Building my own OWB - the lowdown

[trialanderror]

update

adding water to the bottom and sides of ash-pan/area/valley. it's got firebrick on the inside where it V's, then at the bottom of the V is a ashpan pull out, going to put a water jacket around it. may not need it, but, i'd hate to do all this work of adding water to the back and front and end up after burning for 12 hrs discover it gets quite hot on the bottom... :S also end up with probably another 40 gallon of water on the boiler itself as well....

pics as soon as i find time to recompile usb drivers....

for the record; it's a Steel king 4800B i'm modifiying, basically instead of water on top and sides, and no insulation, adding waterjacket to ALL sides and insulating. With help of some good people here, going to add digital control/aquastat.

should be near the quality of a CB

 

[KsWoodsMan]

re-compiled some usb source code and now i b0rk3d it...


jason@anywhere:/usr/src/linux-headers-2.6.27-11/drivers/usb$ dmesg
[123050.037203] sd 2:0:0:0: [sdb] 487425 512-byte hardware sectors (250 MB)
[123050.039007] sd 2:0:0:0: [sdb] Write Protect is off
[123050.039015] sd 2:0:0:0: [sdb] Mode Sense: 0b 00 00 08
[123050.039019] sd 2:0:0:0: [sdb] Assuming drive cache: write through
[123050.043251] sd 2:0:0:0: [sdb] 487425 512-byte hardware sectors (250 MB)
[123050.044757] sd 2:0:0:0: [sdb] Write Protect is off
[123050.044766] sd 2:0:0:0: [sdb] Mode Sense: 0b 00 00 08
[123050.044769] sd 2:0:0:0: [sdb] Assuming drive cache: write through
[123050.046283] sdb: sdb1
[123050.049393] sd 2:0:0:0: [sdb] Attached SCSI removable disk
[123050.050089] sd 2:0:0:0: Attached scsi generic sg2 type 0
[123052.522849] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.522861] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.522869] end_request: I/O error, dev sdb, sector 487424
[123052.522878] Buffer I/O error on device sdb, logical block 487424
[123052.525349] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.525360] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.525367] end_request: I/O error, dev sdb, sector 487424
[123052.525375] Buffer I/O error on device sdb, logical block 487424
[123052.528222] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.528230] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.528237] end_request: I/O error, dev sdb, sector 487416
[123052.528242] Buffer I/O error on device sdb, logical block 487416
[123052.530842] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.530849] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.530855] end_request: I/O error, dev sdb, sector 487417
[123052.530860] Buffer I/O error on device sdb, logical block 487417
[123052.530864] Buffer I/O error on device sdb, logical block 487418
[123052.530867] Buffer I/O error on device sdb, logical block 487419
[123052.530871] Buffer I/O error on device sdb, logical block 487420
[123052.530874] Buffer I/O error on device sdb, logical block 487421
[123052.530878] Buffer I/O error on device sdb, logical block 487422
[123052.530881] Buffer I/O error on device sdb, logical block 487423
[123052.549720] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.549732] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.549740] end_request: I/O error, dev sdb, sector 487416
[123052.553213] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.553222] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.553230] end_request: I/O error, dev sdb, sector 487417
[123052.555960] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.555968] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.555976] end_request: I/O error, dev sdb, sector 487424
[123052.558584] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.558593] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.558600] end_request: I/O error, dev sdb, sector 487424
[123052.562438] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.562449] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.562457] end_request: I/O error, dev sdb, sector 487424
[123052.567593] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.567604] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.567612] end_request: I/O error, dev sdb, sector 487416
[123052.571460] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.571467] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.571474] end_request: I/O error, dev sdb, sector 487417
[123052.583776] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.583788] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.583796] end_request: I/O error, dev sdb, sector 487360
[123052.587469] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.587481] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.587490] end_request: I/O error, dev sdb, sector 487361
[123052.590079] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.590086] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.590093] end_request: I/O error, dev sdb, sector 487424
[123052.593337] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.593346] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.593354] end_request: I/O error, dev sdb, sector 487424
[123052.597330] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.597338] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.597345] end_request: I/O error, dev sdb, sector 96
[123052.600958] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.600966] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.600973] end_request: I/O error, dev sdb, sector 97
[123052.609345] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.609357] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.609365] end_request: I/O error, dev sdb, sector 96
[123052.613961] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.613970] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.613977] end_request: I/O error, dev sdb, sector 97
[123052.617707] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.617717] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.617724] end_request: I/O error, dev sdb, sector 96
[123052.621368] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.621375] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.621382] end_request: I/O error, dev sdb, sector 97
[123052.625173] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.625182] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.625189] end_request: I/O error, dev sdb, sector 96
[123052.628954] sd 2:0:0:0: [sdb] Device not ready: Sense Key : Not Ready [current]
[123052.628962] sd 2:0:0:0: [sdb] Device not ready: Add. Sense: Medium not present
[123052.628969] end_request: I/O error, dev sdb, sector 97
jason@anywhere:/usr/src/linux-headers-2.6.27-11/drivers/usb$


i took some pics, but they're on my phone. i'll get them posted as soon as i figure this out. unless you have an idea what's up with it?

I'm guessing the camera has only a single partition? Seems like the one I had and the kid's MP3 players had 4. The firmware was on the first one and the data on the fourth like a usb floppy.

You might also need a supporting module for the usbfilesystem installed is why it isnt ready. You might take a look at /proc/modules too and see what you have loaded in your kernel.

Sorry if I'm not much help , I havent done a source install in years. The servers run Debian and I have had very few issues. :dunno:

 

[trialanderror]

based on debian. ubuntu actually.

naw, it worked fine with 7.10 or whatever. uppgraded to 8.10, and the high speed 2.0 didn't work specifically with my phone, so i tried removing the enhanced module, that's how i go around it last time, but this time it didn't work, . so i changed some stuff, and now it's whacked. suppose i'll track what changes have been made and go from there.

 

[trialanderror]

almost done! should be able finish welding a few more panels and then pressure test tomorrow and see how many leaks i'll have!

one question, where should i put the thermocouple? on the top where the water is the hottest? or near a return line where the cooled water is returned to the boiler? seems like it might have a tenancy to have a false call for heat? any ideas?

btw, by adding water to front, back, bottom sides, and bottom of firebox, increased water capacity from 38 to about 135.. maybe not exactly 135 i rounded down maybe 5 gallon. i had to cut corners and do some wild math, but, as far as cubic area, what's what i came close to.

 

[dancan]

Borrow someones pc or mac and get them pictures posted .

 

[KsWoodsMan]

I'm guessing the output from dmesg that you posted were the only errors or failures ? And lsmod shows usbdev.o, scsi.o, sg.o and usbfs.o are all loaded ?

There is always DSL Linux or Knoppix. It kills your uptime to reboot. But then it is a good idea to let fsck run every couple of years anyway. Even journaling filesystems need consistancy checks from time to time.

Side note : one of the kid's mp3 players started acting up like this. Everything else we plugged in worked flawlessly. Turned out to be a defective USB cable. or was it the internal connection. cant remember but it wasn't the OS.

 

[trialanderror]

Borrow someones pc or mac and get them pictures posted .

maybe a mac

i refuse to touch a microsoft product. been microsoft free for 9 years.
just can't do cool stuff with ms like you can opensource....

/me ponders as he has happy thoughts of using the aircrack-ng suite.....

 

[cleanburn]

almost done! should be able finish welding a few more panels and then pressure test tomorrow and see how many leaks i'll have!

one question, where should i put the thermocouple? on the top where the water is the hottest? or near a return line where the cooled water is returned to the boiler? seems like it might have a tenancy to have a false call for heat? any ideas?

btw, by adding water to front, back, bottom sides, and bottom of firebox, increased water capacity from 38 to about 135.. maybe not exactly 135 i rounded down maybe 5 gallon. i had to cut corners and do some wild math, but, as far as cubic area, what's what i came close to.

Best place is right in your *SUPPLY* line. Then you know the water temp going into your house. You don't want it in your return line that has nothing to do with your OWB. Or if you are doing tanks put them in right before the water gets put into your house.

 

[trialanderror]

Best place is right in your *SUPPLY* line. Then you know the water temp going into your house. You don't want it in your return line that has nothing to do with your OWB. Or if you are doing tanks put them in right before the water gets put into your house.

what? you sure? the thermocouple for the digital control that controls the draft and blower?

 

[ericjeeper]

what? you sure? the thermocouple for the digital control that controls the draft and blower?

yes. That way it is sensing what the CURRENT temp is in the boiler basically. It will then tell the blower to come on if it is below the setpoint.
Have you actually started on building the boiler unit yet? Made a cut? a weld?
Or are you still in the design process?

 

[cleanburn]

yes. That way it is sensing what the CURRENT temp is in the boiler basically. It will then tell the blower to come on if it is below the setpoint.
Have you actually started on building the boiler unit yet? Made a cut? a weld?
Or are you still in the design process?

^^

You want to control the water temp going into your house/in your boiler so yes its the supply line.

 

[trialanderror]

yes. That way it is sensing what the CURRENT temp is in the boiler basically. It will then tell the blower to come on if it is below the setpoint.
Have you actually started on building the boiler unit yet? Made a cut? a weld?
Or are you still in the design process?

haha, page 6, jan 10th 7:47, check out that post, i did give some info of my progress. or just stop on over and check it out if your so concerned. Your only a few hours away

i finished welding some peices together so i had full sheets to work with. i'm not loaded with dough to just stop at the iron yard and load up 2000# of iron.....i gotta scab together odds and ends to get what i need. car cracked a piston ring on the way up north, so i had to dump the pan and pull the head and knock the pistons out. But ,besides that, peices are cut and fitted and spotted where they need to be, need to run some heavy beads and pressure check. takes, time, i gotta use the chain-hoist and pick/rotate the boiler in such a way so the beads will lay deep and heavy. should be able to finish and do that tomarrow after work. progjress is going to be slow now, burned all my vacation time. took a few more pics today, gonna get drunk tonight and go through some source code and see if ican get these usb drivers to work :S programming drunk is hard, spends hours writing code, and after issuing the famous "make && make install", 10 hours later find out i mixed up semi colons with commas....

 

[ericjeeper]

I got distracted with all the mumbo jumbo about the pictures. Keep up the good work.
I understand how it goes building your own OWB. I have built two of mine.

 

[trialanderror]

my only concern is how i'm going to vent the water being it's an open system.

i'd like to put it between both houses. only problem is. one house is 10ft below the boiler ,the second house his 10ft above the boiler, and the plumbing in the 2nd house needs to be ran high in some areas. should i relocate the boiler and put it beside the higher house? or continue with the boiler between the houses, and just run a really tall vent pipe? or put the vent somewhere in the plumbing in in the garage of the higher house? any ideas?

 

[trialanderror]

pics. proof that i've done a few cuts and a few welds. and maybe a few extra since i had to make everything from garbage laying around. tonight i'm gonna finish welding the bottom together, and take pics of the ID tags and stuff.

 

[trialanderror]

more

 

[trialanderror]

some mroe

 

[trialanderror]

and hey, i know, nothing is square, nor straight. but it's quick, it'll hold water, and i did it while drinking. don't expect too much. sprayfoam will cover my flaws....

 

[KsWoodsMan]

my only concern is how i'm going to vent the water being it's an open system.

i'd like to put it between both houses. only problem is. one house is 10ft below the boiler ,the second house his 10ft above the boiler, and the plumbing in the 2nd house needs to be ran high in some areas. should i relocate the boiler and put it beside the higher house? or continue with the boiler between the houses, and just run a really tall vent pipe? or put the vent somewhere in the plumbing in in the garage of the higher house? any ideas?

Install a water to water exchanger in the boiler and a closed loop to the house with higher elevation. The highest temp of the water to the higher house should never exceed what is in the boiler since you arent heating it directly. Put a purge valve in that house, at the top to expell air from the system and fill it from the bottom.

The lower house could be fed directly from the boiler's holding tank to its reserve tank. Any air in that system would end up at the top of the boiler tank and not get recirculated.

 

[John D]

and hey, i know, nothing is square, nor straight. but it's quick, it'll hold water, and i did it while drinking. don't expect too much. sprayfoam will cover my flaws....

not for nothing,your welds like better than Shavers.I seen mine when I had the blower off,and looked inside.A blind man could have laid a better bead.I can weld better with dirty,rusty metal.It looks like they MIG welded with no argon gas,and to fast a wire speed.