Self producing hydrogen boiler and heating system

Abstract

A hydrogen boiler comprises a self-producing hydrogen system, the hydrogen is produced by electrolysis. A cut off sensor 7.18 is attached to the system to prevent hydrogen leaks and a pressure regulator to keep the gas flow constant. A pressure cut off 7.13 turns off the hydrogen production when the tank is full. A flashback arrestor 8.6 prevents furnace flashback to the main oxyhydrogen production tank 2. The system may be powered by solar panels or standard AC power. The hydrogen is combusted in a furnace 3, which includes a heat exchanger 3.15 connected to the central heating system; heated water is then circulated to the radiators and hot water system. Water produced by the combustion of hydrogen is recovered and returned to the electrolyser. The system may also provide additional hot water systems 9 or a hot air system using a second electrolyser and furnace.

Description

Title: Self Producing Hydrogen Boiler and Heating System Introduction and Background: The boiler uses Hydrogen (H2) and Oxygen (0) to heat a furnace and a heat exchanger to provide heating to the central heating system. This boiler aims to solve the problem of using natural gas (non-renewable) to heat the heat exchanger currently used. This removes the biproduct of greenhouse gasses such as Carbon Monoxide as the Biproduct of this boiler and Heating System is H2O. Unlike other boilers and heating systems which are on the market, this boiler makes the Hydrogen inside itself on a demand basis. By making the Hydrogen itself, it removes the need for a network of piping in the current gas network to be altered for Hydrogen. It also gives and alternative to Electric boilers which work based on using high resistance in heating an element which means that a higher voltage is required to push the amps through working on ohms law to generate the heat. This is an inefficient way to create heat. The key features of this boiler are as follows: • Self-producing Hydrogen system • Hydrogen leak cut off sensor. • Automatic production and cut off Hydrogen production when heat is demanded / demand has been met. • Pressure regulator to keep gas flow constant. • Pressure cut off, turns off Hydrogen production when supply tank is full and begins again as it is being used and pressure is dropping. • Pre purge of system to clear it of air during initial start-up. • Automatic water fill to replace Hydrogen Production Tank (2) with fresh water as it is used and turned into HHO gas (Oxyhydrogen) and repeat the process again. • Cooling fans (7.23) to keep system from overheating. • Flashback arrestor (8.6) to prevent furnace flashback to main Oxyhydrogen Production Tank(2). • Able to be used for heating of Hot water and Hot air. This would include, water central Heating, underfloor heating. This system could also be used as the base for heating other items on the same production system such as tumble driers, ovens etc. Adding additional furnaces / electrolysers to do so. The Hydrogen Boiler and Heating System uses Hydrogen produced from Electrolysis which is then combusted in the furnace to produce heat. This furnace has a heat exchanger going through it connected to a central heating system. The return water is fed into the heated furnace to where the heat transfer takes place. This newly heated water then leaves the furnace and out to the central heating system releasing its heat into radiators. Please note that this water circulation pump on this part of the system can be interchanged with a hot air system. It requires an alteration to the furnace which separates protects the flame from the air being passed through. This alteration can be seen in "Figure 4". The Self producing Hydrogen Boiler and Heating System can be used directly with DC solar batteries. By using this method would create further efficiency as around 20% of energy can be lost converting DC. This is directly advantageous for this boiler / heating system because the electrolysis of water requires this DC energy. The boiler knows when to start producing Oxyhydrogen as soon as the initial ignition. This is due to a Pressure Switch (7.13) connected to the Oxyhydrogen Production Tank (2) which switches the Electrolyser (6) on which begins the production of Oxyhydrogen. Basic Outline of Production and Combustion Electrolyser (6) Produces Oxyhydrogen. The Electrolyser (6) is comprised of a series of stainless steel plates (with the option of being platinum electrocoated to prevent any degradation of the plates) The layout of the Electrolyser (6)can be seen below in "Figure 14". Alternating groups of plates are connected with opposite polarity. With 5 plates being connected to DC+ power supply and 6 plates being connected to DC- power supply. In between each positive and negative plate are 7 neutral plates which will allow for HHO production to take place. The water is fed by gravity in this design which is mixed with the electrolyte. NAOH (sodium hydroxide) is the common electrolyte used. This makes the water conductive to allow electrolysis to take place. On this design the oxygen and the Hydrogen are left to mix and float up to the Hydrogen Production Tank (2) where it becomes an Oxyhydrogen gas mixture. To change the level of gas produced, more power is fed into the Electrolyser (6), this can be changed at the turn Power Control (7.22) The higher the current, the more gas which is then fed through to the burner and the more heat transfer takes place. A Float Switch (7.15) is located in this Oxyhydrogen Production Tank (2) shown in "Figure 2". This Float Switch (7.15) sends a signal to the Water Refill Pump (7.16) as shown in "Figure 2" Oxygen is sent to the burner to be burned. As shown on "Figure 2" when the Heating Thermostat (7.25) calls for heat it sends a signal to the Ignition Control (7.26) to open up the gas valve. Initially there is a small amount of Oxyhydrogen stored in the Oxyhydrogen Production Tank (2)which can start the burning process off. As soon as the Gas Valve (7.27)has opened the pressure will drop in this tank causing the Pressure Switch (7.13) to send a signal to the Electrolyser (6) to begin Oxyhydrogen production. This will carry on indefinitely until the Heating Thermostat (7.25) tells the Ignition Control (7.26) that the temperature of the room as been met. At this point the Gas Valve (7.27)closes, and once this happens the Pressure Switch (7.13) will reach pressure knowing that it is time to stop production of Oxyhydrogen. At this point a signal is sent to the Electrolyser (6) to stop production. This is a key part of the Self Producing Hydrogen Boiler and Heating System. Once burned Oxyhydrogen turns into H2O (water). The biproduct of combusting Hydrogen and Oxygen is H?0 (water). This collects at the bottom of the Furnace (3). H20 drains into Water Tank. The collected water at the bottom of the Furnace (3)during combustion it drains away back to the Water tank (5) via the Condensate Trap (4). H20 pumped into electrolyser tank to repeat sequence. The Water Refill Pump (7.16) is connected to this tank so when the signal sent from the float switch(7.15)from the Oxyhydrogen Production Tank (2) signals, water is pumped back from the Water Tank (5) to the Oxyhydrogen Production Tank (2)where the process can all be carried out again. A flow chart of this process can be seen in "Figure 18" To automate this process the system uses a series of switches and relays to operate. The full process is shown in "Figure 1" Initial Power up Sequence Power on. The power on is when the external power switch is turned on connected to the 240V mains power supply. It can also be alternatively connected to a DC battery and solar system. The system already in place would have to have an automatic transfer switch built into it which upon the loss of energy from the DC system, it would switch the power over to the mains on 240V AC. This automatic transfer switch is fitted on the solar battery itself. It means this boiler / heating system is wired to run off both DC and AC as shown in "Figure 1". 120 second system purge and water fill of Electrolyser (6). From here the system will only supply the Electrolyser, the Water Refill Pump (7.16) and the Purge Vent Valve (7.11)for the first 120 seconds. This allows for the system to only produce Oxyhydrogen for the first 120 seconds while being guided out of the purge vent valve. By doing this it clears the system of air which would cause ignition and burning problems. System switches over to standard running sequence. After the 120 seconds has passed, the system will automatically switch to allow the rest of the system to operate along the Electrolyser (6) and the Water Refill Pump (7.16). The Purge Vent Valve (7.11)however will no longer be active and close. This method of Oxyhydrogen production can be used for various heating systems. The electronics sequence for each method using this technique are shown along with the drawing design. The four methods included in this document are as follows: Water Central Heating Only (Figure 2) and its Electronics Sequence (Figure 1). Water Central Heating and Hot Tap Water (Figure 4) and its Electronics Sequence (Figure 3). Hot Air Heating (Figure 6) and its Electronics Sequence (Figure 5). Hot Air Heating and Hot Tap Water (Figure 8) and its Electronics Sequence (Figure 7). Please note that all these heating systems use the same process of Hydrogen production controlled by the Heating Thermostat (7.25) and Pressure Switch (7.13) with a series of relays to produce and burn the Hydrogen safely automatically. The Additional hot water systems are a result of adding a second system to run alongside the original controlled independently on a separate thermostat. This second system consists of a secondary electrolyser, a secondary furnace, and secondary ignition system all controlled by a secondary thermostat. The system can have as many of these additional and furnaces as required for different systems. For instance, if a hot air system would be needed for a tumble drier or an oven then an additional electrolyser, furnace and ignition system can be added for this purpose. Standard Running Sequence (Once Initial Power up Sequence has been completed) Heating Thermostat (7.25)calls for heat. When the temperature has dropped below the set temperature set on the Heating Thermostat (7.25), it will begin the sequence to call for heat from the system. Sends Signal to Ignition Control (7.26). The signal is sent from the thermostat to the ignition panel telling the Ignition Control (7.26) to begin the sequence of burning Oxyhydrogen. Ignition panel sends signal to furnace gas valve (7.27) and HV spark (7.28)electrode. The Ignition panel sends a signal to the gas valve connecting the Oxyhydrogen production tank to the burner to open up to allow Oxyhydrogen gas through and also to the HV signal to ignite. Pressure drops in Oxyhydrogen production tank (2) and sends signal to electrolyser(6). Once valve has been opened the pressure in the Oxyhydrogen production tank will drop and the pressure switch will send a signal to open up the electrolyser to start up. Electrolyser (6) Begins Producing Oxyhydrogen. High current is sent from the electronics board with a low voltage to start the electrolysis of Oxyhydrogen within the electrolyser(6). Oxyhydrogen is sent through the gas valve (7.27) continuously until demand has been met by the Heating Thermostat (7.25). The Oxyhydrogen will be sent through continuously until the Heating Thermostat(7.25) has reached the temperature set by the user. Once the demand has been met, it will send a signal to the Ignition Control (7.26) as before and this will then send another signal to the Gas Valve (7.27) signalling it to close. Component Identification Identification Number Component 1 Shell Casing 1.1 Back Plate Shell 1.2 Divider Plate 1.3 Stiffening Brackets Production 1.4 Stiffening Brackets Electrical 1.5 Front Cover Production 1.6 Front Cover Electrical 1.7 Water Refill Port 1.8 Furnace - Shell Vent Outlet 1.9 Pressure Relief / Pre Purge Vent 1.10 Shell Vent Outlet 1.11 Shell Water Inlet 1.12 Shell Water Outlet 1.13 Shell Drainage Port 1.14 Perforation Vent Holes 1.15 Shell Wall Bracket 1.16 Earthing Nut 2 Oxyhydrogen Production Tank 2.1 Shell Body 2.2 Bottom Cap 2.3 Top Cap 2.4 Electrolyte Port 2.5 Pressure Switch Port 2.6 Regulator Port 2.7 Electrolyte Feed Outlet 2.8 Oxyhydrogen Return Port 2.9 Oxyhydrogen Production Tank Bracket 2.10 Water Port 2.11 Pre Purge Port 2.12 Float Switch Port 2.13 Electrolyte Feed Pipe 2.14 Gas Production Pipe 2.15 Oxyhydrogen Regulator 2.16 Pipe Compression 1 2.17 Pipe Compression 2 2.18 90 Degree Elbow Connection 3 Furnace 3.1 Shell Body 3.2 End Flange Top 3.3 End Flange Bottom 3.4 Furnace Bracket 3.5 Furnace Water Inlet 3.6 Furnace Water Outlet 3.7 Furnace Vent Outlet 3.8 Compression Inlet 3.9 Compression Outlet 3.10 Copper Inlet 3.11 Copper Outlet 3.12 Sealing Washer Inlet 3.13 Sealing Washer Outlet 3.14 Heat Exchanger Jacket 3.15 Heat Exchanger Inner 3.16 Baffle Rings 3.17 Ignitor Flange 3.18 Spark Return Nut 3.19 Spark Return Electrode 3.20 Gas Furnace Inlet 3.21 Flame Sense Flange 3.22 Flame Sense Inlet 3.23 Furnace Gasket 3.24 H20 Drainage Port 3.25 Burner 4 Condensate Trap 4.1 Bottom Plate 4.2 Top Plate 4.3 Right Plate 4.4 Left Plate 4.5 Front Plate 4.6 Back Plate 4.7 Condensate Water Inlet 4.8 Water Outlet 4.9 Water Fill Nozzle 4.10 Internal Separate Plate 5 Water Tank 5.1 Shell Body 5.2 Top Cap 5.3 Bottom Cap 5.4 Water Refill Inlet 5.5 Condensate Drain Inlet 5.6 Overspill Outlet 5.7 Oxyhydrogen Production Tank Refill Outlet 5.8 Water Level Top 5.9 Water Level Bottom 5.10 Water Tank Bracket 6 Electrolyser 6.1 End Plate 1 6. End Plate 2 6.3 HHO Outlet 6.4 Electrolyser Drainage Port 6.5 NAOH Inlet 6.6 Brass Electrical Rod 6.7 Stainless Steel Rod 6.8 Pipe Compression 3 6.9 Pipe Compression 4 6.10 Drainage Valve 6.11 Negative Electrolyser Plates 6.12 Positive Electrolyser Plates 6.13 Neutral Electrolyser Plates 6.14 Electrolyser Gaskets 6.15 Brass Nuts 6.16 Stainless Steel 316 Nuts 6.17 Brass Washer 6.18 Stainless Steel 316 Washer 6.19 PVC Insulation Sleeve 6.20 Fixing Plates 6.21 PVC Insulation Washer 6.22 Electrolyser Gaskets 7 Electronics PCB Board 7.1 Power On 240V AC 7.2 240V AC Circuit Splitter 7.3 240V AC Line 1 7.4 240V to 24V DC Transformer Rectifier 7.5 LCD Display Screen 7.6 Water Temp Thermostat 7.7 Relay 4 7.8 Pressure Monitor 7.9 Relay 5 7.10 Timer Delay Switch 7.11 Purge Valve 7.12 Relay 2 7.13 Pressure Switch 7.14 Relay 1 7.15 Float Switch 7.16 Water Refill Pump 7.17 Relay 6 7.18 Hydrogen Sensor 7.19 Relay 3 7.20 240V AC Line 1 7.21 240V AC to 24V DC Transformer Recrtifier 7.22 Power Control 7.23 Cooling Fans 7.24 Central Heating Pump / Heat Pump Fan 7.25 Heating Thermostat 7.26 Ignition Control 7.27 Gas Valve 7.28 HV Spark 7.29 Flame Sense 7.30 Water Level Top Sensor 7.31 Water Level Bottom Sensor 7.32 Secondary Hot Water Pump 7.33 Relay 7 7.34 Relay 8 7.35 Secondary Heating Thermostat 7.36 Secondary Ignition Control 7.37 Secondary Gas Valve 7.38 Secondary HV Spark 7.39 Secondary Flame Sense 7.40 Secondary 240V AC to 24V DC Transformer Rectifier 7.41 Secondary power control 7.42 240V AC Line 3 7.43 Relay 9 7.44 Relay 10 7.45 24V DC Line 4 7.46 24V DC Line 5 7.47 24V DC Line 6 7.48 Timer Delay Switch 2 Miscellaneous Items 8.1 Quick Release Female 8.2 Quick Release Male 8.3 Tee 1 8.4 Tee 2 8.5 Tee 3 8.6 Flashback Arrestor 8.7 Non-Return Valve 8.8 Pressure Relief Valve 8.9 Connection Tee 1 8.10 Connection Tee 2 8.11 Pipe Compression 5 8.12 Pipe Compression 6 8.13 Pipe Compression 7 8.14 Pipe Compression 8 8.15 Expansion Vessel 8.16 Insulation Isolation Gasket 9 Alternative Hot Air Circulation System Furnace 9.1 Shell Body 9.2 Cold Air Inlet 9.3 Hot Air Outlet 9.4 Hot Fair Fan 9.5 Cold Duct Pipe 9.6 Hot Duct Pipe 9.7 Hot Air Ignitor Flange 9.8 Hot Air Flame Sensor Flange 9.10 Hot Air Heat Exchanger Shell 9.11 Hot Air Copper Drain Pipe 9.12 Hot Air Copper Vent Pipe 9.13 Hot Air Heat Exchanger Ignitor Flange 9.14 Hot Air Heat Exchanger Flame Sense Flange 9.15 Water Tank Inlet 9.16 Water Tank Outlet 10 Secondary Furnace 10.1 Secondary Shell Body 10.2 Secondary End Flange Top 10.3 Secondary End Flange Bottom 10.4 Secondary Furnace Bracket 10.5 Secondary Furnace Water Inlet 10.6 Secondary Furnace Water Outlet 10.7 Secondary Furnace Vent Outlet 10.8 Secondary Compression Inlet 10.9 Secondary Compression Outlet 10.10 Secondary Copper Inlet 10.11 Secondary Copper Outlet 10.12 Secondary Sealing Washer Inlet 10.13 Secondary Sealing Washer Outlet 10.14 Secondary Heat Exchanger Jacket 10.15 Secondary Heat Exchanger Inner 10.16 Secondary Baffle Rings 10.17 Secondary Ignitor Flange 10.18 Secondary Spark Return Nut 10.19 Secondary Spark Return Electrode 10.20 Secondary Gas Furnace Inlet 10.21 Secondary Flame Sensor Flange 10.22 Secondary Flame Sensor Inlet 10.23 Secondary Furnace Gasket 10.24 Secondary H20 Drainage Port 10.25 Secondary Burner 10.26 Secondary Quick Release Female 10.27 Secondary Quick Release Male 10.28 Secondary Gas Valve 11 Secondary Electrolyser 11.1 Secondary End Plate 1 11.2 Secondary End Plate 2 11.3 Secondary HHO Outlet 11.4 Secondary Electrolyser Drainage Port 11.5 Secondary NAOH Inlet 11.6 Secondary Brass Electrical Rod 11.7 Secondary Stainless Steel Rod 11.8 Secondary Drainage Valve Hose Connections 12.1 Oxyhydrogen Production Tank Refill Outlet Port (5.7) to Water Refill Pump (7.16) 12.2 Water Refill Pump (7.16) to Non Return Valve (8.7) 12.3 Shell Water Inlet (1.1) to Central Heating Pump (7.24) 12.4 Central Heating Pump (7.24) to Tee 1 (8.3) 12.5 Tee 1 (8.3) to Furnace water Inlet (3.5) 12.6 Furnace Water Outlet (3.6) to Tee 2 (8.4) 12.7 Tee 2 (8.4) to Shell water Outlet (1.12) 12.8 Water Refill Inlet (5.4) to Water Refill Port (1.7) 12.9 Tee 3 (8.5) to Tee 4 (8.9) or Gas Valve (7.27) 12.10 Tee 4 (8.9) to Gas Valve (7.27) 12.11 Tee 4 (8.9) to Secondary Gas Valve (7.37) 12.12 Purge Valve (7.11) to Tee 5 (8.10) 12.13 Tee 5 (8.10) to Pressure Relief Valve (8.8) 12.14 Water Tank Inlet (9.5) to Secondary Water Pump (7.32) 12.15 Secondary Water Pump (7.32) to Secondary Furnace Water Inlet (10.5) 12.16 Secondary Furnace Water Outlet (10.6) to Water Tank Outlet (9.16) 12.17 Overspill Outlet (5.6) to Shell Drainage Port (1.13) 12.18 Condensate Drain Inlet (5.5) to Condensate Water Outlet (4.8) 12.19 Furnace Vent Outlet (3.7) to Furnace-Shell Vent Outlet (1.8) or Tee 6 (8.1) 12.20 Secondary Furnace Vent (10.7) to Tee 6 (8.11) 12.21 Tee 2 (8.10) to Pressure Relief / Pre Purge Vent (1-9) Secondary Condensate Trap 13.1 Secondary Bottom Plate 13.2 Secondary Top Plate 13.3 Secondary Right Plate 13.4 Secondary Left Plate 13.5 Secondary Front Plate 13.6 Secondary Back Plate 13.7 Secondary Condensate Water Inlet 13.8 Secondary Water Outlet 13.9 Secondary Water Fill Nozzle 13.10 Secondary Internal Separate Plate Sequence of Electronic Events Detailed 7.1)Power on 240V AC. This is a C14 female plug socket which is where mains voltage is connected via a C13 male plug supplying 240V with a 10 amp fuse capable of carrying 2400W. This can be changed depending on the size of the system. 7.2)240V AC Splitter At this point the 240V AC is split of into separate lines to create different circuits, one powers all the control components and the other is used to power the Electrolyser (6). There is also a third for when the additional Hot Systems are included in the design. 7.3)240V AC Line 1 This 240V AC line is to power most of the controlling components in the system to make it run. It is a separate line so that it can independently work when the Electrolyser (6) power is cut to prevent Oxyhydrogen being produced. 7.4)240V AC to 24V DC Transformer Rectifier At this point the 240V AC power is transformed down to 24V AC then rectified into DC power leaving it as 24V DC power so that it can be used to power all the components which are 24V (or lower) DC controlled. 7.5)LCD Display Screen This LCD Display screen (7.5) is a graphical user interface which shows the end user items such as the pipes water temperature upon leaving the furnace via the Water Temp Thermostat (7.6). It is also where faults would be shown to the end user from components such as if the water temperature was too high and tripped relay 4 (7.9) it shuts off the thermostat and sends a signal back to the LCD Display Screen (5) that it has been tripped. Here the LCD Display Screen (7.5) turns this signal into a visual representation to the end user in form of a fault code. The same applies for the Pressure Monitor (7.8). If pressure gets too high or too low then it trips relay 5 (7.9) and sends the signal back to the LCD Display Screen (7.5) which shows a visual representation of the fault code. 7.6)Water Temp Thermostat Here the Water Temp thermostat (7.6) placed on the furnace outlet once the water has passed through the furnace. It reads the temperature of the water and has a built-in thermostat to cut off if the temperature is to get too high preventing any damaged to the circulation system. If this happens a signal is sent to Relay 4 (7.8) which will cut the main power line to the Heating Thermostat (7.25) and send a signal to the LCD Display Screen (7.5) for it to turn the signal into a fault code for the end user. 7.7)Relay4 This component is designed as a switch to act to turn off the main circuit to the Heating Thermostat (7.25) when it is energized. It gets energized when the Water Temp Thermostat (7.6) sends a signal voltage to it. At this point it will disconnect the circuit. If no signal voltage is sent it will always remain open and let the circuit function normally. 7.8)Pressure Monitor Here the Pressure Monitor (7.8) placed on the furnace outlet once the water has passed through the furnace. It reads the pressure of the water and has a built-in switch to cut off if the pressure is to get too high preventing any damaged to the circulation system. If this happens a signal is sent to Relay 5 (7.9) which will cut the main power line to the Heating Thermostat (26) and send a signal to the LCD Display Screen (7.5) for it to turn the signal into a fault code for the end user. 7.9)Relay5 This component is designed as a switch to act to turn off the main circuit to the Heating Thermostat(7.25) when it is energized. It gets energized when the Pressure Monitor (7.8) sends a signal voltage to it. At this point it will disconnect the circuit. If no signal voltage is sent it will always remain open and let the circuit function normally. 7.10)Timer Delay Switch 1 At the Timer Delay Switch 1 (7.10) the line is split into two different paths. Path one will energise the line and all it is connected to for 120 seconds. After 120 seconds this path shuts off and disconnects the circuits which it is connected to. These would be the Purge Valve (7.11), Relay 2 (7.12) and Relay 1 (7.14). It effectively allows a pre purge of Air from the system by energizing the Purge Valve (7.11) and ensuring the Hydrogen Production tank (2) is full of water by energizing Relay 1(7.14) to allow the Water Refill Pump (7.16) to operate to pump water into the system. The final stage included in this area it the energising of Relay 3(7.19) opens the circuit of 240V AC Line 2 (20) to take power to the Electrolyser (6)to start producing Oxyhydrogen. This method ensures that as the oxyhydrogen is produced it pushes air out the Purge Valve (7.27) into a vent for 120 seconds. After 120 seconds this Line closes and opens the second path. This path has the same circuits as above, but with additional lines to the rest of the system such as, the Heating Thermostat (7.25). Both Lines are fitted with relay 6 (7.17) which is controlled by Hydrogen Sensor (18), a safety device. It is located here so that in the pre purge time and the system start-up and running time is always protected by the Hydrogen Sensor (7.18) shut off safety feature. 7.11)Purge Valve The Purge Valve (7.11) is a solenoid valve connected from the Oxyhydrogen Production Tank(2) to a ventilation pipe. When energised it opens to allow the gas to pass through. It is used on this system to work for the first 120 seconds of initial start-up to push out the existing air which effects ignition combustion. 7.12)Relay2 Relay 2 (7.12) has a purpose being controlled by the Pressure Switch (7.13) which stops all power along the line passing through when the system reaches pressure. This prevents any excess of gas being produced as a safety feature. 7.13)Pressure Switch The Pressure Switch (7.13) has a set pressure to send a voltage signal to the Relay 2 (7.12) for it to close the circuit to the rest of the system past this point. 7.14)Relayl Relay 1(7.14) has a purpose of being controlled by the Float Switch (7.15) which stops all power along the line passing through when the system reaches the set water level height. This prevents any excess of water being produced as a safety feature. 7.15)Float Switch The Float Switch (7.15) has a set water level where it is located. When the water level is reached it sends a voltage signal to the Relay 1 (7.14) for it to close the circuit to the rest of the system past this point. 7.16)Water Refill Pump The Water Refill Pump (7.16) is the pump connected from the Water Tank (5) to the Oxyhydrogen Production tank (2) via the Non return valve (8.7). When the system water is getting low in the Oxyhydrogen Production tank (2) the Float Switch (7.15) will send a signal to relay 1(14) to open the circuit and supply voltage to the water refill pump (7.16). 7.17)Relay6 Relay 6 (7.17) has a purpose of being controlled by the Hydrogen Sensor (7.18) which stops all power along the line passing through if the sensor detects Oxyhydrogen. This prevents the system producing any Oxyhydrogen and sends a signal to the LCD Display Screen (7.5) with a fault code for the end user to see. 7.18)Hydrogen Sensor The Hydrogen Sensor (7.18) is a sensor which detects any trace of Hydrogen and turns it into a signal voltage. This signal voltage is then sent first to Relay 6 (7.17) which will shut off the rest of the system as a safety precaution, at the same time a signal is sent to the LCD Display Screen (7.5) which will give the end user a fault code along with an alarm to the end user. 7.19)Relay3 Relay 3 is a relay switch which uses a DC circuit to open and close the 240V AC circuit coming from 240V AC Line 2 (7.20). If a DC voltage reaches relay 3(7.19) from the line coming into it from the path out of relay 2 (12) then it will close the circuit for 240V AC Line 2 (7.20) and allow the AC voltage to carry on its path towards the 240V AC to 24V DC Transformer Rectifier (7.21) 7.20)240V Line 2 This 240V AC line is to power the Electrolyser (6) along with the circuit boards Cooling Fans (23) and the Central Heating Pump (7.24). By being isolated from the rest of the system it allows the Line 1 (7.3) to turn the power on and off for the Electrolyser (6) to meet the need of demand of the Oxyhydrogen. This line will also be the supply line for the circuit boards Cooling Fans (7.23), this is located on the same line because they are needed when the system is producing Oxyhydrogen and requires the circuit board to be cooled. Also on this line is the Central Heating Pump (7.24). This is located on the same line because it only needs to be pumping around the system when Oxyhydrogen is being produced providing combustion to the Furnace (3). 7.21)240V AC to 24V DC Transformer Rectifier At this point the 240V AC power is transformed down to 24V AC then rectified into DC power leaving it as 24V DC power so that it can be used to power the Electrolyser (6), Cooling Fans(7.23) and the Central Heating Pump (7.24) 7.22) Power Control This is to regulate the power which is going into the Electrolyser (6) controlling the voltage input and can be mounted as a set range in the circuit board or can also be mounted on a turning knob with minimum and maximum ranges for the end user to be able to control. It directly affects the amount of gas which is produced. By turning it up allows more power to the electrolyser to create more oxyhydrogen to burn for the Furnace (3) and increase temperature. Turning it down has the opposite effect of less oxyhydrogen being produced for the Furnace (6) and decreases temperature. 6)Electrolyser At the Electrolyser (6) the system takes in the DC power which was created at the 240V AC to 24V DC Transformer Rectifier (7.21) and uses it to create the Oxyhydrogen. The Electrolyser (6) is the component which produces the Oxyhydrogen. On the end of the Electrolyser (6) are two ports. The first port is the NAOH Inlet (6.5) which connects to beneath the water level in the Oxyhydrogen Production tank and feeds the electrolyser with solution by gravity. The second port is the HHO Outlet (6.3) which is where the Oxyhydrogen gas made in the electrolyser leaves and connects to the oxyhydrogen production (2) tank which is located above the water line. As most Dry Cell electrolysers operate there is a series of stainless steel 316L plates which are alternately wires to positive and negative power source. This is connected to the Oxyhydrogen production tank (2) above it which is filled with a mixture of deionized water (H2O) and NAOH (Sodium Hydroxide) to create an electrolyte. The NAOH is needed to be added to the H2O because the H2O is nonconductive. The NAOH allows this conductivity. As per faradays law of electrolysis, by running a current through the electrolyte it will liberate the Hydrogen and Oxygen. As the gas formation is made it leaves behind the Sodium (NA) in the solution. At this point more water (H2O) is pumped back in to continuously repeat the reaction. As the new water (H2O) is pumped back in it mixes with the left over Sodium (NA) to create more Sodium Hydroxide (NAOH). Once the gas is formed it makes its way through the electrolyser rising and leaves out of the HHO Outlet (6.3) up to the Oxyhydrogen Return Port (2.8) on the Oxyhydrogen Production Tank(2). The number of plates on this Electrolyser can be altered if a larger system is needed for more power. 7.23)Cooling Fans At this point the Cooling Fans (7.23) are connected directly to the same line as the electrolyser (6) is. This means that when the Heating thermostat (7.25) tells the system that the demand has been met. It shuts down the Ignition Control (7.26) which closes the gas valve (7.27). By closing this Gas Valve (7.27) the pressure is slightly raised and the Pressure Switch (7.13) sends a voltage signal to Relay 2 (7.12) to turn off the Electrolyser (6), Cooling Fans(7.23) and Central Heating Pump (7.24) 7.24)Central Heating Pump At this point the Central Heating Pump (7.24) is connected directly to the same line as the electrolyser (6) is. This means that when the Heating thermostat (7.25) tells the system that the demand has been met. It shuts down the Ignition Control (7.26) which closes the gas valve (7.27). By closing this gas valve the pressure is slightly raised and the Pressure Switch (7.13) sends a voltage signal to Relay 2 (7.12) to turn off the Electrolyser (6), Cooling Fans(7.23) and Central Heating Pump (7.24 or Hot Air Fan (9.4) 7.25)Heating Thermostat The Heating Thermostat (7.25)is a traditional thermostat which has a thermocouple located in the room which is to control it. It is set to a desired temperature. If the temperature remains below the set temperature by the end user, then the circuits it controls will remained closed and working. As soon as temperature reaches the set temperature the circuits will open and stop the power going to the Ignition control board (7.26). Which will then close the gas valve (7.27). This shuts off the gas supply to the furnace (3) and also by closing this gas valve the pressure is slightly raised and the pressure switch (7.13) sends a voltage signal to Relay 2 (7.12) to turn off the Electrolyser (6), Cooling Fans(7.23) and Central Heating Pump (7.24 or Hot Air Fan (9.4). 7.26)lgnition Control The Ignition Control (7.26) is a standard 12v / 24v Ignition Control which is added to the circuit board to control the Gas Valve (7.27), HV spark (7.28), and the Flame Sense (7.29). It is programmed with a microcontroller to carry out a sequence of events in order. Firstly, opening up the Gas Valve (7.27) and then giving 7 seconds of High voltage sparks across the HV Spark (7.28) to ignite the gas coming through. The Flame Sense (7.29) is located in the Furnace (3) to detect a flame. If no flame Is detected, then the Gas Valve (7.27) closes to prevent any build-up of Oxyhydrogen Gas inside the Furnace (3). 7.27)Gas Valve A solenoid valve which opens when a voltage signal is sent to it to allow Oxyhydrogen Gas through to the Furnace (3) 7.28)HV Spark An Electrode placed across from the Spark Return Electrode(3.19) to send High voltage sparks across to cause an ignition for combustion of gas. 7.29)Flame Sense The Flame Sense (7.29) is placed inside the Furnace (3) on the opposite side to the HV Spark (7.28) above the Burner (3.25). It is used as a safety feature sending a voltage back to the Ignition Control (7.26). If the Flame Sense(7.29) detects no flame then it will automatically shut the Gas Valve (7.27) to stop excess Oxyhydrogen gas from flowing into the system. 7.30) Water Level Top Sensor Water Level Indicator to indicate when the water level has reached the max fill level 7.31) Water Level Bottom Sensor Water Level Indicator to indicate when the water level has reached the minimum level to operate. 7.32) Secondary Hot Water Pump Secondary Water Pump (7.32)which pumps the secondary heating system lines water 7.33) Relay 7 Relay 7 (7.33) has a purpose being controlled by the pressure switch (7.13) which stops all power along the line passing through when the system reaches pressure. This prevents any excess of gas being produced as a safety feature. 7.34) Relay8 Relay 8 (7.34) is a relay switch which uses a DC circuit to open and close the 240V AC circuit coming from 240V AC Line 3 (7.43). If a DC voltage reaches Relay 8 (7.34) from the line coming into it from the path out of Relay 7 (7.33) then it will close the circuit for 240V AC Line 3 (7.43) and allow the AC voltage to carry on its path towards 240V AC to 24V DC Transformer Rectifier (7.40) and the secondary Hot Water Pump (7.32) 7.35)Secondary Heating Thermostat The Secondary Heating Thermostat (7.35)is a traditional thermostat which has a thermocouple located in water tank or water supply. It is set to a desired temperature. If the temperature remains below the set temperature by the end user, then the circuits it controls will remained closed and working. As soon as temperature reaches the set temperature the circuits will open and stop the power going to the secondary Ignition Control(7.36). Which will then close the Secondary Gas Valve (7.37). This shuts off the gas supply to the Secondary Furnace (10) and by closing this Gas Valve (7.37(the pressure is slightly raised and the Pressure Switch (7.13) sends a voltage signal to Relay 7 (7.33) to turn off the Secondary Electrolyser (11), and Secondary Central Heating Pump (7.24) or Hot Air Fan (9.4). 7.36) Secondary Ignition Control The Secondary Ignition Control (7.36)is a standard 12v / 24v ignition control which is added to the circuit board to control the Secondary Gas Valve (7.37), Secondary HV spark (7.38), and the Secondary Flame Sense (7.39). It is programmed with a microcontroller to carry out a sequence of events in order. Firstly, opening the Secondary Gas Valve (7.37) and then giving 7 seconds of High voltage sparks across the Secondary HV Spark (7.38) to ignite the gas coming through. The Secondary Flame Sense (7.39) is located in the Secondary Furnace (10) to detect a flame. If no flame Is detected, then the Secondary Gas Valve (7.37) closes to prevent any build-up of Oxyhydrogen Gas inside the Secondary Furnace (10). 7.37) Secondary Gas Valve A solenoid valve which opens when a voltage signal is sent to it to allow Oxyhydrogen Gas through to the Secondary Hot Water Furnace (10) 7.38) Secondary HV Spark An Electrode placed across from the Secondary Spark Return Electrode (10.19) to send High voltage sparks across to cause an ignition for combustion of gas. 7.39) Secondary Flame Sense The Secondary Flame Sense (7.39) is placed inside the Secondary Furnace (10) on the opposite side to the Secondary HV Spark (7.38) above the Secondary Burner (10.25). It is used as a safety feature sending a voltage back to the Secondary Ignition Control (7.36). If the Secondary Flame Sense (7.39) detects no flame, then it will automatically shut the Secondary Gas Valve (7.37) to stop excess Oxyhydrogen gas from flowing into the system. 7.40) Secondary 240V AC to 24V DC Transformer Rectifier At this point the 240V AC power is transformed down to 24V AC then rectified into DC power leaving it as 24V DC power so that it can be used to power all the components which are 24V (or lower) DC controlled. 7.41) Secondary Power Control This is to regulate the power which is going into the Secondary Electrolyser (11) controlling the voltage input and can be mounted as a set range in the circuit board or can also be mounted on a turning knob with minimum and maximum ranges for the end user to be able to control. It directly affects the amount of gas which is produced. By turning it up allows more power to the Secondary Electrolyser (11) to create more oxyhydrogen to burn for the Secondary Hot Water Furnace (10) and increase temperature. Turning it down has the opposite effect of less oxyhydrogen being produced for the Secondary Hot Water Furnace (10) and decreases temperature. 7.42)Power ON 24V DC This is a connection which supplies the DC power which comes from DC batteries or a solar system. By coming directly from this source, it means that no transformer or rectification is needed for any of the system inside because it all runs off 24V DC as it is including the production of the Hydrogen which runs on DC power. This increases the efficiency of the system as transforming and rectification loses efficiency. As shown in "Figure 7" the DC skips certain operations and joins the circuit where it would be needed. Please note that if connecting to DC power, the same source where it is connected would be needed to be connected to an automatic transfer switch. This means that if the DC power falls for any reason, it will cut this circuit before sending AC power through the path of the Power on 240V AC (7.1) and make sure only one method of energy supply is given at any one time. 7.43) Relay 9 This Relay is an alternative path for when the DC power source is in use coming from Relay 2 (7.12) Relay 2 will energize relay 9 and allow relay 9 to let the DC current coming from Line 4 (7.45) to pass through to the rest of the system. When the AC power is being used this item would be redundant. 7.44) Relay 10 This Relay is an alternative path for when the DC power source is in use coming from Relay 7 (7.33). Relay 7 (7.33)will energize Relay 10 (7.44) and allow relay 10 (7.44) to let the DC current coming from Line 5 (7.46) to pass through to the rest of the system. When the AC power is being used this item would be redundant. 7.45) 24V DC Line 4 This line is an alternative power source when the system is using DC power. It connects the Power On 24V DC (7.42) to Relay 9 (7.43). 7.46) 24V DC Line 5 This line is an alternative power source when the system is using DC power. It connects the Power On 24V DC (7.42) to join Line 1 (7.3) where it acts as Line 1 would if it was being used on the AC power. 7.47) 24V DC Line 6 This line is an alternative power source when the system is using DC power. It connects the Power On 24V DC (7.42) to join Line 1 (7.3) where it acts as Line 1 would if it was being used on the AC power. 7.48) Timer Delay Switch 2 This timer delay switch is for use for the secondary system. It is set for nothing to be allowed to pass through it for the first 120 seconds of the prepurging time. But once this time has passed, it allows current and voltage to flow through to the various areas in the secondary system. Mechanical Series of Events Detailed l)Shell Casing The shell Is divided into two separate areas. The electrical side and the mechanical side. On the electrical side holds all the electrical components such as the control board. The mechanical side holds all the rest of the items to make the boiler function. The two sides are separated by a box like separation plate which is riveted to the backplate. A few stiffening brackets are added for increased strength of the shell. The front cover for the boiler is split into two sections so that the two sides of the boiler can be accessed separately. The shell has all the threaded fixing holes which the components are fixed to. The central heating water comes in at the Shell Water Inlet (1.11), it leaves again at Shell Water Outlet (1.12). Water overflow from the Water Tank (5) from the Overspill Outlet (5.6) drains through the Shell Drainage Port (1.13). Perforation Vent Holes (1.14) are added to the Shell Casing (1) to allow the air which the Cooling Fans (7.23) have drawn in. The Earthing Nut (1.16) is a safety earthing nut which is for if for any reason the shell becomes electrically energised then it can be connected to the Power On 240V AC (7.1) for a safe path to ground. 2)Oxyhydrogen Production Tank The Oxyhydrogen Production Tank (2) is a tank which acts as a supply tank of electrolyte to the Electrolyser (6). There are various ports located on the tank Including; 2.4)The electrolyte Port The Electrolyte Port (2.4) is the port which connects the Oxyhydrogen Production Tank (2) to the Electrolyser (6). 2.5)Pressure Switch Port The Pressure Switch Port (2.5) where the Pressure switch (7.13) is located which is used to turn off the Oxyhydrogen production when pressure is reached. 2.6)Regulator Port The Regulator Port (2.6) is a port where the Oxyhydrogen Regulator (2.15) is connected to. It is at this point where the Oxyhydrogen in the tank leaves it to go through the system. 2.7)The Electrolyte Feed Outlet The Electrolyte Feed Outlet (2.7) is the port which the Electrolyte feeds down to the Electrolyser (6) via the Electrolyser Feed Pipe (2.13) 2.8)The Oxyhydrogen Return Port The Oxyhydrogen Return Port (2.8) is the port which the Oxyhydrogen Enters the Oxyhydrogen Production Tank (2) once it has been created in the Electrolyser (6) via the Gas Production Pipe (2.14) 2.9) Oxyhydrogen Production Tank Bracket The Oxyhydrogen Production Tank Bracket (2.9) is the bracket fixing which fixes the Oxyhydrogen Production Tank (2) to the Shell Casing (1) 2.10) The Water Port The Water Port (2.10) is the port where the refill of de-ionized water is pumped back into the system when the Float Switch (7.15) detects the level of electrolyte is low. The water port is then connected to the Non-Return Valve 1 (8.7). 2.11)The Prepurge Port The Prepurge Port (2.11) is the port on the Oxyhydrogen Production Tank (2) where the Purge Valve (7.11) is connected. This is where unwanted air in the system is purged away in the initial 120 second start up. 2.12)Float Switch Port Float Switch Port (2.12) is the port on the Oxyhydrogen Production Tank (2) where the Float Switch (7.15) is connected. The Electrolyte Feed Pipe (2.13) is the pipe which connects the Electrolyser (6) to the Hydrogen Production Tank (2). As Oxyhydrogen is produced and more electrolyte is needed to continuously produce the reaction separating the H20, the Electrolyte Feed Pipe (2.13) gives a continuous Gravitational feed of Electrolyte. 2.13)Electrolyte Feed Pipe The stainless steel pipe which allows the movement of the electrolyte from the Oxyhydrogen Production tank (2) down to the Electrolyser (6) 2.14) Gas Production Pipe The stainless steel pipe which allows the movement of the Oxyhydrogen gas from the Electrolyser (6) back to the Oxyhydrogen Production Tank (2) 2.15)Oxyhydrogen Regulator The regulator attached to the Oxyhydrogen Production Tank (2) which allows the Oxyhydrogen gas to pass through to the Gas Valve (7.27) at a constant rate. 3)Furnace The Furnace (3) has various parts to it which makes it up. Essentially it is where the heat transfer from the Burner (3.25) and the water in the Heating Circulation System takes place. The items which make up the furnace are as follows: 3.1) Shell Body The shell Body (3.1) is the main body which the furnace is built from. It houses the rest of the components within it. 3.2)End Flange Top The End Flange Top(3.2) is the Plate which connects to the Shell Body (3.1). It has drilled and tapped holes around its edge so that the Ignitor Flange (3.17) can be fixed to it. 3.3) End Flange Bottom The End Flange Bottom (3.3) is the Plate which connects to the Shell Body (3.1). It has drilled and tapped holes around its edge so that the Flame Sensor Flange (3.22) can be fixed to it. 3.4) Furnace Bracket The Furnace Bracket (3.4) is to connect the Furnace (3) to the Shell Casing (1). 3.5) Furnace Water Inlet The Furnace Water Inlet (3.5) is where the Central Heating Circulation Systems water enters into the furnace. It is connected to Tee 1 (8.3) which is also connected to the Expansion Vessel (8.15) for water returning from the heated radiators. 3.6) Water Outlet The Furnace Water Outlet (3.6) is where the Central Heating Circulation Systems water enters into the furnace. It is connected to Tee 2 (8.4) which is also connected to the Water Temp Thermostat (7.6) for water returning from the heated radiators. 3.7) Furnace Vent Outlet This is a 3 / 8" BSP Male nipple located on the top of the Furnace (3) for the purpose of allowing the ventilation of any gas should ignition not occur. Location is on top of the furnace due to Hydrogen having less density on air so naturally will rise to the top of the Furnace (3). Please note that under combustion that the product will be water, and no toxic gasses are created. This vent is purely for failure to ignite ventilation. A 3 / 8 Hose is connected from the Furnace Vent Outlet (3.7) to the Furnace Vent Outlet (1.10). 3.8)Compression Inlet This is an item which connects the copper inlet (3.10) to the Furnace Water Inlet (3.5). Because the copper inlet (3.10) is 15mm compression n fitting and the Furnace water Inlet (3.5) is 3 / 8 BSP the compression inlet (3.8) acts as an intermediate adapter to join the two so the Heat exchanger can be replaced. It is comprised of a 3 / 8 Male BSP to 15mm compression. This component can be interchanged for a solderable one as opposed to compression 3.9) Compression Outlet This is an item which connects the copper outlet (3.11) to the Furnace Water Outlet (3.6). Because the copper Outlet (3.11) is 15mm compression fitting and the Furnace Water Outlet (3.6) is 3 / 8 BSP the compression Outlet (3.9) acts as an intermediate adapter to join the two so the Heat exchanger can be replaced. It is comprised of a 3 / 8 Male BSP to 15mm compression. This component can be interchanged for a solderable one as opposed to compression 3.10) Copper Inlet Standard Copper pipe to be bonded to the Heat Exchanger Jacket(3.14) for water coming into the heat exchanger for heat transfer. 3.11)Copper Outlet Standard Copper pipe to be bonded to the Heat Exchanger Jacket (3.14) for water leaving the heat exchanger heading for the heating circulation system. 3.12)Sealing washer Inlet This is the sealing washer located at the Copper inlet (3.10) end to enclose the Heat Exchanger Jacket (3.14) to the Heat Exchanger Inner (3.15). It is to keep the water inside the heat exchanger so it doesn't leak from entering at the Copper Inlet (3.10) until it gets to the Copper outlet (3.11) 3.13)Sealing Washer Outlet This is the sealing washer located at the copper outlet (3.11) end to enclose the heat exchanger jacket (3.14) to the Heat Exchanger Inner (3.15). It is to keep the water inside the heat exchanger, so it doesn't leak from entering at the Copper Inlet (3.10) until it gets to the Copper Outlet (3.11) 3.14) Heat Exchanger Jacket The Heat Exchanger Jacket (3.14) is the outside of the heat exchanger holding the circulation water passing through. It is not indirect contact with the Burner (3.25) flame but is the area where the water comes in and out of the Heat Exchanger via the Copper Inlet (3.10) and Copper Outlet (3.11) 3.15)HeatExchanger Inner The Heat Exchanger Inner (3.15) is the inside of the Heat Exchanger holding the circulation water passing through. It is in direct contact with the Burner (3.25) flame and is where the heat transfer takes place. 3.16)Baffle Rings The Baffle Rings are located in between the Heat exchanger Inner (3.15) and the Heat Exchanger Jacket (3.14). The purpose of these items is to guide the water through the heat exchanger itself from the copper inlet (3.10) to the Copper Outlet (3.11) 3.17) Ignitor Flange The ignitor flange is the item where the Spark return Nut (3.18), Spark Return Electrode (3.19) and the Gas Furnace Inlet (3.20) are fixed. Itself fits to the End Flange Top (3.2) To fix this item to the End Flange Top (3.2) M6 Hex Nuts are used with a Furnace Gasket (3.23) in between the two to seal it. 3.18)Spark Return Nut The Spark Return Nut (3.18) is located on the Ignitor flange and is the nut where a negative terminal wire is mounted for the DC- wire to be fitted. It is directly connected to the Spark Return Electrode (3.19) 3.19)Spark Return Electrode The Spark Return Electrode (3.19) is the electrode which the HV Spark (7.28) sends its spark across to. This spark is what ignites the Burner (3.25). The spark return Electrode (3.19) is connected to the DC-ve on the circuit board via the Spark Return Nut (3.18) 3.20)Gas Furnace Inlet The Gas Furnace (3.20) is the % BSP inlet which allows the Gas to flow from the Oxyhydrogen Production tank to the Burner (3.25). It is fixed to the Ignitor Flange (3.17) and also the Flashback Arrestor (8.6). 3.21) Flame Sensor Flange The Flame Sensor Flange is the side of the Furnace (3) where the Flame Sense (7.29) is located. This flange is fixed to the Furnace (3) to the End Flange Bottom (3.3). M6 Hex Nuts are used with a Furnace Gasket (3.24) in between the two to seal it. 3.22) Flame Sensor Inlet The Flame Sense Inlet (3.23) is where the Flame Sense is fitted. 3.23) Furnace Gasket These are Gaskets made from Neoprene to seal both the Ignitor Flange (3.17) and the Flame Sensor Flange (3.22) to the Furnace (3). When the M6 bolts are tightening it creates a seal around the furnace by compressing the Furnace Gasket (3.24). 3.24) H20 Drainage Port The H20 Drainage Port (3.24) is a port where the combustion product of H20 drains. As the Combustion takes place the Hydrogen and the Oxygen form H20. This port is located at the bottom of the Furnace (3) so that this can drain away. It then leads to the Condensate Trap (4) to prevent any Gas entering the other areas of the system. 3.25) Burner The Burner (3.25) is where the combustion of the Oxyhydrogen gas takes place, and the flame remains stable 4)Condensate Trap The Condensate Trap (4) is a device which has a separation plate dividing the top two halves of the trap. When filled to the drain line with water it allows water to drain from it without letting gas pass the water line. It is a common boiler furnace component to stop dangerous gasses entering the rest of the system. It connects to the H20 Drainage Port on the Furnace (3) from the Condensate Water Inlet (4.7). The water leaves the Condensate Trap (4) from the Water Outlet (4.8). There is also a Water Fill Inlet (4.9) located on the top of the Condensate Trap (4) for the initial fill when installed. 5)WaterTank The water tank (5) is a tank holding de-ionized water. It has a Water Refill Inlet (5.4) which allows for the addition of De-ionized water. On the sides are two ports to measure the level of the water. Water Level Top (5.8) measures the high level of the water line while the Water Level Bottom (5.9) measures the low level of the waterline. The Overspill Outlet (5.6) is a port located as the top of the water tank to prevent overfilling. It connects directly to drainage. The Oxyhydrogen Tank Refill Outlet (5.7) is the port which connects to the Water Refill Pump (7.16) 8.1) Quick Release Male This is a male quick release fitting which is screwed into the FbO Drainage Port (3.25) to enable quick release of the Condensate Trap (4) 8.2) This is a female quick release fitting which is screwed into the condensate water inlet (4.7) to enable quick release of the Condensate Trap (4) 8.3) Tee 1 Tee 1 (8.3) is used to add the expansion line to the water return on the circulation system. 8.4) Tee 2 Tee 2 (8.4) is used to add the thermocouple to the water out from the Furnace (3) upon heating. 8.5) Tee 3 Tee 3 (8.5) is used to connect the Pressure Relief (8.8) and the pre purge valve line to the Pressure Relief / Purge Vent (1.9) 8.6)Flash Back arrestor The Flashback Arrestor (8.6) is a safety device which prevents the flame from flashback when the gas supply is prevented. The flame will travel no further than this point when the Gas Valve (7.27) is closed. 8.7)Non Return Valve 1 This is a component which allows the flow of water in one direction and restricts the flow in the other. The purpose of the Non Return Valve (8.7) here is so that the electrolyte doesn't mix and interfere with the Water Refill Pump (7.16) which would cause corrosion damage. 8.8) Pressure Relief Valve A safety device to ensure the system cannot overpressure. If the system builds up too much pressure for any reason this device will release it into the pressure relief / purge vent (1.9) 8.15) Expansion Vessel Vessel to allow for the water expansion as it is heated connected to the water system circuit. 9)Alternative Hot Air Furnace An Alternative Hot Air Furnace (9)can be used with this boiler system so that it can be used with a Hot Air system. This furnace is slightly different because it keeps the Oxyhydrogen flame isolated. The Oxyhydrogen flame in this system is sealed off and heats the Hot Air Heat Exchanger Shell (9.17). directly. This causes convection heating to heat the air being pumped by the Hot Air Fan (9.4) on the other side of the Hot Air Heat Exchanger Shell (9.17). The Cold air comes in from the Cold Air Inlet (9.2) and ones passed through the Alternative Hot Air Furnace (9) it leaves heated by the Hot Air Outlet (9.3) The Alternative Hot Air Furnace (9) can be seen in "Figure 15". 10) Secondary Hot Water Furnace The secondary Hot water furnace works the same as the Furnace (3). It is just a second line for a second heating system so that two heating lines can be used on the same boiler such as one for central heating and one for hot water taps. 11) Secondary Hot Water Electrolyser The secondary Hot Water Electrolyser works the same as the Electrolyser (6). It is just a second line for a second heating system so that two heating lines can be used on the same boiler such as one for central heating and one for hot water taps. It allows a second control to start producing more gas to be produced independently controlled from the original system. Drawing Identification Figure 1) Image of the electronics sequence of events for Self Producing Hydrogen Boiler and Heating System for use for heating a Hot water circulation system only Figure 2) Image of the manufacture drawings for elf Producing Hydrogen Boiler and Heating System for use for heating a Hot water circulation system only Figure 3) Image of the electronics sequence of events for a Self Producing Hydrogen Boiler and Heating System for use for heating a Hot water circulation system along with a secondary system for heating a secondary hot water line Figure 4) Image of the manufacture drawings for a Self Producing Hydrogen Boiler and Heating System for use for heating a Hot water circulation system along with a secondary system for heating a secondary hot water line Figure 5) Image of the electronics sequence of events for a Self Producing Hydrogen Boiler and Heating System for use for heating a Hot Air System only Figure 6) Image of the manufacture for a Self Producing Hydrogen Boiler and Heating System for use for heating a Hot Air System only Figure 7) Image of the electronics sequence of events for a Self Producing Hydrogen Boiler and Heating System for use for heating a Hot Air System along with a secondary system for heating a secondary hot water line Figure 8) Image of the manufacture drawings for a Self Producing Hydrogen Boiler and Heating System for use for heating a Hot Air System along with a secondary system for heating a secondary hot water line Figure 9) Image of the manufacture drawings for the Front Covers of the boiler system Figure 10) Image of the manufacture drawings for the Furnace of the boiler system Figure 11) Image of the manufacture drawings for the Electrolyser Plates and gaskets for the boiler system. Figure 12) Image of the manufacture drawings for the Oxyhydrogen Production Tank (2) Figure 13) Image of the manufacture drawings for the Water Tank (5) Figure 14) Image of manufacture drawings for the Electrolyser (6) Figure 15) Images of manufacture drawings for the Alternative Hot Air Circulation System Furnace (15) Figure 16) Image of the PCB Board for One Heating system for either the Central water heating, or Hot air system. Figure 17) Image of the PCB Board layout adding the secondary additional Hot water System Figure 18) A flow chart showing the continuous cycle between Oxyhydrogen Production to combustion and how it is repeated.

Claims

The Claims1. This is a Self Producing Hydrogen boiler and Heating System which is self contained which begins its own Hydrogen production when the thermostat calls for heat without the need of connecting to an external Hydrogen gas network.

2. This Self producing Hydrogen Boiler and Heating System has a Hydrogen Safety Kill switch if any Hydrogen Leakage occurs which automatically stops hydrogen production upon detection and raises alarm.

3. This Self Producing Hydrogen Boiler and Heating System has self pre purging Sequence to remove Air from the system before it tries to ignite the Hydrogen4. The Self Producing Hydrogen Boiler and Heating System can be used for both heating of hot water and Hot air.

5. Self Producing Hydrogen Boiler and Heating System can be used with direct current from a DC solar battery to function all contained internal components including hydrogen production rather than the need to convert anything to AC and lose efficiency, alongside alternatively using standard AC power supply if desired.'d-CM

Images