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Wefeelfortunateinbeinggiventhe 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 supplementalplansanddocumentstogiveyouthewidestvarietyofoptionsand resourcesavailableasyoubeginthewaterhybridconversionprocess. Copyright2008ALLRIGHTSRESERVED
LEGALDISCLAIMER:Thisbookhasbeeneditedandrevisedforcontentclarity,textreadability, 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 bodyorregulatorstoverifycompliancewithexistingemissionsrequirementsandstandards. Wealsoencourageyoutoverifythatyourvehiclepassesstateorgovernmentemissionstests aftercompletingtheconversion. Althoughtheseplansaredesignedtobe100%reversibleandtoworkwiththevastmajorityof 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,relatingtoorresultingfromuseormisuseoftheseplans.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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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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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
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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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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
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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)
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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
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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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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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Figure13:HousingAttachmentDetails
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Figure14:MoreHousingAttachmentDetails
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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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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
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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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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.
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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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!
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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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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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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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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
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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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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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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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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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