Induction heater is a high stage in the evolution of electrical appliances. Thanks to such a device, energy consumption can be significantly saved. The heat generator used in this device is completely harmless, does not emit soot during operation. For example, in terms of the efficiency of converting electric energy to a thermal heating boiler (the induction heater circuit is shown below) is second only to an infrared heater. However, unlike IR devices, which are sold only in specialized stores, induction heaters can not only be bought, but also assembled with your own hands.
Such devices come in several levels of complexity and purpose, for example, for water and metal. Their devices, of course, are different, but the principle of operation is identical. The photo below shows a diagram of an induction metal heater, it is quite easy to assemble this device with it.
So, in this article we will consider the process of assembling an induction heater from improvised tools that can be found in the "bins" of any home master.
How does a do-it-yourself induction heater work?
The principle of operation of a homemade heater is no different from a factory appliance. That is, the coolant circulates in the core, heating from its walls or contents. It is heated by eddy currents generated by the winding.
Important : polymer cores are stuffed with chopped wire!
In turn, the winding is wound on the core body and closes on a high-frequency current source. It is this kind of energy that can generate an alternating electromagnetic field - the root cause of the appearance of eddy currents in a fixed core (or its filler).
The induction water heater circuit shown below is often used in heating boilers.
The role of a high-frequency alternating current source can be a conventional welding inverter or a more complex system based on a transformer and a frequency converter.
It should be noted that with the right approach to selecting the source and forming the winding, you can create a really effective device that will work no worse than the factory analogue. By the way, in its kit there is always an instruction and a diagram of an induction heater.
With our own hands we assemble an induction device: important details
To collect such a heater you will need:
- welding inverter;
- generating welding current with a force of at least 15 amperes, with a high-frequency type and with smooth adjustment.
It is this device that will be the source of high-frequency alternating current supplying the inductor.
After that it is necessary to take a copper wire. Wind it with a spring on the core body. This device will act as an inductor. It is very important to connect the wire contacts to the terminals of the inverter, avoiding adhesions and twisting. Based on this, the segment of this material used to form the core should have a sufficient length. The number of turns is usually 50, and the diameter of the wire is usually 3 mm. The induction heater circuit shows the connection sequence of the individual components.
Make the core
The core is a regular polymer pipe made of cross-linked polyethylene or polypropylene. These grades of plastics withstand the highest possible temperatures. The throughput diameter of the core pipe should be 50 mm, and the wall thickness should not be less than 2.5-3 mm. Then this part can be used in the role of a caliber, on which a copper wire is wound, forming an inductor.
A rough diagram of the induction heater is shown in this picture.
The heating element of such a boiler will be a polymer core filler - chopped pieces of stainless wire with a diameter of 7 mm. Moreover, their length can not be less than 5 cm.
Assembly of the device using an example of a heating induction boiler
The process of assembling all these components into a single system is as follows:
- First, take a piece of polymer pipe, fix it and wrap 50 turns of 3 mm copper wire over the future core.
- Next, cut the ends of the core, leaving 7-10 cm from the edge of the wire to the bends.
Important : The do-it-yourself induction heater circuit is carried out in several stages, the sequence of which can never be violated. To avoid errors, follow the instructions exactly.
- At the next stage, mount the corner on the lower branch. Moreover, the lateral branch of this fitting will be used as a pipe for returning the system wiring. Moreover, a ball valve needs to be installed on the run-off , by shutting off which the core can be removed without draining the coolant.
- After installing the lower fitting, fill the core with chopped wire, trying to lay it as tight as possible. Indeed, it is she who acts as a water heater.
- Next, mount a tee on the upper pipe. This fitting is used to divert the heated fluid to the pressure circuit of the wiring. Moreover, the tap can be implemented both on the upper and on the side branch, using a free branch pipe of the tee for mounting the safety valve. And of course, the connection of the tee to the pressure branch of the wiring is realized through a ball valve.
- After that, you can mount the entire structure in the housing (metal or plastic cabinet) by installing a welding inverter in its lower part. Moreover, to access the control panel of the inverter, a special window is cut out in the cabinet body.
- Recheck if the induction heater circuit matches the source.
- If everything is connected correctly, then in the final you need to attach the wire to the terminals of the inverter and pour water into the core.
Inductive Heater Safety: Professional Tips
When making an induction heater with your own hands, you need to worry about the safety of the device. To do this, you must be guided by the following rules that increase the level of reliability of the overall system:
- A safety valve should be inserted into the upper tee to relieve excess pressure. Otherwise, if the circulation pump fails, the core simply bursts under the influence of steam. Typically, a simple induction heater circuit provides such points.
- The inverter is connected to the network only through an RCD. This device works in critical situations and will help to avoid short circuit.
- The welding inverter must be grounded, leading the cable to a special metal circuit mounted in the ground outside the walls of the structure.
- The body of the induction heater must be placed at a height of 80 cm above the floor. Moreover, the distance to the ceiling should be at least 70 cm, and to other items of furniture - more than 30 cm.
- An induction heater is a source of a very strong electromagnetic field, so this installation must be kept away from living quarters and aviaries with pets.
Summarizing
A self-made induction heater will work no worse than a factory device. It is not inferior in performance, efficiency and safety, of course, if all the rules were followed.