Congratulations on purchasing your very own instructions for converting your motorvehicleintoawaterburninghybrid!

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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frequencyandduration.TheoverallpowerconsumptionoftheHyTronicmoduleandtheentire waterhybridsystemisfairlylow;actuallylowenoughtobeeasilypoweredbyyourvehicles excesselectricalandheatoutput,andwithenoughreservepowerlefttohelprunallyour vehiclesotherelectricaldevices.

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

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

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

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

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

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

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

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

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

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

Figure1:Hydrogen/OxygenGenerator

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

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

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

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

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

Figure2:InDashIndicators

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

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

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

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

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Figure3:SquareWaveON:OFFRatio1:1

Figure4:SquareWaveON:OFFRATIO3:1

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

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 Figure5:GeneratorElectrodeCircuitSchematic

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

GeneratorCoilCircuitSchematic
ThefollowingFigure6depictstheschematicdiagramforthegeneratorcoilcircuit.Itsoutputis asquarewavepulsewhichisappliedtothecoiloftheHydrogen/OxygenGeneratorshownin figure18.

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Figure6:GeneratorCoilCircuitSchematic

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

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

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

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 Figure7:InDashIndicatorsCircuitSchematic

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

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

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

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Figure8:ElectrodeDetails

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

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

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

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

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OneCPVC4cap,Schedule80(USPlastic#:30047). OneCPVC4threadedcap,Schedule80(USPlastic#:29147). One1/8thick24x48,CPVCsheet(USPlastic#:45299). One1diameter,6length,CPVCrod(USPlastic#:43183). OnepintcanofCPVCcement(USPlastic#:29053). Onepintcanofprimer(USPlastic#:28292). One8ouncecanofpipejointcompound(USPlastic#:16532). StepbyStepDirectionswithIllustrations: 1. CPVC4Schedule80pipeisusedtoconstructtheGeneratorhousing.Sinceoneendofthe pipewillrequirethreading,Irecommendpurchasinga12threadedpipenippleratherthan threadapipeyourself.RefertotheGeneratorDetailsviewofFigure10asanaidto construction. Note CPVC4Schedule80pipehasanoutsidediameterof4.5. Iftheheightofthehousingwillbe10,asdeterminedduringtheprocedureatthe beginningoftheElectrodessection,followthedirectionsofstep2,thengoto step8.Iftheheightwillbegreaterthan10,gotostep3. 2. Usingamiterboxortablesawtoassuresquareness,cutoffoneofthe12pipenipple threadedends23/4fromtheend.Dressthecutedgeswithsandpaperorafinetoothfile. Gotostep8. 3. Usingamiterboxortablesawtoassuresquareness,cutthethreadedpipenipple51/2 fromoneofitsthreadedends.Dressthecutedgeswithsandpaperorafinetoothround file. Caution Readdirectionsprintedontheprimerandcementcanlabelsforproperuseofthe products.Afterpriming,applycementassoonaspossible,toobtainsafeandreliable bonding.Donotlettheprimerdrybeforeapplyingcement.

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

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Figure9:DiskContour

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

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

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Figure10:GeneratorDetails

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

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

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

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

Figure11:ThreadedEndCapDetails

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

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

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

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

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

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

Figure12:CoilMountingBrackets

4. Removetheelectrodeassemblyfromthehousing.

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

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

Figure13:HousingAttachmentDetails

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

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

Figure14:MoreHousingAttachmentDetails

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

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

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

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

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

Figure15:UnthreadedEndCapDetails

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

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

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

Figure16:SloshShieldDetails

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

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 Figure17:FlameArrestorDetails

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

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

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

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

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