Author Topic: Having a good dump  (Read 2069 times)

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jimovonz

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Having a good dump
« on: February 28, 2006, 11:45:56 AM »
Here is a dump load I made from an old induction cook top. The frame is 1/2" copper tube and fittings for the conductive parts and 1/2" fibreglass rod (electric fence standard) for the non conducting parts. The coiled wire is nichrome wire cut into similar lengths and held in place with stainless screws.





The cook top elements (x2) I used were rated at 1.2kW each in their normal duty. After trialing a few I found that the wire was rather fragile at this loading/temp and I decided to derate it 50% to give it some extra strength (the wire is well protected normally where as I wanted to hang it outside in the wind) I calculated the appropriate sizing and cut the wire to length.








Here is the load attached directly to two fully charged T-105's (series connected for 12V nominal) pulling 130 odd amps. The T-105's are sitting just above 12 volts under this load. The load should pull arround 150 amps max connected to a shunt regulator set to 14V (that's over 2kW) so it should handle just about any 12V setup. There is a fair amount of heat comming off the wires as you can imagine but it only just glows orange when viewed at night. No visible glow during the day.


Total cost was around $NZ15 ($US9) for the copper T's,stainless screws and the galv brackets to hold it all to the tower. The copper pipe was scrap and we have about a gazillion fibreglass poles lying around. I have epoxied the fibreglass/copper and soldered the coper/coper joins. I'm not sure about mixing the stainless/copper/nichrome but it might be possible to put it to work as a waterheating element?????

« Last Edit: February 28, 2006, 11:45:56 AM by (unknown) »

windstuffnow

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Re: Having a good dump
« Reply #1 on: February 28, 2006, 09:40:11 AM »
  That's quite clever!   I'll have to keep that in my ideas file for another project I have in mind.  Great thinking!  Quick and simple.


.

« Last Edit: February 28, 2006, 09:40:11 AM by windstuffnow »
Windstuff Ed

DanG

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Re: Having a good dump
« Reply #2 on: February 28, 2006, 12:20:28 PM »
Very nice dump array! In helping make it last longer than 1/2 a forever, I gotta couple of observations...


Spotweld nichrome wire connections to get unattended reliability. Clamping will work if there is plenty of mass in fasteners to dissipate heat but eventually metal oxides and salts will spike resistance and open connections.


Copper grabs heat but tends to 'bank' it and not let it go easily - allowing some smokestacking in your copper verticals by venting at top and bottom (carefully to avoid ice buildup inside) would do alot towards lowered the clamped nichrome fasteners peak temperature.


And I think I would cage the coils (around here) since ice, snow and the odd crow could pull coils down. Again - useful design, thanks for sharing!

-

« Last Edit: February 28, 2006, 12:20:28 PM by DanG »

RobC

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Re: Having a good dump
« Reply #3 on: February 28, 2006, 02:02:46 PM »
If you can find an old electric furnace, the wire is much quality. My dump is similar to yours but each wire is long enough that they don't get much over 400 degrees each when dumping power. Less concentrated heat to deal with and as I need more capacity I can add more wires. It looks like you could easly scale yours up or down as well. There are a lot of old electic furnaces in the scrap yards and I can tell you from experince that the wire and high temp insulators in these are great to work with. RobC
« Last Edit: February 28, 2006, 02:02:46 PM by RobC »

jimovonz

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Re: Having a good dump
« Reply #4 on: February 28, 2006, 07:49:36 PM »
Thanks for the tips. Fortunately we don't have to worry about snow or ice where I live. The heat dissapates quickly and the lugs on the bottom are never too hot to touch. I think the relatively small surface area in contact with the copper compared to the much larger area exposed the to the (windy) air helps - though may also contribute to longer term reliability issues as you say. I have been meaning to borrow my friends laser thermometer to measure the max temps. I have not had trouble with the solder melting during operation. Obviously the unit in its intended application will have the most air movement around it when its at its highest output.
« Last Edit: February 28, 2006, 07:49:36 PM by jimovonz »

willib

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Re: Having a good dump
« Reply #5 on: March 01, 2006, 04:45:50 PM »
Jim, very interesting and cool project.

« Last Edit: March 01, 2006, 04:45:50 PM by willib »
Carpe Ventum (Seize the Wind)

willib

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mini dump
« Reply #6 on: March 01, 2006, 07:48:16 PM »
its funny , i had just built a similar device , although its alot smaller !


http://www.otherpower.com/images/scimages/2965/resistor_bank_2.JPG 55KB


http://www.otherpower.com/images/scimages/2965/resistor_bank.JPG 43KB

i needed a  low resistance load , this one is 0.25 ohms .

made from four 1 ohm resistors  connected by some # 17 wire.

do you know the resistance of you dump load?

i suppose it would work well as a water heater..

« Last Edit: March 01, 2006, 07:48:16 PM by willib »
Carpe Ventum (Seize the Wind)

jimovonz

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Re: mini dump
« Reply #7 on: March 02, 2006, 02:59:50 AM »
Thanks willib, going by the figures above I'd say a tad under 0.1 Ohm (~12v/130A=0.092 Ohm)
« Last Edit: March 02, 2006, 02:59:50 AM by jimovonz »

Catch66

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Re: Having a good dump
« Reply #8 on: May 07, 2006, 03:22:57 PM »


Yes a clever Idea.

If the fiberglass poles were arranged to say hold off "as a seperator" into a sheetmetal enclosure (openings at both ends )with say a 12 v computer fan suppling the airflow could add this to existing ductwork and some nice heat in the winter months.
« Last Edit: May 07, 2006, 03:22:57 PM by Catch66 »