Congratulations on purchasing your very own instructions for converting your motor vehicle into a water burning hybrid!

We feel fortunate in being given the opportunity to bring this valuable information your way. Now, you too can be involved in efforts to help utilize an incredible and priceless technology; harnessingwaterasasourceofenergyforyourvehicle!

We encourage you to also explore our download section for FREE bonuses and supplemental plans and documents to give you the widest variety of options and resourcesavailableasyoubeginthewaterhybridconversionprocess. Copyright2008ALLRIGHTSRESERVED

LEGAL DISCLAIMER: This book has been edited and revised for content clarity, text readability, andtechnologicalsuitabilityformodernfuelinjectionandoldercarburetorbasedvehicles,and isinspiredbytheoriginal,publicdomain,Hydrostarconversionplans. Please be advised that this conversion may measurably modify the exhaust characteristics of your vehicle. Therefore, we strongly advise you to contact your local or national governing body or regulators to verify compliance with existing emissions requirements and standards. Wealsoencourageyoutoverifythatyourvehiclepassesstateorgovernmentemissionstests aftercompletingtheconversion. Although these plans are designed to be 100% reversible and to work with the vast majority of motor vehicles, you acknowledge and understand that by carrying out these plans, you are assuming responsibility for all potential risks and damages, both incidental and consequential, relating to or resulting from use or misuse of these plans. Furthermore, you understand that there are inherent risks relating to any exploratory and pioneering mechanicaltechnology.

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Preface
Thisbookpresentscompleteplansanddetaileddescriptionssufficienttobuildaworkable waterhybridsystemforyourfuelinjectedorcarburetedmotorvehicle.Thetechnology containedhereinhasnotbeenpatentedandhasbeenplacedinthepublicdomain. Thishasbeendoneinhopesofdiscouragingsuppressionofthisknowledgebut,evenmore importantly,toencouragetheopenflowofinformationrelatingtowaterhybrids.We encourageyoutohelpyourfriendsandfamilywiththeirownconversionsonceyouhave graspedtheprinciplesandtechniquesyourself. WealsourgeyoutoexploretheFREEresourceswehaveprovidedtoyouonourdownload page,asthesemaygiveyouadditionalideas,particularlyifyouseekamorecustomsolutionor wanttoexploreadditionalwaystoaccomplishyourwaterhybridgoals. Ifyoudecidetobecomeinvolvedwithyourownconversionproject,orjustwanttooffer advise,anopinion,orconstructivecriticismonhowtoimprovetheseconcepts,pleasefeelfree tocontact,WilliamS.Power,thearchitectoftheoriginalplansthisbookisbasedon. Hewilldohisbesttogetbackwithyou,buthecantguaranteeaninstantresponse.Sometimes hesawayfromtheofficeweeksatatime;testingandperfectingnewconcepts,orjustchasing downparts.Hereswhereyoucanwritehim: PowerProducts,7017NLinchfieldRd.#388,Glendale,AZ85307. Havefunwithyourwaterhybridproject,andhappydriving!

WilliamS.Power

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Contents
Preface ............................................................................................................................................ 3 Contents.......................................................................................................................................... 4 BasicQuestionsandAnswers ......................................................................................................... 7 WhatistheWaterhybridsystem?............................................................................................. 7 Isthewaterhybridsystemaperpetualmotionmachine? ........................................................ 8 Isthewaterhybridsystemsafe?................................................................................................ 8 Whyisthewaterhybridsystemiscalledaconversionsystem? ............................................... 8 Howwelldoesthewaterhybridsystemperform?.................................................................... 8 CantheWaterhybridsystembeusedinotherways?............................................................... 9 IstheWaterhybridsystemdifficulttobuild?............................................................................ 9 CanIbuyareadytoinstallWaterhybridsystem? .................................................................... 9 TheWaterhybridsystem! ............................................................................................................ 10 Hydrogen/OxygenGenerator ................................................................................................... 10 WaterTankandPump .............................................................................................................. 13 InDashIndicators[OPTIONAL]................................................................................................. 14 HyTronicsModule ..................................................................................................................... 15 GeneratorElectrodeCircuitSchematic .................................................................................... 15 GeneratorCoilCircuitSchematic.............................................................................................. 18 InDashIndicatorsCircuitSchematic ........................................................................................ 20 LetsBuildthewaterhybridsystem!:GeneratorConstruction .................................................. 22 Electrodes ................................................................................................................................. 22 Housing ..................................................................................................................................... 26 Listofmaterials:.................................................................................................................... 26 StepbyStepDirectionswithIllustrations: ........................................................................... 27 HousingAttachments................................................................................................................ 39 UnthreadedEndCap................................................................................................................. 43 ListofMaterials: ................................................................................................................... 43

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MaterialSource(Weencourageyoutoresearch(tryGoogle)yourownsources,aswecan notguaranteethesesourceswillofferthebestpricesoralwaysbeavailable: .................. 43 Directions: ............................................................................................................................. 44 SloshShield ............................................................................................................................... 46 FlameArrestor .......................................................................................................................... 47 WaterLevelSwitchTest............................................................................................................ 51 ToroidCoil ................................................................................................................................. 54 ListofMaterials: ................................................................................................................... 54 MaterialSources: .................................................................................................................. 54 Directions: ............................................................................................................................. 55 ToroidCoilInstallation.............................................................................................................. 63 UnthreadedEndCapInstallation.............................................................................................. 67 GeneratorFinalAssembly......................................................................................................... 68 InDashIndicatorPanelAssembly ............................................................................................ 70 ListofMaterials: ................................................................................................................... 70 MaterialSources: .................................................................................................................. 70 Directions: ............................................................................................................................. 71 WaterTankandPump .............................................................................................................. 75 ListofMaterials: ................................................................................................................... 75 MaterialSources: .................................................................................................................. 75 Directions: ............................................................................................................................. 75 HyTronicsModule ..................................................................................................................... 80 MaterialsList:........................................................................................................................ 80 MaterialsSource: .................................................................................................................. 80 Directions: ............................................................................................................................. 80 FuelInjectororCarburetorAdaptor......................................................................................... 83 ThrottleAssembly ..................................................................................................................... 84 ListofMaterials: ................................................................................................................... 84 MaterialsSource: .................................................................................................................. 84

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Directions: ............................................................................................................................. 84 PreliminaryAssemblyandTesting............................................................................................ 88 CylinderHeadTemperature ..................................................................................................... 95 FinalAssemblyandTesting....................................................................................................... 96 HelpfulHintsandTips ................................................................................................................. 109 Maintenance ........................................................................................................................... 109 ColdWeatherOperation......................................................................................................... 110 SpareGenerator...................................................................................................................... 110 GoodOldStainlessSteel ......................................................................................................... 110 GoodOldJBWELD ................................................................................................................. 111 KeepCloseWatch ................................................................................................................... 111 GarrettsGauge...................................................................................................................... 111 Reference .................................................................................................................................... 113 AThoughtorTwo ....................................................................................................................... 114

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BasicQuestionsandAnswers
Agoodstartingpointforunderstandingthewaterhybridtechnologyistoansweravarietyof frequentlyaskedquestionsyoumayhave.Sohereitgoes:

WhatistheWaterhybridsystem?
Thesewaterhybridplansessentiallyconvertyourvehicletousewaterasasourceof supplementaloreven(theoretically)primaryfuel.Theenginederivesfuelfromhydrogenand oxygen,generatedbytheelectrolysisofwater.Althoughpetroleumderivedfuelandan externalelectricalgeneratingsystemisnottheoreticallyrequired,inmostcircumstancesitisa practicalnecessity.Theonlybyproductresultingfromthehydrogenandoxygencomponentsof combustionwithintheengineiswatervapor.Therefore,emissionsareusuallycleaner,emitting fewerpollutingparticles.Inshort,theWaterhybridsystemisacleanersystem;onethat derivessupplementalfuelfromafreeandinexhaustibleresource;WATER!Ithastheunique advantageofbeingabletoremovepollutantsfromtheairduringcombustion,andeven reducesthecarbonresiduewithintheengine(similartotheeffectofhigheroctanefuels). TheWaterhybridsystemisprovenandhasbeenimplementedinvariousformsandvarietiesby engineers,mechanics,andhobbyistsaroundtheworld.Itistheendresultofmanyyearsof testingandexperimentationwithamultitudeofhydrogengeneratingsystemsbasedonthe principleofelectrolysisofwater. Waterelectrolysisissimplythebreakingdownofwaterintoitsbasichydrogenandoxygen atomsbypassinganelectroniccurrentthroughit.Youdontevenhavetoaddanelectrolyte (suchasacid)tothewatertoassureelectricalconductivity,asisrequiredwithabattery;plain oldtapwaterworksfinebecauseitcontainsnaturalelectrolytessuchasminerals,andalso municipaladditivessuchaschlorinewhichalsoaidinelectricalconductivity.Infact,electrolysis isinmanywayssimilartothereactionwhichoccurswithinyourvehiclesbattery.Electrolysisof waterusnothingnew;itwasfirstaccomplishednearlyacenturyago.But,untiltechnologies likethewaterhybridsystemweredeveloped,itrequiredahighvoltagepowersupplyand consumedvastamountsofelectricalenergy.Itactuallyrequiredmuchmoreelectricalenergy thantheenergyderivedfromthecombustionoftheresultinghydrogenandoxygen.Inother words,itwasanextremelyinefficientprocessthathadlimitedpracticaluse. Thewaterhybridsystemisapracticalsolutiondevelopedforuseinfuelinjectedand carburetedmotorvehicles.ThesecretofthewaterhybridsystemlieswithinitsHyTronic module.Itproducedrelativelylowvoltage,butuniquelyshapedelectronicpulsesofprecise

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frequencyandduration.TheoverallpowerconsumptionoftheHyTronicmoduleandtheentire waterhybridsystemisfairlylow;actuallylowenoughtobeeasilypoweredbyyourvehicles excesselectricalandheatoutput,andwithenoughreservepowerlefttohelprunallyour vehiclesotherelectricaldevices.

Isthewaterhybridsystemaperpetualmotionmachine?
Thewaterhybridsystemisnotaperpetualmotionmachine.Itisahighefficiency,water fueled,electromechanicalsystemcapableofproducinghydrogenandoxygeninsufficient quantitytoimprovetheoverallfuelefficiencyofinternalcombustionengines.

Isthewaterhybridsystemsafe?
Vehiclespoweredbythewaterhybridsystemareinherentlysaferthanhydrogenpowered vehicleswhichrequirehydrogentanks.Insteadofhydrogentanks,thewaterhybridsystem extractscombustiblehydrogenasneededfromthewater,andthissteadyreleaseofhydrogen isburnedcontinuously,therebypreventinglargeraccumulationsofhydrogengas.

Whyisthewaterhybridsystemiscalledaconversionsystem?
Thewaterhybridsystemiscalledaconversionsystembecauseitdoesntrequireremoval, modification,ordisablingofanyofyourvehiclesexistingsystems.Therefore,itallowsyouto runyourvehicleoneither100%gasolinesystemsorthewaterhybridsystem.Intheunlikely eventthatyourWaterhybridfails,youcaneasilyswitchbacktosolelyusinggasolinepower. But,youllsoonbegettingyourwaterhybridbackintoworkingorder.Onceyouvedrivenwith thewaterhybridsystemyoullneverbehappywithanythingelse!

Howwelldoesthewaterhybridsystemperform?
Avehiclepoweredbythewaterhybridsystemistheoreticallycapableoftravelingfrom50to 300milesoneachgallonofsupplementalwater,whileimprovingoverallfuelefficiencyupto 45%.However,asistrueforanyengine,actualefficiencydependsonmanyfactorssuchas; drivinghabits,terrain,vehicleweightandshape,andabilitytotweakandoptimizethesystem.

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 CantheWaterhybridsystembeusedinotherways?
Yes,theWaterhybridsystemcanprovidefuelfromwaterforjustaboutanyhomeappliance requiringnaturalgasorpropaneasasourceofheat;therebysavingvaluableanddiminishing naturalresources.Spaceheatersandfurnacesareexcellentcandidates.Stovesandother cookingunitssuchasbarbecuegrillscanalsobefueledbythewaterhybridsystem.Such applicationsrequireaseparatepowersupplytoconvertyourhomes120voltACpowerintothe 12voltDCpowerrequiredbythewaterhybridsystem.Youcanpurchaseaninexpensivepower supplyatanyelectronicsstoresuchasRadioShack,orhavesomeonefamiliarwithelectronics buildoneforyousincethedesignisverysimple.Thecostofhomeelectricityusedbythe waterhybridsystemisinsignificant,probablylessthan$3permonthinmostcases.

IstheWaterhybridsystemdifficulttobuild?
No,thewaterhybridsystemisrelativelyeasytoassembleandveryeasytoinstall,especially comparedwithotherconversionplansonthemarket.Nospecialtoolsarerequired.Theusual toolandequipmentfoundinatypicalhomeworkshopwilldothejob.AssemblingtheHyTronic moduletoachieveitsinherenthighlevelofreliabilityrequirescareandattentiontodetails, alongwithaverageelectronicsskills.Theonlyspecialpieceoftestequipmentyoumaywantto haveaccesstouseisanoscilloscope.ItISNOTnecessary,butmayhelpyouobtainpeak efficiencyfromtheHyTronicsmodule.But,youshouldnthaveanyproblemgettinghelpfroma localelectronicsguruifyoudonthaveanoscilloscope.Mostfolksaresofascinatedbyunusual electronicsystemsanddevicesthattheywouldalmostbewillingtopayyoufortheprivilegeof tweakingyourHyTronicsmodule!

CanIbuyareadytoinstallWaterhybridsystem?
Rightnow,thisspecificwaterhybridsystemisnotbeingcommerciallymanufactured,butthere arevariousdistributorsaroundthecountrywhoofferDIY(Doityourself)partsorfully assembledkitsutilizingsimilartechnologiesandprinciples. PlanningisintheinitialstagesforproducingWaterhybridconversionkitsformostvehicles andeventuallymanufacturingtheentiresystem,oratleastitsmajorcomponents.Were hopingtohavesomeprototypekitstestedsoonanddeliveryofreadytoinstallkitsshould beginsometimebeforetheendof2008.However,youllsoonbebuildingyourown!

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TheWaterhybridsystem!
Figure18inthisbookdepictsthecoreoftheWaterhybridsystem.Whileeachcomponentis essentialtoitsoperation,theheartofthesystemistheHydrogen/OxygenGeneratorsinceit convertswaterintocombustiblegaseousfueltopoweryourengine.Awatertankandpump storeandsupplywaterforthegenerator.SimpleelectronicsignalsfromtheHyTronicsModule initiateandsustainthecreationofhydrogenandoxygenwithintheGenerator.AnInDash GaugeandIndicatorAssemblyallowsyoutoaccuratelymonitorallaspectsoftheWaterhybrid system.EverypartoftheWaterhybridsystemisruggedlydesigned,forreliableoperationand longlife. Letstakeacloserlookateachpartofthesystemtogetabasicunderstandingofhow everythingworksandinteracts.

Hydrogen/OxygenGenerator
ReferringtoFigure1onthefollowingpage,theHydrogen/Oxygengeneratorhousingisaround cylinderconstructedwithhightemperatureCPVCpipe,amaterialwidelyusedbythebuilding industryinplumbingsystems.CPVCpipeisextremelydurableandtemperaturetolerant.Its alsoaveryfriendlymaterialinthatitseasytoworkwithandcanbeusedtofabricateother thingssuchasfurniture,planters,andhousingsforjustaboutanything. TheGeneratorhousingcontainsabasiccoilandtwocylindricalelectrodes;usedtogenerate bothhydrogenandoxygen.Eachcanbemadefromavarietyofmaterialssuchasstainlesssteel and/orceramic,alsoverydurablematerials.However,twoatomicallydifferentformsof hydrogenareproducedwithintheGenerator.Mostofthegeneratedhydrogenis orthohydrogen,averypowerfulandfastburninggascreatedbythetwoelectrodes.Aprecisely controlled,highfrequencyelectronicsignalfromtheHyTronicsModuleactivatesandcontrols theelectrodes. Theotherformofhydrogen,parahydrogen,iscreatedbythecoil,butinmuchlessquantity thanorthohydrogen.Apreciselycontrolled,verylowfrequencyelectronicsignalfroma separatecircuitwithintheHyTronicsModuleactivatesandcontrolsthecoil.Parahydrogenisa lesspowerfulandslowerburninggas,butisnecessarytopreventprecombustion(commonly calledknocking)withinyourengine.Parahydrogenslowstheburningrateofthehydrogen mix,thusboostingitsoctanelevel.Suchprecisecontrolallowsyoutoexactlymatchyour enginesoctanerequirements.Toraiseoctanelevelsingasoline,specificadditivesmustbeused

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toslowitsburningrate.Atbestthisisaninexactsciencesinceitdependsupontryingto averagetheoctanerequirementsformillionsofengines. Technicallyspeaking,theHydrogen/OxygenGeneratoritselfisanelectronicbasedunit.The twoelectrodesformabasiccapacitor,thousandsoftimeslargerthancapacitorsusedintypical circuits,withwateractingasitsdielectric.Theinnerelectrodeisnegativelycharged,andthe outerelectrodeispositivelycharged,bythehighfrequencyHyTronicssignal.Chemically,each watermolecule(H20)iscomposedoftwopositivelychargedatomsofhydrogenandone negativelychargedatomofoxygen.Sinceoppositechargesattract,thepositivelycharged hydrogenatomsarepulledtowardtheinnerelectrode.But,atthesameinstant,thenegatively chargedoxygenatomsarepulledtowardtheouterelectrode.Thisactionalignseverywater moleculebetweentheelectrodes,withtheendsofeachmoleculebeingpulledinopposite directions.Inanutshell,thisisthehydrolysisprocesscentraltohydrogenextraction.

Figure1:Hydrogen/OxygenGenerator

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 Forafewbriefmoments,onlymoreaccuratealignmentandincreasedpullingactionuponthe watermoleculesoccurs.But,theHyTronicssignalpulseskeepchargingthewatercapacitorto higherandhighervoltagelevels;actuallyseveralthousandvolts.Suddenlytheelectricalforces becomesogreatthatthewatermoleculesburstapart(scientistscallthisactiondisassociation) intotheirgaseousformsofhydrogenandoxygen.IfyouwereabletolookintotheGenerator, thisactionwouldbeobviousbecauseoftheformationofmillionsoftinyhydrogenandoxygen gasbubbles.AslongastheHyTronicssignalisapplied,thewatercapacitorremainsfully charged;continuouslycreatingorthohydrogenandoxygen. Anotherelectroniccircuitisformedbythegeneratorcoil.Thisisaninductivecircuit,meaningit createsamagneticfieldasopposedtothechargedfieldcreatedbythewatercapacitor.The verylowfrequencyHyTronicssignal(actuallyashortpulse)activatesthemagneticfieldofthe coil.Assoonasthepulsestops,themagneticfieldcollapses.Thiscreatesanevenstronger magneticfield,butafieldofoppositepolarity.Thatishowaninductivecircuitworks,anaction commonlycalledinductivekick.Eachpulseispreciselytimedsothatalmostimmediately afterthemagneticfieldreverses,anothershortpulsearrives.Onceagainthecoilischargedand itsmagneticfieldcollapses.Butnowthecontinuallyreversingmagneticfieldbecomeseven strongerduetoaddedenergyofeachnewpulse.Eventually(actuallywithinjustafewseconds) thecoilreachesitsmaximummagneticstrength,calleditssaturationpoint. Mostmoleculesareeffectedbymagneticfields.Thecoilsreversingmagneticfieldsvibratethe watermoleculessovigorouslythattheydisassociateintogaseousformsofparahydrogenand oxygen.Disassociationobservablyoccurs,asseenbythecreationofmillionsoftinyhydrogen andoxygengasbubblesaroundthecoil. Atthispoint,wevecoveredtheconceptsneededtounderstandthebasicfunctioningofthe generator.EveryothercomponentoftheWaterhybridsystemissimplyusedtoprecisely controltheactionofthegenerator.ByvaryingthestrengthandfrequencyoftheHyTronic signals,theratebywhichhydrogenandoxygenarecreatedcanbevariedtomatchengine requirementsatanyparticularmoment.Waterissuppliedbythetankandpump,whilewater levelwithintheGeneratoriscontrolledbyalevelsensorandswitch.Forsafetypurposes,a reliefvalveprotectsagainstexcesspressurebuildupwithinthegenerator.Separateportsare providedforattachinghosestoroutegastotheengineandtoanoptionalgaugetomonitorgas pressurebuildupwithinthegenerator.Adrainvalveisinstalledtoallowperiodicflushingof accumulatedmineralsandcontaminants.Thebottomendcapisthreadedsothatthe Generatorcaneasilybeopenedupforinspectionorrepairandforoccasionalcleaningofthe electrodesandcoil.Twopairsofstainlesssteel(copper,oranyconductivemetal)rodends RunaCaronWater 12

protrudefromtheGeneratorbodytoprovideelectricalconnectionoftheelectrodesandcoilto theHyTronicsModule. AsshowninFigure18,thegeneratorgasoutputhoseconnectstoaflamearrestor,whichin turnconnectstopressurefittingsattachedtotheengine.Theflamearrestorprovides protectionagainstcombustionflashbackintotheGeneratorintheeventthatenginebackfiring occurs.AswiththeGenerator,thearrestorbodyisconstructedfromCPVCpipe.Itsasimple unitusingsmalldiameterpipe,endcapswithhosefittings,andstuffedwithstainlesssteel wool.Pressurefittingkitsarereadilyavailableatengineshops.Theyredesignedforconverting enginestorunonpropane,sotheyareperfectlyadaptabletotheWaterhybridsystem. Itisrecommendedtoinstallthegeneratorintheenginecompartment.Itcanbeinstalledjust aboutanywherespacepermitsinthevehicle,eveninthetrunk.But,everythingissimplifiedby placingitneartheenginesincethatminimizesroutingofhoses,gaugelines,andelectrical wiring.

WaterTankandPump
Obviouslythisisthesimplestpartofthewholesystem.Justaboutanylargecontainerwillhold water,butwellrecommendaparticulartankwhenwegetintotheconstructionphase.There areendlesswaystosaveafewbuckshereandtherewhilebuildingthewaterhybridsystem, butIdontrecommendcuttingcornersattheexpenseofquality.Theentiresystemisdesigned tobehighlyreliable,sowhytakeachanceonmessingthingsupbygoingcheap?Forexample,I recommendinstallingawaterlevelsensorinthewatertanksoyoucaneasilymonitorwater quantity,andsensorsarerelativelyexpensive.Otherwiseyoullhavetooccasionallycompare themilesyouvedrivenversusthequantityofwater;withallthatbasedupontheMPGofwater consumption.Theotheralternativeistocheckthewaterlevelfairlyoften,butsomedayyoull runthetankdryandwishyouhadspenttheextramoneyforasensorandindicator. Itsbesttouseagenerouslysizedwatertankof.5to1.5gallonscapacity.ThetankIllbe recommendingholdsover2gallonsandhastranslucentlevelmarkings,soitseasytoseehow muchwaterremains.Theextraofcapacityofwatertakesupverylittlespace,butleavesagood reserveforlessfrequentrefilling.Irecommendinstallinga6inchventtubeintothetankcapto preventspillagefromsloshingwater. Youllalsohavetodecideonpumplocation.IfyouusetheselfprimingpumpIrecommend,you canmountitintheenginecompartment.Ifyoudontuseaselfprimingpump,youllhaveto mountthepumpdirectlyontothetank,orcloseby,andatalevelnearthebottomofthetank.

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Also,ifyoudontuseaselfprimingpump,thewaterhosegoingfromthepumptothe Hydrogen/OxygenGeneratorwillhavetobecapableofwithstandingatleast66PSIwater pressure.Thatstheminimumrecommendedpumppressurecapacityrequiredtoovercome maximumgaspressuresof65PSIwithinthegenerator,withanadditional1PSIneededto activatetheonewayvalveinstalledonthegeneratorhousing.Also,ifyoudontuseaself primer,youllhavetorunanextrapowerleadbacktothetrunk.Forthesakeofsimplicityand reliabilityaselfprimingpumpisthebestwaytogo.

InDashIndicators[OPTIONAL]
ReferringtothefollowingFigure2;topermiteasymonitoringofWaterhybridfunctions,I recommendtwogauges:Generatorpressure(GENPRESS)andenginecylinderhead temperature(CHT).Ialsorecommendfourindicatorlights:GENWATERLOW,PUMPON,TANK WATERLOW,andPWRON.Thesecanbeinstalledintoyourvehicledash,ormountedina nearbyconsole.PLEASENOTE:TheInDashIndicatorsARENOTrequired,butareaniceperkif withinyourbudgetandtechnicalexpertise.

Figure2:InDashIndicators

MonitoringtheGENPRESSandCHTgaugesallowsyoutodevelopafeelforhowthesystem respondstovariousdrivingconditions.Theycanalsobeofhelpintweakingthesystemto obtainmaximumperformanceandeconomy. TheGENWATERLOWlightnormallyremainsunlit.Asfuel(water)isconsumed,theGenerator waterlevelgraduallydropsuntiltheGENWATERLOWlightilluminates.Atthatpointthewater pumpshouldstartpumpingwater,illuminatingthePUMPONlight.WhenGeneratorwaterhas

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risenbacktoitsnormallevel,theGENWATERLOWlightshouldgobackout.Atthesametime, thepumpshouldstoprunning,turningoutthePUMPONlight.So,undernormaloperating conditions,bothlightsshouldbeilluminatedatthesametime,andbothlightsshouldgooutat thesametime.Anyotherlightcombinationindicatesamalfunction. TheTANKWATERLOWlightilluminateswhentankwaterleveldropstoits1/3fullpoint, indicatingthatyoushouldthinkaboutfillingthetankbeforelong.ThePWRON(PowerON) lightshouldlight,andremainlit,aslongastheWaterhybridsystemisoperatingnormally.The signalforthislightcomesfromtheHyTronicsModule.So,ifthePWRONlightevergoesout (exceptwhenthesystemisintentionallyturnedoff),orbecomesintermittent,theHyTronics Moduleismalfunctioning.

HyTronicsModule
TheHyTronicsModulecontainselectronicscircuitsforcontrollingand/orprovidingpowertoall thewaterhybridsystemselectricallyoperateddevices.Separatecircuitsexisttoperformeach ofthefollowingfunctions: ProvidepowertotheGeneratorelectrodesintheformofahighfrequencysignal, creatingorthohydrogenandoxygen. ProvidepowertotheGeneratorcoilintheformofaverylowfrequencysignal,creating parahydrogenandoxygen. ControlpowertothewatertankpumpviasignalsreceivedfromtheGeneratorwater levelsensor. Providebusingandterminalpointsfordistributingpowertosystemgauges,indicators, andsensors.

GeneratorElectrodeCircuitSchematic
Figure5depictstheschematicdiagramfortheGeneratorelectrodecircuit.Itsoutputisa squarewavepulsewhichisappliedtothecylindricalelectrodesoftheHydrogen/Oxygen Generatorshowninfigure18. ReferringtothefollowingFigure3,thissquarewavepulsehasanON:OFFratioof1:1.Thatis, thepulseisturnedONforaslongasitsturnedOFF.Thesquarewavepulseshowninthe followingFigure4hasanON:OFFrationof3:1.Thatis,thepulseisturnedONforthreetimesas longasitsturnedOFF.TheGeneratorelectrodecircuitofFigure5iscapableofvaryingits squarewavepulseratiobetween1:1and10:1.

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Figure3:SquareWaveON:OFFRatio1:1

Figure4:SquareWaveON:OFFRATIO3:1

EachON:OFFpulsesequenceisreferredtoasacyclesinceeachnewpulsesequencekeeps cyclingONandOFFinanidenticalway.Figure3showsthreecyclesofON:OFFpulse sequences.Ifthesecycleswerealltooccurwithinatimespanofonesecond,wewouldreferto thepulseashavingafrequencyof3cps(cyclespersecond).If127cycleswerealltooccur withinatimespanofonesecond,wewouldrefertothepulseashavingafrequencyof127cps. Signalfrequenciesusedtobereferredtoinexactlythatmanner(3cps,127cps,etc.).However, becausesomefolkslovetochangethings,thetermsusedtodaywouldbe3Hzand127Hz.The abbreviationHzisusedtohonorMr.Hertz,ascientistwhohelpedpioneerthetheoriesand practicalusesofelectricalsignals.ThesymbolKisusedtodenoteunitsof1,000.Thus3,000Hz wouldbe3KHz,and127,000Hzwouldbe127KHz.Thesquarewavecreatedbythecircuitof Figure5canbevariedinfrequencyfromapproximately8KHzto260KHz.

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 Figure5:GeneratorElectrodeCircuitSchematic

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ThesquarewavepulseratiodeterminestheamountofcurrentsenttotheGenerator electrodesbythecircuitoffigure5.Iftheratioislow(1:1),verylittlecurrentarrivesatthe electrodes.So,verylittlehydrogenandoxygenareproducedbytheGenerator.Iftheratiois high(10:1),maximumcurrentreachestheelectrodesandtheGeneratorproducesmaximum gasvolume.Varyingvoltageinputfromapotentiometerconnectedviaa10Kresistortopin3of componentLM741causesthecircuittovarythepulseratio,andthereforecontrolstheamount ofgasesproduced.Thepotentiometershaftconnectstothevehiclethrottlelinkage,enabling controlofgasvolumeindirectresponsetovoltagechangescorrelatingwithrotationofthe potentiometershaftinrelationtothrottlepositioning.Atrimmingpotentiometerconnectspins 2and6ofcomponentLM741,enablingpreciseadjustmentofthethrottleinputsignal.A secondtrimmingpotentiometerconnectspins4and7ofcomponentNE555,enablingprecise pulsewidthadjustment. TheelectrodepairsofeachGeneratorexhibitauniquefrequencyofelectricalresonanceat whichoptimumgasvolumeiscreated.Thisfrequencyoftenvariesconsiderablyamong differentGenerators.Severalfactorsdetermineresonancefrequencysuchas:electrodesize andshape,Generatorchambersizeandshape,spacingbetweenelectrodes,coilparameters andrelativepositioning,andpulseamplitude(voltagelevel).Atrimmingpotentiometer connectedbetweenpins1and2ofcomponentCD4069allowstheprecisefrequencytobe obtained.Byselectingvariouscombinationsofdipswitchconnectionstoabankoffour capacitors,pulsefrequencycanbevariedbetweenapproximately8KHzand260KHz.

GeneratorCoilCircuitSchematic
ThefollowingFigure6depictstheschematicdiagramforthegeneratorcoilcircuit.Itsoutputis asquarewavepulsewhichisappliedtothecoiloftheHydrogen/OxygenGeneratorshownin figure18.

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Figure6:GeneratorCoilCircuitSchematic

TheGeneratorcoilcircuitcreatesapulsedsignalverymuchsimilartothatoftheelectrode circuitoffigure5;but,productionofparahydrogenandoxygenbythecoilentailstotally differentoperatingparametersthandoesorthohydrogenandoxygenproductionbythe electrodes.Optimumoperatingfrequencyforthecoilismuchlower,withintherangeof approximately16Hzto25Hz.Coilfrequencydirectlycorrelatestotheoptimumoperating frequencyoftheelectrodecircuitsinceitsinputsignalisreceiveddirectlyfrompin3of electrodecircuitcomponentNE555.TheelectrodecircuitsignalisreceivedviatheDivideby Nlogiccircuitwhichproducesoneoutputsignalinresponsetoaspecificnumberofinput signals.Forexample,iftheoptimalfrequencyoftheelectrodecircuitis19KHzandtheDivide byNlogiccircuitcreatesoneoutputpulseforevery1,000inputpulses,theoutputfrequency oftheDividebyNlogiccircuitwouldbe19Hz.Thatsignalisreceivedviapin2ofcomponent NE555,whichcreatestherequiredsquarewavepulses.Thosepulsesaresentviapin3tothe baseoftransistor2N3055,wheretheyareamplifiedandtransmittedtothecoil.

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Thevolumeofparahydrogenandoxygencreatedbythecoilcanbepreciselyregulatedby adjustingthepulsewidthandamplitudetrimmerpotentiometersofitsassociatedcircuit. Parahydrogenactsasanoctanebooster.Therefore,thevolumerequireddependsentirelyupon theoperatingdemandsofyourengine.Sinceparahydrogencoolsthecombustionprocess, excessvolumetendstoreduceengineefficiency.Withthatinmind,thecoilcircuitshouldbe adjustedsuchthatonlyenoughparahydrogeniscreatedtopreventengineprecombustion (knocking).However,ifengineoperatingtemperatureisrunningonthehighside(as determinedbytheCHTgauge)increasingparahydrogenvolumeisaneffectivewaytolowerthe temperature.

InDashIndicatorsCircuitSchematic
TheoptionalInDashIndicatorsCircuitschematicisdepictedbyfigure7.Twogaugesandfour lightemittingdiodes(LEDs)comprisetheInDashIndicatorsassembly.TheGeneratorpressure (GENPRESS)gaugeconnectsviaahosetoitsrespectivefittingontheGeneratoritself(referto figure13).Thecylinderheadtemperature(CHT)gaugeelectricallyconnectstoasensorplaced underanenginesparkplug. WhentheGeneratorwaterlevelsensorisactivatedbylowwaterlevel,its12VDCsignalissent topin2ofdetectorLM741viaa10Kresistor.Detectoroutputfrompin6triggersthebaseof powertransistorE3055T,completingthecircuittoactivatethewaterpumpandilluminatethe PUMPONLED.The12VDCsensorsignalalsoilluminatestheGENWATERLOWLED.When Generatorwaterrisestoitsnormallevel,thelevelsensoropens;turningoffthepumpandboth LEDs. Whenthetankwaterlevelsensorisactivatedbylowwaterlevel(at1/3tanklevel),its12VDC outputsignalilluminatestheWATERLOWLED.Afterrefueling(addingwater),thelevel sensoropens,turningofftheLED.

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 Figure7:InDashIndicatorsCircuitSchematic

WhentheWaterhybridsystemisturnedon,thePWRONLEDilluminates.TheGenerator electrodecircuit(Figure5)activatestheLED.FailureoftheLEDtoilluminateusuallyindicates anelectrodecircuitmalfunction.

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LetsBuildthewaterhybridsystem!:GeneratorConstruction
Electrodes
Sinceenginerequirementsdictatethevolumeofhydrogenandoxygengasesthatthegenerator mustcreate,andgasvolumeisvariable,Irecommendsizingitaslargeasispracticaltoallow reservecapacity.Maximumoutsidediameterof4.5isalreadydeterminedbytheconstruction materialusedfortheGeneratorhousing:4CPVCSchedule80pipe.Irecommendaminimum heightof10.Maximumheightdependsuponavailablespacewithintheenginecompartment but,forstructuralintegrity,limitheightto18.Carefullychecktheenginecompartmentofyour vehicletoensurethatadequatespaceexistsforgeneratorinstallation.Ifadequatespacedoes notexisteitherlimitthegeneratorheight(butnotlessthan10),orlocatethegeneratorwithin thetrunk,orasfarforwardaspossibleunderthedash. Caution Itmaybepossibletoobtain31/2outsidediameterstainlesssteeltubingwithawall thicknessof.040to.063andt304alloyatalocalshopthatmanufacturesexhaust and/ormufflersystems.Alltubedimensions,includingroundness,mustbeheldwithin .005throughoutitsentirelength.Donotuselowqualitytubing.Ifyoudo,theefficiency ofthewaterhybridsystemwillbeseverelydegraded. 1. AfterdeterminingGeneratorheight,obtaina31/2(3.50)outsidediameterstainlesssteel tubewithwallthicknessof.040to.063andlength5shorterthanthedeterminedheight oftheGenerator.AstandardalloyofT304stainlesssteelisrecommendedforthe electrodes.Thistubewillbeusedtoconstructtheouterelectrode.RefertotheGenerator explodedviewofFigure9asanaidtocorrectconstruction. NOTE Thefollowingsteps2through4willbeusedtodeterminetheoutsidediameterfortheinner electrode.Thisprocedurewillcreatea.045gapbetweentheinsidewalloftheouter electrodeandtheoutsidewalloftheinnerelectrode.Thisvalueisanidealgapformaximum andmostefficientproductionofhydrogenandoxygengaseswiththeWaterhybridsystem.

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2. Multiplythewallthicknessoftheouterelectrodebyafactorof2andrecordtheresultas dimensionA.Forexample,ifthewallthicknessis.050,dimensionAwouldbe.100. 3. Addavalueof.090tothevalueofdimensionAandrecordtheresultasdimensionB.For example,ifdimensionAis.100,dimensionBwouldbe.190. 4. SubtractthevalueofrecordeddimensionBfrom3.50.RecordthisvalueasdimensionC. Forexample,ifdimensionBis.190,dimensionCwouldbe3.31. NOTE TheCAUTIONalsoappliestotheinnerelectrode. 5. Toconstructtheinnerelectrode,obtainastainlesssteeltubewithanoutsidediameter equaltotherecordeddimensionC,withwallthicknessof.40to.063,T304alloy,and lengthequaltothatoftheouterelectrode. 6. ReferringtothefollowingFigure8,drilleight(8)holes,spacedat45degreeintervals, aroundthediameterofoneendoftheouterelectrodetube.Locatetheholecenters11/32 fromthetubeedge.Clampalargediameterwooddowelorrodinavisetobackupthe electrodewhiledrilling.Deburrtheholesafterdrilling. NOTE Forbestresults,drillingstainlesssteelrequiresacarbidetippeddrillbitandlight lubricatingoil.Takeyourtimedrillingsoasnottooverheattheelectrode.

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Figure8:ElectrodeDetails

7. Repeattheprocedureofstep6todrilleight(8)holesatthesamedistancefromtheend oftheinnerelectrodetube. 8. ReferringagaintoFigure8,drill1/8holesaroundtheendoftheouterelectrodeclosestto theholes.Locatetheholecenters3/32fromthetubeedge,withholdcentersspacedat 3/8intervalsaroundtheentirediameter.Deburrtheholesafterdrilling. 9. Repeattheprocedureofstep8todrill1/8holesaroundtheentirediameteroftheendof theinnerelectrode.Deburrtheholesafterdrilling.Thoroughlycleanalloilresiduefrom bothelectrodesusingasoftcleancloth,andMEKoracetoneasacleaningsolvent. NOTE Barestainlesssteelweldingrod,T304alloy,canbeobtainedatanyweldingsupplystore. 10. ReferringtoFigure8,cuttwo(2)3rodlengthsfrom3/32diameterbarestainlesssteel weldingrod,alloyT304.Usingafile,squareoffanddeburrtherodends.

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NOTE Silverbearingsolderandfluxcanbepurchasedatanylargehardwareorelectricalsupply store. 11. ReferringtoFigure8,solderoneoftherodstotheoutsidesurfaceoftheouterelectrode. Positiontherodparalleltothelengthoftheelectrodewith2protrudingpasttheendof thetube.Usesilverbearingsolderandfluxappropriateforsolderingstainlesssteel. 12. Repeattheprocedureofstep11tosoldertheotherrodtotheinsidesurfaceoftheinner electrode. 13. Aftertheelectrodeshavecooled,thoroughlyscrubthesolderjointswithwarmsoapywater usingastiffbristlebrush.Thoroughlyrinsetheelectrodeswithwarmwateranddrywitha softcleancloth.

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Housing
Caution Usecpvcpipe(schedule80)toconstructthegeneratorhousing.Donotusepvc pipe,orcpvcschedule40,sinceitwillnotwithstandhightemperatureorpressure aswell. Donotusecpvcpipeofsizegreaterthan4:sinceitdoesnotofferanadequate safetymarginagainstrupturewhensubjectedtohighpressureandtemperature. Carefulattentiontocraftsmanshipanddetailduringgeneratorconstructionis essentialtoensuresafeandreliableoperation. Note AnylargeplumbingsupplyorplasticssuppliermaybeabletosupplyCPVCSchedule80 pipe,fittings,andaccessoriesrequiredtoconstructthewaterhybridgenerator.Ihighly recommendUnitedStatesPlasticCorporationasanexcellentsource;theyhavealways providedfriendlyanddependableservice.
MailOrders: UnitedStatesPlasticCorp 1390NeubrechtRd Lima,OH458013196 PhoneOrders:18005379724(7:30am7pmEST,MonFri) FAXOrders:18008545498(24/7) TechnicalService:18008210349(8am5pmEST,MonFri) CustomerService:1+8007691157(8am6pmEST,MonFri)

Listofmaterials: OneCPVC4threadedpipenipple,length12,Schedule80(USPlasticStock#:30314). OneCPVC4pipe,length12,Schedule80(USPlastic#:29022)(Onlyneededifhousing heightexceeds10). OneCPVC11/2pipe,length12,Schedule80(USPlastic#:29018). TwoCPVC4StraightCouplings,Schedule80(USPlastic#:30059)(Onlyoneneededif housingheightwillbe10).

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OneCPVC4cap,Schedule80(USPlastic#:30047). OneCPVC4threadedcap,Schedule80(USPlastic#:29147). One1/8thick24x48,CPVCsheet(USPlastic#:45299). One1diameter,6length,CPVCrod(USPlastic#:43183). OnepintcanofCPVCcement(USPlastic#:29053). Onepintcanofprimer(USPlastic#:28292). One8ouncecanofpipejointcompound(USPlastic#:16532).

StepbyStepDirectionswithIllustrations: 1. CPVC4Schedule80pipeisusedtoconstructtheGeneratorhousing.Sinceoneendofthe pipewillrequirethreading,Irecommendpurchasinga12threadedpipenippleratherthan threadapipeyourself.RefertotheGeneratorDetailsviewofFigure10asanaidto construction. Note CPVC4Schedule80pipehasanoutsidediameterof4.5. Iftheheightofthehousingwillbe10,asdeterminedduringtheprocedureatthe beginningoftheElectrodessection,followthedirectionsofstep2,thengoto step8.Iftheheightwillbegreaterthan10,gotostep3. 2. Usingamiterboxortablesawtoassuresquareness,cutoffoneofthe12pipenipple threadedends23/4fromtheend.Dressthecutedgeswithsandpaperorafinetoothfile. Gotostep8. 3. Usingamiterboxortablesawtoassuresquareness,cutthethreadedpipenipple51/2 fromoneofitsthreadedends.Dressthecutedgeswithsandpaperorafinetoothround file. Caution Readdirectionsprintedontheprimerandcementcanlabelsforproperuseofthe products.Afterpriming,applycementassoonaspossible,toobtainsafeandreliable bonding.Donotlettheprimerdrybeforeapplyingcement.

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4. Primetheoutsidematingsurfaceofthecutendofthe51/2pipenippleandoneofthe insidematingsurfacesofthecoupling.Applyanevenlayerofcementtotheprimed surfacesandassembletheparts.Allowthepartstoairdryforatleast10minutesbefore goingtostep5. 5. Primetheoutsidematingsurfaceofthe12pipeandinsidematingsurfaceofthecoupling attachedtothepipenipple.Applyanevenlayerofcementtotheprimedsurfacesand assembletheparts.Allowthepartstoairdryforatleast30minutesbeforegoingtostep6. 6. Iftheheightofthehousingistobe18,gotostep8.Iftheheightistobelessthan18,go tostep7. 7. Usingamiterboxortablesawtoassuresquareness,cutthepipeassemblynearthe unthreadedendtoformatotalpipelengthequaltolessthanthehousingheight.Dress thecutedgeswithsandpaperorafinetoothroundfile. 8. Measuretheinsidediameterofthethreadedendcap.Securelyclamp1/8thickCPVCsheet toadrillpressbed.Drilladiameterholethroughthesheet.Usingaflycutter,cutadisk withthemeasureddiameter.Checkthatthediskfitssnuglyintotheendcap.Ifloose, replacewithaslightlylargerdisk.Iftight,replacewithaslightlysmallerdisk.Besuretodrill aholdfirstifanewdiskiscut.Cutaseconddisktothecorrectdiameterwithcenter hole. 9. Applyprimer,andthencement,toonesurfaceofeachdiskandjointhediskstogether. Alignthediskedgesandwipeexcesscementfromtheedges.Allowthediskstoairdryfor anhourbeforegoingtostep10. 10. Referringtofigure9,beveltheedgesofthedisktofitthecurvedcontourofthebottomof theendcap.Besuretheouteredgeofthediskmeasuresbetween1/32and1/16after beveling. Caution Theelectrodeswillbeattachedtothecontoureddisk.Formthecontouraccuratelyto assurestructuralintegrityofthewaterhybrid.

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Figure9:DiskContour

Caution Theendcapwillbetemporarilythreadedontothehousingtoassureaccurate alignmentofthedisk.Donotuseexcessivecementwheninstallingthediskto preventbondingofthehousingandendcapthreads. Besurepetroleumjellycoatsonlytheendcapthreads. 11. Lightlycoatthethreadsofthehousingendcap,andbottomedgeofthehousing,with petroleumjelly.Applyprimertothematingsurfacesofthediskandendcap.Applycement totheprimedareaoftheendcaponlyandinstallthedisk,seatingitfirmlyandevenly. Removeanycementthatoozesfrombetweenthepartswithcottonswabs. 12. Temporarilythreadtheendcapontothehousing,seatingitslowly,butfirmly.Waitabout 15minutesforthecementtopartiallydryandthenremovetheendcap. Caution Besuretomeasuretheinsidediameteroftheunthreadedendcapbeforecuttingdisks. 13. Repeattheprocedureoftheprecedingsteps8through10fortheunthreadedendcap. Theresnoneedtoapplypetroleumjellytoanyareasoftheunthreadedendcap.Apply primertothematingsurfacesofthediskandendcap.Applycementtotheprimedareaof theendcaponlyandinstallthedisk,seatingitfirmlyandevenly.Removeanycementthat oozesfrombetweenthepartswithcottonswabs.

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14. Sealtheholeinthethreadedendcapdiskwithelectricaltape.Usingastiffbristlebrush andwarmsoapywater,thoroughlycleanpetroleumjellyfromthethreadsandallother areasoftheendcapandhousing.Rinseallpartswithwarmwater. 15. Repeatstep14,andthenwipethepartsdrywithasoftcleancloth. 16. Removetheelectricaltapefromthethreadedendcap.Allowtheendcapstoairdryforat least8hoursbeforegoingtostep17. 17. Completelycovertheinsidesurfacesofbothendcapswithstripsofelectricaltape.Cut awaytapetoopenuptheholdineachdisk. Note Thecavityineachendcapwillbefilledwithepoxycement.Topreventtrappingair bubbles,thecapsmustremainlevelwhiletheepoxycures.Centeringandlevelingthe curvedcapsontheinnercoresoflargerollsoftapeworkwell. Caution Useonlyhighquality,hightemperatureandwaterproofepoxycementtofilltheendcap cavities.Usinganyothercementmayleadtoeventualfailureofthegenerator. 18. Purchaseahighquality,hightemperature,andwaterproofepoxycementtofilltheendcap cavities.IhighlyrecommendJBWELD,whichcanbepurchasedatanylargehardwareor autosupplystore.Itcomespackagedintwo2ouncetubes(onetuberesinandonetube hardener).Youwillprobablyneedatleastonepackagetofilleachendcap.Ifyouhave questionsaboutJBWELD,theycanbecontactedat:
JBWELD POBox483 SulphurSprings,TX75483 Phone:19038857696 TollFree:18005293530 Fax:19038855911

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Figure10:GeneratorDetails

Note Allepoxycementscurebychemicalreaction(afterthehardenerismixedwith resin).JBWELDremainspliableforabout30minutes.Theresnoneedtorush fillingtheendcapcavities,butbeawarethatoncethecementismixed,theresno stoppingitfromcuring.Ifyouhavetoremoveoradjustanythingafteritcures, youllneeddynamitetogetthingsapart. Besuretomixequalamountsofresinandhardener(ifusingJBWELD).Theresin andhardeneraredifferentcolors;oneblackandonewhitetoavoidconfusion. Whenmixedproperly,youendupwithanicedarkgraycement.Ifyouaccidentally mixresinwithresin,orhardenerwithhardener,youendupwithnothingbutabig mess.

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19. Mixabouta4ouncebatchofepoxyinadisposablecontainersuchasasmallpapercup. Slowlyfillthecavity(toavoidtrappingairbubbles)tothetopoftheholeinoneofthe endcaps.Ifnecessary,mixmoreepoxy. Note Besureyouhaveenoughepoxyonhandtototallyfilltheremainingcavity.Ifnot, purchasemorebeforestarting.Afterepoxycures,ithasverypooradhesionwithnewly mixedepoxy. 20. Repeatstep19tofilltheremainingendcapcavity. 21. Allowtheepoxytocureforatleast24hours.Removeallelectricaltapefromtheendcaps. Removeanyepoxyfromabovethetopoftheholeuntilflushwiththedisksurfaceby grinding,scraping,sanding,ordoingwhateverisrequired. 22. Measuretheinsidediameteroftheinnerelectrode.Recordthismeasurementasdimension D. 23. Securelyclamp1/8thickCPVCsheettoadrillpressbed.Usingaflycutter,cutadiskwith diameterequaltodimensionDfromthesheet.Checkthatthediskslideseasilyintotheend oftheinnerelectrodeoppositethesolderedrod,beingneitherloosenortight.Ifloose, replace3withaslightlylargerdisk.Iftight,replacewithaslightlysmallerdisk. 24. Subtractthevalueof.250fromtherecordeddimensionD.Recordthisnewvalueas dimensionE.Forexample,ifdimensionDis3.21,dimensionEwouldbe2.96. 25. Securelyclamp1/8thickCPVCsheettothedrillpressbed.Usingaflycutter,cutanother diskwithdiameterequaltodimensionE. Caution Readdirectionsprintedontheprimerandcementcanlabelsforproperuseofthe products.Afterpriming,applycementassoonaspossible.Toobtainsafeandreliable bonding,donotlettheprimerdrybeforeapplyingcement.

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26. Applyprimer,andthencement,tooneoftheflatsurfacesofeachdisk.Jointhedisks, centeringthesmallerdiskonthelargerdisk. Note Theprocedureofsteps27and28willbeusedtocutaflatringfromCPVCsheet.Donot unclampthesheetfromthedrillpressbeduntilstep28hasbeencompleted. 27. Securelyclamp1/8CPVCsheettothedrillpressbed,centeringthecutteratleast3from anyedgeofthesheet.Cuta31/2holeinthesheet. 28. Adjustthecuttertocutaringwithanoutsidediameterof315/16. 29. Checkthattheringslideseasilyontotheendoftheouterelectrodeoppositethesoldered rod,beingneitherloosenortight.Ifloose,replacewitharingofslightlysmallerinside diameter.Iftight,replacewitharingofslightlylargerinsidediameter. 30. Repeattheprocedureofstep27tocuta35/8holdinto1/8thickCPVCsheet. 31. Repeatexactlytheprocedureofstep28. 32. Applytheprimer,andthencement,tooneoftheflatsurfacesofeachring.Jointherings, aligningtheouteredges.Wipeanyexcesscementfromtheouteredges.Allowtheringsto airdryatleast30minutesbeforegoingtostep33. 33. Grindasmallnotchintotheinneredgeoftheringsjustlargeenoughtoallowtheringsto clearthesolderedrodandsolderwhenslidontotherodendoftheouterelectrode. Note Theprocedureofstep34centerstheringswithinthethreadedendcap.Besurethe wrappingtapedoesnotprotrudebelowtheedgeofthesmallerringatanypoint.Donot overlaptapeendsifmoretapeisadded;simplybuttthetapeendsbeforecontinuingto wrap.

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34. Usingplasticelectricaltape,wraptheouteredgesoftheringsuntiltheyslideeasilyintothe threadedendcap.Iftheringsfitloosely,addmoretape.Iftheringsfittightly,removetape. Note RefertothefollowingFigure11fordetailsrelatedtoinstallingtheringsintothethreaded endcap.Applyprimeronlytotheflatsurfaceofthethreadedendcapcontactedbythe smallerring.Donotremovethetapeuntilinstructedtodoso. 35. Applyprimertotheflatsurfaceofthesmallerring.Usingacottonswab,applyprimertothe flatsurfaceofthethreadedendcapcontactedbythesmallerring.Applyathin,evenlayer ofcementtotheprimedsurfacesandinstalltheringassemblyintotheendcap.Allowthe partstoairdrybeforegoingtostep36.

Figure11:ThreadedEndCapDetails

Note Theprocedureofstep36centersthediskscompletedinstep26withinthethreadedend cap.Besurethewrappingtapedoesnotprotrudebelowthesurfaceofthesmalldiskat anypoint.Donotoverlaptapeendsifmoretapeisadded;simplybuttthetapeends beforecontinuingtowrap.RefertoFigure11fordetailsrelatedtoinstallingthedisksinto thethreadedendcap.

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36. Usingplasticelectricaltape,wraptheedgeofthelargediskuntilthetapecreatesasnugfit withtheinsideedgeoftheringassembly. Note Besuretoalignthediskswiththeirnotchoffsetatleastfromtheringnotch,asshown inFigure11. 37. Applyprimertotheflatsurfaceofthesmalldiskandtheflatinsidesurfaceofthethreaded endcap.Applyanevenlayerofcementtotheprimedsurfacesandinstallthediskassembly intotheendcap.Alignthediskswiththeirnotchoffsetatleastfromtheringnotch,as showninFigure11.UsingalargeCclamp,lightlyclampthedisksandendcap.Allowthe partstoairdryatleast8hoursbeforegoingtostep38. 38. Removeallelectricaltapefromthethreadedendcapassembly.Scrapeawayanyexcess cementthatmayhaveoozedontotheflatinsidesurfaceoftheendcapinthoseareasthat willcontactthebottomedgesoftheelectrodesandthreadedendofthehousing. 39. Drilla37/64holethroughthecenterofthethreadedendcapasshowninFigure11. Note Threadswillbetappedlaterintotheholedrilledthroughthecenteroftheendcapto attachthedraincock. Usinga#41bit,drilltwoholesthroughthebottomofthethreadedendcapatthe locationsshowninFigure11. 40. Temporarilyaligneachelectrodeandrodwithitsrespectiveholedrilledinstep39.Check thateachelectrodeandrodcanbeinstalledintothethreadedendcapandseatedfirmlyon thecapsurface.Makeadjustmentsasnecessarytoachievecorrectseatingofthe electrodes.Usingamarkingpen,markashortreferencelinenearthetopinsideofthe innerelectrode.Markanothershortreferencelinenearthetopinsideoftheouter electrode,aligningitwiththemarkontheinnerelectrode.Removetheelectrodesfromthe endcap.

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Note Theprocedureofstep41centerstheinnerelectrodewithintheouterelectrode.Donot overlaptapeendsifmoretapeisadded;simplybuttthetapeendsbeforecontinuingto wrap. 41. Usingplasticelectricaltape,wrapthetopendoftheinnerelectrodeuntilitfitssnuglyinto theouterelectrode.Allowaboutofthetapetoprotrudeabovetheedgeoftheelectrode tofacilitateeasyremoval.Donotremovethetapeuntilinstructedtodoso. 42. Arrangeawaytosolidlysupportthethreadedendcapwhileinstallingtheelectrodesand whiletheepoxycures(takesabout8hours).Centeringandlevelingthecurvedcaponthe curvedcapontheinnercoreofalargerolloftapeworkswell. 43. Onceagain,cleanthebottomendsoftheelectrodeswithMEKoracetoneusingasoftclean cloth. 44. Sealthebottomsofthetwoholesintheendcapwithshortstripsofelectricaltapeto preventepoxyfromdrippingout.Thetapeswillbepushedasideastheelectroderodspoke through,afterwhichthetapescanberemoved. 45. Mixupabouta2ouncebatchofepoxyinadisposablecontainersuchasasmallpapercup. Filltheslotintheendcap(wheretheelectrodesareinstalled)allthewayaroundtoabout itshalffulllevel. Note Besuretoinstalltheouterelectrodefirst. 46. Usingyourfinger,applyaverythin,butunbroken,coatofepoxycompletelyaroundthe bottomedge(rodend)oftheouterelectrode.Formabandexte4ndingabouthighfrom thebottomedge,coatingboththeinsideandoutsidesurfacesoftheelectrode.

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Caution Thesmallholesaroundthebottomedgesoftheelectrodeshelpsecuretheelectrodesto theendcapbecauseepoxyfillstheholes.Installtheelectrodesslowlyintotheendcap slotsoasnottotrapairbubbleswithintheholes. 47. Installtheouterelectrodeintotheendcap.Astheelectrodestartstoentertheslot,lowerit veryslowlysothattheepoxyhassufficienttimetoflowintothesmallholesdrilledaround thebottomedgewithouttrappingairbubbles.Aftertheelectrodeisfirmlyseatedontothe endcapsurface,removethetapefromthebottomoftheendcap. 48. Applyathinfilmofpetroleumjellytothesurfaceofthetapewrappedaroundthetopof theinnerelectrode. 49. Repeattheproceduresofsteps46through48toinstalltheinnerelectrodeintotheend cap.Usethealignmentmarksonthetopsoftheelectrodesasanaidinlocatingtherod holdintheendcap. 50. Placeaboutfivepoundsofweightontopoftheelectrodestohelpkeepthemfirmlyseated againsttheendcap.Foldingatowelortwointoseveralfoldsandplacingthemontopofthe electrodes,withastackofhardcoverbooksontop,workswell.Thatmethoddistributesthe weightevenly,whichcanotherwisebedifficultbecauseofthetapeprotrudingfromthetop oftheinnerelectrode. 51. Usingcottonswabs,removeanyexcessepoxyoozingfromtheeightholesaroundthe bottomsoftheelectrodes.Ifnecessary,continuetodothisuntiltheepoxybeginstothicken (inabout3045minutes).Usinghouseholdtissuesordisposablerags,cleanepoxyfromthe rodendsprotrudingthroughtheendcap,andfromthesurroundingsurfaceoftheendcap. Caution ALLOWTHEEPOXYTOCUREFORATLEAST24HOURSATTEMPERATURESOF70DEGREES ORHIGHERBEFOREREMOVINGTHEELECTRODEWEIGHTSOROTHERWISEDISTRUBING THEELECTRODEASSEMBLY.FORLOWERTEMPERATURESALLOWEVENLONGERCURE TIME.

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52. Removetheweightsfromtheelectrodeassemblyaftertheepoxyhascuredforatleast24 hours,andremovethetapefromtheinnerelectrode. 53. Using#400grit(orfiner)sandpaper,removeepoxyresiduefromtherodendsprotruding throughthebottomofthethreadedendcap.

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HousingAttachments
1. Temporarilythreadtheelectrodeassemblyontothegeneratorhousing,tighteningitfirmly. Supporttheentireassemblyontheinnercoreofalargerolloftapeaswasdoneinthe precedingstep42. 2. ReferringtothefollowingFigure12,fabricate3coilsupportbrackets(withtheindicated dimensions)from1/8thickCPVCsheet. Note Formostefficientoperation,thecoilmustbelocatedapproximatelyabovethetopsof theelectrodes.Ashimisplacedbetweentheelectrodesandeachbrackettoachieve correctclearance.Exercisecaretoavoidcementingshimstothebrackets. 3. Usescrappiecesof1/8thickCPVCsheetasshimsbetweenthetopsoftheelectrodesand thebrackets.Applyprimer,andthencement,tothebracketsandtheinsidewallofthe housingat120degreeintervalsasshowninFigure11.Attachthebracketsandallow cementtoairdryforatleast30minutesbeforegoingtostep4.

Figure12:CoilMountingBrackets

4. Removetheelectrodeassemblyfromthehousing.

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Note BracketarrangementsformountingtheGeneratoraredictatedbytherequirementsof eachsysteminstallation.Figure13showsoneofthesimplestandmostcommonlyused arrangements.Otherarrangementscanbeeasilyconstructedwith1/8CPVCsheet. Bracketsthickareconstructedfromtwolayersof1/8thickCPVCsheet. 5. Cutfour11/2x6mountingbracketstripsfrom1/8thickCPVCsheet,asshownFigure 13.Dresstheedgesofeachstripusingsandpaperorafinetoothfile.Formeachofthetwo bracketsbyapplyingprimer,andthencement,tothematingsurfacesofeachoftwostrips andjoiningthemtogether.Aligntheedgesofeachstripandwipeexcesscementfromthe edges. Note Materialfromaringcutfromthestraightcouplingwillbeusedtomakepartofthe Generatorhousingbrackets.Itwillalsobeusedtomakeadoublertoincreasewall thicknessofthehousingwhereahosefittingisinstalled. 6. Cuta11/2wideringfromtheendofthecoupling.ReferringtoFigure14,andusinga bandsander,sandthesideoftheringtoformaflatsurfaceapproximately11/4wide. Sandthesideoftheringatanotherpointtoformasimilarsurface.Cuteachoftwoflat surfacesectionsfromtheringbycuttingatbothendsofeachflatsurface.Asshownin Figure14,thiswillformtwosectionsfromthering,eachwithflatoutsidesurfaces11/2 byapproximately11/4.Dresstheedgesofeachsectionandroundthecornersslightly usingsandpaperorafinetoothfile. 7. AsshowninFigure14,attachapipesectiontoeachofthetwobracketsattheirmidpoints, applyingprimertotheflatsurfaceofeachsectionanditsmatingsurfaceonthebracket, andthenapplyingcement.Besuretosquarethecurvedsurfaceofeachsectionwiththe lengthofthebracket. 8. Makeadoublerbycuttingasection11/2widefromtheringasshowninFigure14.Dress theedgesandroundthecornersslightlyusingsandpaperorafinetoothfile.

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 Temporarilythreadtheendcapontothehousing,seatingitfirmly.Chooseapoint anywherearoundthehousingasshowninFigure14,andmarkaspotupfromtheedge oftheendcap.Removetheendcap.Applyprimer,andthencement,tothematingsurfaces ofthedoublerandhousingandattachthedoublertothehousingwithitsloweredgeatthe markedspot.Aligntheedgeparalleltothehousingbottomedge.Allowthecementtoair dryforatleast8hoursbeforegoingtostep9.

Figure13:HousingAttachmentDetails

9. Drilla37/64holethroughthecenterofthe11/2x11/2doublerandhousingwallas showninFigure14.Besuretokeeptheholesquarewiththehousingwall. Note Threadswilllaterbetappedintotheholetoinstallabarbedhosefittingtoconnecttothe checkvalve. 10. Drillafastenerholeneartheendofeachbracket(totalof4holes)atthelocations showninFigure14.Slightlyroundthecornersofeachbracketusingsandpaperorafine toothfile.

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Note Thecheckvalvehoseattachestoabarbedfittingtobeinstalledlaterintotheholedrilled instep9.Determinethedirectioninwhichyoupreferthefittingtopointinrelationtothe mountingbrackets.Irecommendhavingthefittingpointdirectlyleft(asshowninFigure 13)ordirectlyrighttominimizegeneratorspacerequirements. 11. PositionthebracketsasshowninFigure13,andclampthemtoaflatsurface.Checkthat thehousingseatsevenlyintothecurvedsectionofeachbracketwithnogapsbetweenthe housingandcurvedsection.Ifnecessary,loosentheclampstorepositionthebrackets.

Figure14:MoreHousingAttachmentDetails

12. Applyprimer,andthencement,tothematingsurfacesofthebracketsandhousing.Attach thehousingtothebrackets.Placesupportingblocksoneachsideofthehousingtokeepit fromrotatingorshiftingduringassembly.Waitatleast8hoursbeforelooseningtheclamps andmovingthehousingassembly.

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UnthreadedEndCap
ListofMaterials:
Threadtaps,1/8NPTFand3/8NPTF(CuttingToolSupply:specifyGreenfieldtapsforCPVC pipe,orobtainlocally). Two1/8NPTx1/8BarbedHoseFittings(SMCPart#:253490). Two3/8NPTStainlessSteelInlineCheckValves(GenerantPart#:ICVMM375SS1). One3/8NPTpressurereliefvalve(StraValPart#:RVA05,3/8NPT,specifypressuresettingof 85PSI). One3/8NPTInternalSeatDrainCock(FastenerHutPart#:230A). Five3/8PTFx3/8BrassBarbHoseFittings,MalePipeRigid(PTFShort)(FastenerHutPart#: 10506B106A). Four3/8NPTFx3/8BrassBarbHoseFittings,FemalePipeRigid(FastenerHutPart#:10506B 206A). One35SSSeriesStainlessSteelTopMountLevelSwitch,1/8NPT(NorgenPart#:0107024). OneLS11PlasticSideMountLevelSwitch,PBT,5/811UNC(NorgrenPart#:1873024).

MaterialSource(Weencourageyoutoresearch(tryGoogle)yourownsources,aswe cannotguaranteethesesourceswillofferthebestpricesoralwaysbeavailable:
CuttingToolSupply(CTS) 340WGerriLa Addison,IL60101 Phone:16305437171Fax:16305436906 TheSpecialtyMfgCo(SMC) 5858CentervilleRd. St.Paul,MN55127 Phone:16516530599Fax:16526530989 Generant 1865Route23S,POBox768 Butler,NJ07405 Phone:1973886500Fax:19738384888 StraVal 21ColumbusAve. Garfield,NJ07026 Phone:19733409258 TollFree:1888380966Fax:19733409933 FastenerHutInc. 3781GlengarryWayNE Roswell,GA300752615 Phone:17704804617Fax:1+7709982721

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Norgren,c/oKipFluidControls,Inc 72SpringLn Farmington,CT06032 Phone,TollFree:18007225547Fax:18606774999

Note A short length of CPVC rod inside the end cap will be used as a spacer for the water level switch. Directions: 1. Usingamiterboxortablesawtoassuresquareness,cutaspacerapproximately2long from1diameterCPVCrod.UsinganRsizedrillbit,drillaholethroughthecenterofthe roditsentirelength,andparalleltoitslength.Alsodrillaholdthroughthecenteroftheend capwiththeRdrill,asshowninFigure15.

Figure15:UnthreadedEndCapDetails

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Caution BesuretouseonlyNPTFtaps.topreventpossiblewaterandgasleakage,donot useNPTtaps.bothNPTandNPTFthreadswillsealproperlyinNPTFtappedholes. Besuretotaptothecorrectdepthbyturningthetapuntilthe12ththreadfrom thefrontofthetapfullyentersthehole. Besuretoalwayskeepthetapalignedparalleltothesidesofthespacer. 2. Usinga1/827tap,tapthreadsintooneendoftheholedrilledinthespacer.Besureto keepthetapalignedparalleltothesidesofthespacerandtotaptothecorrectdepthof12 threadsfromtheendofthetap. 3. Temporarilythreadthe35SSwaterlevelswitchintothetappedhole,seatingitfirmly.Insert theswitchpowerleadsfrominsidetheendcapthroughthedrilledhole.Measureand recordthedistancefromtheinsidesurfaceoftheendcap,asshowninFigure15. 4. Applyprimer,andthencement,totheuntappedendofthespaceranditsmatingsurface insidetheendcap.Installthespacer,beingcertaintoaligntheholesinthespacerandend cap.Usingacottonswab,removeanyexcessgluethatmayhaveoozedintothehole.

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SloshShield
1. Usingamiterboxortablesawtoassuresquareness,cuta31/16longsectionfrom11/2 CVPCpipe.Drillfour(4)1/8holesintothesidesofthepipe,spacedat90degreeintervals andfromtheedgeasshowninFigure16. Note Sixofthesevendiskscutwillbeusedfortheflamearrestor. 2. Usingaflycutter,cutseven(7)157/64diskfrom1/8thickCPVCsheet.Drilla3/8 diameterholethroughthecenterofoneofthedisks. 3. Applyprimer,andthencement,tothematingsurfacesofthedrilleddiskandtheendofthe pipeoppositethefourholes.Attachthedisktothepipe,beingsuretocenterthediskon thepipe.

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FlameArrestor
1. Usingamiterboxortablesawtoassuresquareness,cuta3longsectionfrom11/2CVPC pipe. 2. Usingaflycutter,cuta11/2diskfrom1/8thickCPVCsheet.Checkthatthediskfits snuglyinsidethepipecutinstep1.Ifitdoesntfitsnugly,adjustthecutterasrequiredand cutatotaloffour(4)disks.

Figure16:SloshShieldDetails

3. Applyprimer,andthencement,tothesurfaceofeachoftwodisksandjointhedisks together.Alignthediskedgesandwipeexcessgluefromtheedgeofthejoineddisks. Repeattheprocedureforthetworemainingdisks. 4. Inthesamemannerasinstep3,make2stacksof3diskseachfromthesixdiskscutinstep 2oftheSloshShieldprocedure.Allowthediskstoairdryforatleastanhourandthendrilla 37/64holethroughthecenterofeachofthetwostackeddisks. 5. ReferringtothefollowingFigure17,drillatotalofthirteen(13)1/8holesthrougheachof thetwo11/2disksattheindicatedlocations.

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 Figure17:FlameArrestorDetails

6. Applyprimertotheedgeofoneofthe11/2disksandabout3/8intoeitherrendofthe 3pipebore.Applycementtotheprimedsurfacesandslidethediskintothepipebore, creatinga1/8gapbetweenthediskandthepipeendasshowninFigure17.Formasmall filletofcementaroundtheouterjunctionofthediskandpipebore.Standthepipeonend for5or10minutes(untilthecementwontrun)topreventpluggingtheholeswithcement. Ifanyholeisplugged,useashortlengthofstainlesssteelrodtoopenitbackup.Allowthe cementtoairdryforaboutanhourbeforegoingtostep7. 7. Packtheinsideoftheflasharrestorwithcoarsestainlesssteelwool.Repeattheprocedure ofstep6toinstalltheremaining11/2disk. Note Stainlesssteelwoolisavailableatsomelargesupermarkets,oryoucanpurchaseitfrom thefollowingsource:
JWP 2575WLemoyne MelrosePark,IL60160 TollFree:18007329336 FAX:170834580810

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Caution BesuretouseonlyNPTFtaps.topreventpossiblewaterandgasleakage.donot useNPTtaps.bothNPTandNPTFthreadswillsealproperlyinNPTFtappedholes. Besuretotaptothecorrectdepthbyturningthetapuntilthe12ththreadfrom thefrontofthetapfullyentersthehole. Besuretoalwayskeepthetapalignedsquarelywiththesurfacearoundthedrilled hole.

Note Besurethetwostacksofthreedisksjoinedintheprecedingstep4haveairdried foratleast24hours. Whendrillingholesinthefollowingstep8,besuretokeepthedrillbitssquared withthecurvedoutersurfaceoftheunthreadedendcap.Thisplacestheaxisof eachofthethreeholesatanangletotheaxisofthecenterholeasshownFigure 15. 8. ReferringtoFigure15,drilltwo37/64holesthroughthetopoftheunthreadedendcap, eachlocated13/4fromthecenterholeinthecap.Besuretokeepthedrillbitsquared withthecurvedoutersurfaceoftheendcap. UsingandRsizebit,drillaholethroughthetopoftheendcap13/4fromthecenter holeinthecapasshowninFigure15. Note Besuretokeepthetapsalignedsquarelywiththesurfacearoundtheholes.Taptothe correctdepthof12threadsfromtheendofeachtap. 9. Tap3/818threadsinto37/64holesatthefollowinglocations: Twoholesontopofunthreadedendcap. Oneholeonbottomofthreadedendcap.

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 Oneholeindoubleronhousingwall. Oneholeineachoftwoflamearrestorendcaps. 10. Tap1/827threadsintotheRsizeholeclosesttotheedgeontopoftheunthreadedend cap. 11. Usinga3/818tap,tapthreadsintothe37/64holeineachofthetwostacksofthreedisks joinedintheprecedingstep4.Applyprimer,andthencement,tothematingsurfacesof oneofthestacksofdisksandthe3flamearrestorpipe.Attachthediskstothepipe,being surethetappedendoftheholefacesoutward.Repeattheprocedurefortheremaining stackofdisks.

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WaterLevelSwitchTest
Note Itisimportanttoverifycorrectoperationofthewaterlevelswitchbeforeinstallingits sloshshield.

Caution Neverattempttocontrolpowertoanyelectricaldevicedirectlythroughthewaterlevel switch.Doingsowilldamageordestroytheswitch.

Note Thewaterlevelswitchcontainsveryhighqualitymagneticreedcontacts.Itwill reliablyoperatethroughmillionsofcycleswhenconnectedtoaproperlydesigned electroniccircuit. ThewaterlevelswitchisusuallysuppliedwithNC(normallyclosed)contact configuration.Step1verifiestheNCconfiguration. 1. Connecttheohmmeterleadstotheswitchpowerleads.Suspendtheswitchfromitspower leadsandverifythattheohmmeterindicatesclosedswitchcontacts.Ifthecontactsarenot closed,gotostep3. 2. Slowlyslidetheswitchfloatupward.Verifythatitscontactsopenatapproximatelythe midpointoffloattravel.Ifthecontactsopenproperly,gotostep4.Ifthecontactsdonot openproperly,theswitchisdefectiveandmustbereplaced. 3. Usingamarkingpen,markasmalldotontopoftheswitchfloat. Note TheswitchprobablyhasNO(normallyopen)contactconfiguration.Invertingthefloat changesittotherequiredNCconfiguration.

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Carefullyremovethefloatretainingclipatthebottomofthecentertube.Removethefloat, invertitandreinstall.Reinstalltheretainingclip.Verifythatthedotonthefloatisnowat thebottomandrepeattheprocedureoftheprecedingsteps1and2. 4. Usingacountersinktool,orlargedrillbit,formasmallbevelintheouterendofthecenter holeintheunthreadedendcapthroughwhichtheswitchleadspass. Note Asanaddedprecautionagainstpossiblewaterand/orgasleakage,Irecommendusing pipejointcompoundonallthreadedGeneratorhousingcomponents.

Caution Donotapplyexcessivetorquetothewaterlevelswitchthreadswhileinstlalingtheswitch intoitsmountingspacer.Excessivetorquecandamagethespacerthreads,causingwater and/orgasleakage,andpossiblesystemfailure. 5. Applyalightcoatingofpipejointcompoundtothethreadsoftheswitchandmounting spaceraccordingtodirectionsontheproductlabel.Inserttheswitchpowerleadsthrough thespacerholeandthreadtheswitchintoplace,seatingitfirmly. Note Thefollowingstepsareusedtoverifycorrectswitchoperationinresponsetowaterlevel changes. 6. Obtainatransparentcontainer(suchasalargeglassjar)withanoutsidediameterof approximately21/2to33/4andinsidedepthofatleast31/2. Placetheunthreadedendcapontopofthecontainerwiththeswitchinside.Besurethe bottomsurfaceoftheendcapseatsevenlyontopofthecontainer.Positiontheendcapso thatatleastoneofthelargetappedholesprojectsinsidethecontainerandtheswitchfloat isatleastawayfromthecontainerwall.

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Note Measurethewaterlevelwiththeswitchfloatinwater. 7. Connecttheohmmeterleadstotheswitchleads.Checkthattheswitchcontactsareclosed. Veryslowlypourwaterthroughthelargetappedholeuntiltheswitchcontactsjustopen, andremainopen.Ifthecontactscloseagain,addaslightamountofwaterandwaitseveral secondsbeforecheckingagain.Keeprepeatingthisprocessuntiltheswitchremainsopen. Checkthatthewaterlevelisatleast2fromthetopedgeofthejar.Ifthewaterlevelisless than2fromthetop,theswitchisdefectiveandmustbereplaced. 8. Removetheendcapassemblyfromthejaranddryasnecessarywithasoftcleancloth. 9. Applyprimer,andthencement,tothematingsurfacesofthesloshshieldandendcap. Attachthesloshshield,centeringitaroundtheswitchfloat.

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ToroidCoil
ListofMaterials: OneFerriteToroidCoilCore,3.50ODx2.00IDx.500Thick(NationalMagneticsPart#: 995). CopperMagnetWire,Tefloncoate4d,HeavyBuild,23AWG,550Ft(MWSWire Industries,mustbecustomordered) TeflonEtchingSolution(FluoroEtch)(ActonTechnologies) OnePackageHeatShrinkTubing,AssortedSizes(RadioShack,Catalog#:2781610). MaterialSources:
NationalMagneticsGroup 1210WinDr. Bethlehem,PA180177061 Phone:16108677600 FAX:16108670200 MWSWireIndustries 31200CedarValleyDr. WestlakeVillage,CA91362 Phone:18189918553 Fax:18187060911 ActonTechnologies 100ThompsonSt. POBox726 Pittston,PA18640 Phone:15706540612 Fax:15706542810 RadioShack (Nationwidestores)

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Note Thewaterhybridcoilishandwoundaroundaferritetoroidcorewithinsulated, hightemperaturecopperwire.Closeattentiontodetailandcraftsmanshipis essentialtobuildinganefficientandreliablecoil.Thereareliterallymillionsof differentcoilconfigurationsinexistence.Itsagreatareaforexperimentingsince coildesignisasmuchartasitisscience.Believeitornot,theresactuallyan organizationdedicatedtothecraft,theInternationalCoilWindingAssociation, basedinEngland. Beforewarnedthatwindinganycoil,especiallyatoroidcoil,isatediousaffair,but Illdomybesttomakethejobaseasyaspossible.Thecoiliscreatedfrom2,000 turnsofinsulatedcopperwirewrappedaroundacircularmagneticallysensitive core.Thatmeansyouhavetodrageachwirewrapthroughthetoriodcorejustas manytimes. Tefloninsulatedcoppermagnetwireistheonlywaytogo.Ithandlesheat extremesverywellandisimpervioustojustaboutanythingyoucanthrowatit.It isntcheap,butwellworththeinvestment. CustomorderitfromMWSWireIndustries.Theycarryover25,000different magnetandspecialtyapplicationwires.BesuretoorderDoubleBuild(extra heavy)insulation,23AWG.Youllneedabout500to550feet,soitsprobablybest toorder550feet. Directions: Afterthecoiliscompleted,itshouldbecoatedwithafewthinlayersofCPVCcement.That wayyouendupwithsomethingthatwilllastforever,ispracticallybombproof,andiseasy tosolidlyattachinsidethehousingwithCPVCcement.But,gettinganythingtostickto Teflontakesspecialchemicaletching(thatswhyTefloncookwareissopopular).Its commerciallydonebyetchingwithsomeprettynastystuff.Severalcompaniesspecializein theprocess,butyoudontwanttoknowthecost.Asafeandeasyetchingprocessthatcan bedoneathome,yetgivesgreatresults,hasrecentlybeendevelopedusingaproduct calledFluoroEtch.YousimplywarmFluoroEtchtoabout130degrees,sloshthecoilaround initforaboutaminute,sloshinisopropylormethylalcohol(sadly,thekindsyoucant drink)foraminuteorso,washinwarmsoapywater,rinsewithwarmwater,andletairdry. Afterdoingthat,justaboutanythingwillsticktotheTefloncoatedcoilwire.Imtellingyou

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allthissothatwhenyoucallthenicefolksatActonTechnologiesyoullsound knowledgeableenoughthattheywonthesitatesellingyouFluoroEtch. 1. Irecommendcuttingthemagnetwireintofour(4)100lengthsandone(1)150length. Otherwise,youhavetodrag550ofwirethroughthecore2,000times.Usingmath,that worksouttojustover104milesofwiredragging(averagedover550feet),oronesorearm andatangledmess!Byworkingwith100and150lengths,youhavetomakefoursolder splicestothewire,butyoucutyourwiredraggingdowntolessthan22miles.Youcould evengowitheleven(11)50lengths;cuttingitto91/2milesand10soldersplices.Or, carriedtotheextreme,550onefootlengthscutsittolessthanmile(1,001feet),butyou havetomake549soldersplices! Donttryshortcuttingthingsbywrappingthewirearoundthecoreseveraltimesand pullingtherestofthewireonthrough.Thecontinualbendingandstraighteningwilldestroy thewirelongbeforeyoureachitsend.Amodifiedversionofthatmethodworks,buttakes afairamountofskillandexperiencetomaster(orrequiresspecialequipment).

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 Figure18:TheIncredibleWaterhybridsystem!

Forminga3.5ODx2IDx.50toroidcoilfrom23AWGwirerequiresabout250turns ofwireperwrappedlayer.Sincethecoilbuildsinsizeasitswrapped,eachwrapuses anaverageofabout3ofwire.So,each100wireprovidesabout400wraps,orslightly over11/2layers.Therefore,four(4)100footlengthsandone(1)150footlengthwill buildan8layercoilofatleast2,000turns.

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Note Savethe150wireforthelastlayerincaseyouneedextrawiretocompletethe 8thlayerwithoutsplicingnearthecoilentrywire.Anytimeyouinterrupt wrapping,besuretotightlywrapastripofplasticelectricaltapecompletely aroundthecoiltosecurethelastwrap.Teflonisextremelyslipperystuff;youdont wanttocomebackonlytofindthatallyourcoilwrapsareloose.Itwillhappenif youdontusetape! Thefirstcompletewrappingoftheentirecoildiameterformslayer#1fortheinner core.Thisistheonlycriticallayersinceeachsubsequentlayerwillautomatically positionitselfbynestingbetweenthewiresofthepreviouswrap. 2. ReferringtoFigure19,slipa1lengthofsmallheatshrinktubingabout4ontothemagnet wireandapplyheattoshrinkitinplace.Ifyouarerighthanded,youllprobablychooseto wrapthecoilinaclockwisedirection,holdingthecorewithyourlefthand.Inthatcase,lay theshrinktubingontopofthecore,angledofftotheleftatabout30degreesfromstraight outasshown.Startthefirstwirewrapoverthetubingataboutitsmidpoint.Thiswillbethe startoflayer#1fortheinnercore.Besuretokeepthewirewrapstightsagainsteachother ontheinsideedgeofthecore,withnooverlapping.Keeptensiononthewire,withthewire alwayspointingstraightoutfromthecore.Precisewirepositioninghaslittletonoeffecton overallcoilperformance.But,thefirstwrapdictatesthewirepositionsofeachsubsequent wrapsinceeachwirewillfallintothedepressionformedbetweenthetwowiresofthe precedingwrap.Inshort,ifyoudoasloppyjobonthefirstlayer,youllendupwithasloppy coil.So,takeyourtimetodothejobright.Continuewrappinguntilyouhavecompleteda fullturn(completingcoilinnerlayer#1).Tightlywrapastripofplasticelectricaltapearound thewireandthecoilentrywireattheendoflayer#1. 3. Checkthepositionofeachwireontheoutsideedgeofthecore.Ifwrappedperfectly (which,ofcourse,isimpossible)therewillbea.019gapbetweenanytwowires.But,you canpositioneachwirecloseenoughbyusingashortpieceofcoilwireasafeelergauge.If thefeelergaugewiretouchesthecoresurfacebetweenanytwowires,thegapistoowide, soatleastoneofthewiresisoutofposition.Usingyourfingernail,orotherbluntended instrumentthatwontdamagethewires,slightlyshiftwirestoclosethegapenoughtokeep thefeelergaugefromcontactingthecoresurface.Anygapthatistoowideindicatesan adjacentgapistoonarrow,sothosewiresshouldbemovedfurtherapart.Aftergoing aroundthecoilafewtimes,youwillalsobeabletovisuallydetectwiresoutofposition.

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 Figure19:ToroidCoilDetails

4. Mixaboutaouncebatchofepoxy(suchasJBWELD).Usingasmallbrush,carefullyapply athinlayerofepoxyaroundtheouteredgeofthecoil.Applywithamotionparalleltothe wirestopreventwiremovement,beingsureepoxycontactsthecoiledsurfacebetween wires.Suspendthecoilfromitswiresandallowtheepoxytocureforatleast8hoursbefore goingtostep5. Note Whilewrappingcoillayer#2,besuretocountandrecordthenumberofturns. 5. Startwrappingcoillayer#2,exercisingcaretopositioneachwireintothegapformed betweenthewiresoflayer#1ontheinnerandouteredgesofthecoil.Countandrecord thenumberofturns. Continuewrappinguntilyougetwithinaboutonefootofthewireend.Securethewireby tightlywrappingplasticelectricaltapearoundthewireandcoil.

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Note Coilthicknesstapersdownbetweentheinnerandouteredges.Tominimizeinnercoil thickness,positionwiresplicesonthetoporbottomofthecoil,midwaybetweenthe edgesasshowninFigure19. 6. Temporarilywrapthewirefortwoorthreemoreturnsandcutitaboutshortofthe outeredge.Tosplicetothenextwirelength,unwrapthewireanduseasharpknifeto scrapetheTefloncoatingfromaboutofeachwireend.Alwayskeeptheknifeblade perpendiculartothewiretopreventdamage. 7. Slidealengthofheatshrinktubingovertheendofthenextlengthofcoilwire.Besure thetubingislargeenoughtofitoverawiresplice.Twistthewireendstogetherfor7or8 turnstoformasplice.Cutthesplicetoalengthofaboutandbenditbacktowardthe coiluntilitlaysflushagainstthecoilwire.Solderthesplice,slidetheshrinktubinguntilits centeredoverthesplice,andapplyheattoshrinkthetubing.Waitaminuteortwoforthe tubingandsplicetocoolandgoontostep8. 8. Removetheelectricaltapefromthecoilandcontinuewrappinguntillayer#2iscompleted. Recordthetotalnumberofturnsrequiredtocompletelayer#2. Note Althoughthetotalnumberofcoilturnsisnotcritical,almostallcoilsrequireatotalof8 wirelayers. 9. Referringtotherecordednumberofcoilturnsneededtocompletelayer#2,determinethe numberofcoillayersrequiredtocompletethecoilwithatotalnumberof1,800to2,100 turns. Note Besuretoendthelastcoillayernearthebeginningoflayer#1.Donotfinishthecoilwith apartiallastlayer.

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10. Repeattheprocedureoftheprecedingsteps5through7untilthelastlayerhasbeen completed.Besurethelastturnendswithinaturnortwoofthecoilentrywire.Cutthelast wiretoalengthofabout12. Note Donotshrinktheheatshrinktubinginthefollowingstep11.Itwillbeusedonly temporarilytosecurethecoilwires. 11. ReferringtoFigure19,temporarilyslidea5lengthofheatshrinktubingovertheendsof thecoilwires.Drawthetubingsnuglyupagainsttheoutercoiledgeandbendthecoilleads backtowardthecoilattheouterendofthetubing.Tightlywrapeachcoilwire4to5turns aroundthetubingabout1fromtheend,andtwistthewirestogetherforatleast5or6 turns. Caution Exerciseextremecaretopreventdamagingthecoilwiresduringthefollowing procedures. ToassureproperbondingofCPVCcementtothecoilafteretching,donothandle thecoilwithbarehands.Ifthecoilmustbehandled,wearcleancottongloves. 12. UsingFluoroEtch,whilesuspendingthecoilbytheheatshrinktubing,etchthesurfacesof theTefloncoatedcoilwires.Closelyfollowthedirectionsontheproductlabel.Ifnecessary asanaidtoetching,refertothegeneraldescriptionoftheetchingprocedurecalledout laterinthisdocument.Alwayshandlethecoilbysuspendingitfromthetubingduringeach phase,frometchingthroughfinalwarmwaterrinse.Usecleanpapertowelstoabsorb waterdripsfromthebottomofthecoiluntildrippingceases.Allowthecoiltoairdryforat least4to5hoursbeforegoingtostep13. 13. Usingasoftbristlebrush,coattheentiresurfaceofthecoilwithathinandevenlayerof CPVCcement.Usecottonswabstowipeawayexcesscementthatmaybedrippingfromthe bottomofthecoiluntildrippingceases.Allowthecementtoairdryforatleastanhourand thenapplyasecondthinandevenlayerofCPVCcementinthesamemanner.

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14. Repeattheprocedureoftheprecedingstep13untilatotalof5or6layersofCPVCcement havebeenappliedtothecoil,allowingatleastonehourdryingtimebetweeneachlayer. Allowthefinallayerofcementtoairdryforatleast8hoursbeforegoingtostep15. Caution Exercisecarenottopullthecoilexitwireawayfromthecoilwhileremovingtheheat shrinktubing. 15. Unwrapthecoilwiresfromtheheatshrinktubingandremovethetubingfromthewires. Cuta1lengthofheatshrinktubinglargeenoughtoslipsnuglyoverthecoilwiresandthe shrinktubingofthecoilentrywire.Drawthetubingtightlyupagainstthecoilouteredge andapplyheattoshrinkthetubing. 16. Usingasoftbristlebrush,applyathinbeadofCPVCcementaboutwidearoundthecoil endofthetubingandsurfaceoftheoutercoiledge.Allowthecementtoairdryforabout anhourandthenapplyasecondbeadofcementoverthefirstbead. 17. Suspendthecoilfromtheendofitswiresandallowittoairdryforatleast24hoursbefore goingtostep18. 18. Cutthecoilwirestoalengthof3fromthecoil.

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ToroidCoilInstallation
Note Irecommendlocatingthecoilelectricalconnectionsonthesideofthehousingdirectly oppositethewaterpumpinletport.Thislocationminimizespossiblecoilwireconnector fatigueduetotheeffectsofwaterturbulenceathighpumppressure. Usinga#41drillbit,drilltwoholesinthehousingwallatthelocationsshownFigure20. Cuttwo(2)4lengthsof3/32barestainlesssteelweldingrod.Createa90degreebendin oneendofeachrodtoformalegapproximately11/2long,asshowninFigure20.Cutthe otherlegtoalengthof.Usingafile,squareofftheendsofeachrodanddeburrthe edges. UseasharpknifetoscrapetheTefloncoatingfromaboutofeachcoilwireend.Always keeptheknifebladeperpendiculartothewiretopreventdamage. Wrapeachcoilwireendaroundthetopofa11/2rodlegforatleast4or5turns.Using silverbearingelectricalsolder,soldereachwiretoitsrodleg.Trimawayanyexcesswire. Formawirestrainreliefatthelegbottombywrappingheavythreadatleast2or3turns aroundthelegandwire.Securethethreadwithaknotplacedontheoutsideoftherod bend.

1. 2.

3.

4.

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 Figure20:ToroidCoilInstallation

5. Usingasoftbristlebrushandwarmsoapywater,cleanthesolderedareasoftherodand wire.Rinsewithwarmwaterandallowthethreadtoairdryforatleastanhourbefore goingtostep6. 6. CoattheentirelengthofthelongrodlegwithathinevenlayerofCPVCcement.Allowthe cementtodryforabout15minutesandapplyasecondthincoatofCPVCcement.Allowthe cementtoairdryforabout15minutesbeforegoingtostep7. 7. Temporarilyinstallthecoilontopofitsthreesupportbracketswithinthehousing.Position thecoilwiththewiresandrodspointingtowardtheholesdrilledintheprecedingstep1. Temporarilyattachthreesmallstripsofelectricaltapeontopofthecoiltomarkthe locationofeachsupportbracket. 8. Removethecoilfromthehousingandapplyprimertothebottomofthecoilatthethree markedlocationsandthetopsurfaceofallthreesupportbrackets.Coatthetopofeach supportbracketwithaheavylayerofCPVCcement.Installthecoilontothesupport brackets,positioningitwiththewiresandrodspointingtowardthetwo#41drilledholes.If

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necessary,shiftthecoilslightlytocenteritsoutsideedgeswithinthehousing.Allowthe cementedrodsandwirestoairdryatleastanhourbeforegoingtostep9. Note Thetwo#41holesintheinsidehousingwallmustbecountersunktoadepthsufficientto cleartheradiusoftheinsidebendofeachrod,allowingthesolderedlegofeachrodtolay flushagainstthehousingwallwiththesolderedlegpointingupward. 9. Removethethreetapestripsfromthetopofthecoil.Usingacountersinktoolorlargedrill bit,Deburrtheinsideendsofthe#41holes.Inserttherodendsintotheholesandcheck thattheinsidebendradiusclearstheedgeofeachhole.Ifnot,countersinkslightlydeeper untilthedesiredclearanceisobtained. 10. Using#400gritorfinersandpaper,polishthesurfaceoftheunsolderedlegofeachrod.Mix asmallquantityofepoxysuchasJBWELD.Applyathincoatofepoxytotheunsolderedleg ofeachrod.Usingatoothpick,orotherprecisetool,applyathincoatofepoxytotheinside ofeach#41hole. 11. ApplyaheavylayerofCPVCcementtothesoldere4dlegofonerod.Fullyinserttherodinto the#41holdwiththesolderedlegpointingdirectlyupward.Holdtherodinplaceforabout 5minutesuntilthecementdriessufficientlytoholditinplace.Whilewaitingforthe cementtopartiallydry,cleanepoxyfromtherodendusingasoftcleanclothandsolvent suchasMEKoracetone.Repeatthisprocedurefortheremainingrod.Allowtheepoxyto cureforabout8hoursbeforegoingtostep12. Note SeverallayersofCPVCcementareusedtosecurethecoiltothehousingbrackets,rods andwirestothehousingwall,andtosealtherodsagainstpossiblegasand/orwater leakagethroughtheholesinthehousing. 12. Arrangethecoilwiressotheycontactthehousingwallasmuchaspossible.Laythehousing onitssideandapplyathicklayerofCPVCcementoverthewiresandsolderedlegofeach rod.Extendthecementlayeraroundtheholewhereeachrodentersthehousingwall,

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formingaboutadiameterpuddlearoundeachhole.Allowthecementtoairdryforat least15minutesbeforegoingtostep13. 13. Standthehousingonend.Usingasoftbristlebrush,applyathicklayerofCPVCcement overandaroundthecoilsurfaceabovewhereitcontactseachofthethreesupport brackets.Besurethelayerextendsthewidthofeachbracket.Allowthecementtoairdry foratleast15minutesbeforegoingtostep14. 14. Repeattheprocedureoftheprecedingsteps12and13atleast4or5timestoobtainthe desiredthicklayerofcement.Allowthecementtoairdryforatleastanhourbetween successivelayers. 15. Aftertheepoxyhascuredforatleast24hours,use#400gritorfinersandpapertoremove epoxyresiduefromtherodends.

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UnthreadedEndCapInstallation
Note Generatorfunctionandefficiencyisnotaffectedinanywaybytherotationalpositionof theunthreadedendcap. 1. Checkthatthematingsurfacesoftheendcapandtopofthehousingarecleanandfreeof debrisofanykind.Cleanthematingsurfacesifnecessaryusingasoftcleanclothandmild solventsuchasisopropylalcohol. 2. Afterdeterminingthedesiredpositionoftheendcap,applyprimertothematingsurfaces oftheendcapandtopoftheGeneratorhousing.ApplyathinlayerofCPVCcementtothe primedareasandslidethepartstogether,seatingthemfirmly. 3. Standthehousingonendtopreventthepossibilityofexcesscementrunningintothreaded holesintheendcap,allowingittoremaininthatpositionforatleastanhourwhilethe cementairdries.

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GeneratorFinalAssembly
1. Cutthetworodendsprotrudingthroughthebottomofthethreadedendcaptoalengthof .Usingafile,squaretheendofeachrodanddeburrtheedges. Note Asanaddedprecautionagainstpossiblewaterand/orgasleakage,Irecommendusing pipejointcompoundonallthreadedGeneratorhousingcomponents.

Caution TopreventdamagetothreadedholesinCPVCmaterial,donotapplyexcessivetorqueto componentswhileinstalling.Threaddamagecancausewaterand/orgasleakage,and possiblesystemfailure. ApplyalightcoatingofpipejointcompoundtoallthreadedholesintheGeneratorhousing andendcapsaccordingtodirectionsontheproductlabel. Applyalightcoatingofpipejointcompoundtothethreadsofthedraincock.Threadthe draincockintothe37/64threadedholeinthebottomofthethreadedendcap,seatingit firmly.Repeatthisproceduretoinstalltheremainingcomponents: One3/8BarbedHoseFittinginto37/64holeinhousingdoubler. One3/8BarbedHoseFittinginto37/64holeontopofhousing. One1/8BarbedHoseFittingintoRsizeholeontopofhousing. OnePressureReliefValveinto37/64holeontopofhousing. Usingatoothpick,orsimilarprecisetool,forceasmallquantityofSiliconeSealant(RTV Cement)intotheholeintheendcapthroughwhichthewaterlevelswitchleadspass.Form asmallandsmoothfilletofsealantaroundtheleadsandendofthehole.Allowthesealant tocureforatleast24hoursbeforegoingtostep5. Visuallyinspectallsurfacesandcomponentsofthehousingandendcaptoverifytheir integrity.Correctpossibledefectsasrequired.

2.

3.

4.

5.

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6. ThoroughlyflushtheinterioroftheGeneratorhousingwithwarmtapwater.Standthe housingonendandallowexcesswatertodrainforatleast15minutes.Usingasoftclean cloth,drythehousingexteriorandthreadsofthehousingandendcap. 7. Applyalightcoatingofpipejointcompoundtothehousingandendcapthreads.Thread theendcapontothehousingandtightenfirmly.

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InDashIndicatorPanelAssembly
Note PersonalpreferencedictatesthelayoutofpanelgaugesandLEDindicators.During assembly,referFigure5,6,and7. ListofMaterials: OneCylinderHeadTemperature(CHT)GaugeKit,21/16Diameter,(includessparkplug mountedthermocouplesensor)(BusBoysPart#:VDO310901). One2GaugeCustomConsole(BusBoysPart#:VDO1108720). OnePressureGauge,21/16Diameter(AutoMeterProductsModel#:2360). TwoBulbandSocketSets,2Watt(AutoMeterProductsModel#:2357). FourLEDIndicators: o TwoGreen(RadioShackPart#:276304). o OneYellow(RadioShackPart#:276351). o OneRed,Blinking(RadioShackPart#:276308). Three55Spools18GaugeInsulated,StrandedHookupWire(RadioShackPart#:278 1220). One9PositionMaleInterlockingConnector(RadioShackPart#:274229). One9PostionFemaleInterlockingConnector(RadioShackPart#:274239). TwoPackagesCrimpOnSnapConnectors(Each:5male,5female)(RadioShackPart#: 643085and643086). OnePackageAssortedRingTerminals(RadioShackPart#:643032). OnePackageAssortedGrommets(RadioShackPart#:643025). One10length1/8SiliconeBraidReinforcedTubing(USPlasticStock#:54051). Twenty(20)SmallStainlessSteelWormThreadHoseClamps(LocalHardware). OnePackageSmallNylonTieWraps(LocalHardware) MaterialSources:
BusBoys,Inc 183LakeBlvdEast Redding,CA96003 Phone:15302441616Fax(7/24):15302240933 AutoMeterProductsInc 413WElmSt. Sycamore,IL60178 Phone:18158958141Fax:18158956786

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UnitedStatesPlasticCorp RadioShack (Nationwidestores)

Note Thequickestandeasiest,andusuallythemostattractive,methodformountinggauges andLEDsistouseaprefabricatedconsoleattachedtothetopofthedashpanel.Other methodsmayworkjustaswell,butImrecommendingtheVDO1108720CustomConsole, whichismoldedfromABSplasticandisbothattractiveanddurable. Directions: 1. TemporarilymounttheCHTandpressuregaugesintheconsole.Referringtofigure2, determinethebestlocationsforthe4LEDsandplacereferencemarksatthoselocationson theoutsideoftheconsole.Drilla7/32holeateachlocation.Toassureproperadhesionof siliconesealanttotheconsoleinteriorsurface,roughenthesurfaceimmediatelyaroundthe areaofthedrilledholeswithsandpaper. 2. TemporarilydisconnecttheCHTgaugethermocoupleleadandmountthegaugeinthe console.Applyalightcoatingofpipejointcompoundtothe1/827threadsofthepressure gaugeand1/827barbedhosefitting.Threadthefittingintothegaugeandtightenfirmly. Slipthe1/8siliconetubingfullyontothebarbedfittingandsecurewithtwosmallstainless steelhoseclamps.Firmlytightenthehoseclampsandmountthepressuregaugeinthe console. Note ThesorterofthetwoLEDleadsisalwaystheanode(+)lead. 3. Identifytheanode(+)leadofeachLEDandcuttoalengthof1.Cutfour(4)3footlengths of18gaugehookupwireandstripofinsulationfromtheendofeachwire.Wrapthe strippedendofeachwireendaroundeachanodeleadandsolder.Slidea11/2lengthof heatshrinktubingovereachwireandflushagainsttheLEDandshrinkthetubing. 4. ReferringtoFigure2,identifytheconsolelocationforeachLED.Usingmaskingtape,or othermeansoflabeling,attachanidentifyinglabeltoeachanodewire. Green,PWRON

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 Green,PUMPON Yellow,GENWATERLOW BlinkingRed,TANKWATERLOW 5. Cuttwolengthsofhookupwiretouseasjumperwiresbetweenthebulbsandsocketsfor thegauges.Stripofinsulationfromtheendsofeachwire.Solderawiretoonesocket centerconnector.Slidea1lengthofheatshrinktubingontothewireandasfaraspossible ontothesocketbase.Shrinkthetubing.Cuta3footlengthofhookupwireandstripof insulationfromoneend.Twisttheendsofthesolderedjumperwireand3footwire together.Slidea1lengthofheatshrinktubingontothewires,andsolderthewirestothe othersocketcenterconnector.Slidethetubingasfaraspossibleontothesocketbaseand shrinkthetubing.LabelthewirePositive(+). 6. Cuta6lengthofhookupwire.Repeattheprocedureofstep5toconnectthe6wireand jumperwirebetweenthetwosocketbaseconnectors.Stripofinsulationfromtheendof the6wire. 7. CutthecathodeleadofthegreenPWRONLEDto11/2long.Cutthecathodeleadofthe yellowGENWTERLOWLEDto1long.Cutanappropriatelengthofhookupwiretoserve asajumperwirebetweenthecathodesofbothLEDs.Stripofinsulationfromeachend ofthewire.SolderthejumperwiretotheyellowLEDcathode.Slidea11/2lengthofheat shrinktubingoverthewireandflushagainsttheLEDandshrinkthetubing. Twistthestrippedendsofthejumperwireand6ofstep6together.Slidea1lengthof tubingoverthetwowiresandsolderthemtothegreenLEDcathode.Slidethetubingflush againsttheLEDandshrinkthetubing.Cuta3footlengthofhookupwireandstripof insulationfromoneend.SolderthewiretothegreenLEDcathode.Slidea11/2lengthof heatshrinktubingoverthewireandasfaraspossibleontotheLEDleadandshrinkthe tubing.LabelthewireasGround. CutthecathodeleadsofthetworemainingLEDsto1long.Cuttwo(2)3footlengthsof hookupwireandstripofinsulationfromtheendofeachwire.Solderthewirestothe LEDcathodes.Slidea11/2lengthofheatshrinktubingovereachwireandflushagainst theLEDandshrinkthetubing.LabelthegreenLEDwireasPUMPONCATHODEandthe redLEDwireasTANKWATERLOWCATHODE.

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Note Siliconesealantcuresbychemicalreactionwithoxygenandwatermoistureintheair, whichiswhyitssometimesreferredtoasRTV(RoomTemperatureVulcanizing)cement. Sealantcuretimecanbeshortenedconsiderablybyplacingawaterdampenedcloth withintheconsoleinteriorandplacingtheconsoleintoaplasticgrocerybag(dontseal thebagsothatitsairtight).Thismethodisespeciallyeffectiveindryclimates. 8. SlideeachLEDintoitscorrectmountingholeontheconsole.SlideoneLEDabout1/16 backfromtheinteriorsurfaceoftheconsoleandapplyasmallamountofsiliconesealant intothegapbetweentheLEDflangeandtheconsolesurface.SlidetheLEDbackintoplace andflushwiththeconsolesurface.ApplyathickbeadofsealantaroundtheLEDflangeand aboutontotheconsolesurface.Repeatthesameprocedureforthethreeremaining LEDs.Allowthesealanttocureforatleast24hoursbeforegoingontostep9l. 9. Installthebulbsandsocketintothegauges.DrawnthesevenLEDwiresandbulbsocket wiretogetherashortdistancefromtheLEDsandsecurethewirebundlewithatiewrap., Tightenthetiewrapandcutoffitsunusedstrap. 10. Drilland/orgrindaholetoinstalla5/8IDgrommetthroughtheenginecompartment firewallatanappropriatelocationforroutingofHyTronicswires,thermocouplelead,and pressuregaugetube.Deburrtheholeandinstalla5/8IDgrommet.Insertthe thermocoupleleadthroughthegrommetfromtheenginecompartmentsideandreattachit toitsCHTgaugeterminal. 11. Permanentlyattachtheconsoletothedashatthedesiredlocation.Securethewires, thermocouplelead,andCHTtubebundlewithatiewrapplacedaboutevery6alongthe lengthofthebundle.Topreventcollapsingthepressuregaugetube,besurenottoover tightenthetiewraps. 12. Cuttheendsoftheeightwirestothesamelengthandstripofinsulationfromtheendof eachwire.Attacheachwiretoaseparatepinofthe9PositionMaleInterlockingconnector bycrimpingorsoldering. 13. Removeasparkplugfromtheengineandplugtheholewithasoftcleancloth.Toassure goodelectricalcontactforthethermocouple,polishtheareacontactedbythesparkplug

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with#400gritorfinersandpaper.Removetheclothfromthesparkplughole.Slipthe thermocoupleringoverthesparkplugthreadsandreinstallthesparkplug.Tightenthe sparkplugtoitsnormaltorquevalue.

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WaterTankandPump
ListofMaterials: OneRectangularPolyethyleneTank,16Gallon,21x14x14(USPlasticPart#:8658). HighLowTemperatureSiliconeTubing,3/8ID,20(USPlasticStock#:54037). SiliconeBraidReinforcedTubing,3/8ID,20(USPlasticStock#:54055). OneHighHeadPump,12vdc,75PSI(minimum)(Flojet) OneBrassBusing,PTFMalex3/8PTFFemale(FastenerHutPart#:3220x12x06A). OnePackageCrimpOnButtConnectors(RadioShackPart#:643037). MaterialSources:
RadioShack(Nationwidestores). FastenerHut,Inc UnitedStatesPlaticCorp FlojetCorporation 20Icon FoothillRanch,CA92610 Phone:19498594945 TollFree:18002356538 Fax:19498591153

Note Watertankcapacityisnotcritical,butshouldbeatleast1gallon.Therecommendedtank issturdilyconstructed,holds16gallons,andisfurnishedwithaFPToutletfitting. Directions: 1. Applyathinfilmofpipejointcompoundtotheinternalthreadsofthex3/8bushing andthreadsofa3/8barbedhosefitting.Threadthefittingintothebushingandtighten firmly. 2. Applyathinfilmofpipejointcompoundtotheexternalthreadsofthebusingandinternal threadsofthewatertankfitting.Threadthebushingintothetankandtightenfirmly.

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Note Thewaterlevelswitchcanbeinstalledatthemidpointofeithersidewallofthetank. Determinethedesiredlocationbasedonroutingofelectricalleads,trunklayout,etc.One switchleadwillbegroundedtothevehicleframeinthetrunkareaandtheotherleadwill beconnectedtotheHyTronicsmodule. 3. Drillorcuta5/8holeinthesidewallofthewatertankatthemidpointofitslengthand4 upfromthebottom.Flushthetankwithtapwatertoremoveplasticshavings. 4. Removethetankcap.Drilla37/64holethroughthecenterofthecapandthreadwitha 3/818tap.Flushthecapwithtapwatertoremoveplasticshavings.Threada3/8barbed hosefittingintothetappedholeandseatfirmly.Cuta6lengthofhighlowtemperature siliconetubing.Slipthetubingontothefittingandsecurewithtwostainlesssteelhose clamps.Tightentheclampsfirmly. Caution Neverattempttocontrolpowertoanyelectricaldevicedirectlythroughthewaterlevel switch.Doingsowilldamageordestroytheswitch.

Note Thewaterlevelswitchcontainsveryhighqualitymagneticreedcontacts.Itwillreliably operatethroughmillionsocycleswhenconnectedtoanLED. 5. Stripofinsulationfromtheendsofthewaterlevelswitchleads.Connectohmmeter leadstotheswitchleads.Pivottheswitchfloatuntilflushagainsttheswitchbody.Verify thattheohmmeterindicatesclosedswitchcontacts.Ifthecontactsarenotclosed,the switchisdefectiveandmustbereplaced. 6. Pivotthefloatswitchawayfromthebodyuntilitiswithin10degreesofitsstop.Verifythat theswitchcontactsareopen.Ifthecontactsarenotopen,theswitchisdefectiveandmust bereplaced.

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7. Usingasoftcleancloth,drythetanksidewallaroundthe5/8hole.Applypipejoint compoundtothethreadsoftheswitchbodyandmountingnut,andtheirmatingsurfaces withthetankwall.Installtheswitchintothetanksothefloatpivotsupward,aligningits pivotingaxisparalleltothetankbottom.Firmlytightentheswitchmountingnut. 8. Attachohmmeterleadstotheswitchleadsandverifytheswitchcontactsareclosed.Plug thetankoutletfittingandfillthetankwithwateruntiltheswitchcontactsopen.Continue fillingthetankuntilthewaterlevelrisesanadditional2.Verifythattheswitchcontactsare stillopen.Unplugthetankoutletandverifythattheswitchcontactsclosewhenthewater leveldropstoapproximatelythe1/3fullpoint,andgotostep9.Iftheswitchcontactsdo notrespondproperlytochangingwaterlevel,checktoverifythattheswitchisproperly installedandthefloatpivotsfreely.Verifythatthefloatisatleastawayfromanypartof thetank.Correctanyinstallationproblems.Iftheswitchhasbeenproperlyinstalled,itis defectiveandmustbereplaced. 9. Drainwaterfromthetankandinstallthecap,tighteningitfirmly.Constructawooedframe 3to4hightosecurethetankagainstslidingwithinthetrunk.Drillaholeorcutanotchin theframelargeenoughtoclearthetankoutletwhilethetankisbeinginstalledorremoved. Ifnecessary,cutanotchtocleartheswitchmountingnutandwires. 10. Drainwaterfromthetankandinstallthecap,tighteningitfirmly.Constructawoodframe 3to4hightosecurethetankagainstslidingwithinthetrunk.Drillaholeorcutanotchin theframelargeenoughtoclearthetankoutletwhilethetankisbeinginstalledorremoved. Ifnecessary,cutanotchtocleartheswitchmountingnutandwires.Fastentheframeto thetrunkflooratthedesiredlocation. 11. Locateaconvenientspotonthevehiclechassisclosetothewatertankanddrilla3/32 groundingringterminalattachmentholeforthetankswitch.Usingacleanragandsolvent, removedirtordebrisfromaroundthehole.Grindorusesandpapertoremovepaint,orany otherinsulatingmaterial,fromtheareaaroundthehole.Stripofinsulationfromtheend ofoneswitchwireandcrimpalargeringterminalontothewire.Donotattachthering terminaluntilinstructedtodosoinstep15.

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Note If,asrecommended,thewaterpumpwillbeinstalledwithintheenginecompartment, highlowtempsiliconetubingwillbeusedtoconnectthetanktothepump.Ifthepumpis installedwithinthetrunkarea,thetubeconnectingthepumptothecheckvalvewillbe pressurized(upto85psi)andsiliconebraidreinforcedtubingmustbeused.Ifthepumpis notselfpriming,itmustbeinstalledinthetrunk. 12. Determinethelengthoftubingneededtoreachfromthepumporwatertanktotheengine compartment.Ifthepumpwillbelocatedwithintheenginecompartment,gotostep14.If thepumpwillbelocatedwithinthetrunk,gotostep13. 13. Mountthepumpatthedesiredlocationwithinthetrunk.Determinethelengthoftubing neededtoattachthetanktothepump.Cuthighlowtemptubingtotherequiredlength andslideontothetankfitting.Securethetubingwithtwosmallstainlesssteelhoseclamps andtightenfirmly.Slidethetankintothewoodframe.Slidetwosmallstainlesssteelhose clampsontothetanktubeandslidethetubeontothepumpinletfitting.Slidethehose clampsoverthefittingandtightenfirmly.Slidebraidtubingontothepumpoutletfitting. Slidetwosmallstainlesssteelhoseclampsoverthefittingandtightenfirmly.Gotostep15. 14. Cuthighlowtemptubingtotherequiredlengthandslideontothetankfitting.Securethe tubingwithtwosmallstainlesssteelhoseclampsandtightenfirmly.Slidethetankintothe woodframe. 15. Attachthetankringterminaltothe3/32holeinthechassiswithasheetmetalscrew. Applyaheavylayerofpetroleumjellyorgreaseovertheterminalandscrew. 16. Stripofinsulationfromtheendoftheremainingswitchwireandcrimpabuttconnector ontothewire.Determinethelengthofhookupwireneededtoextendatleast3intothe enginecompartmentandcuttolength.Stripofinsulationfromtheendofthehookup wireandcrimpittothebuttconnector.Ifthepumpisinstalledinthetrunk,repeatthis proceduretospliceanequallengthofhookupwiretoeachpumppowerlead. 17. Routethetankandpumpwiresandtubingthroughthevehiclestructure.Besuretoinstalla IDgrommetwhereveranaccessholemustbedrilledUsetiewrapsaboutevery6to

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securethewireandtubingbundle.Topreventcrushingthetubing,donotovertightenthe tiewraps. 18. Securelymountthewaterpumpintheenginecompartmentifthepumpwasnotinstalled inthetrunk.Slidetwosmallstainlesssteelhoseclampsontothehighlowtemptubing. Installtubingontothepumpinletfittingandfirmlytightenthehoseclamps.

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HyTronicsModule
MaterialsList: PurchasespecificelectroniccomponentsascalledforinschematicdiagramsFigure5, Figure6,andFigure7(availableatRadioShack). Two12PositionMaleInterlockingConnectors(RadioShackPart#:274232). Two12PostionFemaleInterlockingConnectors(RadioShackPart#:274242). OneUniversalComponentBoard(RadioShackPart#:276168). OnePCBoardKit(RadioShackPart#:2671576). OneEnclosure8x6x3(RadioShackPart#:2701809). MaterialsSource:
RadioShack(Nationwidestores).

Note Sinceboththeelectrodecircuit(Figure5)andcoilcircuit(Figure6)operateat relativelylowfrequencies,physicallayoutoftheHyTronicsmodulecomponentsis notcritical.MountcomponentsusingtheUniversalComponentBoard,ordesign andcreateyourownPCBoardlayoutusingthePCBoardKit(evenincludesneeded chemicalsolutions).TherecommendedEnclosureprovidesprotectionforthe HyTronicscircuitsandisattractiveandeasytomount. Theelectrode,coil,andindicatorcircuitsmaybebuiltonthesameboardoron separateboards,usingthesideboardmountingfeatureoftherecommended Enclosure. Directions: 1. ReferringtoFigure5,buildtheelectrodecircuitusingcomponentsasdetailed. 2. ReferringtoFigure6,buildthecoilcircuitusingcomponentsasdetailed. 3. ReferringtoFigure7,buildtheindicatorscircuitusingcomponentsasdetailed.

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Note AholemustbedrilledintheHyTronicsmoduleenclosureforroutingwirestothe9 positionindicatorspanelconnector.Asecondholemustalsobedrilledforroutingwiresto two12positionconnectorsforalothersystemcomponents.Besuretoinstallan appropriatelysizedgrommetineachhole. 4. Drillaholeintheenclosureandinstalla3/8IDgrommet.Cuteight(8)1footlengthsof hookupwireandstripofinsulationfromoneendofeachwire.Routeonewirethrough thegrommetandsolderittotheHyTronicsGround()bus(seeFigure5)andlabelthe wire.RefertothefollowingFigurestosolderthesevenremainingLEDandbulbsocketwires (besuretolabeleachwire).
PWRONFigure5 AllOtherLEDsFigure7. Positive(+)bulbsocketcenterconnectorwireFigure7

5. Cuttheeightwirestoequallengthandstripofinsulationfromtheendofeachwire. Connectthewirestothe9positionfemaleinterlockingconnector.Besurethewirelabelat eachpositioncorrespondstothewirelabelandeachpositionofthemale9position connector.Afterconnectingwires,removealllabels.Securethewireswithatiewrap placedaboutevery3alongthelengthofthebundle. 6. DrillanotherholeintheenclosureandinstallaIDgrommet.Cutnineteen(19)1foot lengthsofhookupwireandstripofinsulationfromoneendofeachwire.Soldertwo wirestotheappropriateterminalsfortheGeneratorelectrodes(Figure5),andtwowiresto theappropriateterminalsfortheGeneratorcoil(Figure6).Solderonewiretothe appropriateterminalofthepumpcircuit(Figure7).Solderonewiretotheappropriate terminalfortheGeneratorwaterlevelswitch(Figure7).Solderfivewiresbeforethefuse connection(battery+sideofpowerbus,seeFigure5)andfivewirestothenegative()bus. Solderonewiretothethrottle10Kresistor(Figure5).Soldertwowiresforthetankwater levelswitch(Figure7).Besuretoappropriatelylabeleachwire.

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Note Twoconnectorsareusedtoprovideextrapositionsforfutureexpansion,modifications, anddesignimprovement.Besuretouseamale12positioninterlockingconnectoranda female12positioninterlockingconnectortopreventaccidentalconnections. 7. Cutthenineteenwirestoequallengthandstripofinsulationfromtheendofeachwire. Connectanyninewirestoa12posiotnmaleinterlockingconnector.Connecttheremaining ninewirestoa12positionfemaleinterlockingconnector.Securethewireswithatiewrap placedaboutevery3alongthelengthofthebundle. 8. AttachtheHyTronicsmoduleunderthedashpanelandasfarforwardaspractical.Connect the9positioninterlockingconnectorsofthemoduleanddashindicators.

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FuelInjectororCarburetorAdaptor
Note Sincehundredsofvariousfuelflowsystemsexist.IrecommendcontactingImpcoto purchasetheappropriateadapter.Theydealalmostexclusivelyingasolineenginefuel conversionsystems,havethousandsofoptionsavailable,andhavebeeninbusinessfor nearly50years.DescribeyourvehiclesengineandtheWaterhybridsystem,andaskfor theirrecommendations.Inparticular,inquireaboutthepossibilityofinstallingaBeam GarretsonAdapter. 1. Installanappropriateadapteronyourengine.Contactacompanyexperiencedingasoline conversionsystems,explainingthattheWaterhybridsystemisdesignedforswitchingback andforthbetweenhydrogenandgasolinefuels.HeresacompanyIhighlyrecommend:
ImpcoTechnologies 16804GridleyPlace Cerritos,CA90703 Phone:15628606666Fax:15628603088

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ThrottleAssembly
Note TheHyTronicsthrottleusesahighqualityprecisionpot(potentiometer)designedfor reliabilityanddurability(over5millioncompleterevolutions).Cheappotswillsoonfailor causeproblems;donotsubstituteacheappot. ListofMaterials: OnePrecisionPot,Series578,100K(ClarostatPart#:578X1G32P104SW). One1footlengthCPVCRod,diameter(USPlasticPart#:43182). MaterialsSource:
StateElectronics 36Route10 EastHanover,NJ07936 Phone:19738872550TollFree:18006318083 Fax:19738871940 UnitedStatesPlasticCorp

Note Figure21depictsatypicalHyTronicsthrottleassembly.Sincehundredofvarious throttlelinkagesareinuse,thefollowingprocedureisofferedasageneral guideline. Thepotmountingbracketisdesignedtoallowpotcentering(housingrotation)and preciseadjustmentofthrottlesensitivity(bracketrotation).Thethrottlelinkage sleeveallowsprecisepotrotationlimitadjustments(idletofullthrottle)when combinedwithbracketrotation. Directions: 1. Determinethebestlocationintheenginecompartmentforinstallingthesleeveandarm assemblyandpotmountingbracket. 2. FabricateapotmountingbracketwithdimensionsindicatedinFigure21from1/8CPVC sheet.Ifnecessary,modifythebracketsizeandattachmentpointstosuityourvehicle.Do notcutthe3/32slotuntilinstructedtodosoinstep6.

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3.

4.

5.

6.

Cuta11/2lengthodiameterCPVCrod.Locateaconvenientspot.Measurethe diameteroftheexistingthrottlelinkage.Drillaholewiththemeasureddiameterlengthwise throughtherod.Usingathinbladesaw,cuttherodinhalflengthwise.Usingabeltsander, sandaflatsurfaceatleastwideontoonerodhalf. Cutax11/4sleevearmfrom1/8CPVCsheet.Drilla7/64holeinoneendofthearm aboutfromtheend.Usingadrillorcountersinktool,beveleachendoftheholeabout 1/16deep.Applyprimer,andthencement,tothematingsurfacesofthearmandsleeve andjointheparts.Allowthepartstoairdryforatleast2hoursandthendresscutedgesof allthrottlepartswithsandpaper. ReferringtoFigure5,positiontheshaftofthe100Kthrottlepotentiometer(pot)atthe midpointofitsrangeofrotation.Usingamarkingpen,markanalignmentlinebetweenthe potshaftandbushingatthepointshowninFigure21.Usinga#41drillbit,drillaholein theshaftatapointinlinewiththeshaftalignmentmark,and3/16infromtheshaftend. Cuta6lengthof3/32stainlesssteelweldingrod.Temporarilyinstallthepotintothe3/8 holeinthemountingbracket.Slidetheweldingrodintotheshafthole.Aligntheshaftand busingmarksandrotatethepotbodysothattherodpointsdirectlyupward(parallelwith thefrontedgeofthebracket).Placeamarkatthepointwheretheantirotationpin contactsthebracket.Removethepotandrodfromthebracket.AsshowninFigure21,cut acurved3/32wideslotextendingfromeachsideofthemarkedpoint.Temporarily installthepotontothebracketandcheckthattheantirotationpinfitsintotheslotand doesnotbindintheslotasthepotbodyisrotated.Ifnecessary,andusingasmallfinetoo file,filetheslotuntilthepotbodyrotatesfreely.Dresstheslotedgeswithsandpaper.

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Figure21:ThrottleAssemblyDetails

7. Attachthepottothebracketwiththefurnishednutandlockwasher.Temporarilyinstall therodintotheshafthole.Rotatethepotbodytoaligntherodparallelwiththefrontedge ofthebracketandfirmlytightenthemountingnut.Usingafile,squareoffbothendsofthe rodandDeburrwithsandpaperorafinetoothfile.UsingMEKoracetoneandasoftclean cloth,cleanthepotshaftandrod.FlushtheholeinshaftwithMEKoracetone. 8. MixasmallquantityofhighqualityepoxysuchasJBWELD.Usingaprecisioninstrument suchasatoothpick,coattheshaftholewithathinlayerofepoxy.Applyathinlayerof epoxytooneendoftherodandinsertitintotheshafthole,allowingittoextendabout 1/8beyondtheendofthehole.Formasmallfilletofepoxyaroundthejunctionoftherod andshaftatbothsidesoftheshaft.Allowtheepoxytocureforatleast24hoursbefore goingtostep33.

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9. ReferringtoFigure21,attachthesleeveandarmassemblytothethrottlelinkageusinga smallhoseclampateachend.Locatethepotdirectlybelowthearmwiththerod protrudingthroughtheholeinthearm.Positionthebracketforeoraftandsidewaysuntil therodissquarewiththesleevearmandparallelwiththefrontedgeofthebracketwith thethrottlelinkageisapproximatelyatitmidpointoftravel.Positionthebracketupor downuntiltherodrotatesthroughanangleofapproximately60degreeseachsideof centerasthethrottlelinkagemovesthroughitsfullrange. 10. Usingtwobolts,washers,andlocknuts,attachthebrackettotheenginestructure. Positiontheboltintheslotatapproximatelytheslotmidpointtoallowthepottomoveup ordownforpreciseadjustment.Loosentheboltsslightlyandpivotthebracketupand down.Checkthattheboltdoesnotbindintheslotatanypoint.Ifnecessary,andusinga smallfinetoothfile,filetheslotuntilthepotbodyrotatesfreely.Dresstheslotedgeswith sandpaper. 11. Checkthatthepotroddoesnotbindinthearmholeasthethrottlelinkageismoved throughitsfullrangeoftravel.Ifnecessarytoeliminatebinding,rotatethepotslightlyupor downand/orslidethesleeveassemblyslightlyforeoraft.Firmlytightenthebracketbolts andsleevehoseclamps.

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PreliminaryAssemblyandTesting
Caution Donotattempttosolderwiresdirectlytothefourgeneratorelectrodeandcoilpins. Excessheatwilldamagetheepoxybond,possiblycausinggasand/orwaterleakage. Installamalecrimponsnapconnectoroneachofthefourelectrodeandcoilpinsofthe Generator.SecurelyinstalltheGeneratorintheenginecompartmentusingbolts, washers,andlocknuts.BesuretheGeneratorislevelwiththevehicleframe.Ifthewater pumpisinstalledinthetruck,gotostep3.Ifinstalledintheenginecompartment,goto step2. Cutalengthofsiliconebraidtubingtoconnectthewaterpumpoutlettothe3/8fittingon thesideoftheGeneratorhousingnearthebottom.Allowsomeslackinthetubing.Goto step3. Ifthewaterpumphasaninternalcheckvalve,slidetwosmallhoseclampsontothewater tubingandinstallontothe3/8barbfittingtonthesideoftheGeneratorhousingnearthe bottom.Allowsomeslackinthetubingandfirmlytightentheclamps.Ifthepumpdoesnot haveaninternalcheckvalve,installacheckvalveinthetubingafewinchesfromthebarb bitinginthesideoftheGenerator.Allowsomeslackinthetubing.Usetwosmallhose clampsoneachbarbfittingadtightenfirmly.Besuretoinstallthecheckvalvesothatthe flowdirectionarrowonthevalvepointstowardtheGenerator. Cuttwo(2)3lengthsofbraidtubingandattachthemtoeachendofacheckvalvewith smallhoseclamps.Tightentheclampsfirmly.Usingtwosmallhoseclamps,attachavalve hosetothecarbadapterontheenginewiththevalvearrowpointingtowardtheadapter. Tightentheclampsfirmly. Usingtwohoseclamps,attachtheflamearrestortothecheckvalvehose.Firmlytightenthe clamps.Cutalengthofbraidtubingtoconnectthe3/8barbfittingontopoftheGenerator totheflamearrestor.Slidefoursmallhoseclampsontothetubingandconnectthetubing betweentheGeneratorandflamearrestor.Allowsomeslackinthetubingandfirmly tightentheclamps.

1.

2.

3.

4.

5.

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6. Usingtwosmallhoseclamps,attachthepressuregaugetubingtothe1/8fittingontopof theGenerator.Allowsomeslackinthetubingandfirmlytightentheclamps. 7. Cutfour(4)5footlengthsofhookupwireandstripofinsulationfromoneendofeach wire.Twistthestrandedendsoftwowirestogetherandtrimtheendstoalengthof3/8. CrimparingterminaltothesplicedwiresandattachtheterminaltotheHyTronicspower switch.Repeattheprocedurefortheothertwowires.Mounttheswitchataconvenient pointonthedash.Routeonepairofswitchwirestothevehiclepositive(+)powerbusthat isalwayshot(thebatterysideofthebusasshowninFigure5).Cutthewirestolength andstripofinsulationfromthewireends.Twistthewirestogether,trimto3/8,and crimparingterminal(orotherappropriateconnector)tothewireends.Donotattachthe terminal,orotherconnector,tothebusuntilinstructedtodosoinstep16. 8. Cuttwo(2)5footlengthsofhookupwireandsplicetogetherwitharingterminalaswas doneinstep7.Locateaconvenientspotintheenginecompartmenttoattachthering terminaltothevehiclechassis.Drilla3/32holeatthatlocationandattachtheterminal followingtheprocedureofsteps11and15. 9. Routethetwowiresthroughthegrommetinstalledintheenginecompartmentfirewall. Allowingslackinthewires,cutthewirestolengthtoreachthetwo12positionconnectors oftheHyTronicsmodule.Trimofinsulationfromtheendofeachwireandconnecteach wiretoanegative()buspositionofeitherofthe12positioninterlockingconnectors(see step6). 10. Routetheremainingpairofswitchwirestotheconnectorsandcutthewirestolength, allowingsomeslackinthewires.Connectthewirestotheconnectorsattwoofthebattery positive(+)powerbuspositionsinthesamemanneraswasdoneinstep9. 11. Cutfour(4)wiresofappropriatelengthtoconnecttheGeneratorcoilandelectrodepinsto theconnectors.Stripofinsulationfromeachwireandinstallafemalecrimponsnap connectortoeachwire.AttachtheconnectorstotheGeneratorterminals.Routethewires totheHyTronicsconnectorsandcutthewireendstoequallength.Stripofinsulation fromeachwireendandconnecteachwiretotheappropriatepositionoftheHyTronics connectors.

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12. ReferringtoFigure7,connectthetankwaterlevelandGeneratorwaterlevelswitchwires totheappropriatepositionsoftheHyTronicsconnectors.Usingbuttconnectors,splice hookupwirestotheswitchwiresasrequiredtoreachtheHyTronicsconnectors. 13. CuttwolengthsofhookupwiretoconnectthethrottlepottotheHyTronicsconnectors. Stripofinsulationfromoneendofeachwireandsoldereachwiretothepotterminals. Slidea1lengthofheatshrinktubingontoeachwireandoverthesolderedterminalsand shrinkthetubing. 14. RoutethepotleadstotheHyTronicsconnectorsandcuttheirendstoequallength.Strip ofinsulationfromtheendofeachwire.Connectonepotleadtoabatterypositive(+) powerbusconnectorposition.Connecttheotherleadtotheconnectorpositionleadingto the10Kresistorlead(seeFigure5).Rotatethepotshafttoitsmidpointposition. Caution Donotconnectthewaterpumpleadsnoraddwatertothetankuntilinstructedtodoso instep1ofFinalAssemblyandTesting. 15. Usinganohmmeter,verifythattheHyTronicspowerswitchisintheOFFposition.Ifnot, placetheswitchintheOFFposition. 16. Connecttheswitchringterminal,orotherconnector,tothebatterypositive(+)powerbus. Caution PowerwillbeappliedtotheWaterhybridsysteminstep18.Anyincorrectelectricalor electronicconnectioncanleadtosystemorcomponentfailureand/ordamage.Besureto doublecheckallelectricalandelectronicconnectionsbeforeapplyingpower. 17. DoublecheckallelectricalandelectronicconnectionsoftheWaterhybridsystem.Correct anyconnectionerrorsasrequired.Connectthetwo12positioninterlockingconnectorsof theHyTronicsmoduletothematchingsystemconnectors.Verifythatallsystemconnectors areproperlyengaged.Ifstillinplace,removetheHyTronicsmoduleenclosurecover.

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Caution Donotattempttostarttheengineuntilinstructedtodoso.Thisisapreliminarytestto verifybasicsystemfunctioning.Ifanyproblemexists,shutoffpowerimmediately. 18. Immediatelyafterapplyingpower,checkforthefollowingsystemresponsesintheorder noted.Ifanyproblemexist,shutpowerOFFimmediately. Smokeand/orelectricalsparkingdoesnotoccur. Electricaloverheatingofanysystemcomponentdoesnotoccur. Ontheindicatorpanel,checkthattheLEDsfunctionasfollows: PWRON,PUMPON,andGENWATERLOWLEDsarelit. TANKWATERLOWLEDisblinking. Ontheindicatorpanel,checkthatthegaugelightsarelit. PlacethewaterhybridsystempowerswitchtotheONposition.Verifythatnoproblem exists.Ifaproblemexists,turnpowerOFFimmediately. 19. Ifnoproblemexists,gotostep20.Ifaproblemexists,troubleshoottolocateandrepair(or replace)thefailedcomponent.Afterreplacementorrepairisaccomplished,gobacktostep 18. 20. Usingyourfingerssheatsensors,checkthatnosystemcomponentisoverheating.If overheatinghasnotoccurred,gottostep21.Ifoverheatingoccurred,turnpowerOFFand returntostep19. 21. Checkthatthevehiclegaspedalisinthefullidleposition.Ifnot,placeitistheidleposition. Connectadigitalvoltmetertopin6ofamplifierLM741(refertoFigure5)andrecordthe voltagelevelthere.Ifvoltageispresent,gotostep22.Ifnovoltageexists,acomponentis defectiveandmustbereplaced.Afterreplacingthecomponent,gobacktostep18. Note Asthegaspedalismovedfromidletofullpower,thevoltagelevelatpin6ofamplifier LM741shouldincreaseslightly.Expectanincreaseofapproximately1VDCto4VDC.

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22. Movethegaspedaltofullpower.Recordthevoltagelevelatpin6.Comparethevoltage withthatrecordedinstep21.Ifthevoltagelevelhasincreasedbyatleast1VDC,gotostep 23.Ifthevoltagelevelhasnotchangedatall,acomponentisdefectiveandmustbe replaced.Afterreplacingthecomponent,gobacktostep21. 23. Rotatethe20KThrottleAdjustpotfromstoptostop.Verifythatvoltageatpin6variesas thepotisrotated.Ifvoltagevaries,gotostep24.Ifvoltagedoesnotvary,acomponentis defectiveandmustbereplaced.Afterreplacingthecomponent,repeatthisprocedure. 24. SettheThrottleAdjustpottoitsmidpointofrotation. Note AhighlystablesquarewavepulseiscreatedbytheNE555controller.Asthegaspedalis movedtowardfullpower,theinputvoltagetothecontrollerfromtheLM741amplifier increases,increasingthepulsewidthratioofthecontrollersquarewaveoutputatpin3. 25. Connectanoscilloscopeleadtopin3oftheNE555controller.Verifythatasquarewave pulseexistsandthatthepulsewidthratioincreasesasthegaspedalismovedfromfullidle tofullpower.Ifasquarewaveexistsandthepulsewidthratioincreases,gotostep26.Ifa pulsedoesnotexist,orthepulsewidthratiodoesnotincreaseasagaspedalismoved,a componentisdefectiveandmustbereplaced.Afterreplacingthecomponent,repeatthis procedure. 26. Rotatethe2Kpulsewidthadjusttrimpotfromstoptostop.Verifythatthepulsewidth changesasthepotisrotated.Ifthepulsewidthchanges,gotostep27.Ifthepulsewidth doesnotchange,acomponentisdefectiveandmustbereplaced.Afterreplacingthe component,repeatthisprocedure. 27. Setthe2Ktrimpottoitsmidpointofrotations.

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Note Thefrequencyofthesquarewavepulsefallsintherangeof15KHzto20KHz.Thetrigger oscillatorcircuitprovidesvariablefrequencyinputpulsestotheNE55controllerin responsetoadjustmenttothe2Ktrimpotanddipswitchsettings. 28. Connecttheoscilloscopeleadtopin3oftheNE555controller.Verifythatsquarewave frequencychangesastheoscillator2Kpotisrotated.Ifthefrequencychanges,gotostep 29.Ifthefrequencydoesnotchange,acomponentisdefectiveandmustbereplaced.After replacingthecomponent,repeatthisprocedure. 29. Settheoscillatorpottoitsmidpointofrotation. Note ReferringtoFigure5,ThefrequencyofthecoilcircuitiscontrolledbytheCD4059ADivide byNCounter,andfallsintherangeof15Hzto20Hz.Inputtothecounterisreceived fromtheelectrodecircuit(Figure5).Whenthefrequencyoftheelectrodecircuitis changed,thefrequencyofthecoilcircuitchangesaccordingly.Pulsewidthofthecoil circuitisadjustedwiththe10KPulseWidthAdjustpot. 30. Connectanoscilloscopeleadtopin8oftheNE555controller.RotatethePulseWidth Adjustpotfromstoptostop.Verifythatthepulsewidthchangesasthepotisrotated.If thepulsewidthchanges,gotostep31.Ifthepulsewidthdoesnotchange,acomponentis defectiveandmustbereplaced.Afterreplacingthecomponent,repeatthisstep. 31. SetthePulseWidthAdjustpottoitsmidpointofrotation. 32. Connectadigitalvoltmeterleadtopin8oftheNE555controller.Rotatethe10KStrength Adjustpotfromstoptostop.Verifythatthevoltagelevelchangesasthepotisrotated.If thevoltagelevelchanges,gotostep33.Ifthevoltageleveldoesnotchange,acomponent isdefectiveandmustbereplaced.Afterreplacingthecomponent,repeatthisstep. 33. SettheStrengthAdjustpottoitsmidpointofrotation.

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 34. ReferringtoFigure5,setthedipswitchesaccordingtooscillatorDC4069manufacturer instructionstoobtainafrequencybetween15KHzand20KHz. Connectanoscilloscopeorfrequencymeterleadtopin6ofoscillatorCD4069.Verifythat theoscillatorfrequencyisbetween15KHzand20KHz.Ifthefrequencyisnotbetween15 KHzand20KHz,adjustthe2KFrequencyAdjustpottoobtainafrequencywithinthat range.Ifthecorrectfrequencycannotbeobtained,thereisadefectivecomponent(most likelyCD4069)intheoscillatorcircuit.Locateandreplacethedefectivecomponentand returntothisstep. 35. ReferringtoFigure6,andusinganoscilloscopeorfrequencymeter,verifythatthe frequencyofthepulseappearingatthecollectorofcomponent2N3055isfrom15Hzto20 Hz.Ifthefrequencyiswithinthatrange,gotostep37.Ifthefrequencyisnotwithinthat range,gotostep36. 36. SettheDividebyNcounterforanNfactorof1,000accordingtothemanufacturers instructions.Verifyafrequencyof15Hzto20Hzatthecollectorofcomponent2N3055.If thefrequencyiswithinthatrange,gotostep37.Ifthefrequencyisnotwithinthatrange,a componentisdefectiveandmustbereplaced.Afterreplacingthecomponent,gobackto step35. 37. ShutpowerOFF.

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CylinderHeadTemperature
Note Hydrogenburnsslightlyhotterthangasoline,soyoushouldexpectslightlyhighercylinder headtemperature(CHT).ItsagoodideatoestablishCHTreferencepointsbydrivingfirst solelyongasoline,andIrecommendthatapproach.Thewaterhybridsystemusesavery highqualityfastresponseCHTgauge,sensingCHTdirectlyfromthebaseofasparkplug. 1. Driveyourvehicleforatleast15minutes(30minutesincoldweather)onopenhighwayto assurethattheengineisuptonormaloperatingtemperature.NoteandrecordCHT(in degreesFahrenheit)undereachofthefollowingdrivingconditions: Parkedatfullidle,transmissioninneutral,forthreeminutes. 25MPHinresidentialareasforatleasttwominutes. 60MPH(orfullpower)onsteepgradeforatleast30seconds.

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FinalAssemblyandTesting
1. Ifthewaterpumpisinstalledinthetrunk,connectitspositive(+)powerleadtoabattery positive(+)powerbusconnectorposition.Ifthepumpisinstalledintheengine compartment,spliceahookupwiretitspositive(+)powerleawithabuttconnectorand connectittoabatterypositive(+)powerbusconnectorposition.Inlikemanner,connect thepumpnegative()powerleadtotheconnectorpositionleadingtothecollectorleadof theE3055TswitchasshownonFigure7. 2. Fillthewaterhybridsystemtankwithwater.Checkthatnowaterleaksfromthetankor anyofitstubingconnections.Ifnecessary,correctorrepairanyleaks. Note Yourvehicleisnowreadytorunwithsupplementalwaterforthefirsttimewiththe Waterhybridsystem.Forinitialoperation,itsbestthattheengineisalreadywarmedup tonormaloperatingtemperature.Ifnotuptothetemperature,driveonsolelygasoline power for at least 15 minutes. 3. Parkyourvehicleonalevelsurfacewithparkingbrakeengagedandtransmissioninneutral. Liftthetrunklidifthewaterpumpisinstalledinthetrunk.Liftthehood,orengine compartmentcover. 4. Followingmanufacturersinstructions,settheengineadapterforhydrogenoperation. Caution Closelymonitorthepressuregauge.ifgeneratorgaspressureexceeds70psi,shut poweroffimmediately.Asasafetyprecaution,pressureexceeding85psiisvented bythepressurereliefvalve.Donotdependonthereliefvalvetorelieveexcess pressure. Ifanysystemproblemexists,shutoffpowerimmediately.

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Note Atidle,gaspressureshouldbeintherangeofabout12psito28psi.ATfullpower,about 28psito62psi.

5.

6.

7.

8.

ReferringtoFigure5andFigure6,settheThrottleAdjust,PulseWidthAdjust(onein eachcircuit),FrequencyAdjust,andStrengthAdjustpotstotheirmidpointofrotation. Immediatelyafterapplyingpower,checkforthepossibilityofanyofthefollowing problems.Ifanyproblemexists,immediatelyshutpowerOFF. Smokeand/orelectricalsparking. Generatorpressureexceeds70PSI. Electricaloverheatingofanysystemcomponent. Gasand/orwaterleakagefromtheGenerator. Waterleakagefromthetubes,fittings,andothercomponents. TurnpowerON.WaitforGeneratorpressuretoreachatleast25PSI.IfGeneratorpressure willnotreachatleast25PSI,gotostep7.Whenpressurereachesatleast25PSI,startthe engine.Runtheengineatidlespeeduntilinstructedtodootherwise.Checkthatnoneof theproblemsnotedaboveexists.Ifanyproblemexists,immediatelyshutpowerOFFandgo tostep6. CheckthefollowingIfconditions: o Iftheenginestarts,gotostep26. o Iftheenginewillnotstart,gotostep7. o Ifanyproblemnotedatthebeginningofthisstepexists,gotostep6. VerifythatpowerisOFF.Asystemcomponenthaseitherfailedorisdefective.Troubleshoot tolocatethecomponent.Repairorreplacethecomponentandgobacktostep5. ShutpowerOFF.Obtainasmallbucketorlargecontainer.OpentheGeneratordraincock anddrainuntilempty.Closethedraincock.Ifnowaterdrained,gotostep8.Ifatleast somewaterdrained,gotostep14. TurnpowerON.Verifythatthewaterpumpruns.Ifthepumpruns,gotostep9.Ifthe pumpdoesnotrun,turnpowerOFFandgotostep25.

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 9. Verifythatwaterisreachingthepumpinlet.Ifwaterreachestheinlet,gotostep13.If waterdoesnotreachtheinlet,gotostep10. 10. Disconnectthetubingfromthepumpoutlet.Verifythatwaternowreachesthepumpinlet. Ifwaterreachestheinlet,gotostep12.Ifwaterdoestoreachtheinlet,gotostep11. 11. TurnpowerOFF.Checkforrestrictionsonthetubingleadingtothepumpinlet.Ifa restrictionislocated,repairasnecessary,reconnecttubing,andgobacktostep5.Ifno restrictionexists,thepumpisdefectiveandmustberepairedorreplaced.Afterpump repairorreplacement,reconnectthepumpandgobacktostep5. 12. VerifythatwaterisflowingfromthepumpoutletandturnpowerOFF.Ifwaterwasflowing, thecheckvalveiseitherdefectiveorhasbeeninstalledbackward.Replacethecheckvalve orreinstallitwiththeflowarrowpointingtowardstheGenerator,reconnecttubing,andgo backtostep5.Ifwaterwasnotflowing,thepumpisdefectiveandmustberepairedor replaced.Afterpumprepairorreplacement,reconnectthepumpandgobacktostep5. 13. Disconnectthetubingfromthepumpoutlet.Verifythatwaternowflowsfromthepump outletandturnpowerOFF.Ifwaterwasflowing,thecheckvalveiseitherdefectiveorhas beeninstalledbackwards.Replacethecheckvalveorreinstallitwiththearrowpointing towardstheGeneratorandgobacktostep5.Ifwaterwasnotflowing,thepumpis defectiveandmustberepairedorreplaced.Afterpumprepairorreplacement,reconnect thepumpandgobacktostep5. 14. TurnpowerON.VerifythatnowaterispresentinthetubingleadingfromtheGeneratorto theflamearrestor.TurnpowerOFF.Ifwaterwaspresent,gotostep15.Ifwaterwasnot present,gotostep17. 15. RefertoFigure7.CuttheGeneratorwaterlevelswitchwireconnectedtotheHyTronics positive(+)powerbuswithinabout6oftheGenerator.Stripfromeachendofthecut lead.ConnectasohmmeterleadtothewireexitingtheGeneratorandtheotherleadto vehicleground().Verifythattheohmmeterindicatesthattheswitchcontactsareopen.If theswitchcontactsareopen,gotostep16.Iftheswitchcontactsareclosed,theswitch sloshshieldhasbeenincorrectlyinstalled.Removethesloshshieldandreinstallit.Besure theshieldisaccuratelycenteredaroundtheswitchfloat.Reconnecttheswitchwireswitha buttconnectorandgobacktostep5.

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 16. Reconnecttheswitchwireswithabuttconnector.Adefectivecomponentexistsinthe pumpcontrolcircuit.Replacethedefectivecomponentandgobacktostep5. 17. Verifythatthecheckvalveinthetubingleadingtotheengineisinstalledwiththeflow arrowpointingtowardtheengine.Ifthecheckvalveisinstalledcorrectly,gotostep18.If thecheckvalveisnotinstalledcorrectly,removeitfromthetubingandreinstallitcorrectly. Gobacktostep5. 18. Setthewatercontaineronalevelsurface,markthewaterlevelonthesideofthe container,anddisposeofwater.ClosetheGeneratordraincock. 19. DisconnectthegasoutlethosefromthetopoftheGenerator.TurnpowerON,waitforthe waterpumptostoprunning,andshutpowerOFF.Openthedraincockanddrainwaterinto thecontaineruntiltheGeneratorisempty.Closethedraincock.Checkthewaterleveland disposeofwater.Ifthewaterlevelwashigherthanthelevelmarkedinstep18,gotostep 20.Ifthewaterlevelwasaboutthesame,gotostep26. 20. Reconnectthetubinganddisconnectthetubingfromthecarburetoradapter.Turnpower ON,waitforthewaterpumptostoprunning,andshutpowerOFF.Openthedraincockand drainwaterintothecontaineruntiltheGeneratorisempty.Closethedraincock.Checkthe waterlevelanddisposeofwater.Ifthewaterlevelwashigherthanthelevelmarkedinstep 18,gotostep21.Ifthewaterlevelwasaboutthesame,gotostep22. 21. Theadaptor(oritsassociatedparts)iseitherdefectiveorrequiresadjustment.Following themanufacturersinstructions,eitheradjusttheadapterorreturnittothemanufacturer foradjustmentorrepair.Afteradjustmentorrepair,reconnectthetubingandgobackto step5. 22. Reconnectthetubinganddisconnectthetubingbetweentheflamearrestorandcheck valve.TurnpowerON,waitforthewaterpumptostoprunning,andshutpowerOFF.Open thedraincockanddrainwaterintothecontaineruntiltheGeneratorisempty.Closethe draincock.Checkthewaterlevelanddisposeofwater.Ifthewaterlevelwashigherthan thelevelmarkedinstep18,gotostep23.Ifthewaterlevelwasaboutthesame,gotostep 24.

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 23. Thecheckvalveisdefective.Replacethevalve,reconnectthetubing,andgobacktostep5. 24. Theflamearrestorhasbeenconstructedincorrectly.Removetheflamearrestorfromthe tubing,removeitsendfittings,anddisposeoftheflamearrestor.ReturntotheFlame Arrestorprocedure.Followingtheinstructionsthere,constructanewflamearrestor.Allow theCPVCcementtoairdryforatlest24hours.Applyathincoatingforpipejoint compoundtothetappedthreadsintheendsoftheflamearrestorandfittings.Threadthe fittingsintotheflamearrestorandtightenfirmly.Installthenewflamearrestorintothe tubingandgobacktostep5. 25. TurnpowerOff.Themostlikelycandidateforpumpfailureisthepumpitself.Cutthepump negative()buswireandcheckpumpoperationwhiledisconnectedfromtheHyTronics module.Ifthepumpstilldoesnotrun,ordrawscurrentinexcessof15ampsduringstart up,repairorreplaceitandreconnectthepumpwiresusingbuttconnectors.Alsocheckto seeifthemainfusehasblown(refertoFigure5).Ifthefusehasblown,replaceitandgo backtostep5. Ifthepumpoperatesnormally,reconnectthewirewithabuttconnector.Checktoverify thattheE30556Tswitch(refertoFigure7)hasnotfailedduetopumpcurrentoverload.If theswitchhasfailed,replaceitwithaswitchofhighercurrentcapacityandgobacktostep 5.Iftheswitchhasnotfailed,cuttheGeneratorwaterlevelswitchwireconnectedtothe HyTronicspositive(+)powerbuswithinabout6oftheGenerator.Stripfromeachend ofthecutlead.ConnectanohmmeterleadtothewireexitingtheGeneratorandtheother leadtovehicleground().Verifythattheohmmeterindicatesthattheswitchcontactsare closed.Iftheswitchcontactsareclosed,eitherthepumpisdefective,apumpcircuit componentisdefective(refertoFigure7),orwiringerrorsexist.Troubleshoottolocatethe problemandrepairorreplaceasnecessary.Aftercorrectingtheproblem,gobacktostep5. Iftheswitchcontactsareopen,theswitchsloshshieldhasbeenincorrectlyinstalled. Removethesloshshieldandreinstallit.Besuretheshieldisaccuratelycenteredaroundthe switchfloat.Reconnecttheswitchwireswithabuttconnectorandgobacktostep. 26. VerifythatnowaterispresentinthetubingleadingfromtheGeneratortotheflame arrestor.Ifwaterispresent,turnpowerOFFandgobacktostep15.Ifwaterisnotpresent, readthefollowingnotesbeforegoingtostep27.

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Note Thewaterhybridsystemisdesignedtooperatewelloverawiderangeofdifferent electronicsettingsandadjustment.Itistolerantofjustaboutanythingshortofgross adjustmenterrors.However,sinceeachenginehasuniquerequirements,obtaining optimalperformanceismostlyamatterofmakingsimpletrialanderroradjustment. Herearesomegeneralguidelinesforgainingoptimalperformancebytheveryeffective methodknownastweaking: Atidle,Generatorpressureshouldbe12PSIto28PSI. Atfullpower,Generatorpressureshouldbe28PSIto62PSI. Foreachdriving(oridle)condition,besureCHTneverexceeds40degreesmorethanthe valuerecordedinstep1. BesureCHTneverexceeds400degrees. Note Tweakingthewaterhybridsystemiseasier,safer,andfasterifanotherpersondoesthe drivingwhileyoudothetweaking. 27. Parkyourvehiclewiththeengineatidle,transmissioninneutral,andparkingbrakeset. WaituntilGeneratorpressurestabilizesandgotostep30. 28. Driveyourvehicleat25MPHinresidentialareas.IftheFrequencyAdjustpotisrotated CWtoincreaseGeneratorpressure,gotostep30. IftheFrequencyAdjustpotisrotatedCCWtoincreaseGeneratorpressure,gotostep37. 29. Driveyourvehicleat60MPH(orfullpower)onasteepgrade.IftheFrequencyAdjustpot isrotatedCWtoincreaseGeneratorpressure,gotostep30. IftheFrequencyAdjustpotisrotatedCCWtoincreaseGeneratorpressure,gotostep37.

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30. ReferringtoFigure5,rotatetheFrequencyAdjusttrimpotfullycounterclockwise(CCW). Slowlyrotateclockwise(CW).IfGeneratorpressurestartstoincreasebeforerotatingabout 90%oftotalrotation,gotostep31.Ifpressuredoesnotincrease,gotostep37. 31. RotateslowlyCWuntilpressurestopsincreasing.Rotateanadditional10degrees.Wait untilpressurestabilizesandrecordpressure.SlowlyrotateCCWuntilpressurestartsto drop.SlowlyrotateCWuntilpressureincreasestotherecordedvalue.Recordthatthe FrequencyAdjustpotisrotatedCWtoincreasepressure.IfyourWaterhybridisbeing tunedwhileidling,gotostep32.Ifyourvehicleisbeingtunedwhiledriving,gotostep43. 32. RotatethePulseWidthAdjusttrimpotfullCCW.SlowlyrotateCW.Ifpressurestartsto increasebeforerotatingabout90%oftotalrotation,gotostep33.Ifpressuredoesnot increase,gotostep39. 33. RotateslowlyCWuntilpressurestopsincreasing.Rotateanadditional10degrees.Wait untilpressurestabilizesandrecordpressure.SlowlyrotateCCWuntilpressurestartsto drop.SlowlyrotateCWuntilpressureincreasestotherecordedvalue.Recordthatthe PulseWidthAdjustpotisrotatedCWtoincreasepressure.Gotostep34. 34. IfyouaretweakingyourWaterhybridwiththeengineatidle,gotostep35.Ifyouare tweakingyourWaterhybridwhiledriving,gotostep36. 35. RefertoFigure21.Ifnecessary,adjustengineidlespeedbylooseninghoseclampsand slidingthearmandsleeveassemblyeitherforeoraft.Tightenhoseclampsfirmly.If pressureexceeds28PSI,gotostep41.Ifpressureis28PSIorless,gobacktostep28. 36. Ifpressureexceeds62PSI,gotostep42.Ifpressureis62PSIorless,gotostep44. 37. RotatetheFrequencyAdjustpotfullyCW.SlowlyrotateCCW.Ifpressurestartsto increasebeforerotatingabout90%oftotalrotation,gotostep38.Ifpressuredoesnot increase,rotatethepotCWtoitsmidpointandgobacktostep32. 38. RotateslowlyCCWuntilpressurestopsincreasing.Rotateanadditional10degrees.Wait untilpressurestabilizesandrecordpressure.SlowlyrotateCWuntilpressurestartstodrop. SlowlyrotateCCWuntilpressureincreasestotherecordedvalue.Recordthatthe FrequencyAdjustpotisrotatedCCWtoincreasepressure.IfyourWaterhybridisbeing

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tunedwhileidling,gobacktostep32.IfyourWaterhybridisbeingtunedwhiledriving,go tostep43. 39. RotatethePulseWidthAdjustpotfullyCW.SlowlyrotateCCW.Ifpressurestartsto increasebeforerotatingabout90%oftotalrotation,gotostep40.Ifpressuredoesnot increase,rotatethepotCWtoitsmidpointandgobacktostep34. 40. RotateslowlyCCWuntilpressurestopsincreasing.Rotateanadditional10degrees.Wait untilpressurestabilizesandrecordpressure.SlowlyrotateCWuntilpressurestartstodrop. SlowlyrotateCCWuntilpressureincreasestotherecordedvalue.RecordthatthePulse WidthAdjustpotisrotatedCCWtoincreasepressure.Gobacktostep34. 41. Usingamarkingpen,placeanalignmentmarkontheFrequencyAdjustandPulseWidth Adjustpots.Determinetheamountofpressureexceeding28PSI.(Forexample,ifpressure is32PSI,excesspressureis4PSI).Reducepressureto28PSIbyalternatelyrotatingeach potinthecorrectdirectionafewdegreesatatime.Attempttodividetheexcesspressure equallybetweenthetwopots.(Forexample:ifexcesspressureis4PSI,attempttoreduce pressure2PSIwitheachpot).Gobacktostep28. 42. Usingamarkingpen,placeanalignmentmarkontheFrequencyAdjustandPulseWidth Adjustpots.Determinetheamountofpressureexceeding62PSI.(Forexample,ifpressure is70PSI,excesspressureis8PSI)Reducepressureto62PSIbyalternatelyrotatingeachpot inthecorrectdirectionafewdegreesatatime.Attempttodividetheexcesspressure equallybetweenthetwopots.(Forexample,ifexcesspressureis8PSI,attempttoreduce pressure4PSIwitheachpot.)Gotostep44. 43. IfthePulseWidthAdjustpotisrotatedCWtoincreaseGeneratorpressure,gobackto step32. IfthePulseWidthAdjustpotisrotatedCCWtoincreaseGeneratorpressure,gobackto step39. 44. IfyoujustcompletedWaterhybridtuningafterdriving25MPHinresidentialareas,goto step45.IfyoujustcompletedWaterhybridtuningafterdriving60MPH(orfullpower)ona steepgrade,gotostep67.

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45. ReferringtoFigure21,besurethethrottlelinkagemovesthroughitsfullrangeoftravel fromidletofullpowerwithoutbindingoftherodwithinthearm.Performtheprocedureof step66beforeproceeding. Driveyourvehicleat60MPH(orfullpower)onasteepgrade.Listencloselyforthesoundof engineprecombustion(ping).Iftheenginepings,gotostep46.Iftheenginedoesnot ping,gotostep56. Note Theproceduresofsteps45through65tunethecoilcircuittocreateanidealmixtureof parahydrogen(createdbythecoil)andorthohydrogen(createdbytheelectrodes).Low levelsofparahydrogen(toolean)canresultinexcessivelyhighcylinderheadtemperature (CHT),acommoncauseofengineprecombustion(ping).Highlevelsofparahydrogen (toorich)resultinlowCHT;coolingcombustion,decreasingefficiency,andpossibly causingengineroughness. Optimalmixtureisachievedbyleaningparahydrogentothepointofcreatingpingandthen slightlyricheninguntilpingdisappears.Youwillbesequentiallyfinetuningtwodifferent pots.ItsveryimportanttocloselymonitorCHTwhileleaningtopreventexcessivelyhigh CHT;refertoCHTrecordedinstep1fordriving60MPH(orfullpower)onasteepgrade.Be sureCHTdoesnotexceedtherecordedvaluebymorethan40degrees.NeverallowCHTto exceed400degrees. 46. ReferringtoFigure6,rotatethePulseWidthAdjustpotfullycounterclockwise(CCW).If theenginepings,gotostep47.Iftheenginedoesnotping,gotostep53. 47. Rotatefullyclockwise(CW).Iftheenginepings,gotostep48.Iftheenginedoesnotping, gotostep53. 48. SlowlyrotateCCW.IfCHTdecreases,continuerotatingCCWuntilCHTstopsdecreasing.Go tostep49.IfCHTincreaseswhilerotatingCCW,rotatefullyCCW.SlowlyrotateCWuntil CHTstopsdecreasing.Gotostep49. 49. RotatetheStrengthAdjustpotfullyCCW.Iftheenginepings,gotostep50.Iftheengine doesnotping,gotostep54.

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 50. RotatefullyCW.Iftheenginepings,rotateeachpottoitsmidpointandgotostep51.Ifthe enginedoesnotping,gotostep55. 51. TurnpowerOFF.ReferringtoFigure6,thecoilcircuitisnotproducingenough parahydrogen.Replacethe10Kresistorconnectingpin3ofcomponentNE555tothebase ofcomponent2N3055witha10Kpot.Adjustthepotforabout9Kresistance.Gobackto step45.Ifyoureachthisstepagain,adjustthepotforabout8Kandgobacktostep45.If necessary,eachtimeyoureachthisstep,adjustthepotforabout1Klessandgobackto step45.Ifthepotiseventuallyadjustedfor2Korless,acircuitcomponentisdefective. Locateandreplacethedefectivecomponent.Adjustthepotfor10K.TurnpowerONandgo backtostep45. 52. Slowlyrotateclockwise(CW)untilpingstarts.SlowlyrotateCCWuntilpingstopsand continuetorotateCCWabout5moredegrees.IfCHTismorethan40degreeshigherthan thevaluerecordedinstep1,continueslowlyrotatingCCWuntilCHTdecreasesto40 degreesabovetherecordedvalue.Gobacktostep29. 53. SlowlyrotateCCWuntilpingstarts.SlowlyrotateCWuntilpingstopsandcontinuetorotate CWabout5moredegrees.IfCHTismorethan40degreeshigherthanthevaluerecordedin step1,continueslowlyrotatingCWuntilCHTdecreasesto40degreesabovetherecorded value.Gobacktostep29.] 54. SlowlyrotateCWuntilpingstarts.SlowlyrotateCCWuntilpingstopsandcontinuetorotate CCWabout5moredegrees.IfCHTismorethan40degreeshigherthanthevaluerecorded instep1,continueslowlyrotatingCCWuntilCHTdecreasesto40degreesabovethe recordedvalue.Gobacktostep29. 55. SlowlyrotateCCWuntilpingstarts.SlowlyrotateCWuntilpingstopsandcontinuetorotate CWabout5moredegrees.IfCHTismorethan40degreeshigherthanthevaluerecordedin step1,continueslowlyrotatingCWuntilCHTdecreasesto40degreesabovetherecorded value.Gobacktostep29. 56. ReferringtoFigure6,rotatethePulseWidthAdjustpotfullycounterclockwise(CCW).If theenginepings,gotostep62.Iftheenginedoesnotping,gotostep57.

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57. Rotatefullyclockwise(CW).Iftheenginepings,gotostep63.Iftheenginedoesnotping, gotostep58. 58. SlowlyrotateCCW.IfCHTincreases,continuerotatingCCWuntilCHTstopsincreasing.Go tostep59.IfCHTdecreaseswhilerotatingCCW,rotatefullyCCW.SlowlyrotateCWuntil CHTstopsincreasing.Gotostep59. 59. RotatetheStrengthAdjustpotfullyCCW.Iftheenginepings,gotostep64.Iftheengine doesnotping,gotostep60. 60. RotatefullyCW.Iftheenginepings,gotostep65.Iftheenginedoesnotping,rotateeach pottoitsmidpointandgotostep61. 61. TurnpowerOFF.ReferringtoFigure6,thecoilcircuitisproducingexcessiveparahydrogen. Replacethe10Kresistorconnectingpin3ofcomponentNE555tothebaseofcomponent 2N3055witha20Kpot.Adjustthepotforabout11Kresistance.Gobacktostep45.Ifyou reachthisstepagain,adjustthepotforabout12Kresistanceandgobacktostep45.If necessary,eachtimeyoureachthisstep,adjustthepotforabout1Kmoreresistanceand gobacktostep45.Ifthepotiseventuallyadjustedforabout18Kresistanceormore,a circuitcomponentisdefective.Locateandreplacethedefectivecomponent.Adjustthepot for10K.TurnpowerONandgobacktostep45. 62. Slowlyrotateclockwise(CW)untilpingstopsandcontinuetorotateCWabout5more degrees.IfCHTismorethan40degreeshigherthanthevaluerecordedinstep1,continue slowlyrotatingCWuntilCHTdecreasesto40degreesabovetherecordedvalue.Gotostep 66. 63. SlowlyrotateCCWuntilpingstopsandcontinuetorotateCWabout5moredegrees.IfCHT ismorethan40degreeshigherthanthevaluerecordedinstep1,continueslowlyrotating CWuntilCHTdecreasesto40degreesabovetherecordedvalue.Gotostep66. 64. Slowlyrotateclockwise(CW)untilpingstopsandcontinuetorotateCWabout5more degrees.IfCHTismorethan40degreeshigherthanthevaluerecordedinstep1,continue slowlyrotatingCWuntilCHTdecreasesto40degreesabovetherecordedvalue.Gotostep 66.

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65. SlowlyrotateCCWuntilpingstopsandcontinuetorotateCWabout5moredegrees.IfCHT ismorethan40degreeshigherthanthevaluerecordedinstep1,continueslowlyrotating CWuntilCHTdecreasesto40degreesabovetherecordedvalue.Gobacktostep29. 66. Precisethrottleadjustmentiseasyusingthespecialfeatureofthewaterhybridsystem throttleassembly(RefertoFigure21).Herestherecommendedmethod: a. Disengagethearmfromthethrottlerod.Rotatethepotshaftthroughthetotal rangeofrotationrequiredtogofromidletofullpower.Usingaruler,measureand recordthetotaldistancetraveledbythetipofthethrottlerodasthepotisrotated. b. Rotatethepotshafttoitsmidpointofrotationandpositionthethrottlelinkageat itsmidpointoftravel.Slidethearmontothethrottlerodandattachthearmand sleeveontothethrottlelinkagewithhoseclamps. c. Raiseorlowerthepotbyrotatingitsmountingbracketaboutboltuntilthrottle linkagemovesthroughitsfullrangeoftravel.Ifnecessary,toobtainaddeddistance betweenthepotandarm,thearmandsleeveassemblycanbeinvertedtoposition thearmabovethelinkage. d. Toassuresmoothoperationwithoutbinding,besurethethrottlerodissquared withthesurfaceofthearmwhenthelinkageisatitsmidpointoftravel.Ifnecessary, rotatethepotbodywithinthelimitsofthe3/32slotandrotatethesleeveabout theaxisofthelinkageuntilthethrottlerodissquarewiththearm. e. Adjustidletodesiredspeed.Operatethethrottlethroughseveralcyclestoverify smoothoperationwithoutbinding. f. Firmlytightenmountingbolts,hoseclamps,andthepotretainingnut.Withthe throttleatidleposition,trimthethrottlerodtolengthsothatitprotrudesabout abovethearm.SquaretherodendwithafileandDeburrwithsandpaper.Mixa smallquantityofepoxy,suchasJBWELD,andapplyintothe3/32slotinthearea oftheantirotationpintosecurethepotagainstrotation. 67. Whiledriving,verifythatthefourLEDsoperateasfollows: GreenPWRONlightswhenpowerisONandisnotlitwhenpowerisOFF. GreenPUMPONandyellowGENWATERLOWbothlightwhenthewaterpumpis runningandarenotlitatallothertimes. RedTANKWATERLOWisnotlitwhentankwaterlevelismorethanabout1/3full,and blinkswhenwaterfallsbelowthatlevel.

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IfallfourLEDsoperateproperly,gotostep68.Ifnotoperatingproperly,refertoFigures5, 6and7andtroubleshoottolocatethedefectivecomponentorwiringerror.Repairor replaceasnecessaryandgotostep68. 68. Congratulations,yourWaterhybridsystemisworkingperfectly!Afterabout25hoursof driving,firmlytightenhoseclampsonallfittings.Happydriving!

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HelpfulHintsandTips
HerearesomehintsandtipstohelpyougetthemostfromyourWaterhybridsystem:

Maintenance
YourWaterhybridispracticallymaintenancefree;justfillupwithwateranddrive.But,tap watercontainsmineralswhichaccumulatewithintheGeneratorandcoatparts.Theelectrode gapwillgraduallyfillwithdeposits,andefficiencywillkeepdroppinguntilinsufficienthydrogen andoxygenareavailabletopoweryourengine.Preventmineralbuildupbyperiodicallyflushing andcleaningtheGenerator. FlushingSinceitssoquick,easy,andeffective,IhighlyrecommendflushingtheGeneratorat leasteveryweekortwo.Theresnoneedtostarttheengine.Simplyopenthedraincockand turnpowerONforaminuteortwo.(Thewaterpumpwillprovideplentyoffreshwatertodoa goodjob.)Closethedraincock,waitfortheGeneratortopumpfull,andturnpowerOFF.Be suretotopofferthewatertank. CleaningAthinlayerofmineralswilleventuallycoattheGeneratorparts,andmustbe periodicallyremoved.Dependingonthemineralcontentofthewaterandtheamountof driving,cleaningrequirementsmayvaryconsiderably.Tobeonthesafeside,Irecommend cleaningeverymonthortwo.AmildlyacidicmineraldepositcleanersuchasCLR(availableat largegroceryandhardwarestores)worksverywell.Dozensofsimilarproductsareonthe market;mostbeingusedtocleandepositsfromhumidifiers.Anystorecarryinghumidifiers shouldalsohaveaneffectivecleaner. MakesurepowerisOFF.DraintheGenerator,disconnecttheoutlettubeattheflamearrestor, andclosethedraincock.Wearingprotectivegloves,mixcleanerabout50/50withwater (followmanufacturerdirections)andpourthroughthetubeuntiltheGeneratorisfull.Allow thecleanertoworkforafewminutes(followmanufacturerdirections)anddrainintoabucket orlargecontainer.Repeatthisprocedureonemoretime.Examinethedrainedcleanerand,if necessary,repeatuntilthedrainedcleanerisfairlyclear. Closethedraincock,filltheGeneratorwithfreshwaterthroughthetubing,anddrain.Repeat twomoretimes.TurnpowerONandflushforaminuteortwo.Closethedraincock,waitfor theGeneratortopumpfull,andclosethedraincock.TurnpowerOFFandreconnectthetube totheflamearrestor.Besuretotopoffthewatertank.

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ColdWeatherOperation
Ifoutsidetemperaturesarebelowfreezing,isopropylalcoholshouldbemixedwiththewater topreventfreezing.Sincealcoholchangesthedielectricpropertiesofwater,thewaterhybrid systemoperatingfrequencymustbechangedbyadjustingtheFrequencyAdjusttrimpotfor peakperformance(refertoFigure5).Workiswellunderwaytodevelopnichromewireelectric heatingdevicesforcoldweatheroperation.Youwillbenotifiedwhenthedevices,orplansfor theirconstruction,becomeavailable.

SpareGenerator
Becauseofitsgreatreliabilityandlowmaintenancefactor,itseasytoforgetthatthewater hybridsystemrequiresatleastsomeperiodicattention.EventuallytheprimaryGeneratormay becomecloggedwithmineraldepositsduetoneglectedmaintenance,ormayevenfailsince nothingisperfect.Sincesuchthingsalwaysseemtohappenattheworstpossiblemoment,you maywanttoconsiderbuildingandinstallingaspareGeneratorjusttoactasabackup.Ifyou do,besuretokeepalldimensionsthesameastheprimaryGeneratorsothatnoretuningis needed.Thatwayallyouhavetodoisswitchafewwiresandtubesovertothespare Generatorandyourebackontheroad.

GoodOldStainlessSteel
TheonlycombustionproductthatyourWaterhybridpoweredenginecontributestotheoverall exhaustcompositioniswatervapor.Andweallknowwhatwater,especiallyhotwater,does tosteel.Unlessyourenginehasalreadybeenequippedwithstainlesssteelvalves,youshould lookintohavingtheminstalledassoonaspossibletopreventvalvecorrosionproblems(which couldeventuallyleadtoothermoreseriousproblems).Stainlesssteelvalvesarerelatively inexpensive,andalmostanyhighperformanceshopcaninstallthem.Yourexhaustsystemis alsovulnerabletorust.Butyouhavemoreoptionsthere.Ifthesystemisold,youmaychoose toletiteventuallyrustoutandreplaceitwithastainlesssteelsystem.Or,ifthesystemisnew, anyoneofthenewandreadilyavailableceramiccoatingprocesseswillpreventrusting.The mostpracticalanswertotherustprobleminvolvesdevelopingawatercompatibleadditivethat inhibitscorrosion.Apparentlysuchanadditiveisveryclosetobeingmarketed;aliquidwitha ratioof3partsadditiveto100partswater.

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GoodOldJBWELD
Firstchanceyouget,Irecommendsealingthewireendsofallconnectorswithahighquality epoxysuchasJBWELD.Notonlydoesthisaddphysicalstrengthtotheconnector,buthelps sealagainstcorrosion.Thisisespeciallyeffectiveforconnectorsinsidetheengine compartment.Useonlyasmallamountofepoxy.Dontoverdoittothepointthatepoxyflows ontotheconnectorcontactsthemselves.

KeepCloseWatch
AlwayskeepanattentiveeyeontheCHTandpressuregauges.Theycantellyoualotabout howthesystemisperformingatanyparticularmoment.Anysuddenorunexpectedchangein temperatureand/orpressureusuallysignalsthataproblemhasoccurred,orisabouttooccur. Eventuallyyoulldevelopafeelforinterpretingthegauges.

GarrettsGauge
Heresacompletehydrogen/oxygensystem(refertoFigure22)allwrappedupinaneatlittle package.Itwasaningeniousconcept,allthebasicelementsarethere.Butitwentthewayof countlessotherinventorsdreams,doomedtofailonlybecauseoflackofvitaltechnology. CharlesGarrettoriginallypatentedthisgadgetbackin1932(USPatent2,006,676),termingitan ElectrolyticCarburetor.Heproposedchargingtheelectrodeswithastoragebattery,a hopelesslyinadequatepowersource. Leadplatesservedasthewatercapacitorandweaksulfuricacidaselectrolyte.Sincethewater chamberhastobeelectricallynonconductive,itwasconstructedofbakelite(anearlydayform ofplastic).Anelectricmotordroveagearwithanoffsetpinandlinkage,actuatingaswitchto reversebatterypolaritytotheplates.(Mechanicallycreatingaverylowfrequency,lowvoltage, pulse).Waterlevelwasmechanicallycontrolledbymeansofafloatandneedlevalveassembly designedtorestrictthewaterinletport. LookingattheGarrettGadget,wecanseethatthebasicconceptofawaterpoweredengineis notanewideabyanymeans.Hewasontherighttrack:allheneededwas70moreyearsof evolvingtechnology.

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 Figure22:Garrett'sGadget

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Reference
StephenChambers,ApparatusforProducingOrthohydrogenand/orParahydrogenUSPatent 6,126,794andPrototypeVaporFuelSystem. StanleyMeyer,MethodforProductionofaFuelGasUSPatent4,936,961. CarlCella,AWaterFueledCarNexusMagazine,OctNov1996. PeterLindemann,WhereintheWorldisAlltheFreeEnergy. WilliamS.Power,TheHydrostar GeorgeWiseman,TheGasSaverandHyCoSeries. C.MichaelHoller,TheDromedaryNewsletterandSuperCarbTechniques.

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AThoughtorTwo
Duringcountlesshoursspentresearchingandcompilingmaterialforthisbook,Iwasconstantly amazedattheingenuityofthehundredsofpatentedinventionsIhappenedupon. Ihopeyouenjoythisbook.Itwasarealchallengeforme,butIhadagreattimeputtingit together.DontforgettoletmeknowaboutyourexperienceswithyourownWater hybridand, Happy Driving!!

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