- #1
LotusDome
- 15
- 3
Greetings, folks!
I have spent the past six years developing a matching pair of 13"-square heating plates to mount to the inside bottom (front and rear) of a Sun-Mar Excel NE composting toilet drum. The heating plates are necessary to keep the compost in the composting drum between 70º and 100ºF.
I have been using Chromel-A nickel chromium resistance wire (see http://www.amazonsupply.com/dp/B000FMW8X0/ref=sp_dp_g2c_asin) mounted to aluminum plates and it works very well! The challenge is that after an average of about eighteen months, the nichrome wire breaks at some point in the circuit, thus requiring replacing both heating plates. (If one has failed, prudence requires that both be replaced.)
In the latest incarnation of each of the two assemblies, I used fifteen feet of 16-gauge nichrome wire, carefully laid out in a grid pattern, pressed between two anodized, 1/8" thick aluminum plates, bolted together with stainless steel bolts, lock nuts, and neoprene rubber washers. Nine bolts are used for each heating plate assembly to ensure that there is no point where the resistance wire is not in direct contact with both of the two plates.
The finished plates are sealed shut with a large bead of 100% silicone sealant, inside the edges of the two plates. The resistance wires are connected to 12-gauge THHN solid-core wire at the point where they leave the heating plate assembly, and the splices are sealed and secured to the plate assembly with epoxy. A PID controller is used to maintain the temperature of the compost.
It really does work quite well! Each assembly has a resistance of about 3.7 ohms and draws about 2.7A at a nominal 12-15V DC, fed by Trojan T-105 batteries, charged by solar panels. (Details HERE.)
I am offering all this (perhaps excessive!) information because, once again, after seventeen months, one of the heating plate assemblies has stopped working. I knew as soon as it happened, because its reed-switch-controlled LED indicator light ( thank you! ) went out, and after careful inspection, the cause can only be that the resistance wire has, once again (for the fourth time!), broken inside the heating plate assembly.
The two plates were tested extensively before mounting them inside the composting drum; it is a multi-day process to replace them, after the replacements have been assembled, and I am a monk, camped out in the wilderness, in the mountains of Utah. This is a really bad time for one of the heating plates to fail!
Can anyone offer any reason why such nichrome resistance wire, especially 16-gauge!, would fail so consistently, when it is in a sealed environment, and only gets its two heating plates up to no more than 140ºF, when tested in the summer in open-air conditions.
Is there any better solution for heating these two heating plate assemblies? Any heat source outside of the composting drum is not possible, as it does get “a bit chilly” high up in the mountains of Utah! :-)
Blessings and thanks in advance!,
Richard Fairbanks
I have spent the past six years developing a matching pair of 13"-square heating plates to mount to the inside bottom (front and rear) of a Sun-Mar Excel NE composting toilet drum. The heating plates are necessary to keep the compost in the composting drum between 70º and 100ºF.
I have been using Chromel-A nickel chromium resistance wire (see http://www.amazonsupply.com/dp/B000FMW8X0/ref=sp_dp_g2c_asin) mounted to aluminum plates and it works very well! The challenge is that after an average of about eighteen months, the nichrome wire breaks at some point in the circuit, thus requiring replacing both heating plates. (If one has failed, prudence requires that both be replaced.)
In the latest incarnation of each of the two assemblies, I used fifteen feet of 16-gauge nichrome wire, carefully laid out in a grid pattern, pressed between two anodized, 1/8" thick aluminum plates, bolted together with stainless steel bolts, lock nuts, and neoprene rubber washers. Nine bolts are used for each heating plate assembly to ensure that there is no point where the resistance wire is not in direct contact with both of the two plates.
The finished plates are sealed shut with a large bead of 100% silicone sealant, inside the edges of the two plates. The resistance wires are connected to 12-gauge THHN solid-core wire at the point where they leave the heating plate assembly, and the splices are sealed and secured to the plate assembly with epoxy. A PID controller is used to maintain the temperature of the compost.
It really does work quite well! Each assembly has a resistance of about 3.7 ohms and draws about 2.7A at a nominal 12-15V DC, fed by Trojan T-105 batteries, charged by solar panels. (Details HERE.)
I am offering all this (perhaps excessive!) information because, once again, after seventeen months, one of the heating plate assemblies has stopped working. I knew as soon as it happened, because its reed-switch-controlled LED indicator light ( thank you! ) went out, and after careful inspection, the cause can only be that the resistance wire has, once again (for the fourth time!), broken inside the heating plate assembly.
The two plates were tested extensively before mounting them inside the composting drum; it is a multi-day process to replace them, after the replacements have been assembled, and I am a monk, camped out in the wilderness, in the mountains of Utah. This is a really bad time for one of the heating plates to fail!
Can anyone offer any reason why such nichrome resistance wire, especially 16-gauge!, would fail so consistently, when it is in a sealed environment, and only gets its two heating plates up to no more than 140ºF, when tested in the summer in open-air conditions.
Is there any better solution for heating these two heating plate assemblies? Any heat source outside of the composting drum is not possible, as it does get “a bit chilly” high up in the mountains of Utah! :-)
Blessings and thanks in advance!,
Richard Fairbanks
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