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Congratulationsonpurchasingyour veryown instructionsfor convertingyourmotorvehicleintoawaterburninghybrid!Wefeelfortunateinbeinggiventheopportunitytobringthisvaluable informationyourway.Now,youtoocanbeinvolved in efforts to help utilize an incredible and priceless technology;harnessingwaterasasourceofenergyforyourvehicle!Weencourageyou toalsoexplore our download section forFREEbonusesand
supplementalplansanddocumentstogiveyouthewidestvarietyofoptionsand
resourcesavailableasyoubeginthewaterhybridconversionprocess.
Copyright2008ALLRIGHTSRESERVED
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2 RunaCaronWater
LEGALDISCLAIMER:Thisbookhasbeeneditedandrevisedforcontentclarity,textreadability,
andtechnologicalsuitabilityformodernfuelinjectionandoldercarburetorbasedvehicles,and
isinspiredbytheoriginal,publicdomain,Hydrostarconversionplans.
Pleasebe
advised
that
this
conversion
may
measurably
modify
the
exhaust
characteristics
of
yourvehicle. Therefore,westronglyadviseyou tocontactyour localornationalgoverning
bodyorregulatorstoverifycompliancewithexistingemissionsrequirementsandstandards.
Wealsoencourageyoutoverifythatyourvehiclepassesstateorgovernmentemissionstests
aftercompletingtheconversion.
Althoughtheseplansaredesignedtobe100%reversibleandtoworkwiththevastmajorityof
motorvehicles,youacknowledgeandunderstand thatbycarryingout theseplans,youare
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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3 RunaCaronWater
Preface
Thisbookpresentscompleteplansanddetaileddescriptionssufficienttobuildaworkablewaterhybridsystemforyourfuelinjectedorcarburetedmotorvehicle.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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4 RunaCaronWater
Contents
Preface ........................................................................................................................ .................... 3
Contents.......................................................................................................................................... 4
BasicQuestions
and
Answers ......................................................................................................... 7
WhatistheWaterhybridsystem?............................................................................................. 7
Isthewaterhybridsystemaperpetualmotionmachine? ........................................................ 8
Isthewaterhybridsystemsafe?................................................................................................ 8
Whyisthewaterhybridsystemiscalledaconversionsystem? ............................................... 8
Howwelldoesthewaterhybridsystemperform?.................................................................... 8
CantheWaterhybridsystembeusedinotherways?............................................................... 9
Isthe
Water
hybrid
system
difficult
to
build?............................................................................ 9
CanIbuyareadytoinstallWaterhybridsystem? .................................................................... 9
TheWaterhybridsystem! ............................................................................................................ 10
Hydrogen/OxygenGenerator ................................................................................................... 10
WaterTankandPump .............................................................................................................. 13
InDashIndicators[OPTIONAL]................................................................................................. 14
HyTronicsModule..................................................................................................................... 15
GeneratorElectrode
Circuit
Schematic .................................................................................... 15
GeneratorCoilCircuitSchematic.............................................................................................. 18
InDashIndicatorsCircuitSchematic ........................................................................................ 20
LetsBuildthewaterhybridsystem!:GeneratorConstruction .................................................. 22
Electrodes ................................................................................................................................. 22
Housing ........................................................................................................................ ............. 26
Listofmaterials:.................................................................................................................... 26
Stepby
Step
Directions
with
Illustrations:........................................................................... 27
HousingAttachments................................................................................................................ 39
UnthreadedEndCap................................................................................................................. 43
ListofMaterials: ................................................................................................................... 43
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5 RunaCaronWater
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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6 RunaCaronWater
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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7 RunaCaronWater
BasicQuestionsandAnswers
Agoodstartingpointforunderstandingthewaterhybridtechnologyistoansweravarietyof
frequentlyaskedquestionsyoumayhave. Sohereitgoes:
WhatistheWater-hybridsystem?
Thesewaterhybridplansessentiallyconvertyourvehicletousewaterasasourceof
supplementaloreven(theoretically)primaryfuel. Theenginederivesfuelfromhydrogenand
oxygen,generatedbytheelectrolysisofwater.Althoughpetroleumderivedfuelandan
externalelectricalgeneratingsystemisnottheoreticallyrequired,inmostcircumstancesitisa
practicalnecessity.Theonlybyproductresultingfromthehydrogenandoxygencomponentsof
combustionwithintheengineiswatervapor.Therefore,emissionsareusuallycleaner,emitting
fewerpolluting
particles.
In
short,
the
Water
hybrid
system
is
acleaner
system;
one
that
derivessupplementalfuelfromafreeandinexhaustibleresource;WATER!Ithastheunique
advantageofbeingabletoremovepollutantsfromtheairduringcombustion,andeven
reducesthecarbonresiduewithintheengine(similartotheeffectofhigheroctanefuels).
TheWaterhybridsystemisprovenandhasbeenimplementedinvariousformsandvarietiesby
engineers,mechanics,andhobbyistsaroundtheworld. Itistheendresultofmanyyearsof
testingandexperimentationwithamultitudeofhydrogengeneratingsystemsbasedonthe
principleofelectrolysisofwater.
Waterelectrolysis
is
simply
the
breaking
down
of
water
into
its
basic
hydrogen
and
oxygen
atomsbypassinganelectroniccurrentthroughit.Youdontevenhavetoaddanelectrolyte
(suchasacid)tothewatertoassureelectricalconductivity,asisrequiredwithabattery;plain
oldtapwaterworksfinebecauseitcontainsnaturalelectrolytessuchasminerals,andalso
municipaladditivessuchaschlorinewhichalsoaidinelectricalconductivity.Infact,electrolysis
isinmanywayssimilartothereactionwhichoccurswithinyourvehiclesbattery.Electrolysisof
waterusnothingnew;itwasfirstaccomplishednearlyacenturyago.But,untiltechnologies
likethewaterhybridsystemweredeveloped,itrequiredahighvoltagepowersupplyand
consumedvastamountsofelectricalenergy.Itactuallyrequiredmuchmoreelectricalenergy
thanthe
energy
derived
from
the
combustion
of
the
resulting
hydrogen
and
oxygen.
In
other
words,itwasanextremelyinefficientprocessthathadlimitedpracticaluse.
Thewaterhybridsystemisapracticalsolutiondevelopedforuseinfuelinjectedand
carburetedmotorvehicles.ThesecretofthewaterhybridsystemlieswithinitsHyTronic
module.Itproducedrelativelylowvoltage,butuniquelyshapedelectronicpulsesofprecise
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8 RunaCaronWater
frequencyandduration.TheoverallpowerconsumptionoftheHyTronicmoduleandtheentire
waterhybridsystemisfairlylow;actuallylowenoughtobeeasilypoweredbyyourvehicles
excesselectricalandheatoutput,andwithenoughreservepowerlefttohelprunallyour
vehiclesotherelectricaldevices.
Isthewater-hybridsystemaperpetualmotionmachine?
Thewaterhybridsystemisnotaperpetualmotionmachine. Itisahighefficiency,water
fueled,electromechanicalsystemcapableofproducinghydrogenandoxygeninsufficient
quantitytoimprovetheoverallfuelefficiencyofinternalcombustionengines.
Isthewater-hybridsystemsafe?
Vehiclespowered
by
the
water
hybrid
system
are
inherently
safer
than
hydrogen
powered
vehicleswhichrequirehydrogentanks. Insteadofhydrogentanks,thewaterhybridsystem
extractscombustiblehydrogenasneededfromthewater,andthissteadyreleaseofhydrogen
isburnedcontinuously,therebypreventinglargeraccumulationsofhydrogengas.
Whyisthewater-hybridsystemiscalledaconversionsystem?
Thewaterhybridsystemiscalledaconversionsystembecauseitdoesntrequireremoval,
modification,ordisablingofanyofyourvehiclesexistingsystems.Therefore,itallowsyouto
runyour
vehicle
on
either
100%
gasoline
systems
or
the
water
hybrid
system.
In
the
unlikely
eventthatyourWaterhybridfails,youcaneasilyswitchbacktosolelyusinggasolinepower.
But,youllsoonbegettingyourwaterhybridbackintoworkingorder.Onceyouvedrivenwith
thewaterhybridsystemyoullneverbehappywithanythingelse!
Howwelldoesthewater-hybridsystemperform?
Avehiclepoweredbythewaterhybridsystemistheoreticallycapableoftravelingfrom50to
300milesoneachgallonofsupplementalwater,whileimprovingoverallfuelefficiencyupto
45%. However,asistrueforanyengine,actualefficiencydependsonmanyfactorssuchas;
drivinghabits,terrain,vehicleweightandshape,andabilitytotweakandoptimizethesystem.
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9 RunaCaronWater
CantheWater-hybridsystembeusedinotherways?
Yes,theWaterhybridsystemcanprovidefuelfromwaterforjustaboutanyhomeappliance
requiringnaturalgasorpropaneasasourceofheat;therebysavingvaluableanddiminishing
naturalresources.
Space
heaters
and
furnaces
are
excellent
candidates.
Stoves
and
other
cookingunitssuchasbarbecuegrillscanalsobefueledbythewaterhybridsystem.Such
applicationsrequireaseparatepowersupplytoconvertyourhomes120voltACpowerintothe
12voltDCpowerrequiredbythewaterhybridsystem.Youcanpurchaseaninexpensivepower
supplyatanyelectronicsstoresuchasRadioShack,orhavesomeonefamiliarwithelectronics
buildoneforyousincethedesignisverysimple.Thecostofhomeelectricityusedbythe
waterhybridsystemisinsignificant,probablylessthan$3permonthinmostcases.
IstheWater-hybridsystemdifficulttobuild?
No,thewaterhybridsystemisrelativelyeasytoassembleandveryeasytoinstall,especially
comparedwithotherconversionplansonthemarket.Nospecialtoolsarerequired.Theusual
toolandequipmentfoundinatypicalhomeworkshopwilldothejob.AssemblingtheHyTronic
moduletoachieveitsinherenthighlevelofreliabilityrequirescareandattentiontodetails,
alongwithaverageelectronicsskills.Theonlyspecialpieceoftestequipmentyoumaywantto
haveaccesstouseisanoscilloscope.ItISNOTnecessary,butmayhelpyouobtainpeak
efficiencyfromtheHyTronicsmodule.But,youshouldnthaveanyproblemgettinghelpfroma
localelectronicsguruifyoudonthaveanoscilloscope.Mostfolksaresofascinatedbyunusual
electronicsystemsanddevicesthattheywouldalmostbewillingtopayyoufortheprivilegeof
tweakingyourHyTronicsmodule!
CanIbuyaready-to-installWater-hybridsystem?
Rightnow,thisspecificwaterhybridsystemisnotbeingcommerciallymanufactured,butthere
arevariousdistributorsaroundthecountrywhoofferDIY(Doityourself)partsorfully
assembledkitsutilizingsimilartechnologiesandprinciples.
Planningis
in
the
initial
stages
for
producing
Water
hybrid
conversion
kits
for
most
vehicles
andeventuallymanufacturingtheentiresystem,oratleastitsmajorcomponents.Were
hopingtohavesomeprototypekitstestedsoonanddeliveryofreadytoinstallkitsshould
beginsometimebeforetheendof2008. However,youllsoonbebuildingyourown!
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10 RunaCaronWater
TheWater-hybridsystem!
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
bothhydrogen
and
oxygen.
Each
can
be
made
from
avariety
of
materials
such
as
stainless
steel
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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11 RunaCaronWater
toslowitsburningrate.Atbestthisisaninexactsciencesinceitdependsupontryingto
averagetheoctanerequirementsformillionsofengines.
Technicallyspeaking,theHydrogen/OxygenGeneratoritselfisanelectronicbasedunit.The
twoelectrodesformabasiccapacitor,thousandsoftimeslargerthancapacitorsusedintypical
circuits,with
water
acting
as
its
dielectric.
The
inner
electrode
is
negatively
charged,
and
the
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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12 RunaCaronWater
Forafewbriefmoments,onlymoreaccuratealignmentandincreasedpullingactionuponthe
watermoleculesoccurs.But,theHyTronicssignalpulseskeepchargingthewatercapacitorto
higherandhighervoltagelevels;actuallyseveralthousandvolts.Suddenlytheelectricalforces
becomeso
great
that
the
water
molecules
burst
apart
(scientists
call
this
action
disassociation)
intotheirgaseousformsofhydrogenandoxygen.IfyouwereabletolookintotheGenerator,
thisactionwouldbeobviousbecauseoftheformationofmillionsoftinyhydrogenandoxygen
gasbubbles.AslongastheHyTronicssignalisapplied,thewatercapacitorremainsfully
charged;continuouslycreatingorthohydrogenandoxygen.
Anotherelectroniccircuitisformedbythegeneratorcoil.Thisisaninductivecircuit,meaningit
createsamagneticfieldasopposedtothechargedfieldcreatedbythewatercapacitor.The
verylowfrequencyHyTronicssignal(actuallyashortpulse)activatesthemagneticfieldofthe
coil.As
soon
as
the
pulse
stops,
the
magnetic
field
collapses.
This
creates
an
even
stronger
magneticfield,butafieldofoppositepolarity.Thatishowaninductivecircuitworks,anaction
commonlycalledinductivekick.Eachpulseispreciselytimedsothatalmostimmediately
afterthemagneticfieldreverses,anothershortpulsearrives.Onceagainthecoilischargedand
itsmagneticfieldcollapses.Butnowthecontinuallyreversingmagneticfieldbecomeseven
strongerduetoaddedenergyofeachnewpulse.Eventually(actuallywithinjustafewseconds)
thecoilreachesitsmaximummagneticstrength,calleditssaturationpoint.
Mostmoleculesareeffectedbymagneticfields.Thecoilsreversingmagneticfieldsvibratethe
watermoleculessovigorouslythattheydisassociateintogaseousformsofparahydrogenand
oxygen.Disassociation
observably
occurs,
as
seen
by
the
creation
of
millions
of
tiny
hydrogen
andoxygengasbubblesaroundthecoil.
Atthispoint,wevecoveredtheconceptsneededtounderstandthebasicfunctioningofthe
generator.EveryothercomponentoftheWaterhybridsystemissimplyusedtoprecisely
controltheactionofthegenerator.ByvaryingthestrengthandfrequencyoftheHyTronic
signals,theratebywhichhydrogenandoxygenarecreatedcanbevariedtomatchengine
requirementsatanyparticularmoment.Waterissuppliedbythetankandpump,whilewater
levelwithintheGeneratoriscontrolledbyalevelsensorandswitch.Forsafetypurposes,a
reliefvalve
protects
against
excess
pressure
buildup
within
the
generator.
Separate
ports
are
providedforattachinghosestoroutegastotheengineandtoanoptionalgaugetomonitorgas
pressurebuildupwithinthegenerator.Adrainvalveisinstalledtoallowperiodicflushingof
accumulatedmineralsandcontaminants.Thebottomendcapisthreadedsothatthe
Generatorcaneasilybeopenedupforinspectionorrepairandforoccasionalcleaningofthe
electrodesandcoil.Twopairsofstainlesssteel(copper,oranyconductivemetal)rodends
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13 RunaCaronWater
protrudefromtheGeneratorbodytoprovideelectricalconnectionoftheelectrodesandcoilto
theHyTronicsModule.
AsshowninFigure18,thegeneratorgasoutputhoseconnectstoaflamearrestor,whichin
turnconnectstopressurefittingsattachedtotheengine.Theflamearrestorprovides
protectionagainst
combustion
flashback
into
the
Generator
in
the
event
that
engine
backfiring
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
recommendinstalling
awater
level
sensor
in
the
water
tank
so
you
can
easily
monitor
water
quantity,andsensorsarerelativelyexpensive.Otherwiseyoullhavetooccasionallycompare
themilesyouvedrivenversusthequantityofwater;withallthatbasedupontheMPGofwater
consumption.Theotheralternativeistocheckthewaterlevelfairlyoften,butsomedayyoull
runthetankdryandwishyouhadspenttheextramoneyforasensorandindicator.
Itsbesttouseagenerouslysizedwatertankof.5to1.5gallonscapacity.ThetankIllbe
recommendingholdsover2gallonsandhastranslucentlevelmarkings,soitseasytoseehow
muchwaterremains.Theextraofcapacityofwatertakesupverylittlespace,butleavesagood
reserve
for
less
frequent
refilling.
I
recommend
installing
a
6
inch
vent
tube
into
the
tank
cap
to
preventspillagefromsloshingwater.
Youllalsohavetodecideonpumplocation.IfyouusetheselfprimingpumpIrecommend,you
canmountitintheenginecompartment.Ifyoudontuseaselfprimingpump,youllhaveto
mountthepumpdirectlyontothetank,orcloseby,andatalevelnearthebottomofthetank.
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14 RunaCaronWater
Also,ifyoudontuseaselfprimingpump,thewaterhosegoingfromthepumptothe
Hydrogen/OxygenGeneratorwillhavetobecapableofwithstandingatleast66PSIwater
pressure.Thatstheminimumrecommendedpumppressurecapacityrequiredtoovercome
maximumgaspressuresof65PSIwithinthegenerator,withanadditional1PSIneededto
activate
the
one
way
valve
installed
on
the
generator
housing.
Also,
if
you
dont
use
a
self
primer,youllhavetorunanextrapowerleadbacktothetrunk.Forthesakeofsimplicityand
reliabilityaselfprimingpumpisthebestwaytogo.
In-DashIndicators[OPTIONAL]
ReferringtothefollowingFigure2;topermiteasymonitoringofWaterhybridfunctions,I
recommendtwogauges:Generatorpressure(GENPRESS)andenginecylinderhead
temperature(CHT).Ialsorecommendfourindicatorlights:GENWATERLOW,PUMPON,TANK
WATERLOW,
and
PWR
ON.
These
can
be
installed
into
your
vehicle
dash,
or
mounted
in
a
nearbyconsole. PLEASENOTE:TheInDashIndicatorsARENOTrequired,butareaniceperkif
withinyourbudgetandtechnicalexpertise.
Figure2:InDashIndicators
MonitoringtheGENPRESSandCHTgaugesallowsyoutodevelopafeelforhowthesystem
respondsto
various
driving
conditions.
They
can
also
be
of
help
in
tweaking
the
system
to
obtainmaximumperformanceandeconomy.
TheGENWATERLOWlightnormallyremainsunlit.Asfuel(water)isconsumed,theGenerator
waterlevelgraduallydropsuntiltheGENWATERLOWlightilluminates.Atthatpointthewater
pumpshouldstartpumpingwater,illuminatingthePUMPONlight.WhenGeneratorwaterhas
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15 RunaCaronWater
risenbacktoitsnormallevel,theGENWATERLOWlightshouldgobackout.Atthesametime,
thepumpshouldstoprunning,turningoutthePUMPONlight.So,undernormaloperating
conditions,bothlightsshouldbeilluminatedatthesametime,andbothlightsshouldgooutat
thesametime.Anyotherlightcombinationindicatesamalfunction.
TheTANK
WATER
LOW
light
illuminates
when
tank
water
level
drops
to
its
1/3
full
point,
indicatingthatyoushouldthinkaboutfillingthetankbeforelong.ThePWRON(PowerON)
lightshouldlight,andremainlit,aslongastheWaterhybridsystemisoperatingnormally.The
signalforthislightcomesfromtheHyTronicsModule.So,ifthePWRONlightevergoesout
(exceptwhenthesystemisintentionallyturnedoff),orbecomesintermittent,theHyTronics
Moduleismalfunctioning.
HyTronicsModule
TheHyTronicsModulecontainselectronicscircuitsforcontrollingand/orprovidingpowertoall
thewaterhybridsystemselectricallyoperateddevices.Separatecircuitsexisttoperformeach
ofthefollowingfunctions:
ProvidepowertotheGeneratorelectrodesintheformofahighfrequencysignal,creatingorthohydrogenandoxygen.
ProvidepowertotheGeneratorcoilintheformofaverylowfrequencysignal,creatingparahydrogenandoxygen.
ControlpowertothewatertankpumpviasignalsreceivedfromtheGeneratorwaterlevel
sensor.
Providebusingandterminalpointsfordistributingpowertosystemgauges,indicators,andsensors.
GeneratorElectrodeCircuitSchematic
Figure5depictstheschematicdiagramfortheGeneratorelectrodecircuit.Itsoutputisa
squarewavepulsewhichisappliedtothecylindricalelectrodesoftheHydrogen/Oxygen
Generatorshowninfigure18.
Referringto
the
following
Figure
3,
this
square
wave
pulse
has
an
ON:OFF
ratio
of
1:1.
That
is,
thepulseisturnedONforaslongasitsturnedOFF.Thesquarewavepulseshowninthe
followingFigure4hasanON:OFFrationof3:1.Thatis,thepulseisturnedONforthreetimesas
longasitsturnedOFF.TheGeneratorelectrodecircuitofFigure5iscapableofvaryingits
squarewavepulseratiobetween1:1and10:1.
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16 RunaCaronWater
Figure3:SquareWave ON:OFFRatio1:1
Figure4:SquareWave ON:OFFRATIO3:1
EachON:OFFpulsesequenceisreferredtoasacyclesinceeachnewpulsesequencekeeps
cyclingONandOFFinanidenticalway. Figure3showsthreecyclesofON:OFFpulse
sequences.Ifthesecycleswerealltooccurwithinatimespanofonesecond,wewouldreferto
thepulseashavingafrequencyof3cps(cyclespersecond).If127cycleswerealltooccur
within
a
time
span
of
one
second,
we
would
refer
to
the
pulse
as
having
a
frequency
of
127
cps.
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
gas
volume.
Varying
voltage
input
from
a
potentiometer
connected
via
a
10K
resistor
to
pin
3
of
componentLM741causesthecircuittovarythepulseratio,andthereforecontrolstheamount
ofgasesproduced.Thepotentiometershaftconnectstothevehiclethrottlelinkage,enabling
controlofgasvolumeindirectresponsetovoltagechangescorrelatingwithrotationofthe
potentiometershaftinrelationtothrottlepositioning.Atrimmingpotentiometerconnectspins
2and6ofcomponentLM741,enablingpreciseadjustmentofthethrottleinputsignal.A
secondtrimmingpotentiometerconnectspins4and7ofcomponentNE555,enablingprecise
pulsewidthadjustment.
TheelectrodepairsofeachGeneratorexhibitauniquefrequencyofelectricalresonanceat
whichoptimum
gas
volume
is
created.
This
frequency
often
varies
considerably
among
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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19 RunaCaronWater
Figure6:GeneratorCoilCircuitSchematic
TheGeneratorcoilcircuitcreatesapulsedsignalverymuchsimilartothatoftheelectrode
circuitoffigure5;but,productionofparahydrogenandoxygenbythecoilentailstotally
differentoperatingparametersthandoesorthohydrogenandoxygenproductionbythe
electrodes.Optimumoperatingfrequencyforthecoilismuchlower,withintherangeof
approximately16Hzto25Hz.Coilfrequencydirectlycorrelatestotheoptimumoperating
frequencyoftheelectrodecircuitsinceitsinputsignalisreceiveddirectlyfrompin3of
electrodecircuitcomponentNE555.TheelectrodecircuitsignalisreceivedviatheDivideby
Nlogiccircuitwhichproducesoneoutputsignalinresponsetoaspecificnumberofinput
signals.Forexample,iftheoptimalfrequencyoftheelectrodecircuitis19KHzandtheDivide
byNlogiccircuitcreatesoneoutputpulseforevery1,000inputpulses,theoutputfrequency
oftheDividebyNlogiccircuitwouldbe19Hz.Thatsignalisreceivedviapin2ofcomponent
NE555,whichcreatestherequiredsquarewavepulses.Thosepulsesaresentviapin3tothe
baseoftransistor2N3055,wheretheyareamplifiedandtransmittedtothecoil.
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Thevolumeofparahydrogenandoxygencreatedbythecoilcanbepreciselyregulatedby
adjustingthepulsewidthandamplitudetrimmerpotentiometersofitsassociatedcircuit.
Parahydrogenactsasanoctanebooster.Therefore,thevolumerequireddependsentirelyupon
theoperatingdemandsofyourengine.Sinceparahydrogencoolsthecombustionprocess,
excess
volume
tends
to
reduce
engine
efficiency.
With
that
in
mind,
the
coil
circuit
should
be
adjustedsuchthatonlyenoughparahydrogeniscreatedtopreventengineprecombustion
(knocking).However,ifengineoperatingtemperatureisrunningonthehighside(as
determinedbytheCHTgauge)increasingparahydrogenvolumeisaneffectivewaytolowerthe
temperature.
In-DashIndicatorsCircuitSchematic
TheoptionalInDashIndicatorsCircuitschematicisdepictedbyfigure7. Twogaugesandfour
lightemitting
diodes
(LEDs)
comprise
the
In
Dash
Indicators
assembly.
The
Generator
pressure
(GENPRESS)gaugeconnectsviaahosetoitsrespectivefittingontheGeneratoritself(referto
figure13).Thecylinderheadtemperature(CHT)gaugeelectricallyconnectstoasensorplaced
underanenginesparkplug.
WhentheGeneratorwaterlevelsensorisactivatedbylowwaterlevel,its12VDCsignalissent
topin2ofdetectorLM741viaa10Kresistor.Detectoroutputfrompin6triggersthebaseof
powertransistorE3055T,completingthecircuittoactivatethewaterpumpandilluminatethe
PUMPONLED.The12VDCsensorsignalalsoilluminatestheGENWATERLOWLED.When
Generatorwaterrisestoitsnormallevel,thelevelsensoropens;turningoffthepumpandboth
LEDs.
Whenthetankwaterlevelsensorisactivatedbylowwaterlevel(at1/3tanklevel),its12VDC
outputsignalilluminatestheWATERLOWLED.Afterrefueling(addingwater),thelevel
sensoropens,turningofftheLED.
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Figure7:InDashIndicatorsCircuitSchematic
WhentheWaterhybridsystemisturnedon,thePWRONLEDilluminates.TheGenerator
electrodecircuit(Figure5)activatestheLED.FailureoftheLEDtoilluminateusuallyindicates
anelectrodecircuitmalfunction.
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LetsBuildthewater-hybridsystem!:GeneratorConstruction
Electrodes
Sinceenginerequirementsdictatethevolumeofhydrogenandoxygengasesthatthegenerator
mustcreate,
and
gas
volume
is
variable,
Irecommend
sizing
it
as
large
as
is
practical
to
allow
reservecapacity.Maximumoutsidediameterof4.5isalreadydeterminedbytheconstruction
materialusedfortheGeneratorhousing:4CPVCSchedule80pipe.Irecommendaminimum
heightof10.Maximumheightdependsuponavailablespacewithintheenginecompartment
but,forstructuralintegrity,limitheightto18.Carefullychecktheenginecompartmentofyour
vehicletoensurethatadequatespaceexistsforgeneratorinstallation.Ifadequatespacedoes
notexisteitherlimitthegeneratorheight(butnotlessthan10),orlocatethegeneratorwithin
thetrunk,orasfarforwardaspossibleunderthedash.
1. AfterdeterminingGeneratorheight,obtaina31/2(3.50)outsidediameterstainlesssteeltube
with
wall
thickness
of
.040
to
.063
and
length
5
shorter
than
the
determined
height
oftheGenerator.AstandardalloyofT304stainlesssteelisrecommendedforthe
electrodes.Thistubewillbeusedtoconstructtheouterelectrode.RefertotheGenerator
explodedviewofFigure9asanaidtocorrectconstruction.
NOTE
Thefollowingsteps2through4willbeusedtodeterminetheoutsidediameterfortheinner
electrode.Thisprocedurewillcreatea.045gapbetweentheinsidewalloftheouter
electrodeand
the
outside
wall
of
the
inner
electrode.
This
value
is
an
ideal
gap
for
maximum
andmostefficientproductionofhydrogenandoxygengaseswiththeWaterhybridsystem.
Caution
Itmaybepossibletoobtain31/2outsidediameterstainlesssteeltubingwithawall
thicknessof.040to.063andt304alloyatalocalshopthatmanufacturesexhaust
and/ormufflersystems.Alltubedimensions,includingroundness,mustbeheldwithin
.005throughoutitsentirelength.Donotuselowqualitytubing. Ifyoudo,theefficiency
ofthewaterhybridsystemwillbeseverelydegraded.
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23 RunaCaronWater
2. Multiplythewallthicknessoftheouterelectrodebyafactorof2andrecordtheresultasdimensionA.Forexample,ifthewallthicknessis.050,dimensionAwouldbe.100.
3. Addavalueof.090tothevalueofdimensionAandrecordtheresultasdimensionB.Forexample,
if
dimension
A
is
.100,
dimension
B
would
be
.190.
4. SubtractthevalueofrecordeddimensionBfrom3.50.RecordthisvalueasdimensionC.Forexample,ifdimensionBis.190,dimensionCwouldbe3.31.
5. Toconstructtheinnerelectrode,obtainastainlesssteeltubewithanoutsidediameterequaltotherecordeddimensionC,withwallthicknessof.40to.063,T304alloy,and
lengthequaltothatoftheouterelectrode.
6. ReferringtothefollowingFigure8,drilleight(8)holes,spacedat45degreeintervals,aroundthediameterofoneendoftheouterelectrodetube.Locatetheholecenters11/32
fromthetubeedge.Clampalargediameterwooddowelorrodinavisetobackupthe
electrodewhiledrilling.Deburrtheholesafterdrilling.
NOTE
Forbestresults,drillingstainlesssteelrequiresacarbidetippeddrillbitandlight
lubricatingoil.Takeyourtimedrillingsoasnottooverheattheelectrode.
NOTE
TheCAUTIONalsoappliestotheinnerelectrode.
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Figure8:ElectrodeDetails
7. Repeattheprocedureofstep6todrilleight(8)holesatthesamedistancefromtheendoftheinnerelectrodetube.
8. ReferringagaintoFigure8,drill1/8holesaroundtheendoftheouterelectrodeclosesttotheholes.Locatetheholecenters3/32fromthetubeedge,withholdcentersspacedat
3/8intervalsaroundtheentirediameter.Deburrtheholesafterdrilling.
9.
Repeat
the
procedure
of
step
8
to
drill
1/8
holes
around
the
entire
diameter
of
the
end
of
theinnerelectrode.Deburrtheholesafterdrilling.Thoroughlycleanalloilresiduefrom
bothelectrodesusingasoftcleancloth,andMEKoracetoneasacleaningsolvent.
10.ReferringtoFigure8,cuttwo(2)3rodlengthsfrom3/32diameterbarestainlesssteelweldingrod,alloyT304.Usingafile,squareoffanddeburrtherodends.
NOTE
Barestainlesssteelweldingrod,T304alloy,canbeobtainedatanyweldingsupplystore.
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11.ReferringtoFigure8,solderoneoftherodstotheoutsidesurfaceoftheouterelectrode.Positiontherodparalleltothelengthoftheelectrodewith2protrudingpasttheendof
thetube.Usesilverbearingsolderandfluxappropriateforsolderingstainlesssteel.
12.Repeattheprocedureofstep11tosoldertheotherrodtotheinsidesurfaceoftheinnerelectrode.
13.Aftertheelectrodeshavecooled,thoroughlyscrubthesolderjointswithwarmsoapywaterusingastiffbristlebrush.Thoroughlyrinsetheelectrodeswithwarmwateranddrywitha
softcleancloth.
NOTE
Silverbearingsolderandfluxcanbepurchasedatanylargehardwareorelectricalsupply
store.
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26 RunaCaronWater
Housing
Listofmaterials:
OneCPVC4threadedpipenipple,length12,Schedule80(USPlasticStock#:30314). OneCPVC4pipe,length12,Schedule80(USPlastic#:29022)(Onlyneededifhousing
heightexceeds10).
OneCPVC11/2pipe,length12,Schedule80(USPlastic#:29018). TwoCPVC4StraightCouplings,Schedule80(USPlastic#:30059)(Onlyoneneededif
housingheightwillbe10).
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)
Caution
Usecpvcpipe(schedule80)toconstructthegeneratorhousing.Donotusepvcpipe,
or
cpvc
schedule
40,
since
it
will
not
withstand
high
temperature
or
pressure
aswell.
Donotusecpvcpipeofsizegreaterthan4:sinceitdoesnotofferanadequatesafetymarginagainstrupturewhensubjectedtohighpressureandtemperature.
Carefulattentiontocraftsmanshipanddetailduringgeneratorconstructionisessentialtoensuresafeandreliableoperation.
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27 RunaCaronWater
OneCPVC4cap,Schedule80(USPlastic#:30047). OneCPVC4threadedcap,Schedule80(USPlastic#:29147). One1/8thick24x48,CPVCsheet(USPlastic#:45299). One1diameter,6length,CPVCrod(USPlastic#:43183).
One
pint
can
of
CPVC
cement
(US
Plastic
#:
29053).
Onepintcanofprimer(USPlastic#:28292). One8ouncecanofpipejointcompound(USPlastic#:16532).
Step-by-StepDirectionswithIllustrations:
1. CPVC4Schedule80pipeisusedtoconstructtheGeneratorhousing.Sinceoneendofthepipewillrequirethreading,Irecommendpurchasinga12threadedpipenippleratherthan
threadapipeyourself.RefertotheGeneratorDetailsviewofFigure10asanaidto
construction.
2. Usingamiterboxortablesawtoassuresquareness,cutoffoneofthe12pipenipplethreadedends23/4fromtheend.Dressthecutedgeswithsandpaperorafinetoothfile.
Gotostep8.
3. Usingamiterboxortablesawtoassuresquareness,cutthethreadedpipenipple51/2fromoneofitsthreadedends.Dressthecutedgeswithsandpaperorafinetoothround
file.
Caution
Readdirections
printed
on
the
primer
and
cement
can
labels
for
proper
use
of
the
products.Afterpriming,applycementassoonaspossible,toobtainsafeandreliable
bonding.Donotlettheprimerdrybeforeapplyingcement.
Note
CPVC4Schedule80pipehasanoutsidediameterof4.5. Iftheheightofthehousingwillbe10,asdeterminedduringtheprocedureatthe
beginningoftheElectrodessection,followthedirectionsofstep2,thengoto
step8.Iftheheightwillbegreaterthan10,gotostep3.
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28 RunaCaronWater
4. Primetheoutsidematingsurfaceofthecutendofthe51/2pipenippleandoneoftheinsidematingsurfacesofthecoupling.Applyanevenlayerofcementtotheprimed
surfacesandassembletheparts.Allowthepartstoairdryforatleast10minutesbefore
goingtostep5.
5. Primetheoutsidematingsurfaceofthe12pipeandinsidematingsurfaceofthecouplingattachedtothepipenipple.Applyanevenlayerofcementtotheprimedsurfacesand
assembletheparts.Allowthepartstoairdryforatleast30minutesbeforegoingtostep6.
6. Iftheheightofthehousingistobe18,gotostep8.Iftheheightistobelessthan18,gotostep7.
7. Usingamiterboxortablesawtoassuresquareness,cutthepipeassemblyneartheunthreadedendtoformatotalpipelengthequaltolessthanthehousingheight.Dress
thecutedgeswithsandpaperorafinetoothroundfile.
8. Measuretheinsidediameterofthethreadedendcap.Securelyclamp1/8thickCPVCsheettoadrillpressbed.Drilladiameterholethroughthesheet.Usingaflycutter,cutadisk
withthemeasureddiameter.Checkthatthediskfitssnuglyintotheendcap.Ifloose,
replacewithaslightlylargerdisk.Iftight,replacewithaslightlysmallerdisk.Besuretodrill
aholdfirstifanewdiskiscut.Cutaseconddisktothecorrectdiameterwithcenter
hole.
9. Applyprimer,andthencement,toonesurfaceofeachdiskandjointhediskstogether.Alignthediskedgesandwipeexcesscementfromtheedges.Allowthediskstoairdryfor
anhourbeforegoingtostep10.
10.Referringtofigure9,beveltheedgesofthedisktofitthecurvedcontourofthebottomoftheendcap.Besuretheouteredgeofthediskmeasuresbetween1/32and1/16after
beveling.
Caution
Theelectrodeswillbeattachedtothecontoureddisk.Formthecontouraccuratelyto
assurestructuralintegrityofthewaterhybrid.
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29 RunaCaronWater
Figure9:DiskContour
11.Lightlycoatthethreadsofthehousingendcap,andbottomedgeofthehousing,withpetroleumjelly.Applyprimertothematingsurfacesofthediskandendcap.Applycement
totheprimedareaoftheendcaponlyandinstallthedisk,seatingitfirmlyandevenly.
Removeanycementthatoozesfrombetweenthepartswithcottonswabs.
12.Temporarilythreadtheendcapontothehousing,seatingitslowly,butfirmly.Waitabout15minutesforthecementtopartiallydryandthenremovetheendcap.
13.Repeattheprocedureoftheprecedingsteps8through10fortheunthreadedendcap.Theresnoneedtoapplypetroleumjellytoanyareasoftheunthreadedendcap.Apply
primertothematingsurfacesofthediskandendcap.Applycementtotheprimedareaof
theendcaponlyandinstallthedisk,seatingitfirmlyandevenly.Removeanycementthat
oozesfrombetweenthepartswithcottonswabs.
Caution
Besuretomeasuretheinsidediameteroftheunthreadedendcapbeforecuttingdisks.
Caution
Theendcapwillbetemporarilythreadedontothehousingtoassureaccuratealignment
of
the
disk.
Do
not
use
excessive
cement
when
installing
the
disk
to
preventbondingofthehousingandendcapthreads.
Besurepetroleumjellycoatsonlytheendcapthreads.
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30 RunaCaronWater
14.Sealtheholeinthethreadedendcapdiskwithelectricaltape.Usingastiffbristlebrushandwarmsoapywater,thoroughlycleanpetroleumjellyfromthethreadsandallother
areasoftheendcapandhousing.Rinseallpartswithwarmwater.
15.Repeat
step
14,
and
then
wipe
the
parts
dry
with
a
soft
clean
cloth.
16.Removetheelectricaltapefromthethreadedendcap.Allowtheendcapstoairdryforatleast8hoursbeforegoingtostep17.
17.Completelycovertheinsidesurfacesofbothendcapswithstripsofelectricaltape.Cutawaytapetoopenuptheholdineachdisk.
18.Purchaseahighquality,hightemperature,andwaterproofepoxycementtofilltheendcapcavities.IhighlyrecommendJBWELD,whichcanbepurchasedatanylargehardwareor
autosupplystore.Itcomespackagedintwo2ouncetubes(onetuberesinandonetube
hardener).Youwillprobablyneedatleastonepackagetofilleachendcap.Ifyouhave
questionsaboutJBWELD,theycanbecontactedat:
JBWELD
POBox483
SulphurSprings,TX75483
Phone:1903
885
7696
TollFree:18005293530
Fax:19038855911
Caution
Useonlyhighquality,hightemperatureandwaterproofepoxycementtofilltheendcap
cavities.Usinganyothercementmayleadtoeventualfailureofthegenerator.
Note
Thecavity
in
each
end
cap
will
be
filled
with
epoxy
cement.
To
prevent
trapping
air
bubbles,thecapsmustremainlevelwhiletheepoxycures.Centeringandlevelingthe
curvedcapsontheinnercoresoflargerollsoftapeworkwell.
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31 RunaCaronWater
Figure10:
Generator
Details
Note
Allepoxycementscurebychemicalreaction(afterthehardenerismixedwithresin).JBWELDremainspliableforabout30minutes.Theresnoneedtorush
fillingtheendcapcavities,butbeawarethatoncethecementismixed,theresno
stoppingitfromcuring.Ifyouhavetoremoveoradjustanythingafteritcures,
youllneeddynamitetogetthingsapart.
Besuretomixequalamountsofresinandhardener(ifusingJBWELD).Theresinand
hardener
are
different
colors;
one
black
and
one
white
to
avoid
confusion.
Whenmixedproperly,youendupwithanicedarkgraycement.Ifyouaccidentally
mixresinwithresin,orhardenerwithhardener,youendupwithnothingbutabig
mess.
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19.Mixabouta4ouncebatchofepoxyinadisposablecontainersuchasasmallpapercup.Slowlyfillthecavity(toavoidtrappingairbubbles)tothetopoftheholeinoneofthe
endcaps.Ifnecessary,mixmoreepoxy.
20.Repeatstep19tofilltheremainingendcapcavity.21.Allowtheepoxytocureforatleast24hours.Removeallelectricaltapefromtheendcaps.
Remove
any
epoxy
from
above
the
top
of
the
hole
until
flush
with
the
disk
surface
by
grinding,scraping,sanding,ordoingwhateverisrequired.
22.Measuretheinsidediameteroftheinnerelectrode.RecordthismeasurementasdimensionD.
23.Securelyclamp1/8thickCPVCsheettoadrillpressbed.Usingaflycutter,cutadiskwithdiameterequaltodimensionDfromthesheet.Checkthatthediskslideseasilyintotheend
oftheinnerelectrodeoppositethesolderedrod,beingneitherloosenortight.Ifloose,
replace3
with
a
slightly
larger
disk.
If
tight,
replace
with
a
slightly
smaller
disk.
24.Subtractthevalueof.250fromtherecordeddimensionD.RecordthisnewvalueasdimensionE.Forexample,ifdimensionDis3.21,dimensionEwouldbe2.96.
25.Securelyclamp1/8thickCPVCsheettothedrillpressbed.Usingaflycutter,cutanotherdiskwithdiameterequaltodimensionE.
Caution
Readdirections
printed
on
the
primer
and
cement
can
labels
for
proper
use
of
the
products.Afterpriming,applycementassoonaspossible.Toobtainsafeandreliable
bonding,donotlettheprimerdrybeforeapplyingcement.
Note
Besureyouhaveenoughepoxyonhandtototallyfilltheremainingcavity.Ifnot,
purchasemorebeforestarting.Afterepoxycures,ithasverypooradhesionwithnewly
mixedepoxy.
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33 RunaCaronWater
26.Applyprimer,andthencement,tooneoftheflatsurfacesofeachdisk.Jointhedisks,centeringthesmallerdiskonthelargerdisk.
27.Securelyclamp1/8CPVCsheettothedrillpressbed,centeringthecutteratleast3fromanyedgeofthesheet.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,
aligningthe
outer
edges.
Wipe
any
excess
cement
from
the
outer
edges.
Allow
the
rings
to
airdryatleast30minutesbeforegoingtostep33.
33.Grindasmallnotchintotheinneredgeoftheringsjustlargeenoughtoallowtheringstoclearthesolderedrodandsolderwhenslidontotherodendoftheouterelectrode.
Note
Theprocedureofstep34centerstheringswithinthethreadedendcap.Besurethe
wrappingtape
does
not
protrude
below
the
edge
of
the
smaller
ring
at
any
point.
Do
not
overlaptapeendsifmoretapeisadded;simplybuttthetapeendsbeforecontinuingto
wrap.
Note
Theprocedure
of
steps
27
and
28
will
be
used
to
cut
aflat
ring
from
CPVC
sheet.
Do
not
unclampthesheetfromthedrillpressbeduntilstep28hasbeencompleted.
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34 RunaCaronWater
34.Usingplasticelectricaltape,wraptheouteredgesoftheringsuntiltheyslideeasilyintothethreadedendcap.Iftheringsfitloosely,addmoretape.Iftheringsfittightly,removetape.
35.Applyprimertotheflatsurfaceofthesmallerring.Usingacottonswab,applyprimertotheflatsurfaceofthethreadedendcapcontactedbythesmallerring.Applyathin,evenlayer
ofcementtotheprimedsurfacesandinstalltheringassemblyintotheendcap.Allowthe
partstoairdrybeforegoingtostep36.
Figure11:ThreadedEndCapDetails
Note
Theprocedureofstep36centersthediskscompletedinstep26withinthethreadedend
cap.Be
sure
the
wrapping
tape
does
not
protrude
below
the
surface
of
the
small
disk
at
anypoint.Donotoverlaptapeendsifmoretapeisadded;simplybuttthetapeends
beforecontinuingtowrap.RefertoFigure11fordetailsrelatedtoinstallingthedisksinto
thethreadedendcap.
Note
Referto
the
following
Figure
11
for
details
related
to
installing
the
rings
into
the
threaded
endcap.Applyprimeronlytotheflatsurfaceofthethreadedendcapcontactedbythe
smallerring.Donotremovethetapeuntilinstructedtodoso.
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35 RunaCaronWater
36.Usingplasticelectricaltape,wraptheedgeofthelargediskuntilthetapecreatesasnugfitwiththeinsideedgeoftheringassembly.
37.Applyprimertotheflatsurfaceofthesmalldiskandtheflatinsidesurfaceofthethreadedendcap.Applyanevenlayerofcementtotheprimedsurfacesandinstallthediskassembly
intotheendcap.Alignthediskswiththeirnotchoffsetatleastfromtheringnotch,as
showninFigure11.UsingalargeCclamp,lightlyclampthedisksandendcap.Allowthe
partstoairdryatleast8hoursbeforegoingtostep38.
38.Removeallelectricaltapefromthethreadedendcapassembly.Scrapeawayanyexcesscementthatmayhaveoozedontotheflatinsidesurfaceoftheendcapinthoseareasthat
willcontactthebottomedgesoftheelectrodesandthreadedendofthehousing.
39.Drilla37/64holethroughthecenterofthethreadedendcapasshowninFigure11.
40.Temporarilyaligneachelectrodeandrodwithitsrespectiveholedrilledinstep39.Checkthateachelectrodeandrodcanbeinstalledintothethreadedendcapandseatedfirmlyon
the
cap
surface.
Make
adjustments
as
necessary
to
achieve
correct
seating
of
the
electrodes. Usingamarkingpen,markashortreferencelinenearthetopinsideofthe
innerelectrode.Markanothershortreferencelinenearthetopinsideoftheouter
electrode,aligningitwiththemarkontheinnerelectrode.Removetheelectrodesfromthe
endcap.
Note
Threadswillbetappedlaterintotheholedrilledthroughthecenteroftheendcapto
attachthedraincock.
Usinga#41bit,drilltwoholesthroughthebottomofthethreadedendcapatthe
locationsshowninFigure11.
Note
Besure
to
align
the
disks
with
their
notch
offset
at
least
from
the
ring
notch,
as
shown
inFigure11.
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36 RunaCaronWater
41.Usingplasticelectricaltape,wrapthetopendoftheinnerelectrodeuntilitfitssnuglyintotheouterelectrode.Allowaboutofthetapetoprotrudeabovetheedgeoftheelectrode
tofacilitateeasyremoval.Donotremovethetapeuntilinstructedtodoso.
42.Arrangeawaytosolidlysupportthethreadedendcapwhileinstallingtheelectrodesandwhiletheepoxycures(takesabout8hours).Centeringandlevelingthecurvedcaponthe
curvedcapontheinnercoreofalargerolloftapeworkswell.
43.Onceagain,cleanthebottomendsoftheelectrodeswithMEKoracetoneusingasoftcleancloth.
44.Sealthebottomsofthetwoholesintheendcapwithshortstripsofelectricaltapetopreventepoxyfromdrippingout.Thetapeswillbepushedasideastheelectroderodspoke
through,afterwhichthetapescanberemoved.
45.Mixupabouta2ouncebatchofepoxyinadisposablecontainersuchasasmallpapercup.Fill
the
slot
in
the
end
cap
(where
the
electrodes
are
installed)
all
the
way
around
to
about
itshalffulllevel.
46.Usingyourfinger,applyaverythin,butunbroken,coatofepoxycompletelyaroundthebottomedge(rodend)oftheouterelectrode.Formabandexte4ndingabouthighfrom
thebottomedge,coatingboththeinsideandoutsidesurfacesoftheelectrode.
Note
Besuretoinstalltheouterelectrodefirst.
Note
Theprocedureofstep41centerstheinnerelectrodewithintheouterelectrode.Donot
overlaptapeendsifmoretapeisadded;simplybuttthetapeendsbeforecontinuingto
wrap.
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37 RunaCaronWater
47.Installtheouterelectrodeintotheendcap.Astheelectrodestartstoentertheslot,loweritveryslowlysothattheepoxyhassufficienttimetoflowintothesmallholesdrilledaround
thebottomedgewithouttrappingairbubbles.Aftertheelectrodeisfirmlyseatedontothe
endcapsurface,removethetapefromthebottomoftheendcap.
48.Applyathinfilmofpetroleumjellytothesurfaceofthetapewrappedaroundthetopoftheinnerelectrode.
49.Repeattheproceduresofsteps46through48toinstalltheinnerelectrodeintotheendcap.Usethealignmentmarksonthetopsoftheelectrodesasanaidinlocatingtherod
holdintheendcap.
50.Placeaboutfivepoundsofweightontopoftheelectrodestohelpkeepthemfirmlyseatedagainsttheendcap.Foldingatowelortwointoseveralfoldsandplacingthemontopofthe
electrodes,withastackofhardcoverbooksontop,workswell.Thatmethoddistributesthe
weightevenly,whichcanotherwisebedifficultbecauseofthetapeprotrudingfromthetop
oftheinnerelectrode.
51.Usingcottonswabs,removeanyexcessepoxyoozingfromtheeightholesaroundthebottomsoftheelectrodes.Ifnecessary,continuetodothisuntiltheepoxybeginstothicken
(inabout3045minutes).Usinghouseholdtissuesordisposablerags,cleanepoxyfromthe
rodendsprotrudingthroughtheendcap,andfromthesurroundingsurfaceoftheendcap.
Caution
ALLOWTHE
EPOXY
TO
CURE
FOR
AT
LEAST
24
HOURS
AT
TEMPERATURES
OF
70
DEGREES
ORHIGHERBEFOREREMOVINGTHEELECTRODEWEIGHTSOROTHERWISEDISTRUBING
THEELECTRODEASSEMBLY.FORLOWERTEMPERATURESALLOWEVENLONGERCURE
TIME.
Caution
Thesmallholesaroundthebottomedgesoftheelectrodeshelpsecuretheelectrodesto
theendcapbecauseepoxyfillstheholes.Installtheelectrodesslowlyintotheendcap
slot
so
as
not
to
trap
air
bubbles
within
the
holes.
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38 RunaCaronWater
52.Removetheweightsfromtheelectrodeassemblyaftertheepoxyhascuredforatleast24hours,andremovethetapefromtheinnerelectrode.
53.Using#400grit(orfiner)sandpaper,removeepoxyresiduefromtherodendsprotrudingthrough
the
bottom
of
the
threaded
end
cap.
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39 RunaCaronWater
HousingAttachments
1. Temporarilythreadtheelectrodeassemblyontothegeneratorhousing,tighteningitfirmly.Supporttheentireassemblyontheinnercoreofalargerolloftapeaswasdoneinthe
precedingstep42.
2. ReferringtothefollowingFigure12,fabricate3coilsupportbrackets(withtheindicateddimensions)from1/8thickCPVCsheet.
3. Usescrappiecesof1/8thickCPVCsheetasshimsbetweenthetopsoftheelectrodesandthebrackets.Applyprimer,andthencement,tothebracketsandtheinsidewallofthe
housingat120degreeintervalsasshowninFigure11.Attachthebracketsandallow
cementtoairdryforatleast30minutesbeforegoingtostep4.
Figure12:CoilMountingBrackets
4. Removetheelectrodeassemblyfromthehousing.
Note
Formostefficientoperation,thecoilmustbelocatedapproximatelyabovethetopsof
theelectrodes.Ashimisplacedbetweentheelectrodesandeachbrackettoachieve
correctclearance.Exercisecaretoavoidcementingshimstothebrackets.
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40 RunaCaronWater
5. Cutfour11/2x6mountingbracketstripsfrom1/8thickCPVCsheet,asshownFigure13. Dresstheedgesofeachstripusingsandpaperorafinetoothfile.Formeachofthetwo
bracketsbyapplyingprimer,andthencement,tothematingsurfacesofeachoftwostrips
andjoiningthemtogether.Aligntheedgesofeachstripandwipeexcesscementfromthe
edges.
6. Cuta11/2wideringfromtheendofthecoupling.ReferringtoFigure14,andusingabandsander,sandthesideoftheringtoformaflatsurfaceapproximately11/4wide.
Sandthesideoftheringatanotherpointtoformasimilarsurface.Cuteachoftwoflat
surfacesectionsfromtheringbycuttingatbothendsofeachflatsurface.Asshownin
Figure14, thiswillformtwosectionsfromthering,eachwithflatoutsidesurfaces11/2
byapproximately11/4.Dresstheedgesofeachsectionandroundthecornersslightly
usingsandpaperorafinetoothfile.
7. AsshowninFigure14,attachapipesectiontoeachofthetwobracketsattheirmidpoints,applyingprimertotheflatsurfaceofeachsectionanditsmatingsurfaceonthebracket,
andthenapplyingcement.Besuretosquarethecurvedsurfaceofeachsectionwiththe
lengthofthebracket.
8. Makeadoublerbycuttingasection11/2widefromtheringasshowninFigure14.Dresstheedgesandroundthecornersslightlyusingsandpaperorafinetoothfile.
Note
Materialfromaringcutfromthestraightcouplingwillbeusedtomakepartofthe
Generatorhousingbrackets.Itwillalsobeusedtomakeadoublertoincreasewall
thicknessofthehousingwhereahosefittingisinstalled.
Note
BracketarrangementsformountingtheGeneratoraredictatedbytherequirementsof
eachsysteminstallation.Figure13showsoneofthesimplestandmostcommonlyused
arrangements.Other
arrangements
can
be
easily
constructed
with
1/8
CPVC
sheet.
Bracketsthickareconstructedfromtwolayersof1/8thickCPVCsheet.
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41 RunaCaronWater
Temporarilythreadtheendcapontothehousing,seatingitfirmly.Chooseapoint
anywherearoundthehousingasshowninFigure14,andmarkaspot upfromtheedge
oftheendcap.Removetheendcap.Applyprimer,andthencement,tothematingsurfaces
of
the
doubler
and
housing
and
attach
the
doubler
to
the
housing
with
its
lower
edge
at
the
markedspot.Aligntheedgeparalleltothehousingbottomedge.Allowthecementtoair
dryforatleast8hoursbeforegoingtostep9.
Figure13:HousingAttachmentDetails
9. Drilla37/64holethroughthecenterofthe11/2x11/2doublerandhousingwallasshowninFigure14. Besuretokeeptheholesquarewiththehousingwall.
10.Drillafastenerholeneartheendofeachbracket(totalof4holes)atthelocationsshowninFigure14. Slightlyroundthecornersofeachbracketusingsandpaperorafine
toothfile.
Note
Threadswilllaterbetappedintotheholetoinstallabarbedhosefittingtoconnecttothe
checkvalve.
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42 RunaCaronWater
11.PositionthebracketsasshowninFigure13,andclampthemtoaflatsurface.Checkthatthehousingseatsevenlyintothecurvedsectionofeachbracketwithnogapsbetweenthe
housingandcurvedsection.Ifnecessary,loosentheclampstorepositionthebrackets.
Figure14:MoreHousingAttachmentDetails
12.Applyprimer,andthencement,tothematingsurfacesofthebracketsandhousing.Attachthehousingtothebrackets.Placesupportingblocksoneachsideofthehousingtokeepit
fromrotatingorshiftingduringassembly.Waitatleast8hoursbeforelooseningtheclamps
andmovingthehousingassembly.
Note
Thecheckvalvehoseattachestoabarbedfittingtobeinstalledlaterintotheholedrilled
instep9.Determinethedirectioninwhichyoupreferthefittingtopointinrelationtothe
mountingbrackets.
Irecommend
having
the
fitting
point
directly
left
(as
shown
in
Figure
13)ordirectlyrighttominimizegeneratorspacerequirements.
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43 RunaCaronWater
UnthreadedEndCap
ListofMaterials:
Threadtaps,1/8NPTFand3/8NPTF(CuttingToolSupply:specifyGreenfieldtapsforCPVCpipe,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#:10506B206A).
One35SSSeriesStainlessSteelTopMountLevelSwitch,1/8NPT(NorgenPart#:0107024). OneLS11PlasticSideMountLevelSwitch,PBT,5/811UNC(NorgrenPart#:1873024).
MaterialSource
(We
encourage
you
to
research
(try
Google)
your
own
sources,
as
we
cannotguaranteethesesourceswillofferthebestpricesoralwaysbeavailable:
CuttingToolSupply(CTS)
340WGerriLa
Addison,IL60101
Phone:16305437171 Fax:16305436906
TheSpecialtyMfgCo(SMC)
5858CentervilleRd.
St.Paul,MN55127
Phone:16516530599 Fax:16526530989
Generant
1865Route23S,POBox768
Butler,NJ07405
Phone:1973886500 Fax:19738384888
StraVal
21ColumbusAve.
Garfield,NJ07026
Phone:19733409258
TollFree:1888380966 Fax:19733409933
FastenerHutInc.
3781GlengarryWayNE
Roswell,GA300752615
Phone:17704804617 Fax:1+7709982721
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44 RunaCaronWater
Norgren,c/oKipFluidControls,Inc
72SpringLn
Farmington,CT06032
Phone,TollFree:18007225547 Fax:18606774999
Directions:
1. Usingamiterboxortablesawtoassuresquareness,cutaspacerapproximately2longfrom1diameterCPVCrod.UsinganRsizedrillbit,drillaholethroughthecenterofthe
roditsentirelength,andparalleltoitslength.Alsodrillaholdthroughthecenteroftheend
capwith
the
R
drill,
as
shown
in
Figure
15.
Figure15:UnthreadedEndCapDetails
Note
A short length of CPVC rod inside the end cap will be used as a spacer for the water levelswitch.
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45 RunaCaronWater
2. Usinga1/827tap,tapthreadsintooneendoftheholedrilledinthespacer.Besuretokeepthetapalignedparalleltothesidesofthespacerandtotaptothecorrectdepthof12
threadsfromtheendofthetap.
3.
Temporarily
thread
the
35SS
water
level
switch
into
the
tapped
hole,
seating
it
firmly.
Insert
theswitchpowerleadsfrominsidetheendcapthroughthedrilledhole.Measureand
recordthedistancefromtheinsidesurfaceoftheendcap,asshowninFigure15.
4. Applyprimer,andthencement,totheuntappedendofthespaceranditsmatingsurfaceinsidetheendcap.Installthespacer,beingcertaintoaligntheholesinthespacerandend
cap.Usingacottonswab,removeanyexcessgluethatmayhaveoozedintothehole.
Caution
BesuretouseonlyNPTFtaps.topreventpossiblewaterandgasleakage,donotuseNPTtaps.bothNPTandNPTFthreadswillsealproperlyinNPTFtappedholes.
Besuretotaptothecorrectdepthbyturningthetapuntilthe12ththreadfromthefrontofthetapfullyentersthehole. Besuretoalwayskeepthetapalignedparalleltothesidesofthespacer.
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SloshShield
1. Usingamiterboxortablesawtoassuresquareness,cuta31/16longsectionfrom11/2CVPCpipe.Drillfour(4)1/8holesintothesidesofthepipe,spacedat90degreeintervals
andfromtheedgeasshowninFigure16.
2. Usingaflycutter,cutseven(7)157/64diskfrom1/8thickCPVCsheet.Drilla3/8diameterholethroughthecenterofoneofthedisks.
3. Applyprimer,andthencement,tothematingsurfacesofthedrilleddiskandtheendofthepipeoppositethefourholes.Attachthedisktothepipe,beingsuretocenterthediskon
thepipe.
Note
Sixofthesevendiskscutwillbeusedfortheflamearrestor.
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FlameArrestor
1. Usingamiterboxortablesawtoassuresquareness,cuta3longsectionfrom11/2CVPCpipe.
2.
Using
a
fly
cutter,
cut
a
1
1/2
disk
from
1/8
thick
CPVC
sheet.
Check
that
the
disk
fits
snuglyinsidethepipecutinstep1.Ifitdoesntfitsnugly,adjustthecutterasrequiredand
cutatotaloffour(4)disks.
Figure16:SloshShieldDetails
3. Applyprimer,andthencement,tothesurfaceofeachoftwodisksandjointhediskstogether.
Align
the
disk
edges
and
wipe
excess
glue
from
the
edge
of
the
joined
disks.
Repeattheprocedureforthetworemainingdisks.
4. Inthesamemannerasinstep3,make2stacksof3diskseachfromthesixdiskscutinstep2oftheSloshShieldprocedure.Allowthediskstoairdryforatleastanhourandthendrilla
37/64holethroughthecenterofeachofthetwostackeddisks.
5. ReferringtothefollowingFigure17,drillatotalofthirteen(13)1/8holesthrougheachofthetwo11/2disksattheindicatedlocations.
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48 RunaCaronWater
Figure17:FlameArrestorDetails
6. Applyprimertotheedgeofoneofthe11/2disksandabout3/8intoeitherrendofthe3pipebore.Applycementtotheprimedsurfacesandslidethediskintothepipebore,
creatinga1/8gapbetweenthediskandthepipeendasshowninFigure17.Formasmall
filletofcementaroundtheouterjunctionofthediskandpipebore.Standthepipeonend
for5or10minutes(untilthecementwontrun)topreventpluggingtheholeswithcement.
Ifanyholeisplugged,useashortlengthofstainlesssteelrodtoopenitbackup.Allowthe
cementtoairdryforaboutanhourbeforegoingtostep7.
7. Packtheinsideoftheflasharrestorwithcoarsestainlesssteelwool.Repeattheprocedureofstep6toinstalltheremaining11/2disk.
Note
Stainlesssteelwoolisavailableatsomelargesupermarkets,oryoucanpurchaseitfrom
thefollowingsource:
JWP
2575WLemoyne
MelrosePark,IL60160
TollFree:18007329336
FAX:170834580810
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8. ReferringtoFigure15,drilltwo37/64holesthroughthetopoftheunthreadedendcap,eachlocated13/4fromthecenterholeinthecap.Besuretokeepthedrillbitsquared
withthecurvedoutersurfaceoftheendcap.
UsingandRsizebit,drillaholethroughthetopoftheendcap13/4fromthecenter
holeinthecapasshowninFigure15.
9. Tap3/818threadsinto37/64holesatthefollowinglocations: Twoholesontopofunthreadedendcap. Oneholeonbottomofthreadedendcap.
Note
Besuretokeepthetapsalignedsquarelywiththesurfacearoundtheholes.Taptothe
correctdepthof12threadsfromtheendofeachtap.
Note
Be
sure
the
two
stacks
of
three
disks
joined
in
the
preceding
step
4
have
air
dried
foratleast24hours.
Whendrillingholesinthefollowingstep8,besuretokeepthedrillbitssquaredwiththecurvedoutersurfaceoftheunthreadedendcap.Thisplacestheaxisof
eachofthethreeholesatanangletotheaxisofthecenterholeasshownFigure
15.
Caution
BesuretouseonlyNPTFtaps.topreventpossiblewaterandgasleakage.donotuseNPTtaps.bothNPTandNPTFthreadswillsealproperlyinNPTFtappedholes.
Besuretotaptothecorrectdepthbyturningthetapuntilthe12ththreadfromthefrontofthetapfullyentersthehole.
Besuretoalwayskeepthetapalignedsquarelywiththesurfacearoundthedrilledhole.
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50 RunaCaronWater
Oneholeindoubleronhousingwall. Oneholeineachoftwoflamearrestorendcaps.
10.Tap1/827threadsintotheRsizeholeclosesttotheedgeontopoftheunthreadedendcap.
11.Usinga3/818tap,tapthreadsintothe37/64holeineachofthetwostacksofthreedisksjoinedintheprecedingstep4.Applyprimer,andthencement,tothematingsurfacesof
oneofthestacksofdisksandthe3flamearrestorpipe.Attachthediskstothepipe,being
surethetappedendoftheholefacesoutward.Repeattheprocedurefortheremaining
stackofdisks.
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51 RunaCaronWater
WaterLevelSwitchTest
1. Connecttheohmmeterleadstotheswitchpowerleads.Suspendtheswitchfromitspowerleadsandverifythattheohmmeterindicatesclosedswitchcontacts.Ifthecontactsarenotclosed,gotostep3.
2. Slowlyslidetheswitchfloatupward.Verifythatitscontactsopenatapproximatelythemidpointoffloattravel.Ifthecontactsopenproperly,gotostep4.Ifthecontactsdonot
openproperly,theswitchisdefectiveandmustbereplaced.
3. Usingamarkingpen,markasmalldotontopoftheswitchfloat.Note
TheswitchprobablyhasNO(normallyopen)contactconfiguration.Invertingthefloat
changesittotherequiredNCconfiguration.
Note
Thewaterlevelswitchcontainsveryhighqualitymagneticreedcontacts.Itwillreliablyoperatethroughmillionsofcycleswhenconnectedtoaproperlydesigned
electroniccircuit.
ThewaterlevelswitchisusuallysuppliedwithNC(normallyclosed)contactconfiguration.Step1verifiestheNCconfiguration.
Caution
Neverattempttocontrolpowertoanyelectricaldevicedirectlythroughthewaterlevel
switch. Doingsowilldamageordestroytheswitch.
Note
Itisimportanttoverifycorrectoperationofthewaterlevelswitchbeforeinstallingits
sloshshield.
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52 RunaCaronWater
Carefullyremovethefloatretainingclipatthebottomofthecentertube.Removethefloat,
invertitandreinstall.Reinstalltheretainingclip.Verifythatthedotonthefloatisnowat
thebottomandrepeattheprocedureoftheprecedingsteps1and2.
4.
Using
a
countersink
tool,
or
large
drill
bit,
form
a
small
bevel
in
the
outer
end
of
the
center
holeintheunthreadedendcapthroughwhichtheswitchleadspass.
5. Applyalightcoatingofpipejointcompoundtothethreadsoftheswitchandmountingspaceraccordingtodirectionsontheproductlabel.Inserttheswitchpowerleadsthrough
thespacerholeandthreadtheswitchintoplace,seatingitfirmly.
6. Obtainatransparentcontainer(suchasalargeglassjar)withanoutsidediameterofapproximately21/2to33/4andinsidedepthofatleast31/2.
Placetheunthreadedendcapontopofthecontainerwiththeswitchinside.Besurethe
bottomsurfaceoftheendcapseatsevenlyontopofthecontainer.Positiontheendcapso
thatatleastoneofthelargetappedholesprojectsinsidethecontainerandtheswitchfloat
isatleastawayfromthecontainerwall.
Note
Thefollowingstepsareusedtoverifycorrectswitchoperationinresponsetowaterlevel
changes.
Caution
Donotapplyexcessivetorquetothewaterlevelswitchthreadswhileinstlalingtheswitch
intoitsmountingspacer.Excessivetorquecandamagethespacerthreads,causingwater
and/orgasleakage,andpossiblesystemfailure.
Note
Asanaddedprecautionagainstpossiblewaterand/orgasleakage,Irecommendusing
pipejointcompoundonallthreadedGeneratorhousingcomponents.
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53 RunaCaronWater
7. Connecttheohmmeterleadstotheswitchleads.Checkthattheswitchcontactsareclosed.Veryslowlypourwaterthroughthelargetappedholeuntiltheswitchcontactsjustopen,
andremainopen.Ifthecontactscloseagain,addaslightamountofwaterandwaitseveral
secondsbeforecheckingagain.Keeprepeatingthisprocessuntiltheswitchremainsopen.
Checkthatthewaterlevelisatleast2fromthetopedgeofthejar.Ifthewaterlevelisless
than2fromthetop,theswitchisdefectiveandmustbereplaced.
8. Removetheendcapassemblyfromthejaranddryasnecessarywithasoftcleancloth.9. Applyprimer,andthencement,tothematingsurfacesofthesloshshieldandendcap.
Attachthesloshshield,centeringitaroundtheswitchfloat.
Note
Measurethewaterlevelwiththeswitchfloatinwater.
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ToroidCoil
ListofMaterials:
OneFerriteToroidCoilCore,3.50ODx2.00IDx.500Thick(NationalMagneticsPart#:995).
CopperMagnetWire,Tefloncoate4d,HeavyBuild,23AWG,550Ft(MWSWireIndustries,mustbecustomordered)
TeflonEtchingSolution(FluoroEtch)(ActonTechnologies) OnePackageHeatShrinkTubing,AssortedSizes(RadioShack,Catalog#:2781610).
MaterialSources:
NationalMagneticsGroup
1210WinDr.
Bethlehem,PA180177061
Phone:16108677600
FAX:1610
867
0200
MWSWireIndustries
31200CedarValleyDr.
WestlakeVillage,CA91362
Phone:18189918553
Fax:18187060911
ActonTechnologies
100ThompsonSt.
POBox726
Pittston,PA18640
Phone:15706540612
Fax:15706542810
RadioShack
(Nationwidestores)
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55 RunaCaronWater
Directions:
Afterthecoiliscompleted,itshouldbecoatedwithafewthinlayersofCPVCcement.That
wayyouendupwithsomethingthatwilllastforever,ispracticallybombproof,andiseasy
tosolidlyattachinsidethehousingwithCPVCcement.But,gettinganythingtostickto
Teflontakesspecialchemicaletching(thatswhyTefloncookwareissopopular).Its
commerciallydonebyetchingwithsomeprettynastystuff.Severalcompaniesspecializein
theprocess,butyoudontwanttoknowthecost.Asafeandeasyetchingprocessthatcan
bedoneathome,yetgivesgreatresults,hasrecentlybeendevelopedusingaproduct
calledFluoroEtch.
You
simply
warm
FluoroEtch
to
about
130
degrees,
slosh
the
coil
around
initforaboutaminute,sloshinisopropylormethylalcohol(sadly,thekindsyoucant
drink)foraminuteorso,washinwarmsoapywater,rinsewithwarmwater,andletairdry.
Afterdoingthat,justaboutanythingwillsticktotheTefloncoatedcoilwire.Imtellingyou
Note
Thewaterhybridcoilishandwoundaroundaferritetoroidcorewithinsulated,hightemperaturecopperwire.Closeattentiontodetailandcraftsmanshipis
essentialto
building
an
efficient
and
reliable
coil.
There
are
literally
millions
of
differentcoilconfigurationsinexistence.Itsagreatareaforexperimentingsince
coildesignisasmuchartasitisscience.Believeitornot,theresactuallyan
organizationdedicatedtothecraft,theInternationalCoilWindingAssociation,
basedinEngland.
Beforewarnedthatwindinganycoil,especiallyatoroidcoil,isatediousaffair,butIlldomybesttomakethejobaseasyaspossible.Thecoiliscreatedfrom2,000
turnsofinsulatedcopperwirewrappedaroundacircularmagneticallysensitive
core.Thatmeansyouhavetodrageachwirewrapthroughthetoriodcorejustas
manytimes.
Tefloninsulatedcoppermagnetwireistheonlywaytogo.Ithandlesheatextremesverywellandisimpervioustojustaboutanythingyoucanthrowatit.It
isntcheap,butwellworththeinvestment.
CustomorderitfromMWSWireIndustries.Theycarryover25,000differentmagnetandspecialtyapplicationwires.BesuretoorderDoubleBuild(extra
heavy)insulation,23AWG.Youllneedabout500to550feet,soitsprobablybest
toorder550feet.
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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!
Donttry
short
cutting
things
by
wrapping
the
wire
around
the
core
several
times
and
pullingtherestofthewireonthrough.Thecontinualbendingandstraighteningwilldestroy
thewirelongbeforeyoureachitsend.Amodifiedversionofthatmethodworks,buttakes
afairamountofskillandexperiencetomaster(orrequiresspecialequipment).
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Figure18:TheIncredibleWaterhybridsystem!
Forminga3.5
OD
x2
ID
x.50
toroid
coil
from
23
AWG
wire
requires
about
250
turns
ofwireperwrappedlayer.Sincethecoilbuildsinsizeasitswrapped,eachwrapuses
anaverageofabout3ofwire.So,each100wireprovidesabout400wraps,orslightly
over11/2layers.Therefore,four(4)100footlengthsandone(1)150footlengthwill
buildan8layercoilofatleast2,000turns.
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2. ReferringtoFigure19,slipa1lengthofsmallheatshrinktubingabout4ontothemagnetwireandapplyheattoshrinkitinplace.Ifyouarerighthanded,youllprobablychooseto
wrapthecoilinaclockwisedirection,holdingthecorewithyourlefthand.Inthatcase,lay
theshrinktubingontopofthecore,angledofftotheleftatabout30degreesfromstraight
outasshown.Startthefirstwirewrapoverthetubingataboutitsmidpoint.Thiswillbethe
startoflayer#1fortheinnercore.Besuretokeepthewirewrapstightsagainsteachother
ontheinsideedgeofthecore,withnooverlapping.Keeptensiononthewire,withthewire
alwayspointingstraightoutfromt