How To Build & Intergrate Your Own Temperature Control Electronics Using Redox Flow Heater Units

Cartridges

The size has to be exactly 1/4” (6.35mm) thickness, with relatively long length (to ensure even heat distribution in the heater), like this cartridge from Sensor Shop24. If you use two heaters, the total maximum heating power would be around 300 W. However, the dimensioning of the power is somewhat dependent on the setup. In our tests we have used plate heaters with a total of about 400 W, however, in these tests a large fraction of the heat is dissipated into the surroundings. Approximately,  300 W should be sufficient as the heat cartridge option will have much less heat loss.

Controlling the temperature

In general, we recommend to control the temperature by a thermometer in the cell (Tc – see image below from manual). However, this comes with a safety risk. I.e., if there for some reason is no flow in the circuit, Tc will remain constant while the heater increases power and the heating unit can reach very high temperature and cause damage/leaks. For this reason we STRONGLY recommend to have an additional thermometer (Th) in the heating unit. This thermometer can be used in a safety circuit that turns of the heater if the temperature increases above a certain safety value e.g. 130C (or whatever value is being considered safe). There are many PID controllers that have this additional built in safety feature/temperature measurement option. Sensorshop24.de also have PID controllers, however, it is uncertain if any of the controllers also have a ‘safety feature/loop’ option. From the specs, at least the ‘high-end’ version (about 200 EUR) has that (but please check yourself).

Thermal fuse

As an alternative to the electronic safety, you could also integrate a ‘thermal fuse‘ in the heating cartridge circuit. The thermal fuse acts as a high resistance when the temperature exceeds a certain threshold, preventing power from being supplied to the cartridge. A large disadvantage is that you need to change the fuse if you want a different maximum temperature. We would only recommend this, if you have a setup that is fully tested and you do not need to change it.

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