained the same. Only a few manufacturers have made minor changes to the layout of parts.

Characteristics of a single- and two-phase boiler

Externally, it is a cylinder measuring 30-50 mm in diameter with a thickening at the base in which the switching unit is located. A ½ or ¾ inch pipe is welded in slightly above it; a contour “return” is used to introduce coolant into the apparatus. The inlet pipe to the thermal circuit is soldered on top of the main cylinder, sometimes it is on the side, next to the “return”.

An electrode is located inside the cylindrical body, without contacting its walls. There is one if the device operates from a 220 V power supply, or three if it is an industrial design that requires a three-phase 380 V connection. These differences indicate different power. Efficiency depends on the amount of energy consumed. A device with a three-phase connection heats an area of ​​about 1000 square meters.

The electrodes are fixed in the lower thickened part of the housing (switching unit), it is collapsible, with reliable electrical insulation from electric shocks. Usually it is polyamide.

Device diagram

The overall dimensions of the boiler, depending on the power, are slightly different, but are about 30 cm in length and 4 cm in width, weighing 15 kg, power varies from 2 to 50 kW. The energy consumption of single-phase does not exceed 6 kW, three-phase 50 kW. Operating temperature is 75 °C – at this temperature the device functions efficiently.

Each installation is additionally equipped with electromechanical control - these units differ both in size and function.

Electromechanical units are needed to control the electrode boiler. Thermal sensors are also installed: at the input and output of the circuit. They process the readings, calculate the temperature difference and control the power supply of the device (on, off). In addition to the basic options, expensive variations have more sophisticated functions, for example, determining hysteresis values, etc.

What to follow

When asked how to choose a heating boiler, they often answer that the main criterion is the availability of a particular fuel. In this context, we will highlight several types of boilers.

Gas boilers

Gas boilers are the most common types of heating equipment. This is due to the fact that fuel for such boilers is not very expensive and is available to a wide range of consumers. What types of gas heating boilers are there? They differ from each other depending on what type of burner is atmospheric or inflatable. In the first case, the exhaust gas goes through the chimney, and in the second, all combustion products escape through a special pipe using a fan. Of course, the second version will be a little more expensive, but it will not require smoke removal.

Wall-mounted gas boiler

As for the method of placing boilers, the choice of heating boiler involves the presence of floor and wall models. Which heating boiler is better in this case - there is no answer. After all, everything will depend on what goals you are pursuing. If, in addition to heating, you need to supply hot water, then you can install modern wall-mounted heating boilers. This way you won’t need to install a boiler to heat the water, and this will save money. Also, in the case of wall-mounted models, combustion products can be discharged directly onto the street. And the small size of such devices will allow them to fit perfectly into the interior.

The disadvantage of wall-mounted models is their dependence on electrical energy.

Electric boilers

Next, we will consider electric heating boilers. If there is no mains gas in your area, an electric boiler can save you. These types of heating boilers are small in size, so they can be used in small houses, as well as in cottages with an area of ​​100 sq.m. All combustion products will be harmless from an environmental point of view. And installation of such a boiler does not require special skills. It is worth noting that electric boilers are not very common. After all, fuel is expensive, and its prices are rising and rising. If you are asking which heating boilers are better in terms of economy, then this is not an option in this case. Very often, electric boilers serve as backup heating devices.

Solid fuel boilers

Now it’s time to consider what solid fuel heating boilers are available. Such boilers are considered the most ancient; such a system has been used for heating premises for a long time. And the reason for this is simple - fuel for such devices is available, its quality can be firewood, coke, peat, coal, etc. The only drawback is that such boilers are not able to operate in autonomous mode.

Gas generating solid fuel boiler

A modification of such boilers is gas generator devices. This boiler differs in that it is possible to control the combustion process, and the productivity is regulated within the range of 30-100 percent. When you are thinking about how to choose a heating boiler, you should know that the fuel that such boilers use is wood, and their humidity should not be less than 30%. Gas fired boilers depend on the supply of electrical energy. But they also have advantages over solid fuel ones. They have high efficiency, which is two times higher than solid fuel devices. And from the point of view of environmental pollution, they are environmentally friendly, since combustion products will not enter the chimney, but will serve to generate gas.

The rating of heating boilers shows that single-circuit gas generator boilers cannot be used for heating water. And if we consider automation, it is great. You can often find programmers on such devices - they regulate the temperature of the coolant and give signals if there is an emergency.

Gas generator boilers in a private home are an expensive pleasure. After all, the cost of a heating boiler is high.

Liquid fuel boilers

Now let's look at liquid fuel boilers. Such devices use diesel fuel as a working resource. To operate such boilers, you will need additional components - fuel containers and a room specifically for the boiler. If you are thinking about which boiler to choose for heating, then we note that liquid fuel boilers have a very expensive burner, which can sometimes cost as much as a gas boiler with an atmospheric burner. But such a device has different power levels, which is why it is profitable to use it from an economic point of view.

In addition to diesel fuel, liquid fuel boilers can also use gas. For this purpose, replaceable burners or special burners are used that can operate on two types of fuel.

Liquid fuel boiler

Simple DIY design

From the general description of the boiler it is clear that its mechanical component is elementary and not so complicated; more confusion is associated with the electromechanical control. But everything is in order.

To assemble this miracle device you will need tools and materials:

• a piece of pipe 1½-2 inches, 30-50 cm long;
• two small ½-inch pieces of pipe for the nozzles;
• copper wires with a cross-section of at least 3 mm²;
• electrode (steel rod) with a diameter of 1-1.5 cm;
• metal tee;
• coupling;
• welding machine, if the elements will be welded;
• tap and lever for cutting threads;
• rubber gaskets, fum tape.

From a pipe with your own hands
When starting work, repeat three simple requirements for the homemade system you are constructing:

1. Phase to the electrode, zero to the body.
2. It is prohibited to turn on the installation without grounding.
3. Connect only through a machine (about 40 A), since the current increases as it heats up.

The boiler assembly procedure is as follows:

• a previously prepared section of pipe 30-50 cm long will serve as the body;
• the case should not contain defects, chips, the edges should be thoroughly cleaned;
• An electrode is placed on one edge of the housing, and a coupling for connecting to the thermal circuit is placed on the other.

To install the electrode rod, you need a steel tee; the return line is connected through it.

• The electrode is connected through a gasket, which insulates from electricity and seals the boiler body.

For the insulating layer, high quality plastic with heat-resistant properties is used.

• Two bolts are welded to the pipe-body using a welding machine to secure the ground and zero terminals.

One bolt can be welded. It will combine zero output and grounding.

• The finished ion boiler must be painted to preserve the metal from corrosion and to reduce the risk of electric shock.

After assembling and painting the boiler, you can begin to insert it into the system.

Conclusion

An electrode boiler is a good solution for dachas and country houses. Its installation does not require permits or a separate room, and its operation does not require increased safety requirements. You can make such a device yourself, but how practical it is is up to you to decide. Although the water heater has a very high efficiency, its use is still much more expensive than the operation of its gas counterpart. It is also worth noting that the ion boiler is demanding on the coolant and heating system. If you do not comply with the mandatory requirements, the device will work ineffectively and will last much less than the stated period.

Installation features

To install an energy-saving boiler, it is necessary to install a safety valve, pressure gauge and automatic air vent. The horizontal position of the equipment is unacceptable; install it only vertically, without displacement.

The insertion into the thermal circuit is made so that the zero terminal is at the bottom. Wires connected to the boiler must have a cross-section of at least 4 mm². Connect only through machines, in accordance with all rules of the PUE.

For installation in a new main, only a used boiler is treated with inhibitors. Follow the recommendations for using cleaning products. Ignoring this point will lead to difficulties when setting the ohmic indicators of the liquid in the system.

For heating, the choice of radiators is important. Cast iron samples are not acceptable as they are prone to increased scale formation and other contaminants. It is better to select small radiator batteries, made of lightweight materials (aluminum), so that 1 kW of energy is consumed per 8 liters.

Parallel connection - power amplification

When choosing batteries, it is preferable to choose primary-type aluminum structures, since they contain significantly fewer impurities - this will reduce the overall resistance.

How to choose an ion boiler

The required power unit is selected from the condition that 1 kW of thermal power is sufficient to heat an area of ​​10 m2. You need to add approximately another 20% to the calculation to take into account the heat losses of the object.

In addition, before choosing, you need to clarify what function it will perform in the heat supply scheme, as the main source of heat or auxiliary to maintain the temperature at night or during periods of extremely low outside temperatures.

It will also be necessary to take into account the electrical load mode of 220V or 380V, and the possibility of an intra-house electrical network carrying the load through such a boiler. To select a specific model, you will need to take into account the heating scheme, so if the house has a “warm floor” system, the boiler power is selected 30% more.

Manufacturers and average cost

There is a wide variety of electric boilers on the market. Among them, heating devices manufactured by the following companies are popular:

• JSC "Galan" - Russia;
• LLC “Stafor_eko” – Latvia;
• LLC "EOU" - Ukraine.

Boilers and related equipment (electromechanics) for them are sold separately. The price of household products for 220 V electrical networks, with a power of 2 to 6 W, is determined by the amount of about 4-6 thousand rubles. Automation costs about the same - 6-7 thousand rubles.

When purchasing, pay attention to the warranty and service period. Usually it does not exceed 3 years, based on this, you can be sure that the boiler will last no less than this time. However, if you carry out maintenance of the equipment and change the electrodes and gaskets once every two years, you can increase the service life to 10-12 years.