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Controlling 3800W 230V Water Heater Power for Stable Temperature—Microcontroller vs Analog

6 9
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  • #1 21682712
    Jose Martinez
    Anonymous  
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  • #2 21682713
    Aubrey Kagan
    Anonymous  
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  • #3 21682714
    David Ashton
    Anonymous  
  • #4 21682715
    Aubrey Kagan
    Anonymous  
  • #5 21682716
    Jose Martinez
    Anonymous  
  • #6 21682717
    David Ashton
    Anonymous  
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  • #7 21682718
    Aubrey Kagan
    Anonymous  
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  • #8 21682719
    Jose Martinez
    Anonymous  
  • #9 21682720
    Aubrey Kagan
    Anonymous  
  • #10 21682721
    Aubrey Kagan
    Anonymous  

Topic summary

Controlling a 3800W, 230V water heater to maintain stable water temperature involves selecting an appropriate temperature sensing method and power regulation technique. Temperature sensors such as thermistors, RTDs, thermocouples, diodes, or semiconductor sensors can be used, with options ranging from simple thermostats to more complex proportional or PID control systems. Power regulation can be achieved via analog electronics or microcontrollers, but safety and isolation are critical due to the high voltage and current (approximately 16.5A). Zero-crossing triac switching is recommended to minimize electromagnetic interference by switching at the AC waveform zero crossing, reducing high-current transients. Triac optocouplers (e.g., MOC306x for zero-crossing or MOC301x/302x for phase control) provide isolation between control and power circuits. A 555 timer-based circuit can be used for simple control but may require additional components like relays or beefier triacs to handle the high current. Heat sinking for triacs is necessary due to power dissipation. Safety precautions include consulting qualified personnel, using isolation transformers, and ensuring measurement instruments are rated for mains voltage. Boiling water naturally stabilizes at 100°C, so control may only be necessary for temperatures below boiling.
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