DIY metal induction heater for car service. Induction heater: do-it-yourself heating circuit, how to make a vortex heater from a welding inverter. Working principle of induction heating

Induction heating boilers are devices that are characterized by very high efficiency. They can significantly reduce energy costs compared to traditional devices equipped with heating elements.

Industrial production models are not cheap. However, any home craftsman who owns a simple set of tools can make an induction heater with his own hands. To help him, we offer a detailed description of the principle of operation and assembly of an effective heater.

Induction heating is impossible without the use of three main elements:

inductor;
generator;
heating element.

An inductor is a coil, usually made of copper wire, that generates a magnetic field. An alternator is used to produce a high-frequency current from the standard 50 Hz household electrical current.

A metal object capable of absorbing thermal energy under the influence of a magnetic field is used as a heating element. If you connect these elements correctly, you can get a high-performance device that is perfect for heating coolant liquid and.

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Induction water heater: principle of operation and manufacture of the device

Induction heating technology allows you to solve problems with hot water supply, while due to the full automation of boiler operation, the comfort of living in a private home is significantly increased. An induction water heater is functional while providing quick heating of water for heating your home. Due to the simplicity of the design, making such a heater is not difficult, which allows you to save on the purchase of equipment. Induction heaters have gained popularity in the market due to their efficiency and simplicity of design. Such heaters consist of the following main elements:

The inductor has the form of a metal coil made of copper wire. Its main purpose is to create a vortex magnetic field. An alternating current generator is necessary to obtain high-frequency flow from electricity from a household network. A metal filler is used as heating elements, which emits heat under the influence of a magnetic field.

The entire operation of an induction heater can be fully controlled by automation, which, using special sensors, analyzes the temperature of the coolant, reducing or increasing the heating intensity. The control units used are responsible for the safety of the boiler, preventing its overheating and failure of the power unit due to overvoltage.

The most widely used are induction-type vortex heaters, which combine simplicity of design, are distinguished by fuel efficiency and versatility of use. The latter allows them to be used not only to solve problems of hot water supply, but also to heat the coolant when heating a private house.

Modern modifications of induction water heaters for heating systems have gained popularity in the market, which is explained by their numerous advantages. The advantages of this type of equipment include the following:

Simplicity of design.
Heating efficiency.
Possibility of self-production.
Full automation.
Operational safety.

Making ultra-economical water heaters with your own hands does not present any difficulty, which allows you to do all the work yourself. The device consists of a minimum of parts that do not break and do not require any special care. During operation, water heaters vibrate slightly, which helps solve the problem of scale and deposits on the heating elements.

The disadvantages of induction water heaters include mediocre fuel efficiency. However, today, with the development of solar energy, when owners of private houses can install inexpensive panels on the roof that generate electricity, there is an opportunity to significantly reduce utility costs.

During operation, induction heaters can become very hot, so it is necessary to install emergency sensors that will turn off the devices when the peak temperature is reached. In the absence of protective shutdown relays, overheating of the coolant may occur, which leads to an increase in pressure in the system and rupture of the connections of the thermal circuit.

A low-power induction heater, which is designed to heat water, can be made on the basis of a simple transformer having a primary and secondary winding. In the primary circuit, electricity is converted into eddy currents. A magnetic field is created, which provides powerful induction, directional action. The second circuit of the transformer is responsible for rapid heating of the coolant.

Powerful direct-flow water heaters can be made on the basis of a high-frequency welding inverter. The generators and transformers used smoothly change the current range, which makes it possible to adjust the heating intensity by increasing or decreasing the temperature of the coolant in the external circuit. The core in powerful induction heaters can be made of a polymer or metal pipe.

Required tools and materials:

Transformers or welding inverter.
Metal pipes of various diameters.
Welding machine and soldering iron.
Screwdriver and wire cutters.

In each specific case, the necessary components will vary, depending on the selected heater design. You need to remember that there must be built-in automation that will monitor the temperature of the heated water. The presence of a control relay allows you to guarantee trouble-free operation of the device, increasing its safety and preventing the failure of a homemade heat generator.

In industrial models, the water jacket is made of metal pipes with thick walls. However, in homemade columns, in which the induction thermal power does not exceed 5 kW, it can be difficult to heat metal pipes with coolant. Therefore, it is preferable to use plastic tubes through which the coolant is circulated using a pump or by gravity.

A housing for an induction heater based on a welding inverter can be made from a plastic pipe. The length of the heater is approximately 1 meter, and the internal diameter can vary from 50 to 80 millimeters.

To simplify the connection of the induction heater to the heating system, it is necessary to install appropriate adapter fittings in the upper and lower parts of the housing. The lower part of the pipe is covered with a grid, after which a filler consisting of rods, metal wire or similar elements is placed inside the column.

When choosing filler that is cut into small pieces, preference should be given to steel with high magnetic resistance . Subsequently, such metal will heat up well, ensuring the highest possible efficiency of the heater. After filling with filler, the housing is closed from above with a metal mesh.

An induction grill is made, for which copper wire is wound over the body. To ensure high-quality heating, it is necessary to make at least 90 turns of the coil. The turns should be positioned as closely as possible to each other without a gap, which will ensure the formation of a high-quality magnetic vortex field, which is necessary for heating the filler. The winding is made of insulated copper wire with a thickness of 1-1.5 millimeters.

To make an alternating current generator, the easiest way is to use an inverter from welding machines. The contacts from the coil are connected to the poles of the generator. A homemade induction instantaneous water heater is supplied with power from an AC inverter, after which the boiler will immediately begin to heat the water, which will move through the pipes due to the temperature difference.

You can increase the efficiency of the heater, as well as improve the safety indicators of using homemade equipment, by connecting a thermostat sensor to the supply line near the adapter. The installed module will monitor the temperature, if necessary, turning off the power supply from the inverter, which will protect the heater and the entire system from overheating and failure.

Nuances

When conducting experiments on heating and hardening of metals , the temperature inside the induction coil can be significant and amount to 100 degrees Celsius. This thermal heating effect can be used to heat water for domestic use or for heating a home.
The heater circuit discussed above (Figure 3) , at maximum load, is capable of providing radiation of magnetic energy inside the coil equal to 500 W. This power is not enough to heat a large volume of water, and the construction of a high-power induction coil will require the manufacture of a circuit in which it will be necessary to use very expensive radio elements.
A budget solution for organizing induction heating of liquid is to use several devices described above, located in series. In this case, the spirals must be on the same line and not have a common metal conductor.
A stainless steel pipe with a diameter of 20 mm is used as a heat exchanger Several induction spirals are “strung” onto the pipe, so that the heat exchanger is in the middle of the spiral and does not come into contact with its turns. When 4 such devices are turned on simultaneously, the heating power will be about 2 kW, which is already sufficient for flow-through heating of liquid with a small circulation of water, to values that allow this design to be used in supplying warm water to a small house.
If you connect such a heating element with a well-insulated tank , which will be located above the heater, the result will be a boiler system in which the liquid will be heated inside a stainless pipe, the heated water will rise upward, and its place will be taken by a colder liquid.
If the area of the house is significant , then the number of induction coils can be increased to 10 pieces.
The power of such a boiler can be easily adjusted by turning off or turning on the spirals. The more sections that are turned on at the same time, the greater the power of the heating device operating in this way.
To power such a module you will need a powerful power supply. If you have a DC inverter welding machine, you can use it to make a voltage converter of the required power.
Due to the fact that the system operates on direct electric current , which does not exceed 40 V, the operation of such a device is relatively safe; the main thing is to provide a fuse box in the generator power circuit, which in the event of a short circuit will de-energize the system, thereby eliminating the possibility of a fire.
In this way, it is possible to organize “free” heating of the house , provided that batteries are installed to power the induction devices, the charging of which will be carried out using the energy of the sun and wind.
The batteries should be combined into sections of 2, connected in series. As a result, the supply voltage with such a connection will be at least 24 V, which will ensure the boiler operates at high power. In addition, a series connection will reduce the current in the circuit and increase the service life of the batteries.

How to make an induction water heater with your own hands

Here you will learn:

The modern and most economical device for heating water is an induction water heater. Unlike analogues, it is completely environmentally friendly, does not dry out or burn out air, and meets modern safety requirements. It can be used both as a flow-through water heater and as a boiler for heating a room. The device is usually bought in a store, but we offer an alternative - making it yourself. In the latter case, the device may not have such an attractive appearance, but it will cost much less.

DIY induction water heater: diagram

The device is a transformer with two windings: primary and secondary. The first circuit converts electrical energy into eddy currents, thereby creating a directed induction field, which provides induction heating. In the secondary circuit, the converted energy is transferred to the coolant (in our case, it is water).

In addition to the transformer, the device contains a generator and a pump (optional).

Diagram of a simple induction water heater. As you can see, the device has a fairly simple design and a small number of elements.

Heat generator components and parts

The device includes:

an alternating current generator that increases the frequency of the current;
the inductor, which transforms electricity into magnetic energy, is a coil of copper wire;
heating element, most often its role is played by a metal pipe.

Principle of operation

An induction water heater consists of a generator, a coil and a core, the latter is heated by electromagnetic energy

The device converts electrical energy into electromagnetic energy. The latter, in turn, acts on the core (pipe), which heats up and transfers thermal energy to the water. All these energies are converted by an inductor consisting of a coil and a core. The generator is used to increase the frequency of the current, since with a standard frequency of 50 Hz it is difficult to achieve high heating.

High precision induction heating

This heating has the simplest principle, since it is non-contact. High-frequency pulse heating makes it possible to achieve the highest temperature conditions, at which it is possible to process the most difficult metals to melt. To perform induction heating, you need to create the required voltage of 12V (volts) and inductance frequency in electromagnetic fields.

This can be done in a special device - an inductor. It is powered by electricity from an industrial power supply at 50 Hz.

It is possible to use individual power supplies for this – converters/generators. The simplest device for a low-frequency device is a spiral (insulated conductor), which can be placed in the inside of a metal pipe or wound around it. The flowing currents heat the tube, which subsequently supplies heat to the living space.

The use of induction heating at minimum frequencies is not common. The most common processing of metals is at higher or medium frequencies. Such devices are distinguished by the fact that the magnetic wave travels to the surface, where it attenuates. The energy is converted into heat. For the best effect, both components must have a similar shape. Where is heat applied?

Today, the use of high-frequency heating is widespread:

For melting metals and soldering them using a non-contact method;
Mechanical engineering industry;
Jewelry;
Creation of small elements (boards) that can be damaged when using other techniques;
Hardening of surfaces of parts of various configurations;
Heat treatment of parts;
Medical practice (disinfection of devices/instruments).

Heating can solve many problems.

DIY instantaneous induction water heater

Before you begin installation, you need to stock up on the necessary parts. So, the best option would be a high-frequency welding inverter with a smoothly varying current range . Such a device will cost the least. A more expensive option would be a three-phase transformer, which is the AC power source for the water heater inductor. In this case, you should use a coil of 50-90 turns, and use copper wire with a diameter of 3 or more millimeters as the material.

As a core, you can use either a metal or polymer pipe together with wire (used as a heating element). In the latter case, the thickness of the walls should not be less than 3 mm in order to easily withstand high temperatures.

To assemble the water heater you will need: wire cutters, screwdrivers, a soldering iron and a welding machine if a metal pipe is used.

Installation of an induction water heater

Wrap the pipe with copper wire, making about 90 turns.

There are many options for assembling the device. We suggest trying to assemble the device according to the following scheme:

Prepare your workplace, materials and tools.
Fix a small piece of polymer pipe (remember that the minimum wall thickness should be 3 mm).
Trim the ends of the core to leave 10 cm of wire left for taps.
Mount a corner on the lower outlet. In the future, the return from the heating should be connected here (if the heater is used as a boiler).
Place the chopped wire tightly around the pipe. It is necessary to make at least 90 turns.
Install a tee on the top pipe through which hot water will flow out.
Install the protective circuit of the device. It can be made from either polymer or metal.
Connect copper wire to the water heater terminals, then fill the core with water.
Check the functionality of the inductor.

Manufacturing instructions

Blueprints

To make a stove you will need the following materials and tools:

soldering iron;
solder;
textolite board.
mini drill.
radioelements.
thermal paste.
chemical reagents for etching the board.

Additional materials and their features:

To make a coil that will emit the alternating magnetic field necessary for heating, it is necessary to prepare a piece of copper tube with a diameter of 8 mm and a length of 800 mm.
Powerful power transistors are the most expensive part of a homemade induction installation. To install the frequency generator circuit, you need to prepare 2 such elements. Transistors of the following brands are suitable for these purposes: IRFP-150; IRFP-260; IRFP-460. When manufacturing the circuit, 2 identical of the listed field-effect transistors are used.
To manufacture an oscillating circuit, you will need ceramic capacitors with a capacity of 0.1 mF and an operating voltage of 1600 V. In order for high-power alternating current to form in the coil, 7 such capacitors will be required.
When operating such an induction device , field-effect transistors will become very hot and if aluminum alloy radiators are not attached to them, then after just a few seconds of operation at maximum power, these elements will fail. Transistors should be placed on heat sinks through a thin layer of thermal paste, otherwise the effectiveness of such cooling will be minimal.
Diodes used in an induction heater must be ultra-fast. The most suitable diodes for this circuit are: MUR-460; UF-4007; HER – 307.
Resistors used in circuit 3: 10 kOhm with a power of 0.25 W - 2 pcs. and 440 Ohm power - 2 W. Zener diodes: 2 pcs. with an operating voltage of 15 V. The power of the zener diodes must be at least 2 W. A choke for connecting to the power terminals of the coil is used with induction.
To power the entire device you will need a power supply with a power of up to 500 W. and voltage 12 - 40 V. This device can be powered from a car battery, but it will not be possible to obtain the highest power readings at this voltage.

The manufacturing process of the electronic generator and coil itself takes a little time and is carried out in the following sequence:

from a copper pipe . To make a spiral, the copper tube should be screwed onto a rod with a flat surface with a diameter of 4 cm. The spiral should have 7 turns, which should not touch. Fastening rings are soldered to the 2 ends of the tube for connection to the transistor radiators.
The printed circuit board is made according to the diagram. If it is possible to install polypropylene capacitors, then due to the fact that such elements have minimal losses and stable operation at large amplitudes of voltage fluctuations, the device will operate much more stable. The capacitors in the circuit are installed in parallel to form an oscillating circuit with a copper coil.
Heating of the metal occurs inside the coil after the circuit is connected to the power supply or battery. When heating the metal, it is necessary to ensure that there is no short circuit in the spring windings. If you touch 2 turns of the coil at the same time with heated metal, the transistors will fail instantly.

Induction water heaters for heating

Heating circuit, where an induction boiler serves as a coolant heater.

Such a device has proven itself not only as an instantaneous water heater, but also as a heating boiler. True, in this case the welding machine will no longer work as a generator; you will have to use a transformer with two windings . The latter transforms eddy currents arising on the primary winding into an electromagnetic field that is created on the secondary circuit.

An induction water heater boiler must be equipped with two pipes for hot and cold water. Cold water will flow from the lower one; it must be mounted on the inlet section of the line, and on top it is necessary to place a pipe that will supply hot water to the heating system. As a result, water circulates naturally under the influence of convection without a pump.

What you need to know about security

Do not forget that we are dealing with a source of increased danger - an electric heating device, therefore, when assembling and using it, you must follow some rules:

Be sure to use a separate electrical line to connect the induction boiler, and also equip it with a safety group.

If water circulates naturally in the boiler, be sure to equip it with a temperature sensor so that if it overheats, the device turns off automatically.
Do not connect a homemade water heater to an outlet; it is better to draw a separate line for this with a larger cable cross-section.
All exposed sections of wires must be insulated to protect people from electric shock or burns.
Do not turn on the inductor under any circumstances if the pipe is not filled with water . Otherwise, the pipe will melt and the device will short out or it may even catch fire.
The device must be mounted at a height of 80 cm from the floor, but so that about 30 cm remains from the ceiling. Also, you should not install it in a residential area, since the electromagnetic field has a bad effect on people’s health.
Don't forget to ground the inductor.
Be sure to connect the device through an automatic circuit breaker so that in the event of an accident, the latter will cut off the power from the water heater.
A safety valve must be installed in the pipeline system, which will automatically reduce the pressure in the system.

Important features of using an adapter disc for an induction cooker

If you have made your own induction hob adapter, it is important to use it correctly. It is not recommended to install such a device if the stove is heated to the maximum permissible temperature. Otherwise the disk may be damaged. Therefore, do not allow the burner to turn on at maximum power if you decide to use an adapter.

For cooking, it is advisable to use utensils whose diameter is almost equal to the size of the adapter. It is important to consider that any container that you will use for cooking using an adapter must have a flat bottom. Re-inspect the dishes if you are unsure.

It is not recommended to leave the burner on for more than 30 seconds if you place an empty adapter on it without any cookware. It is better to install it on the stove and dishes together with the disk. Otherwise, do not rush to turn on the burner.

Pay attention to the rules for completing work on an induction cooker. After cooking, do not rush to remove it. It is important to turn off the stove first. After removing the dishes, do not forget to remove the adapter disk.

You can also make an adapter for induction cookers yourself in order to use it as a stand for hot pots or pans. The device can also be suitable for adapting a large burner to smaller cookware, regardless of the type of stove.

Operating principle and design of a solar heater

The sun shines all year round, and no one takes money for this energy. How can you turn it to your advantage? Make a solar-powered boiler. The efficiency of its operation depends on the region: the more rays penetrate the ground, the better the device heats. If we take factory-made devices, their power is even suitable for heating.

How do industrial solar heaters work? They consist of:

A collector is a container through which heated water flows.
Quartz glass tubes with hoses inside (they contain the working fluid - a substance that turns into steam). It is quartz that transmits UV rays for optimal heating of water even in cloudy weather. The tubes have a vacuum, so they retain heat perfectly.
Pump or other devices for creating pressure. Some non-pressure models operate on the principle of convection.
Pipeline.
Storage tank.

How factory vacuum units work:

Inside the tubes there is a working fluid. Under the influence of sunlight, it turns into steam and rises, thus heating the water tank.
If the water heater is storage, then it is connected to the boiler in the house or apartment using a coil.

Flat heater design:

It consists of a rectangular body, the back wall of which is covered with heat-insulating material.
A copper coil is attached to the body. It connects to the tank.
Water circulates under the influence of convection or a pump.
The plate is painted black and protected with glass on top.

This option is cheaper than a vacuum one, but its efficiency is also lower, especially in cloudy weather.

Types of solar heaters

In addition to those mentioned above, there are simpler devices. They are divided into two types depending on the water supply:

Active . Water circulates through the system using a pump, valve, or manifold. There are open and closed types. The latter contain antifreeze inside, which prevents the water from freezing even in negative temperatures.

Passive. They have low productivity and operate in a non-pressure manner.

Also, solar water heaters (SW) are instantaneous and storage. A homemade boiler can be used for a summer shower, for a swimming pool, for a bath and other needs.

Induction heater circuit

Thanks to the discovery of the phenomenon of electromagnetic induction by M. Faraday in 1831, many devices that heat water and other media have appeared in our modern life. Every day we use an electric kettle with a disk heater, a multicooker, and an induction hob, since it was only in our time that we were able to realize this discovery for everyday use. Previously it was used in the metallurgical and other metalworking industries.

A factory induction boiler uses in its operation the principle of the action of eddy currents on a metal core placed inside the coil. Foucault eddy currents are of a surface nature, so it makes sense to use a hollow metal pipe as a core through which a heated coolant flows.

Operating principle of an induction heater

The occurrence of currents is due to the supply of alternating electrical voltage to the winding, causing the appearance of an alternating electromagnetic field that changes potentials 50 times per second at a normal industrial frequency of 50 Hz. In this case, the induction coil is designed in such a way that it can be connected to the AC mains directly. In industry, high-frequency currents are used for such heating - up to 1 MHz, so it is quite difficult to achieve operation of the device at a frequency of 50 Hz.

The thickness of the copper wire and the number of turns of the winding used by induction water heaters are calculated separately for each unit using a special method for the required thermal power. The product must work efficiently, quickly heat the water flowing through the pipe and not overheat. Enterprises invest a lot of money in the development and implementation of such products, so all problems are solved successfully, and the heater efficiency is 98%.

In addition to high efficiency, what is particularly attractive is the speed with which the medium flowing through the core is heated. The figure shows a diagram of the operation of an induction heater made in a factory. This scheme is used in units of the well-known VIN brand, produced by the Izhevsk plant.

Heater operation diagram

The longevity of the heat generator depends only on the tightness of the housing and the integrity of the insulation of the wire turns, and this turns out to be a fairly long period; manufacturers declare up to 30 years. For all these advantages that these devices actually have, you have to pay a lot of money; an induction water heater is the most expensive of all types of electrical heating installations. For this reason, some craftsmen have taken to making a homemade device with the goal of using it to heat a house.

Blitz tips

The operation of homemade induction heating devices does not always eliminate the spread of electromagnetic radiation harmful to humans, therefore the induction boiler should be installed in a non-residential area and shielded with galvanized steel.
When working with electricity, it is imperative to follow safety regulations , especially for 220 V AC networks.
As an experiment , you can make a hob for cooking according to the scheme specified in the article, but it is not recommended to use this device constantly due to the imperfection of the self-made shielding of this device, because of this, the human body may be exposed to harmful electromagnetic radiation that can negatively affect health .

Homemade products from a washing machine engine:

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Ultra-economical DIY water heater

Electricity prices make up a significant portion of the family budget, especially if you often need to heat water in large quantities from the network. General view of the device in the photo.

The water heater circuit presented below can significantly reduce energy costs. Judge for yourself, consuming only 150 watts from the network, the device heats water in the same way as a heater with a power of 1.5 - 2 kilowatts! The secret of this efficiency lies in the use of reactive current.

Any home craftsman can make such a super efficient water heater. You will need one working LATR + core from LATR, a coil of copper wire and a copper tube. Please note that the jumper is made from a piece of rubber hose! Carefully insulate the copper tube from the core. The water heats up almost instantly.

There are craftsmen who have connected such a heater to the heating system of the house (warm floors) or to radiators.

Induction heating boilers are devices that are characterized by very high efficiency. They can significantly reduce energy costs compared to traditional devices equipped with heating elements.

Homemade induction boilers

The simplest circuit of the device, which is assembled, consists of a piece of plastic pipe, into the cavity of which various metal elements are placed in order to create a core. This can be thin stainless wire rolled into balls, wire cut into small pieces - wire rod with a diameter of 6-8 mm, or even a drill with a diameter corresponding to the internal size of the pipe. From the outside, fiberglass sticks are glued to it, and a wire 1.5-1.7 mm thick in glass insulation is wound on them. The length of the wire is about 11 m. The manufacturing technology can be studied by watching the video:

The homemade induction heater was then tested by filling it with water and connecting it to a factory-made ORION 2 kW induction cooktop instead of the stock inductor. The test results are shown in the following video:

Other craftsmen recommend using a low-power welding inverter as a source, connecting the secondary winding terminals to the coil terminals. If you carefully study the work done by the author, the following conclusions arise:

The author did a good job and his product undoubtedly works.
No calculations were made on the thickness of the wire, the number and diameter of the coil turns. The winding parameters were adopted by analogy with the hob; accordingly, the induction water heater will have a power of no more than 2 kW.
In the best case, a homemade unit will be able to heat water for two heating radiators of 1 kW each, which is enough to heat one room. In the worst case, the heating will be weak or disappear altogether, because the tests were carried out without coolant flow.

It is difficult to draw more precise conclusions due to the lack of information on further testing of the device. Another way to independently organize induction heating of water for heating is shown in the following video:

The radiator, welded from several metal pipes, acts as an external core for the eddy currents created by the coil of the same induction hob. The conclusions are as follows:

The thermal power of the resulting heater does not exceed the electrical power of the panel.
The number and size of the pipes were chosen randomly but provided sufficient surface area to transfer the heat generated by the eddy currents.
This induction heater circuit turned out to be successful for a specific case where the apartment is surrounded by the premises of other heated apartments. In addition, the author did not show the operation of the installation in the cold season with recording of the air temperature in the rooms.

To confirm the conclusions drawn, it is proposed to watch a video where the author tried to use a similar heater in a free-standing, insulated building:

Advantages: induction heating of metal

Heating has many benefits. With its help, it is possible to quickly heat and melt any conductive material to a liquid state. Makes it possible to perform heating in any environment that does not conduct current, that is, the melting-working function.

Because only the conductor heats up, the walls remain cold. This type of heating does not pollute the environment. If gas burners pollute the air, then induction heating eliminates this, because of how electromagnetic radiation works. Compact dimensions of the inductor. Possibility of creating a device of any shape.

Heating is indispensable if you need to heat only a selected area on the surface. The device can also configure such special equipment to the required mode and adjust it.