Heating Element Control

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winestill
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Re: Heating Element Control

Post by winestill »

If I use this schematic, which you call Phase angle control, I have some questions.

Image

Would it affect the other electronics somehow?
Would the electric company shut me down, if there are some ripples?
If there are any ripples in the system, what schematic can I use to eliminate (filter) it?
Is it OK to use BTA26 400V 25A for 1500W heating element?
Does the pot need to be log?
The final question, the earthing. I've read that you have to earth(ground) the triac. Should I solder the earthing to the triac heatsink which is screwed into the heatsink?
rad14701
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Re: Heating Element Control

Post by rad14701 »

winestill, will you be running this controller on 120V or 240V...??? The voltage makes a difference in what size potentiometer you use... The 500K is for 240V, and you would use a 250K for 120V... You might also need to play with the other resistors and capacitor for 120V...

The potentiometer needs to be linear taper, not audio taper...

The BTA26 400V 25A would work fine with an ample heat sink...

You don't necessarily have to ground the triac itself, but you do need to ground the controller circuit to the boiler...
winestill
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Re: Heating Element Control

Post by winestill »

Damn....sorry.
To tell you all I have:
I have a boiling pot, you can see my setup at viewtopic.php?f=50&t=13948
1500W stoveplate
230V 50Hz
I meant lin not log, sorry :P but you answered my question.

What about the EMI, the ripple or what you call it, the interference? Does it happen with this controller?
rad14701
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Re: Heating Element Control

Post by rad14701 »

winestill wrote:What about the EMI, the ripple or what you call it, the interference? Does it happen with this controller?
You can add a snubber circuit to any triac based controller as well as an inductor... I'd go with the snubber circuit first, which only requires an additional resistor and capacitor... Refer to your triacs spec sheet for proper values of those components... The values are usually a 100 Ohm resistor and a 0.1uF capacitor of proper voltage rating...

For more information see the AN1003 PDF or locate the one for your brand of triac...
MuleKicker
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Re: Heating Element Control

Post by MuleKicker »

What about the EMI, the ripple or what you call it, the interference? Does it happen with this controller?
Doesnt that model fire at zero cross? If so (and im not mistaken) you wont have interference/ripple, as this will function as a burstfire controller.

On another note, I build phase angle controllers, which have been known to create some nasty interference. Although I have never experienced it, and I do not run any kind of filter/suppression. So if your running <25A I dont think you will have an issue.
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winestill
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Re: Heating Element Control

Post by winestill »

In this image we can see a capacitor connected to the brown line and the blue line
before the element and inductor is added after the resistor and before the capacitor.
This is to elimnate RFI. It is written that we must have 0.1 uF cap and 200 uH inductor (toroid).
There is also a snubber network connected to the M1 and M2 on the triac.
100.jpg
100.jpg (15.8 KiB) Viewed 9737 times
I added all that we saw to this image
newphase.jpg
newphase.jpg (24.28 KiB) Viewed 9737 times
Would this drawing make sense?


Now here are the components I can have:

Capacitor:
3x Polyester Film Capacitor 0.1 uF 400V

Resistor:
100 ohm 1/2W 5%
10K ohm 1W 5%
1M ohm 1W 5%

Potentiometer:
500K Lin 1/2W up to 2W (is 1/2W ok?)

Diac:
DB3

Triac:
BTA41-700B

Inductor:
200 uH

How does this inductor look like? Is it like that from the image?
Can I make it with my amateur skills?
How do you know what wattage the resistor should have?

Do you think I am just overreacting over the EMI/RFI?
Should I not bother make any changes to the schematic?
rad14701
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Re: Heating Element Control

Post by rad14701 »

winestill, the addition of both the snubber and RFI circuits is optional... You may choose to either include or omit both of them...
winestill
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Re: Heating Element Control

Post by winestill »

Okay...Thank you :oops:
I will just use the original :)
tafinaf
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Re: Heating Element Control

Post by tafinaf »

MuleKicker wrote:Doesnt that model fire at zero cross?
"That model" being a phase angle controller, the answer is no. It's either-or: phase angle or zero cross, you can't have both. The former creates a heluva lot interference, the latter none at all. Heck, the picture on my TV jumps when my fridge compressor kicks in! I would use a snubber with phase angle. Doesn't have to be big, only rated for a big current. If your heating element is a coil, it may even act as one.
winestill
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Re: Heating Element Control

Post by winestill »

Here is my schematic of the Phase angle controller
schematic.png
And here is the PCB of it
pcb.png
But here is the deal, it isn't working. The triac allowes the current to go through
it and the meter shows 230V. When I cut both the snubber circuit and the C3
the voltage goes down to ca 219V by turning the pot.

What seemes to be wrong with it?
rad14701
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Re: Heating Element Control

Post by rad14701 »

winestill, that's a complex way to make a phase angle controller... Did you actually make a PCB or is that just an example...??? How about a picture of the slapped together parts...

My initial guess is that the voltage divider resistors, R2 and R3, are the culprits, allowing too much power to the potentiometer... You really only need a Triac, Diac, Potentiometer, one Resistor, and one Capacitor, to make the circuit work...

Simplify... You can get more complex once you have a working circuit...

EDIT: Check for discrepancies between the two schematics... Pay close attention to the wiring at the potentiometer... See the difference between them...??? The PCB version is wrong when compared to the original schematic...
Ben Stillin
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Re: Heating Element Control

Post by Ben Stillin »

Can I simply slip in any triac? I have 4 oddball Q5040P Teccor triacs, 500V 40A in a fastpak (to-3) package. Will the discrete components in the design still work or would the values need to be changed?
2" Boka on a sanke and a 4" 6 plate flute (learning setups)

Current setup
Wall mounted steam stripper
Wall mounted 6 plate "flute"
50 gallon immersion heated mash kettle
rad14701
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Re: Heating Element Control

Post by rad14701 »

Ben Stillin wrote:Can I simply slip in any triac? I have 4 oddball Q5040P Teccor triacs, 500V 40A in a fastpak (to-3) package. Will the discrete components in the design still work or would the values need to be changed?
You may need to experiment with values but any 240V circuit should work with that Triac...
Centimeter
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Re: Heating Element Control

Post by Centimeter »

Please forgive me but I must ask a lazy question. These threads have simply gotten WAY too long to sift through. I don't know what happened in the past couple years but god damn.

Is there something wrong with Pint's old control? I guess I'm just thrown off by the fact that he posted a control that seemed to work splendidly on page two, yet here we are at page 40. Is it not safe or something? What makes the MK5500 >$200 better than pint's control?

Like I said, I'm sorry for the lazy question. I hope my thoughtful responses of the past will grant me clemency!
Ben Stillin
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Re: Heating Element Control

Post by Ben Stillin »

I like to play with electricity and all the parts for mine cost about 14$
:-)
2" Boka on a sanke and a 4" 6 plate flute (learning setups)

Current setup
Wall mounted steam stripper
Wall mounted 6 plate "flute"
50 gallon immersion heated mash kettle
rad14701
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Re: Heating Element Control

Post by rad14701 »

Centimeter wrote:Please forgive me but I must ask a lazy question. These threads have simply gotten WAY too long to sift through. I don't know what happened in the past couple years but god damn.

Is there something wrong with Pint's old control? I guess I'm just thrown off by the fact that he posted a control that seemed to work splendidly on page two, yet here we are at page 40. Is it not safe or something? What makes the MK5500 >$200 better than pint's control?

Like I said, I'm sorry for the lazy question. I hope my thoughtful responses of the past will grant me clemency!
Whether the MK5500 is better or not is not the issue... Finding a versatile controller within the skill set and budget of each individual is... There are other topics which are dedicated to specific controllers... This one just happens to have just about everything lumped together... It is a good place for folks to come and see a little bit of everything... Pintoshines controller is not the be-all end-all of controllers by any means... Much of what he posted was copied from manufacturer specification sheets... In fact many of the designs I have tested are also variations of designs which can be found in manufacturer specification sheets... Single Time Constant, Double Time Constant, Full Range using a diode bride rectifier, and 555 timer based are all referenced within manufacturer product documentation... I have PDF's for just about every brand and type of triac commonly available and have read them and deciphered the the calculations, yet the component values provided by the manufacturers still seem to work best...

For a 120V controller that is intended to be used to power a 1500W or 2000W element you can't get any simpler than using an off the shelf light dimmer, a resistor, and a high power triac... Nice and simple if you don't mind a little hysteresis, meaning that you need to turn it up about a third of the way to get it to come on at around 32 volts, afterwhich you can back it down to under 5 volts before it shuts down again... Realistically, you should never need to be worried about the lower half of the voltage range anyway so this design would work for most folks heating with 120 volt electric... Use a voltmeter to draw a few reference marks onto the controller and you're good to go...

My favorite full range 120V controller is the diode bridge design... I've built several different variations and am hoping to find time to do a documented build that doesn't require a printed circuit board or uses an off the shelf PCB... They kick on in the 5 volt range and produce power up to about 106 volts, for a 5% - 95% duty cycle range... With a bypass switch you would be able to push 100% power for warm-ups...

I have no immediate need for a 240V controller so I have not done anything beyond researching them... I'm sure I'll get around to building one at some point, however...
duracell
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Re: Heating Element Control

Post by duracell »

I built the diac/triac version above for my 220v 5500w element. It worked good for a long time but recently it has been acting weird. I have a panel ammeter on it so I can see how much power it is putting out. If I set it on say 9 amps it will jump around randomly between 6-12 amps. Really annoying when you are trying to equalize a column.

I have a good heatsink on it but didn't have a fan on it. In the winter it was fine, but now in the summer I noticed that during heat up the heat sink would get hot enough that you could only touch it for 1 or 2 seconds. Is it possible I fried the triac? Are these symptoms indicative of a failing triac?

I have since rebuilt my circuit, I replaced the triac and the capacitor, and I also installed a power converter to run a fan on the heatsink which will prevent it from getting too hot anymore. Unfortunately I don't have another diac but I ordered a few so they should be here soon. I won't get a chance to try it out for a few days so I wanted some advice from you guys.
rad14701
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Re: Heating Element Control

Post by rad14701 »

duracell, are you still getting smooth performance when making adjustments...??? For the price I'd suggest replacing the potentiometer with a 2 watt one... Triacs don't generally act up only in a narrow band of the operational range, they'll usually fail fully on or fully off... But with electronics it can be difficult to track down which component is causing the problem until something fails, and even then the failed part may not be the original culprit...
the_bard
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Re: Heating Element Control

Post by the_bard »

is this thread applicable to pot stilling only ?

I cant see the point of controlling heat when using a reflux - just control the water temp right ?

Bard
rad14701
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Re: Heating Element Control

Post by rad14701 »

the_bard wrote:is this thread applicable to pot stilling only ?

I cant see the point of controlling heat when using a reflux - just control the water temp right ?

Bard
Wrong... You control the amount of heat applied to a reflux column in conjunction with proper cooling... How that combination is handled depends on the type of reflux column, whether Vapor Management, Liquid Management, Cooling Management, or Power Management... Reflux columns definitely need fine grained power input adjustment capabilities...

See the Reading Lounge for several topics related to controlling reflux columns for more information...
the_bard
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Re: Heating Element Control

Post by the_bard »

my still must be different i guess.

The power is just on and as long i as i keep the right coolent exit temp to an exactish (55-60) it makes 93-5%. Seems a nice easy method.

BArd
rad14701
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Re: Heating Element Control

Post by rad14701 »

the_bard wrote:my still must be different i guess.

The power is just on and as long i as i keep the right coolent exit temp to an exactish (55-60) it makes 93-5%. Seems a nice easy method.

BArd
What still design are you using...???
the_bard
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Re: Heating Element Control

Post by the_bard »

oh sorry i didnt mention!

Its a T500 and I'm really pleased with it I have to say. Very easy to operate.

Bard
rad14701
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Re: Heating Element Control

Post by rad14701 »

the_bard wrote:oh sorry i didnt mention!

Its a T500 and I'm really pleased with it I have to say. Very easy to operate.

Bard
That unit has a built in heat source and control which was engineered for that specific application... When a member builds a still he may want more power for initially brining the rig up to temperature and then backing down for optimal performance by adjusting heat, cooling, and spirit take off rate...

EDIT: The T500 is a Cooling Management reflux column still...
duracell
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Re: Heating Element Control

Post by duracell »

Thanks Rad, I don't know why I never thought to change the pot. In any case I ran it last night, but this time on a higher power setting of 13 amps (1200w), and it was rock steady. If I run into more problems at least I'll know what to try next.
Bob421
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Re: Heating Element Control

Post by Bob421 »

the_bard wrote:my still must be different i guess.

The power is just on and as long i as i keep the right coolent exit temp to an exactish (55-60) it makes 93-5%. Seems a nice easy method.

BArd
Me too. I have and offset head reflux design and as long as I don't flood the 2 inch column its fine.
I turn it way up to get up to temp and back it down for the run. I might edge it up a little at the end of the run but mostly I use my element control in conjunction with my coolant valve to keep my coolant output at around 120 to 130f
winestill
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Re: Heating Element Control

Post by winestill »

Sorry big time for posting this late.

The circuit has being working for a while. Just wanted you to know.
But I have been having some noise from it. As an non-elecritian I don't
know what that nois is, but it seems to be working.
rad14701
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Re: Heating Element Control

Post by rad14701 »

There are two common methods of eliminating noise... One is to add a 100 or 200 Henry inductor into the output of the circuit... The second is to add a Capacitor + Resistor pair into the circuit... See some of the common Triac controller diagrams for more information on how to implement these...

Image
Last edited by rad14701 on Sun Jun 26, 2011 4:47 pm, edited 1 time in total.
Reason: To add image
pumpman
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Re: Heating Element Control

Post by pumpman »

If one were to use a pot instead of a dimmer on a 120v triac controler are there any other parts you wold need to add besides the pot?
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rad14701
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Re: Heating Element Control

Post by rad14701 »

pumpman wrote:If one were to use a pot instead of a dimmer on a 120v triac controler are there any other parts you wold need to add besides the pot?
Minimum components are:
Triac
Diac
Potentiometer
Resistor
Capacitor

See diagrams throughout this topic which depict these simple single time constant phase angle circuits for both 120 and 240 volts...
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