run a car on water

5/26/2018 Run a Car on Water

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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


MaterialSources:.................................................................................................................. 54

Directions:............................................................................................................................. 55

ToroidCoilInstallation.............................................................................................................. 63

UnthreadedEndCapInstallation.............................................................................................. 67

GeneratorFinalAssembly......................................................................................................... 68

InDashIndicatorPanelAssembly ............................................................................................ 70



Directions:............................................................................................................................. 71

WaterTankandPump .............................................................................................................. 75



Directions:............................................................................................................................. 75

HyTronicsModule..................................................................................................................... 80

MaterialsList:........................................................................................................................ 80

MaterialsSource: .................................................................................................................. 80

Directions:............................................................................................................................. 80

FuelInjectororCarburetorAdaptor......................................................................................... 83

ThrottleAssembly ..................................................................................................................... 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.


17/114

17 RunaCaronWater

Figure5:GeneratorElectrodeCircuitSchematic


18/114

18 RunaCaronWater

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.


19/114

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.


20/114

20 RunaCaronWater

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.


21/114

21 RunaCaronWater

Figure7:InDashIndicatorsCircuitSchematic

WhentheWaterhybridsystemisturnedon,thePWRONLEDilluminates.TheGenerator

electrodecircuit(Figure5)activatestheLED.FailureoftheLEDtoilluminateusuallyindicates

anelectrodecircuitmalfunction.


22/114

22 RunaCaronWater

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.


23/114

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.


24/114

24 RunaCaronWater

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.


25/114

25 RunaCaronWater

11.ReferringtoFigure8,solderoneoftherodstotheoutsidesurfaceoftheouterelectrode.Positiontherodparalleltothelengthoftheelectrodewith2protrudingpasttheendof

thetube.Usesilverbearingsolderandfluxappropriateforsolderingstainlesssteel.

12.Repeattheprocedureofstep11tosoldertheotherrodtotheinsidesurfaceoftheinnerelectrode.

13.Aftertheelectrodeshavecooled,thoroughlyscrubthesolderjointswithwarmsoapywaterusingastiffbristlebrush.Thoroughlyrinsetheelectrodeswithwarmwateranddrywitha

softcleancloth.

NOTE

Silverbearingsolderandfluxcanbepurchasedatanylargehardwareorelectricalsupply

store.


26/114

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.


27/114

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.


28/114

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.


29/114

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.


30/114

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.


31/114

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.


32/114

32 RunaCaronWater

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.


33/114

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.


34/114

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.


35/114

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.


36/114

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.


37/114

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.


38/114

38 RunaCaronWater

52.Removetheweightsfromtheelectrodeassemblyaftertheepoxyhascuredforatleast24hours,andremovethetapefromtheinnerelectrode.

53.Using#400grit(orfiner)sandpaper,removeepoxyresiduefromtherodendsprotrudingthrough

the

bottom

of

the

threaded

end

cap.


39/114

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.


40/114

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.


41/114

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.


42/114

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.


43/114

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


44/114

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.


45/114

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.


46/114

46 RunaCaronWater

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.


47/114

47 RunaCaronWater

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.


48/114

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


49/114

49 RunaCaronWater

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.


50/114

50 RunaCaronWater

Oneholeindoubleronhousingwall. Oneholeineachoftwoflamearrestorendcaps.

10.Tap1/827threadsintotheRsizeholeclosesttotheedgeontopoftheunthreadedendcap.

11.Usinga3/818tap,tapthreadsintothe37/64holeineachofthetwostacksofthreedisksjoinedintheprecedingstep4.Applyprimer,andthencement,tothematingsurfacesof

oneofthestacksofdisksandthe3flamearrestorpipe.Attachthediskstothepipe,being

surethetappedendoftheholefacesoutward.Repeattheprocedurefortheremaining

stackofdisks.


51/114

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.


52/114

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.


53/114

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.


54/114

54 RunaCaronWater

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)


55/114

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.


56/114

56 RunaCaronWater

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).


57/114

57 RunaCaronWater

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.


58/114

58 RunaCaronWater

2. ReferringtoFigure19,slipa1lengthofsmallheatshrinktubingabout4ontothemagnetwireandapplyheattoshrinkitinplace.Ifyouarerighthanded,youllprobablychooseto

wrapthecoilinaclockwisedirection,holdingthecorewithyourlefthand.Inthatcase,lay

theshrinktubingontopofthecore,angledofftotheleftatabout30degreesfromstraight

outasshown.Startthefirstwirewrapoverthetubingataboutitsmidpoint.Thiswillbethe

startoflayer#1fortheinnercore.Besuretokeepthewirewrapstightsagainsteachother

ontheinsideedgeofthecore,withnooverlapping.Keeptensiononthewire,withthewire

alwayspointingstraightoutfromt

run a car on water

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