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
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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, relating to or resulting from use or misuse of these plans. Furthermore, you
understand that there are inherent risks relating to any exploratory and pioneering
mechanicaltechnology.

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

WilliamS.Power
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Contents
Preface ............................................................................................................................................ 3
Contents.......................................................................................................................................... 4
BasicQuestionsandAnswers ......................................................................................................... 7
WhatistheWaterhybridsystem?............................................................................................. 7
Isthewaterhybridsystemaperpetualmotionmachine? ........................................................ 8
Isthewaterhybridsystemsafe?................................................................................................ 8
Whyisthewaterhybridsystemiscalledaconversionsystem? ............................................... 8
Howwelldoesthewaterhybridsystemperform?.................................................................... 8
CantheWaterhybridsystembeusedinotherways?............................................................... 9
IstheWaterhybridsystemdifficulttobuild?............................................................................ 9
CanIbuyareadytoinstallWaterhybridsystem?.................................................................... 9
TheWaterhybridsystem! ............................................................................................................ 10
Hydrogen/OxygenGenerator ................................................................................................... 10
WaterTankandPump .............................................................................................................. 13
InDashIndicators[OPTIONAL]................................................................................................. 14
HyTronicsModule..................................................................................................................... 15
GeneratorElectrodeCircuitSchematic .................................................................................... 15
GeneratorCoilCircuitSchematic.............................................................................................. 18
InDashIndicatorsCircuitSchematic ........................................................................................ 20
LetsBuildthewaterhybridsystem!:GeneratorConstruction .................................................. 22
Electrodes ................................................................................................................................. 22
Housing ..................................................................................................................................... 26
Listofmaterials:.................................................................................................................... 26
StepbyStepDirectionswithIllustrations: ........................................................................... 27
HousingAttachments................................................................................................................ 39
UnthreadedEndCap................................................................................................................. 43
ListofMaterials: ................................................................................................................... 43
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MaterialSource(Weencourageyoutoresearch(tryGoogle)yourownsources,aswecan
notguaranteethesesourceswillofferthebestpricesoralwaysbeavailable: .................. 43
Directions: ............................................................................................................................. 44
SloshShield ............................................................................................................................... 46
FlameArrestor .......................................................................................................................... 47
WaterLevelSwitchTest............................................................................................................ 51
ToroidCoil ................................................................................................................................. 54
ListofMaterials: ................................................................................................................... 54
MaterialSources: .................................................................................................................. 54
Directions: ............................................................................................................................. 55
ToroidCoilInstallation.............................................................................................................. 63
UnthreadedEndCapInstallation.............................................................................................. 67
GeneratorFinalAssembly......................................................................................................... 68
InDashIndicatorPanelAssembly ............................................................................................ 70
ListofMaterials: ................................................................................................................... 70
MaterialSources: .................................................................................................................. 70
Directions: ............................................................................................................................. 71
WaterTankandPump .............................................................................................................. 75
ListofMaterials: ................................................................................................................... 75
MaterialSources: .................................................................................................................. 75
Directions: ............................................................................................................................. 75
HyTronicsModule..................................................................................................................... 80
MaterialsList:........................................................................................................................ 80
MaterialsSource: .................................................................................................................. 80
Directions: ............................................................................................................................. 80
FuelInjectororCarburetorAdaptor......................................................................................... 83
ThrottleAssembly..................................................................................................................... 84
ListofMaterials: ................................................................................................................... 84
MaterialsSource: .................................................................................................................. 84
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Directions: ............................................................................................................................. 84
PreliminaryAssemblyandTesting............................................................................................ 88
CylinderHeadTemperature ..................................................................................................... 95
FinalAssemblyandTesting....................................................................................................... 96
HelpfulHintsandTips ................................................................................................................. 109
Maintenance........................................................................................................................... 109
ColdWeatherOperation......................................................................................................... 110
SpareGenerator...................................................................................................................... 110
GoodOldStainlessSteel ......................................................................................................... 110
GoodOldJBWELD................................................................................................................. 111
KeepCloseWatch ................................................................................................................... 111
GarrettsGauge...................................................................................................................... 111
Reference.................................................................................................................................... 113
AThoughtorTwo ....................................................................................................................... 114

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BasicQuestionsandAnswers
Agoodstartingpointforunderstandingthewaterhybridtechnologyistoansweravarietyof
frequentlyaskedquestionsyoumayhave.Sohereitgoes:

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

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

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

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

Howwelldoesthewaterhybridsystemperform?
Avehiclepoweredbythewaterhybridsystemistheoreticallycapableoftravelingfrom50to
300milesoneachgallonofsupplementalwater,whileimprovingoverallfuelefficiencyupto
45%.However,asistrueforanyengine,actualefficiencydependsonmanyfactorssuchas;
drivinghabits,terrain,vehicleweightandshape,andabilitytotweakandoptimizethesystem.
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CantheWaterhybridsystembeusedinotherways?
Yes,theWaterhybridsystemcanprovidefuelfromwaterforjustaboutanyhomeappliance
requiringnaturalgasorpropaneasasourceofheat;therebysavingvaluableanddiminishing
naturalresources.Spaceheatersandfurnacesareexcellentcandidates.Stovesandother
cookingunitssuchasbarbecuegrillscanalsobefueledbythewaterhybridsystem.Such
applicationsrequireaseparatepowersupplytoconvertyourhomes120voltACpowerintothe
12voltDCpowerrequiredbythewaterhybridsystem.Youcanpurchaseaninexpensivepower
supplyatanyelectronicsstoresuchasRadioShack,orhavesomeonefamiliarwithelectronics
buildoneforyousincethedesignisverysimple.Thecostofhomeelectricityusedbythe
waterhybridsystemisinsignificant,probablylessthan$3permonthinmostcases.

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

CanIbuyareadytoinstallWaterhybridsystem?
Rightnow,thisspecificwaterhybridsystemisnotbeingcommerciallymanufactured,butthere
arevariousdistributorsaroundthecountrywhoofferDIY(Doityourself)partsorfully
assembledkitsutilizingsimilartechnologiesandprinciples.
PlanningisintheinitialstagesforproducingWaterhybridconversionkitsformostvehicles
andeventuallymanufacturingtheentiresystem,oratleastitsmajorcomponents.Were
hopingtohavesomeprototypekitstestedsoonanddeliveryofreadytoinstallkitsshould
beginsometimebeforetheendof2008.However,youllsoonbebuildingyourown!
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TheWaterhybridsystem!
Figure18inthisbookdepictsthecoreoftheWaterhybridsystem.Whileeachcomponentis
essentialtoitsoperation,theheartofthesystemistheHydrogen/OxygenGeneratorsinceit
convertswaterintocombustiblegaseousfueltopoweryourengine.Awatertankandpump
storeandsupplywaterforthegenerator.SimpleelectronicsignalsfromtheHyTronicsModule
initiateandsustainthecreationofhydrogenandoxygenwithintheGenerator.AnInDash
GaugeandIndicatorAssemblyallowsyoutoaccuratelymonitorallaspectsoftheWaterhybrid
system.EverypartoftheWaterhybridsystemisruggedlydesigned,forreliableoperationand
longlife.
Letstakeacloserlookateachpartofthesystemtogetabasicunderstandingofhow
everythingworksandinteracts.

Hydrogen/OxygenGenerator
ReferringtoFigure1onthefollowingpage,theHydrogen/Oxygengeneratorhousingisaround
cylinderconstructedwithhightemperatureCPVCpipe,amaterialwidelyusedbythebuilding
industryinplumbingsystems.CPVCpipeisextremelydurableandtemperaturetolerant.Its
alsoaveryfriendlymaterialinthatitseasytoworkwithandcanbeusedtofabricateother
thingssuchasfurniture,planters,andhousingsforjustaboutanything.
TheGeneratorhousingcontainsabasiccoilandtwocylindricalelectrodes;usedtogenerate
bothhydrogenandoxygen.Eachcanbemadefromavarietyofmaterialssuchasstainlesssteel
and/orceramic,alsoverydurablematerials.However,twoatomicallydifferentformsof
hydrogenareproducedwithintheGenerator.Mostofthegeneratedhydrogenis
orthohydrogen,averypowerfulandfastburninggascreatedbythetwoelectrodes.Aprecisely
controlled,highfrequencyelectronicsignalfromtheHyTronicsModuleactivatesandcontrols
theelectrodes.
Theotherformofhydrogen,parahydrogen,iscreatedbythecoil,butinmuchlessquantity
thanorthohydrogen.Apreciselycontrolled,verylowfrequencyelectronicsignalfroma
separatecircuitwithintheHyTronicsModuleactivatesandcontrolsthecoil.Parahydrogenisa
lesspowerfulandslowerburninggas,butisnecessarytopreventprecombustion(commonly
calledknocking)withinyourengine.Parahydrogenslowstheburningrateofthehydrogen
mix,thusboostingitsoctanelevel.Suchprecisecontrolallowsyoutoexactlymatchyour
enginesoctanerequirements.Toraiseoctanelevelsingasoline,specificadditivesmustbeused
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toslowitsburningrate.Atbestthisisaninexactsciencesinceitdependsupontryingto
averagetheoctanerequirementsformillionsofengines.
Technicallyspeaking,theHydrogen/OxygenGeneratoritselfisanelectronicbasedunit.The
twoelectrodesformabasiccapacitor,thousandsoftimeslargerthancapacitorsusedintypical
circuits,withwateractingasitsdielectric.Theinnerelectrodeisnegativelycharged,andthe
outerelectrodeispositivelycharged,bythehighfrequencyHyTronicssignal.Chemically,each
watermolecule(H20)iscomposedoftwopositivelychargedatomsofhydrogenandone
negativelychargedatomofoxygen.Sinceoppositechargesattract,thepositivelycharged
hydrogenatomsarepulledtowardtheinnerelectrode.But,atthesameinstant,thenegatively
chargedoxygenatomsarepulledtowardtheouterelectrode.Thisactionalignseverywater
moleculebetweentheelectrodes,withtheendsofeachmoleculebeingpulledinopposite
directions.Inanutshell,thisisthehydrolysisprocesscentraltohydrogenextraction.

Figure1:Hydrogen/OxygenGenerator
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Forafewbriefmoments,onlymoreaccuratealignmentandincreasedpullingactionuponthe
watermoleculesoccurs.But,theHyTronicssignalpulseskeepchargingthewatercapacitorto
higherandhighervoltagelevels;actuallyseveralthousandvolts.Suddenlytheelectricalforces
becomesogreatthatthewatermoleculesburstapart(scientistscallthisactiondisassociation)
intotheirgaseousformsofhydrogenandoxygen.IfyouwereabletolookintotheGenerator,
thisactionwouldbeobviousbecauseoftheformationofmillionsoftinyhydrogenandoxygen
gasbubbles.AslongastheHyTronicssignalisapplied,thewatercapacitorremainsfully
charged;continuouslycreatingorthohydrogenandoxygen.
Anotherelectroniccircuitisformedbythegeneratorcoil.Thisisaninductivecircuit,meaningit
createsamagneticfieldasopposedtothechargedfieldcreatedbythewatercapacitor.The
verylowfrequencyHyTronicssignal(actuallyashortpulse)activatesthemagneticfieldofthe
coil.Assoonasthepulsestops,themagneticfieldcollapses.Thiscreatesanevenstronger
magneticfield,butafieldofoppositepolarity.Thatishowaninductivecircuitworks,anaction
commonlycalledinductivekick.Eachpulseispreciselytimedsothatalmostimmediately
afterthemagneticfieldreverses,anothershortpulsearrives.Onceagainthecoilischargedand
itsmagneticfieldcollapses.Butnowthecontinuallyreversingmagneticfieldbecomeseven
strongerduetoaddedenergyofeachnewpulse.Eventually(actuallywithinjustafewseconds)
thecoilreachesitsmaximummagneticstrength,calleditssaturationpoint.
Mostmoleculesareeffectedbymagneticfields.Thecoilsreversingmagneticfieldsvibratethe
watermoleculessovigorouslythattheydisassociateintogaseousformsofparahydrogenand
oxygen.Disassociationobservablyoccurs,asseenbythecreationofmillionsoftinyhydrogen
andoxygengasbubblesaroundthecoil.
Atthispoint,wevecoveredtheconceptsneededtounderstandthebasicfunctioningofthe
generator.EveryothercomponentoftheWaterhybridsystemissimplyusedtoprecisely
controltheactionofthegenerator.ByvaryingthestrengthandfrequencyoftheHyTronic
signals,theratebywhichhydrogenandoxygenarecreatedcanbevariedtomatchengine
requirementsatanyparticularmoment.Waterissuppliedbythetankandpump,whilewater
levelwithintheGeneratoriscontrolledbyalevelsensorandswitch.Forsafetypurposes,a
reliefvalveprotectsagainstexcesspressurebuildupwithinthegenerator.Separateportsare
providedforattachinghosestoroutegastotheengineandtoanoptionalgaugetomonitorgas
pressurebuildupwithinthegenerator.Adrainvalveisinstalledtoallowperiodicflushingof
accumulatedmineralsandcontaminants.Thebottomendcapisthreadedsothatthe
Generatorcaneasilybeopenedupforinspectionorrepairandforoccasionalcleaningofthe
electrodesandcoil.Twopairsofstainlesssteel(copper,oranyconductivemetal)rodends
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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.
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
RunaCaronWater

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.
21
RunaCaronWater

Figure7:InDashIndicatorsCircuitSchematic
WhentheWaterhybridsystemisturnedon,thePWRONLEDilluminates.TheGenerator
electrodecircuit(Figure5)activatestheLED.FailureoftheLEDtoilluminateusuallyindicates
anelectrodecircuitmalfunction.
22
RunaCaronWater

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.

1. AfterdeterminingGeneratorheight,obtaina31/2(3.50)outsidediameterstainlesssteel
tubewithwallthicknessof.040to.063andlength5shorterthanthedeterminedheight
oftheGenerator.AstandardalloyofT304stainlesssteelisrecommendedforthe
electrodes.Thistubewillbeusedtoconstructtheouterelectrode.RefertotheGenerator
explodedviewofFigure9asanaidtocorrectconstruction.

NOTE
Thefollowingsteps2through4willbeusedtodeterminetheoutsidediameterfortheinner
electrode.Thisprocedurewillcreatea.045gapbetweentheinsidewalloftheouter
electrodeandtheoutsidewalloftheinnerelectrode.Thisvalueisanidealgapformaximum
andmostefficientproductionofhydrogenandoxygengaseswiththeWaterhybridsystem.
Caution
Itmaybepossibletoobtain31/2outsidediameterstainlesssteeltubingwithawall
thicknessof.040to.063andt304alloyatalocalshopthatmanufacturesexhaust
and/ormufflersystems.Alltubedimensions,includingroundness,mustbeheldwithin
.005throughoutitsentirelength.Donotuselowqualitytubing.Ifyoudo,theefficiency
ofthewaterhybridsystemwillbeseverelydegraded.
23
RunaCaronWater

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.

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.
NOTE
TheCAUTIONalsoappliestotheinnerelectrode.
24
RunaCaronWater

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.

10. ReferringtoFigure8,cuttwo(2)3rodlengthsfrom3/32diameterbarestainlesssteel
weldingrod,alloyT304.Usingafile,squareoffanddeburrtherodends.
NOTE
Barestainlesssteelweldingrod,T304alloy,canbeobtainedatanyweldingsupplystore.
25
RunaCaronWater

11. ReferringtoFigure8,solderoneoftherodstotheoutsidesurfaceoftheouterelectrode.
Positiontherodparalleltothelengthoftheelectrodewith2protrudingpasttheendof
thetube.Usesilverbearingsolderandfluxappropriateforsolderingstainlesssteel.

12. Repeattheprocedureofstep11tosoldertheotherrodtotheinsidesurfaceoftheinner
electrode.

13. Aftertheelectrodeshavecooled,thoroughlyscrubthesolderjointswithwarmsoapywater
usingastiffbristlebrush.Thoroughlyrinsetheelectrodeswithwarmwateranddrywitha
softcleancloth.

NOTE
Silverbearingsolderandfluxcanbepurchasedatanylargehardwareorelectricalsupply
store.
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.Donotusepvc
pipe,orcpvcschedule40,sinceitwillnotwithstandhightemperatureorpressure
aswell.
Donotusecpvcpipeofsizegreaterthan4:sinceitdoesnotofferanadequate
safetymarginagainstrupturewhensubjectedtohighpressureandtemperature.
Carefulattentiontocraftsmanshipanddetailduringgeneratorconstructionis
essentialtoensuresafeandreliableoperation.
27
RunaCaronWater

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.

2. Usingamiterboxortablesawtoassuresquareness,cutoffoneofthe12pipenipple
threadedends23/4fromtheend.Dressthecutedgeswithsandpaperorafinetoothfile.
Gotostep8.

3. Usingamiterboxortablesawtoassuresquareness,cutthethreadedpipenipple51/2
fromoneofitsthreadedends.Dressthecutedgeswithsandpaperorafinetoothround
file.

Caution
Readdirectionsprintedontheprimerandcementcanlabelsforproperuseofthe
products.Afterpriming,applycementassoonaspossible,toobtainsafeandreliable
bonding.Donotlettheprimerdrybeforeapplyingcement.
Note
CPVC4Schedule80pipehasanoutsidediameterof4.5.

Iftheheightofthehousingwillbe10,asdeterminedduringtheprocedureatthe
beginningoftheElectrodessection,followthedirectionsofstep2,thengoto
step8.Iftheheightwillbegreaterthan10,gotostep3.
28
RunaCaronWater

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.
29
RunaCaronWater

Figure9:DiskContour

11. Lightlycoatthethreadsofthehousingendcap,andbottomedgeofthehousing,with
petroleumjelly.Applyprimertothematingsurfacesofthediskandendcap.Applycement
totheprimedareaoftheendcaponlyandinstallthedisk,seatingitfirmlyandevenly.
Removeanycementthatoozesfrombetweenthepartswithcottonswabs.

12. Temporarilythreadtheendcapontothehousing,seatingitslowly,butfirmly.Waitabout
15minutesforthecementtopartiallydryandthenremovetheendcap.

13. Repeattheprocedureoftheprecedingsteps8through10fortheunthreadedendcap.
Theresnoneedtoapplypetroleumjellytoanyareasoftheunthreadedendcap.Apply
primertothematingsurfacesofthediskandendcap.Applycementtotheprimedareaof
theendcaponlyandinstallthedisk,seatingitfirmlyandevenly.Removeanycementthat
oozesfrombetweenthepartswithcottonswabs.

Caution
Besuretomeasuretheinsidediameteroftheunthreadedendcapbeforecuttingdisks.
Caution
Theendcapwillbetemporarilythreadedontothehousingtoassureaccurate
alignmentofthedisk.Donotuseexcessivecementwheninstallingthediskto
preventbondingofthehousingandendcapthreads.
Besurepetroleumjellycoatsonlytheendcapthreads.
30
RunaCaronWater

14. Sealtheholeinthethreadedendcapdiskwithelectricaltape.Usingastiffbristlebrush
andwarmsoapywater,thoroughlycleanpetroleumjellyfromthethreadsandallother
areasoftheendcapandhousing.Rinseallpartswithwarmwater.

15. Repeatstep14,andthenwipethepartsdrywithasoftcleancloth.

16. Removetheelectricaltapefromthethreadedendcap.Allowtheendcapstoairdryforat
least8hoursbeforegoingtostep17.

17. Completelycovertheinsidesurfacesofbothendcapswithstripsofelectricaltape.Cut
awaytapetoopenuptheholdineachdisk.

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
Caution
Useonlyhighquality,hightemperatureandwaterproofepoxycementtofilltheendcap
cavities.Usinganyothercementmayleadtoeventualfailureofthegenerator.
Note
Thecavityineachendcapwillbefilledwithepoxycement.Topreventtrappingair
bubbles,thecapsmustremainlevelwhiletheepoxycures.Centeringandlevelingthe
curvedcapsontheinnercoresoflargerollsoftapeworkwell.
31
RunaCaronWater

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.
32
RunaCaronWater

19. Mixabouta4ouncebatchofepoxyinadisposablecontainersuchasasmallpapercup.
Slowlyfillthecavity(toavoidtrappingairbubbles)tothetopoftheholeinoneofthe
endcaps.Ifnecessary,mixmoreepoxy.

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.
Note
Besureyouhaveenoughepoxyonhandtototallyfilltheremainingcavity.Ifnot,
purchasemorebeforestarting.Afterepoxycures,ithasverypooradhesionwithnewly
mixedepoxy.
33
RunaCaronWater

26. Applyprimer,andthencement,tooneoftheflatsurfacesofeachdisk.Jointhedisks,
centeringthesmallerdiskonthelargerdisk.

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.
Note
Theprocedureofsteps27and28willbeusedtocutaflatringfromCPVCsheet.Donot
unclampthesheetfromthedrillpressbeduntilstep28hasbeencompleted.
34
RunaCaronWater

34. Usingplasticelectricaltape,wraptheouteredgesoftheringsuntiltheyslideeasilyintothe
threadedendcap.Iftheringsfitloosely,addmoretape.Iftheringsfittightly,removetape.

35. Applyprimertotheflatsurfaceofthesmallerring.Usingacottonswab,applyprimertothe
flatsurfaceofthethreadedendcapcontactedbythesmallerring.Applyathin,evenlayer
ofcementtotheprimedsurfacesandinstalltheringassemblyintotheendcap.Allowthe
partstoairdrybeforegoingtostep36.

Figure11:ThreadedEndCapDetails

Note
Theprocedureofstep36centersthediskscompletedinstep26withinthethreadedend
cap.Besurethewrappingtapedoesnotprotrudebelowthesurfaceofthesmalldiskat
anypoint.Donotoverlaptapeendsifmoretapeisadded;simplybuttthetapeends
beforecontinuingtowrap.RefertoFigure11fordetailsrelatedtoinstallingthedisksinto
thethreadedendcap.
Note
RefertothefollowingFigure11fordetailsrelatedtoinstallingtheringsintothethreaded
endcap.Applyprimeronlytotheflatsurfaceofthethreadedendcapcontactedbythe
smallerring.Donotremovethetapeuntilinstructedtodoso.
35
RunaCaronWater

36. Usingplasticelectricaltape,wraptheedgeofthelargediskuntilthetapecreatesasnugfit
withtheinsideedgeoftheringassembly.

37. Applyprimertotheflatsurfaceofthesmalldiskandtheflatinsidesurfaceofthethreaded
endcap.Applyanevenlayerofcementtotheprimedsurfacesandinstallthediskassembly
intotheendcap.Alignthediskswiththeirnotchoffsetatleastfromtheringnotch,as
showninFigure11.UsingalargeCclamp,lightlyclampthedisksandendcap.Allowthe
partstoairdryatleast8hoursbeforegoingtostep38.

38. Removeallelectricaltapefromthethreadedendcapassembly.Scrapeawayanyexcess
cementthatmayhaveoozedontotheflatinsidesurfaceoftheendcapinthoseareasthat
willcontactthebottomedgesoftheelectrodesandthreadedendofthehousing.

39. Drilla37/64holethroughthecenterofthethreadedendcapasshowninFigure11.

40. Temporarilyaligneachelectrodeandrodwithitsrespectiveholedrilledinstep39.Check
thateachelectrodeandrodcanbeinstalledintothethreadedendcapandseatedfirmlyon
thecapsurface.Makeadjustmentsasnecessarytoachievecorrectseatingofthe
electrodes.Usingamarkingpen,markashortreferencelinenearthetopinsideofthe
innerelectrode.Markanothershortreferencelinenearthetopinsideoftheouter
electrode,aligningitwiththemarkontheinnerelectrode.Removetheelectrodesfromthe
endcap.
Note
Threadswillbetappedlaterintotheholedrilledthroughthecenteroftheendcapto
attachthedraincock.
Usinga#41bit,drilltwoholesthroughthebottomofthethreadedendcapatthe
locationsshowninFigure11.
Note
Besuretoalignthediskswiththeirnotchoffsetatleastfromtheringnotch,asshown
inFigure11.
36
RunaCaronWater

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.

46. Usingyourfinger,applyaverythin,butunbroken,coatofepoxycompletelyaroundthe
bottomedge(rodend)oftheouterelectrode.Formabandexte4ndingabouthighfrom
thebottomedge,coatingboththeinsideandoutsidesurfacesoftheelectrode.
Note
Besuretoinstalltheouterelectrodefirst.
Note
Theprocedureofstep41centerstheinnerelectrodewithintheouterelectrode.Donot
overlaptapeendsifmoretapeisadded;simplybuttthetapeendsbeforecontinuingto
wrap.
37
RunaCaronWater

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.
Caution
Thesmallholesaroundthebottomedgesoftheelectrodeshelpsecuretheelectrodesto
theendcapbecauseepoxyfillstheholes.Installtheelectrodesslowlyintotheendcap
slotsoasnottotrapairbubbleswithintheholes.
38
RunaCaronWater

52. Removetheweightsfromtheelectrodeassemblyaftertheepoxyhascuredforatleast24
hours,andremovethetapefromtheinnerelectrode.

53. Using#400grit(orfiner)sandpaper,removeepoxyresiduefromtherodendsprotruding
throughthebottomofthethreadedendcap.
39
RunaCaronWater

HousingAttachments
1. Temporarilythreadtheelectrodeassemblyontothegeneratorhousing,tighteningitfirmly.
Supporttheentireassemblyontheinnercoreofalargerolloftapeaswasdoneinthe
precedingstep42.

2. ReferringtothefollowingFigure12,fabricate3coilsupportbrackets(withtheindicated
dimensions)from1/8thickCPVCsheet.

3. Usescrappiecesof1/8thickCPVCsheetasshimsbetweenthetopsoftheelectrodesand
thebrackets.Applyprimer,andthencement,tothebracketsandtheinsidewallofthe
housingat120degreeintervalsasshowninFigure11.Attachthebracketsandallow
cementtoairdryforatleast30minutesbeforegoingtostep4.

Figure12:CoilMountingBrackets
4. Removetheelectrodeassemblyfromthehousing.
Note
Formostefficientoperation,thecoilmustbelocatedapproximatelyabovethetopsof
theelectrodes.Ashimisplacedbetweentheelectrodesandeachbrackettoachieve
correctclearance.Exercisecaretoavoidcementingshimstothebrackets.
40
RunaCaronWater

5. Cutfour11/2x6mountingbracketstripsfrom1/8thickCPVCsheet,asshownFigure
13.Dresstheedgesofeachstripusingsandpaperorafinetoothfile.Formeachofthetwo
bracketsbyapplyingprimer,andthencement,tothematingsurfacesofeachoftwostrips
andjoiningthemtogether.Aligntheedgesofeachstripandwipeexcesscementfromthe
edges.

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.
Note
Materialfromaringcutfromthestraightcouplingwillbeusedtomakepartofthe
Generatorhousingbrackets.Itwillalsobeusedtomakeadoublertoincreasewall
thicknessofthehousingwhereahosefittingisinstalled.
Note
BracketarrangementsformountingtheGeneratoraredictatedbytherequirementsof
eachsysteminstallation.Figure13showsoneofthesimplestandmostcommonlyused
arrangements.Otherarrangementscanbeeasilyconstructedwith1/8CPVCsheet.
Bracketsthickareconstructedfromtwolayersof1/8thickCPVCsheet.

41
RunaCaronWater

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

Figure13:HousingAttachmentDetails
9. Drilla37/64holethroughthecenterofthe11/2x11/2doublerandhousingwallas
showninFigure14.Besuretokeeptheholesquarewiththehousingwall.

10. Drillafastenerholeneartheendofeachbracket(totalof4holes)atthelocations
showninFigure14.Slightlyroundthecornersofeachbracketusingsandpaperorafine
toothfile.
Note
Threadswilllaterbetappedintotheholetoinstallabarbedhosefittingtoconnecttothe
checkvalve.
42
RunaCaronWater

11. PositionthebracketsasshowninFigure13,andclampthemtoaflatsurface.Checkthat
thehousingseatsevenlyintothecurvedsectionofeachbracketwithnogapsbetweenthe
housingandcurvedsection.Ifnecessary,loosentheclampstorepositionthebrackets.

Figure14:MoreHousingAttachmentDetails
12. Applyprimer,andthencement,tothematingsurfacesofthebracketsandhousing.Attach
thehousingtothebrackets.Placesupportingblocksoneachsideofthehousingtokeepit
fromrotatingorshiftingduringassembly.Waitatleast8hoursbeforelooseningtheclamps
andmovingthehousingassembly.
Note
Thecheckvalvehoseattachestoabarbedfittingtobeinstalledlaterintotheholedrilled
instep9.Determinethedirectioninwhichyoupreferthefittingtopointinrelationtothe
mountingbrackets.Irecommendhavingthefittingpointdirectlyleft(asshowninFigure
13)ordirectlyrighttominimizegeneratorspacerequirements.
43
RunaCaronWater

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

44
RunaCaronWater

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

Directions:
1. Usingamiterboxortablesawtoassuresquareness,cutaspacerapproximately2long
from1diameterCPVCrod.UsinganRsizedrillbit,drillaholethroughthecenterofthe
roditsentirelength,andparalleltoitslength.Alsodrillaholdthroughthecenteroftheend
capwiththeRdrill,asshowninFigure15.

Figure15:UnthreadedEndCapDetails
Note
A short length of CPVC rod inside the end cap will be used as a spacer for the water level
switch.
45
RunaCaronWater

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.
Caution
BesuretouseonlyNPTFtaps.topreventpossiblewaterandgasleakage,donot
useNPTtaps.bothNPTandNPTFthreadswillsealproperlyinNPTFtappedholes.
Besuretotaptothecorrectdepthbyturningthetapuntilthe12ththreadfrom
thefrontofthetapfullyentersthehole.
Besuretoalwayskeepthetapalignedparalleltothesidesofthespacer.
46
RunaCaronWater

SloshShield
1. Usingamiterboxortablesawtoassuresquareness,cuta31/16longsectionfrom11/2
CVPCpipe.Drillfour(4)1/8holesintothesidesofthepipe,spacedat90degreeintervals
andfromtheedgeasshowninFigure16.

2. Usingaflycutter,cutseven(7)157/64diskfrom1/8thickCPVCsheet.Drilla3/8
diameterholethroughthecenterofoneofthedisks.

3. Applyprimer,andthencement,tothematingsurfacesofthedrilleddiskandtheendofthe
pipeoppositethefourholes.Attachthedisktothepipe,beingsuretocenterthediskon
thepipe.
Note
Sixofthesevendiskscutwillbeusedfortheflamearrestor.
47
RunaCaronWater

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.
48
RunaCaronWater

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
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
Besurethetwostacksofthreedisksjoinedintheprecedingstep4haveairdried
foratleast24hours.
Whendrillingholesinthefollowingstep8,besuretokeepthedrillbitssquared
withthecurvedoutersurfaceoftheunthreadedendcap.Thisplacestheaxisof
eachofthethreeholesatanangletotheaxisofthecenterholeasshownFigure
15.
Caution
BesuretouseonlyNPTFtaps.topreventpossiblewaterandgasleakage.donot
useNPTtaps.bothNPTandNPTFthreadswillsealproperlyinNPTFtappedholes.
Besuretotaptothecorrectdepthbyturningthetapuntilthe12ththreadfrom
thefrontofthetapfullyentersthehole.
Besuretoalwayskeepthetapalignedsquarelywiththesurfacearoundthedrilled
hole.
50
RunaCaronWater

Oneholeindoubleronhousingwall.
Oneholeineachoftwoflamearrestorendcaps.

10. Tap1/827threadsintotheRsizeholeclosesttotheedgeontopoftheunthreadedend
cap.

11. Usinga3/818tap,tapthreadsintothe37/64holeineachofthetwostacksofthreedisks
joinedintheprecedingstep4.Applyprimer,andthencement,tothematingsurfacesof
oneofthestacksofdisksandthe3flamearrestorpipe.Attachthediskstothepipe,being
surethetappedendoftheholefacesoutward.Repeattheprocedurefortheremaining
stackofdisks.
51
RunaCaronWater

WaterLevelSwitchTest

1. Connecttheohmmeterleadstotheswitchpowerleads.Suspendtheswitchfromitspower
leadsandverifythattheohmmeterindicatesclosedswitchcontacts.Ifthecontactsarenot
closed,gotostep3.

2. Slowlyslidetheswitchfloatupward.Verifythatitscontactsopenatapproximatelythe
midpointoffloattravel.Ifthecontactsopenproperly,gotostep4.Ifthecontactsdonot
openproperly,theswitchisdefectiveandmustbereplaced.

3. Usingamarkingpen,markasmalldotontopoftheswitchfloat.

Note
TheswitchprobablyhasNO(normallyopen)contactconfiguration.Invertingthefloat
changesittotherequiredNCconfiguration.
Note
Thewaterlevelswitchcontainsveryhighqualitymagneticreedcontacts.Itwill
reliablyoperatethroughmillionsofcycleswhenconnectedtoaproperlydesigned
electroniccircuit.
ThewaterlevelswitchisusuallysuppliedwithNC(normallyclosed)contact
configuration.Step1verifiestheNCconfiguration.
Caution
Neverattempttocontrolpowertoanyelectricaldevicedirectlythroughthewaterlevel
switch.Doingsowilldamageordestroytheswitch.
Note
Itisimportanttoverifycorrectoperationofthewaterlevelswitchbeforeinstallingits
sloshshield.
52
RunaCaronWater

Carefullyremovethefloatretainingclipatthebottomofthecentertube.Removethefloat,
invertitandreinstall.Reinstalltheretainingclip.Verifythatthedotonthefloatisnowat
thebottomandrepeattheprocedureoftheprecedingsteps1and2.

4. Usingacountersinktool,orlargedrillbit,formasmallbevelintheouterendofthecenter
holeintheunthreadedendcapthroughwhichtheswitchleadspass.

5. Applyalightcoatingofpipejointcompoundtothethreadsoftheswitchandmounting
spaceraccordingtodirectionsontheproductlabel.Inserttheswitchpowerleadsthrough
thespacerholeandthreadtheswitchintoplace,seatingitfirmly.

6. Obtainatransparentcontainer(suchasalargeglassjar)withanoutsidediameterof
approximately21/2to33/4andinsidedepthofatleast31/2.

Placetheunthreadedendcapontopofthecontainerwiththeswitchinside.Besurethe
bottomsurfaceoftheendcapseatsevenlyontopofthecontainer.Positiontheendcapso
thatatleastoneofthelargetappedholesprojectsinsidethecontainerandtheswitchfloat
isatleastawayfromthecontainerwall.
Note
Thefollowingstepsareusedtoverifycorrectswitchoperationinresponsetowaterlevel
changes.
Caution
Donotapplyexcessivetorquetothewaterlevelswitchthreadswhileinstlalingtheswitch
intoitsmountingspacer.Excessivetorquecandamagethespacerthreads,causingwater
and/orgasleakage,andpossiblesystemfailure.
Note
Asanaddedprecautionagainstpossiblewaterand/orgasleakage,Irecommendusing
pipejointcompoundonallthreadedGeneratorhousingcomponents.
53
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
RunaCaronWater

ToroidCoil
ListofMaterials:
OneFerriteToroidCoilCore,3.50ODx2.00IDx.500Thick(NationalMagneticsPart#:
995).
CopperMagnetWire,Tefloncoate4d,HeavyBuild,23AWG,550Ft(MWSWire
Industries,mustbecustomordered)
TeflonEtchingSolution(FluoroEtch)(ActonTechnologies)
OnePackageHeatShrinkTubing,AssortedSizes(RadioShack,Catalog#:2781610).
MaterialSources:
NationalMagneticsGroup
1210WinDr.
Bethlehem,PA180177061
Phone:16108677600
FAX:16108670200

MWSWireIndustries
31200CedarValleyDr.
WestlakeVillage,CA91362
Phone:18189918553
Fax:18187060911

ActonTechnologies
100ThompsonSt.
POBox726
Pittston,PA18640
Phone:15706540612
Fax:15706542810

RadioShack
(Nationwidestores)
55
RunaCaronWater

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

Donttryshortcuttingthingsbywrappingthewirearoundthecoreseveraltimesand
pullingtherestofthewireonthrough.Thecontinualbendingandstraighteningwilldestroy
thewirelongbeforeyoureachitsend.Amodifiedversionofthatmethodworks,buttakes
afairamountofskillandexperiencetomaster(orrequiresspecialequipment).
57
RunaCaronWater

Figure18:TheIncredibleWaterhybridsystem!
Forminga3.5ODx2IDx.50toroidcoilfrom23AWGwirerequiresabout250turns
ofwireperwrappedlayer.Sincethecoilbuildsinsizeasitswrapped,eachwrapuses
anaverageofabout3ofwire.So,each100wireprovidesabout400wraps,orslightly
over11/2layers.Therefore,four(4)100footlengthsandone(1)150footlengthwill
buildan8layercoilofatleast2,000turns.
58
RunaCaronWater

2. ReferringtoFigure19,slipa1lengthofsmallheatshrinktubingabout4ontothemagnet
wireandapplyheattoshrinkitinplace.Ifyouarerighthanded,youllprobablychooseto
wrapthecoilinaclockwisedirection,holdingthecorewithyourlefthand.Inthatcase,lay
theshrinktubingontopofthecore,angledofftotheleftatabout30degreesfromstraight
outasshown.Startthefirstwirewrapoverthetubingataboutitsmidpoint.Thiswillbethe
startoflayer#1fortheinnercore.Besuretokeepthewirewrapstightsagainsteachother
ontheinsideedgeofthecore,withnooverlapping.Keeptensiononthewire,withthewire
alwayspointingstraightoutfromthecore.Precisewirepositioninghaslittletonoeffecton
overallcoilperformance.But,thefirstwrapdictatesthewirepositionsofeachsubsequent
wrapsinceeachwirewillfallintothedepressionformedbetweenthetwowiresofthe
precedingwrap.Inshort,ifyoudoasloppyjobonthefirstlayer,youllendupwithasloppy
coil.So,takeyourtimetodothejobright.Continuewrappinguntilyouhavecompleteda
fullturn(completingcoilinnerlayer#1).Tightlywrapastripofplasticelectricaltapearound
thewireandthecoilentrywireattheendoflayer#1.

3. Checkthepositionofeachwireontheoutsideedgeofthecore.Ifwrappedperfectly
(which,ofcourse,isimpossible)therewillbea.019gapbetweenanytwowires.But,you
canpositioneachwirecloseenoughbyusingashortpieceofcoilwireasafeelergauge.If
thefeelergaugewiretouchesthecoresurfacebetweenanytwowires,thegapistoowide,
soatleastoneofthewiresisoutofposition.Usingyourfingernail,orotherbluntended
instrumentthatwontdamagethewires,slightlyshiftwirestoclosethegapenoughtokeep
thefeelergaugefromcontactingthecoresurface.Anygapthatistoowideindicatesan
adjacentgapistoonarrow,sothosewiresshouldbemovedfurtherapart.Aftergoing
aroundthecoilafewtimes,youwillalsobeabletovisuallydetectwiresoutofposition.
Note
Savethe150wireforthelastlayerincaseyouneedextrawiretocompletethe
8thlayerwithoutsplicingnearthecoilentrywire.Anytimeyouinterrupt
wrapping,besuretotightlywrapastripofplasticelectricaltapecompletely
aroundthecoiltosecurethelastwrap.Teflonisextremelyslipperystuff;youdont
wanttocomebackonlytofindthatallyourcoilwrapsareloose.Itwillhappenif
youdontusetape!
Thefirstcompletewrappingoftheentirecoildiameterformslayer#1fortheinner
core.Thisistheonlycriticallayersinceeachsubsequentlayerwillautomatically
positionitselfbynestingbetweenthewiresofthepreviouswrap.
59
RunaCaronWater

Figure19:ToroidCoilDetails
4. Mixaboutaouncebatchofepoxy(suchasJBWELD).Usingasmallbrush,carefullyapply
athinlayerofepoxyaroundtheouteredgeofthecoil.Applywithamotionparalleltothe
wirestopreventwiremovement,beingsureepoxycontactsthecoiledsurfacebetween
wires.Suspendthecoilfromitswiresandallowtheepoxytocureforatleast8hoursbefore
goingtostep5.

5. Startwrappingcoillayer#2,exercisingcaretopositioneachwireintothegapformed
betweenthewiresoflayer#1ontheinnerandouteredgesofthecoil.Countandrecord
thenumberofturns.

Continuewrappinguntilyougetwithinaboutonefootofthewireend.Securethewireby
tightlywrappingplasticelectricaltapearoundthewireandcoil.
Note
Whilewrappingcoillayer#2,besuretocountandrecordthenumberofturns.
60
RunaCaronWater

6. Temporarilywrapthewirefortwoorthreemoreturnsandcutitaboutshortofthe
outeredge.Tosplicetothenextwirelength,unwrapthewireanduseasharpknifeto
scrapetheTefloncoatingfromaboutofeachwireend.Alwayskeeptheknifeblade
perpendiculartothewiretopreventdamage.

7. Slidealengthofheatshrinktubingovertheendofthenextlengthofcoilwire.Besure
thetubingislargeenoughtofitoverawiresplice.Twistthewireendstogetherfor7or8
turnstoformasplice.Cutthesplicetoalengthofaboutandbenditbacktowardthe
coiluntilitlaysflushagainstthecoilwire.Solderthesplice,slidetheshrinktubinguntilits
centeredoverthesplice,andapplyheattoshrinkthetubing.Waitaminuteortwoforthe
tubingandsplicetocoolandgoontostep8.

8. Removetheelectricaltapefromthecoilandcontinuewrappinguntillayer#2iscompleted.
Recordthetotalnumberofturnsrequiredtocompletelayer#2.

9. Referringtotherecordednumberofcoilturnsneededtocompletelayer#2,determinethe
numberofcoillayersrequiredtocompletethecoilwithatotalnumberof1,800to2,100
turns.

Note
Besuretoendthelastcoillayernearthebeginningoflayer#1.Donotfinishthecoilwith
apartiallastlayer.
Note
Althoughthetotalnumberofcoilturnsisnotcritical,almostallcoilsrequireatotalof8
wirelayers.
Note
Coilthicknesstapersdownbetweentheinnerandouteredges.Tominimizeinnercoil
thickness,positionwiresplicesonthetoporbottomofthecoil,midwaybetweenthe
edgesasshowninFigure19.
61
RunaCaronWater

10. Repeattheprocedureoftheprecedingsteps5through7untilthelastlayerhasbeen
completed.Besurethelastturnendswithinaturnortwoofthecoilentrywire.Cutthelast
wiretoalengthofabout12.

11. ReferringtoFigure19,temporarilyslidea5lengthofheatshrinktubingovertheendsof
thecoilwires.Drawthetubingsnuglyupagainsttheoutercoiledgeandbendthecoilleads
backtowardthecoilattheouterendofthetubing.Tightlywrapeachcoilwire4to5turns
aroundthetubingabout1fromtheend,andtwistthewirestogetherforatleast5or6
turns.

12. UsingFluoroEtch,whilesuspendingthecoilbytheheatshrinktubing,etchthesurfacesof
theTefloncoatedcoilwires.Closelyfollowthedirectionsontheproductlabel.Ifnecessary
asanaidtoetching,refertothegeneraldescriptionoftheetchingprocedurecalledout
laterinthisdocument.Alwayshandlethecoilbysuspendingitfromthetubingduringeach
phase,frometchingthroughfinalwarmwaterrinse.Usecleanpapertowelstoabsorb
waterdripsfromthebottomofthecoiluntildrippingceases.Allowthecoiltoairdryforat
least4to5hoursbeforegoingtostep13.

13. Usingasoftbristlebrush,coattheentiresurfaceofthecoilwithathinandevenlayerof
CPVCcement.Usecottonswabstowipeawayexcesscementthatmaybedrippingfromthe
bottomofthecoiluntildrippingceases.Allowthecementtoairdryforatleastanhourand
thenapplyasecondthinandevenlayerofCPVCcementinthesamemanner.

Caution
Exerciseextremecaretopreventdamagingthecoilwiresduringthefollowing
procedures.
ToassureproperbondingofCPVCcementtothecoilafteretching,donothandle
thecoilwithbarehands.Ifthecoilmustbehandled,wearcleancottongloves.
Note
Donotshrinktheheatshrinktubinginthefollowingstep11.Itwillbeusedonly
temporarilytosecurethecoilwires.
62
RunaCaronWater

14. Repeattheprocedureoftheprecedingstep13untilatotalof5or6layersofCPVCcement
havebeenappliedtothecoil,allowingatleastonehourdryingtimebetweeneachlayer.
Allowthefinallayerofcementtoairdryforatleast8hoursbeforegoingtostep15.

15. Unwrapthecoilwiresfromtheheatshrinktubingandremovethetubingfromthewires.
Cuta1lengthofheatshrinktubinglargeenoughtoslipsnuglyoverthecoilwiresandthe
shrinktubingofthecoilentrywire.Drawthetubingtightlyupagainstthecoilouteredge
andapplyheattoshrinkthetubing.

16. Usingasoftbristlebrush,applyathinbeadofCPVCcementaboutwidearoundthecoil
endofthetubingandsurfaceoftheoutercoiledge.Allowthecementtoairdryforabout
anhourandthenapplyasecondbeadofcementoverthefirstbead.

17. Suspendthecoilfromtheendofitswiresandallowittoairdryforatleast24hoursbefore
goingtostep18.

18. Cutthecoilwirestoalengthof3fromthecoil.
Caution
Exercisecarenottopullthecoilexitwireawayfromthecoilwhileremovingtheheat
shrinktubing.
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ToroidCoilInstallation

1. Usinga#41drillbit,drilltwoholesinthehousingwallatthelocationsshownFigure20.

2. Cuttwo(2)4lengthsof3/32barestainlesssteelweldingrod.Createa90degreebendin
oneendofeachrodtoformalegapproximately11/2long,asshowninFigure20.Cutthe
otherlegtoalengthof.Usingafile,squareofftheendsofeachrodanddeburrthe
edges.

3. UseasharpknifetoscrapetheTefloncoatingfromaboutofeachcoilwireend.Always
keeptheknifebladeperpendiculartothewiretopreventdamage.

4. Wrapeachcoilwireendaroundthetopofa11/2rodlegforatleast4or5turns.Using
silverbearingelectricalsolder,soldereachwiretoitsrodleg.Trimawayanyexcesswire.
Formawirestrainreliefatthelegbottombywrappingheavythreadatleast2or3turns
aroundthelegandwire.Securethethreadwithaknotplacedontheoutsideoftherod
bend.
Note
Irecommendlocatingthecoilelectricalconnectionsonthesideofthehousingdirectly
oppositethewaterpumpinletport.Thislocationminimizespossiblecoilwireconnector
fatigueduetotheeffectsofwaterturbulenceathighpumppressure.
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RunaCaronWater

Figure20:ToroidCoilInstallation
5. Usingasoftbristlebrushandwarmsoapywater,cleanthesolderedareasoftherodand
wire.Rinsewithwarmwaterandallowthethreadtoairdryforatleastanhourbefore
goingtostep6.

6. CoattheentirelengthofthelongrodlegwithathinevenlayerofCPVCcement.Allowthe
cementtodryforabout15minutesandapplyasecondthincoatofCPVCcement.Allowthe
cementtoairdryforabout15minutesbeforegoingtostep7.

7. Temporarilyinstallthecoilontopofitsthreesupportbracketswithinthehousing.Position
thecoilwiththewiresandrodspointingtowardtheholesdrilledintheprecedingstep1.
Temporarilyattachthreesmallstripsofelectricaltapeontopofthecoiltomarkthe
locationofeachsupportbracket.

8. Removethecoilfromthehousingandapplyprimertothebottomofthecoilatthethree
markedlocationsandthetopsurfaceofallthreesupportbrackets.Coatthetopofeach
supportbracketwithaheavylayerofCPVCcement.Installthecoilontothesupport
brackets,positioningitwiththewiresandrodspointingtowardthetwo#41drilledholes.If
65
RunaCaronWater

necessary,shiftthecoilslightlytocenteritsoutsideedgeswithinthehousing.Allowthe
cementedrodsandwirestoairdryatleastanhourbeforegoingtostep9.

9. Removethethreetapestripsfromthetopofthecoil.Usingacountersinktoolorlargedrill
bit,Deburrtheinsideendsofthe#41holes.Inserttherodendsintotheholesandcheck
thattheinsidebendradiusclearstheedgeofeachhole.Ifnot,countersinkslightlydeeper
untilthedesiredclearanceisobtained.

10. Using#400gritorfinersandpaper,polishthesurfaceoftheunsolderedlegofeachrod.Mix
asmallquantityofepoxysuchasJBWELD.Applyathincoatofepoxytotheunsolderedleg
ofeachrod.Usingatoothpick,orotherprecisetool,applyathincoatofepoxytotheinside
ofeach#41hole.

11. ApplyaheavylayerofCPVCcementtothesoldere4dlegofonerod.Fullyinserttherodinto
the#41holdwiththesolderedlegpointingdirectlyupward.Holdtherodinplaceforabout
5minutesuntilthecementdriessufficientlytoholditinplace.Whilewaitingforthe
cementtopartiallydry,cleanepoxyfromtherodendusingasoftcleanclothandsolvent
suchasMEKoracetone.Repeatthisprocedurefortheremainingrod.Allowtheepoxyto
cureforabout8hoursbeforegoingtostep12.

12. Arrangethecoilwiressotheycontactthehousingwallasmuchaspossible.Laythehousing
onitssideandapplyathicklayerofCPVCcementoverthewiresandsolderedlegofeach
rod.Extendthecementlayeraroundtheholewhereeachrodentersthehousingwall,
Note
SeverallayersofCPVCcementareusedtosecurethecoiltothehousingbrackets,rods
andwirestothehousingwall,andtosealtherodsagainstpossiblegasand/orwater
leakagethroughtheholesinthehousing.
Note
Thetwo#41holesintheinsidehousingwallmustbecountersunktoadepthsufficientto
cleartheradiusoftheinsidebendofeachrod,allowingthesolderedlegofeachrodtolay
flushagainstthehousingwallwiththesolderedlegpointingupward.
66
RunaCaronWater

formingaboutadiameterpuddlearoundeachhole.Allowthecementtoairdryforat
least15minutesbeforegoingtostep13.

13. Standthehousingonend.Usingasoftbristlebrush,applyathicklayerofCPVCcement
overandaroundthecoilsurfaceabovewhereitcontactseachofthethreesupport
brackets.Besurethelayerextendsthewidthofeachbracket.Allowthecementtoairdry
foratleast15minutesbeforegoingtostep14.

14. Repeattheprocedureoftheprecedingsteps12and13atleast4or5timestoobtainthe
desiredthicklayerofcement.Allowthecementtoairdryforatleastanhourbetween
successivelayers.

15. Aftertheepoxyhascuredforatleast24hours,use#400gritorfinersandpapertoremove
epoxyresiduefromtherodends.
67
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UnthreadedEndCapInstallation

1. Checkthatthematingsurfacesoftheendcapandtopofthehousingarecleanandfreeof
debrisofanykind.Cleanthematingsurfacesifnecessaryusingasoftcleanclothandmild
solventsuchasisopropylalcohol.

2. Afterdeterminingthedesiredpositionoftheendcap,applyprimertothematingsurfaces
oftheendcapandtopoftheGeneratorhousing.ApplyathinlayerofCPVCcementtothe
primedareasandslidethepartstogether,seatingthemfirmly.

3. Standthehousingonendtopreventthepossibilityofexcesscementrunningintothreaded
holesintheendcap,allowingittoremaininthatpositionforatleastanhourwhilethe
cementairdries.
Note
Generatorfunctionandefficiencyisnotaffectedinanywaybytherotationalpositionof
theunthreadedendcap.
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RunaCaronWater

GeneratorFinalAssembly

1. Cutthetworodendsprotrudingthroughthebottomofthethreadedendcaptoalengthof
.Usingafile,squaretheendofeachrodanddeburrtheedges.

2. ApplyalightcoatingofpipejointcompoundtoallthreadedholesintheGeneratorhousing
andendcapsaccordingtodirectionsontheproductlabel.

3. Applyalightcoatingofpipejointcompoundtothethreadsofthedraincock.Threadthe
draincockintothe37/64threadedholeinthebottomofthethreadedendcap,seatingit
firmly.Repeatthisproceduretoinstalltheremainingcomponents:
One3/8BarbedHoseFittinginto37/64holeinhousingdoubler.
One3/8BarbedHoseFittinginto37/64holeontopofhousing.
One1/8BarbedHoseFittingintoRsizeholeontopofhousing.
OnePressureReliefValveinto37/64holeontopofhousing.

4. Usingatoothpick,orsimilarprecisetool,forceasmallquantityofSiliconeSealant(RTV
Cement)intotheholeintheendcapthroughwhichthewaterlevelswitchleadspass.Form
asmallandsmoothfilletofsealantaroundtheleadsandendofthehole.Allowthesealant
tocureforatleast24hoursbeforegoingtostep5.

5. Visuallyinspectallsurfacesandcomponentsofthehousingandendcaptoverifytheir
integrity.Correctpossibledefectsasrequired.

Caution
TopreventdamagetothreadedholesinCPVCmaterial,donotapplyexcessivetorqueto
componentswhileinstalling.Threaddamagecancausewaterand/orgasleakage,and
possiblesystemfailure.
Note
Asanaddedprecautionagainstpossiblewaterand/orgasleakage,Irecommendusing
pipejointcompoundonallthreadedGeneratorhousingcomponents.
69
RunaCaronWater

6. ThoroughlyflushtheinterioroftheGeneratorhousingwithwarmtapwater.Standthe
housingonendandallowexcesswatertodrainforatleast15minutes.Usingasoftclean
cloth,drythehousingexteriorandthreadsofthehousingandendcap.

7. Applyalightcoatingofpipejointcompoundtothehousingandendcapthreads.Thread
theendcapontothehousingandtightenfirmly.
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InDashIndicatorPanelAssembly

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

AutoMeterProductsInc
413WElmSt.
Sycamore,IL60178
Phone:18158958141Fax:18158956786

Note
PersonalpreferencedictatesthelayoutofpanelgaugesandLEDindicators.During
assembly,referFigure5,6,and7.
71
RunaCaronWater

UnitedStatesPlasticCorp
RadioShack
(Nationwidestores)

Directions:
1. TemporarilymounttheCHTandpressuregaugesintheconsole.Referringtofigure2,
determinethebestlocationsforthe4LEDsandplacereferencemarksatthoselocationson
theoutsideoftheconsole.Drilla7/32holeateachlocation.Toassureproperadhesionof
siliconesealanttotheconsoleinteriorsurface,roughenthesurfaceimmediatelyaroundthe
areaofthedrilledholeswithsandpaper.

2. TemporarilydisconnecttheCHTgaugethermocoupleleadandmountthegaugeinthe
console.Applyalightcoatingofpipejointcompoundtothe1/827threadsofthepressure
gaugeand1/827barbedhosefitting.Threadthefittingintothegaugeandtightenfirmly.
Slipthe1/8siliconetubingfullyontothebarbedfittingandsecurewithtwosmallstainless
steelhoseclamps.Firmlytightenthehoseclampsandmountthepressuregaugeinthe
console.

3. Identifytheanode(+)leadofeachLEDandcuttoalengthof1.Cutfour(4)3footlengths
of18gaugehookupwireandstripofinsulationfromtheendofeachwire.Wrapthe
strippedendofeachwireendaroundeachanodeleadandsolder.Slidea11/2lengthof
heatshrinktubingovereachwireandflushagainsttheLEDandshrinkthetubing.

4. ReferringtoFigure2,identifytheconsolelocationforeachLED.Usingmaskingtape,or
othermeansoflabeling,attachanidentifyinglabeltoeachanodewire.
Green,PWRON
Note
ThesorterofthetwoLEDleadsisalwaystheanode(+)lead.
Note
Thequickestandeasiest,andusuallythemostattractive,methodformountinggauges
andLEDsistouseaprefabricatedconsoleattachedtothetopofthedashpanel.Other
methodsmayworkjustaswell,butImrecommendingtheVDO1108720CustomConsole,
whichismoldedfromABSplasticandisbothattractiveanddurable.
72
RunaCaronWater

Green,PUMPON
Yellow,GENWATERLOW
BlinkingRed,TANKWATERLOW

5. Cuttwolengthsofhookupwiretouseasjumperwiresbetweenthebulbsandsocketsfor
thegauges.Stripofinsulationfromtheendsofeachwire.Solderawiretoonesocket
centerconnector.Slidea1lengthofheatshrinktubingontothewireandasfaraspossible
ontothesocketbase.Shrinkthetubing.Cuta3footlengthofhookupwireandstripof
insulationfromoneend.Twisttheendsofthesolderedjumperwireand3footwire
together.Slidea1lengthofheatshrinktubingontothewires,andsolderthewirestothe
othersocketcenterconnector.Slidethetubingasfaraspossibleontothesocketbaseand
shrinkthetubing.LabelthewirePositive(+).

6. Cuta6lengthofhookupwire.Repeattheprocedureofstep5toconnectthe6wireand
jumperwirebetweenthetwosocketbaseconnectors.Stripofinsulationfromtheendof
the6wire.

7. CutthecathodeleadofthegreenPWRONLEDto11/2long.Cutthecathodeleadofthe
yellowGENWTERLOWLEDto1long.Cutanappropriatelengthofhookupwiretoserve
asajumperwirebetweenthecathodesofbothLEDs.Stripofinsulationfromeachend
ofthewire.SolderthejumperwiretotheyellowLEDcathode.Slidea11/2lengthofheat
shrinktubingoverthewireandflushagainsttheLEDandshrinkthetubing.

Twistthestrippedendsofthejumperwireand6ofstep6together.Slidea1lengthof
tubingoverthetwowiresandsolderthemtothegreenLEDcathode.Slidethetubingflush
againsttheLEDandshrinkthetubing.Cuta3footlengthofhookupwireandstripof
insulationfromoneend.SolderthewiretothegreenLEDcathode.Slidea11/2lengthof
heatshrinktubingoverthewireandasfaraspossibleontotheLEDleadandshrinkthe
tubing.LabelthewireasGround.

CutthecathodeleadsofthetworemainingLEDsto1long.Cuttwo(2)3footlengthsof
hookupwireandstripofinsulationfromtheendofeachwire.Solderthewirestothe
LEDcathodes.Slidea11/2lengthofheatshrinktubingovereachwireandflushagainst
theLEDandshrinkthetubing.LabelthegreenLEDwireasPUMPONCATHODEandthe
redLEDwireasTANKWATERLOWCATHODE.
73
RunaCaronWater

8. SlideeachLEDintoitscorrectmountingholeontheconsole.SlideoneLEDabout1/16
backfromtheinteriorsurfaceoftheconsoleandapplyasmallamountofsiliconesealant
intothegapbetweentheLEDflangeandtheconsolesurface.SlidetheLEDbackintoplace
andflushwiththeconsolesurface.ApplyathickbeadofsealantaroundtheLEDflangeand
aboutontotheconsolesurface.Repeatthesameprocedureforthethreeremaining
LEDs.Allowthesealanttocureforatleast24hoursbeforegoingontostep9l.

9. Installthebulbsandsocketintothegauges.DrawnthesevenLEDwiresandbulbsocket
wiretogetherashortdistancefromtheLEDsandsecurethewirebundlewithatiewrap.,
Tightenthetiewrapandcutoffitsunusedstrap.

10. Drilland/orgrindaholetoinstalla5/8IDgrommetthroughtheenginecompartment
firewallatanappropriatelocationforroutingofHyTronicswires,thermocouplelead,and
pressuregaugetube.Deburrtheholeandinstalla5/8IDgrommet.Insertthe
thermocoupleleadthroughthegrommetfromtheenginecompartmentsideandreattachit
toitsCHTgaugeterminal.

11. Permanentlyattachtheconsoletothedashatthedesiredlocation.Securethewires,
thermocouplelead,andCHTtubebundlewithatiewrapplacedaboutevery6alongthe
lengthofthebundle.Topreventcollapsingthepressuregaugetube,besurenottoover
tightenthetiewraps.

12. Cuttheendsoftheeightwirestothesamelengthandstripofinsulationfromtheendof
eachwire.Attacheachwiretoaseparatepinofthe9PositionMaleInterlockingconnector
bycrimpingorsoldering.

13. Removeasparkplugfromtheengineandplugtheholewithasoftcleancloth.Toassure
goodelectricalcontactforthethermocouple,polishtheareacontactedbythesparkplug
Note
Siliconesealantcuresbychemicalreactionwithoxygenandwatermoistureintheair,
whichiswhyitssometimesreferredtoasRTV(RoomTemperatureVulcanizing)cement.
Sealantcuretimecanbeshortenedconsiderablybyplacingawaterdampenedcloth
withintheconsoleinteriorandplacingtheconsoleintoaplasticgrocerybag(dontseal
thebagsothatitsairtight).Thismethodisespeciallyeffectiveindryclimates.
74
RunaCaronWater

with#400gritorfinersandpaper.Removetheclothfromthesparkplughole.Slipthe
thermocoupleringoverthesparkplugthreadsandreinstallthesparkplug.Tightenthe
sparkplugtoitsnormaltorquevalue.
75
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WaterTankandPump
ListofMaterials:
OneRectangularPolyethyleneTank,16Gallon,21x14x14(USPlasticPart#:8658).
HighLowTemperatureSiliconeTubing,3/8ID,20(USPlasticStock#:54037).
SiliconeBraidReinforcedTubing,3/8ID,20(USPlasticStock#:54055).
OneHighHeadPump,12vdc,75PSI(minimum)(Flojet)
OneBrassBusing,PTFMalex3/8PTFFemale(FastenerHutPart#:3220x12x06A).
OnePackageCrimpOnButtConnectors(RadioShackPart#:643037).
MaterialSources:
RadioShack(Nationwidestores).

FastenerHut,Inc

UnitedStatesPlaticCorp

FlojetCorporation
20Icon
FoothillRanch,CA92610
Phone:19498594945
TollFree:18002356538
Fax:19498591153

Directions:
1. Applyathinfilmofpipejointcompoundtotheinternalthreadsofthex3/8bushing
andthreadsofa3/8barbedhosefitting.Threadthefittingintothebushingandtighten
firmly.

2. Applyathinfilmofpipejointcompoundtotheexternalthreadsofthebusingandinternal
threadsofthewatertankfitting.Threadthebushingintothetankandtightenfirmly.
Note
Watertankcapacityisnotcritical,butshouldbeatleast1gallon.Therecommendedtank
issturdilyconstructed,holds16gallons,andisfurnishedwithaFPToutletfitting.
76
RunaCaronWater

3. Drillorcuta5/8holeinthesidewallofthewatertankatthemidpointofitslengthand4
upfromthebottom.Flushthetankwithtapwatertoremoveplasticshavings.

4. Removethetankcap.Drilla37/64holethroughthecenterofthecapandthreadwitha
3/818tap.Flushthecapwithtapwatertoremoveplasticshavings.Threada3/8barbed
hosefittingintothetappedholeandseatfirmly.Cuta6lengthofhighlowtemperature
siliconetubing.Slipthetubingontothefittingandsecurewithtwostainlesssteelhose
clamps.Tightentheclampsfirmly.

5. Stripofinsulationfromtheendsofthewaterlevelswitchleads.Connectohmmeter
leadstotheswitchleads.Pivottheswitchfloatuntilflushagainsttheswitchbody.Verify
thattheohmmeterindicatesclosedswitchcontacts.Ifthecontactsarenotclosed,the
switchisdefectiveandmustbereplaced.

6. Pivotthefloatswitchawayfromthebodyuntilitiswithin10degreesofitsstop.Verifythat
theswitchcontactsareopen.Ifthecontactsarenotopen,theswitchisdefectiveandmust
bereplaced.

Note
Thewaterlevelswitchcontainsveryhighqualitymagneticreedcontacts.Itwillreliably
operatethroughmillionsocycleswhenconnectedtoanLED.
Caution
Neverattempttocontrolpowertoanyelectricaldevicedirectlythroughthewaterlevel
switch.Doingsowilldamageordestroytheswitch.
Note
Thewaterlevelswitchcanbeinstalledatthemidpointofeithersidewallofthetank.
Determinethedesiredlocationbasedonroutingofelectricalleads,trunklayout,etc.One
switchleadwillbegroundedtothevehicleframeinthetrunkareaandtheotherleadwill
beconnectedtotheHyTronicsmodule.
77
RunaCaronWater

7. Usingasoftcleancloth,drythetanksidewallaroundthe5/8hole.Applypipejoint
compoundtothethreadsoftheswitchbodyandmountingnut,andtheirmatingsurfaces
withthetankwall.Installtheswitchintothetanksothefloatpivotsupward,aligningits
pivotingaxisparalleltothetankbottom.Firmlytightentheswitchmountingnut.

8. Attachohmmeterleadstotheswitchleadsandverifytheswitchcontactsareclosed.Plug
thetankoutletfittingandfillthetankwithwateruntiltheswitchcontactsopen.Continue
fillingthetankuntilthewaterlevelrisesanadditional2.Verifythattheswitchcontactsare
stillopen.Unplugthetankoutletandverifythattheswitchcontactsclosewhenthewater
leveldropstoapproximatelythe1/3fullpoint,andgotostep9.Iftheswitchcontactsdo
notrespondproperlytochangingwaterlevel,checktoverifythattheswitchisproperly
installedandthefloatpivotsfreely.Verifythatthefloatisatleastawayfromanypartof
thetank.Correctanyinstallationproblems.Iftheswitchhasbeenproperlyinstalled,itis
defectiveandmustbereplaced.

9. Drainwaterfromthetankandinstallthecap,tighteningitfirmly.Constructawooedframe
3to4hightosecurethetankagainstslidingwithinthetrunk.Drillaholeorcutanotchin
theframelargeenoughtoclearthetankoutletwhilethetankisbeinginstalledorremoved.
Ifnecessary,cutanotchtocleartheswitchmountingnutandwires.

10. Drainwaterfromthetankandinstallthecap,tighteningitfirmly.Constructawoodframe
3to4hightosecurethetankagainstslidingwithinthetrunk.Drillaholeorcutanotchin
theframelargeenoughtoclearthetankoutletwhilethetankisbeinginstalledorremoved.
Ifnecessary,cutanotchtocleartheswitchmountingnutandwires.Fastentheframeto
thetrunkflooratthedesiredlocation.

11. Locateaconvenientspotonthevehiclechassisclosetothewatertankanddrilla3/32
groundingringterminalattachmentholeforthetankswitch.Usingacleanragandsolvent,
removedirtordebrisfromaroundthehole.Grindorusesandpapertoremovepaint,orany
otherinsulatingmaterial,fromtheareaaroundthehole.Stripofinsulationfromtheend
ofoneswitchwireandcrimpalargeringterminalontothewire.Donotattachthering
terminaluntilinstructedtodosoinstep15.
78
RunaCaronWater

12. Determinethelengthoftubingneededtoreachfromthepumporwatertanktotheengine
compartment.Ifthepumpwillbelocatedwithintheenginecompartment,gotostep14.If
thepumpwillbelocatedwithinthetrunk,gotostep13.

13. Mountthepumpatthedesiredlocationwithinthetrunk.Determinethelengthoftubing
neededtoattachthetanktothepump.Cuthighlowtemptubingtotherequiredlength
andslideontothetankfitting.Securethetubingwithtwosmallstainlesssteelhoseclamps
andtightenfirmly.Slidethetankintothewoodframe.Slidetwosmallstainlesssteelhose
clampsontothetanktubeandslidethetubeontothepumpinletfitting.Slidethehose
clampsoverthefittingandtightenfirmly.Slidebraidtubingontothepumpoutletfitting.
Slidetwosmallstainlesssteelhoseclampsoverthefittingandtightenfirmly.Gotostep15.

14. Cuthighlowtemptubingtotherequiredlengthandslideontothetankfitting.Securethe
tubingwithtwosmallstainlesssteelhoseclampsandtightenfirmly.Slidethetankintothe
woodframe.

15. Attachthetankringterminaltothe3/32holeinthechassiswithasheetmetalscrew.
Applyaheavylayerofpetroleumjellyorgreaseovertheterminalandscrew.

16. Stripofinsulationfromtheendoftheremainingswitchwireandcrimpabuttconnector
ontothewire.Determinethelengthofhookupwireneededtoextendatleast3intothe
enginecompartmentandcuttolength.Stripofinsulationfromtheendofthehookup
wireandcrimpittothebuttconnector.Ifthepumpisinstalledinthetrunk,repeatthis
proceduretospliceanequallengthofhookupwiretoeachpumppowerlead.

17. Routethetankandpumpwiresandtubingthroughthevehiclestructure.Besuretoinstalla
IDgrommetwhereveranaccessholemustbedrilledUsetiewrapsaboutevery6to
Note
If,asrecommended,thewaterpumpwillbeinstalledwithintheenginecompartment,
highlowtempsiliconetubingwillbeusedtoconnectthetanktothepump.Ifthepumpis
installedwithinthetrunkarea,thetubeconnectingthepumptothecheckvalvewillbe
pressurized(upto85psi)andsiliconebraidreinforcedtubingmustbeused.Ifthepumpis
notselfpriming,itmustbeinstalledinthetrunk.
79
RunaCaronWater

securethewireandtubingbundle.Topreventcrushingthetubing,donotovertightenthe
tiewraps.

18. Securelymountthewaterpumpintheenginecompartmentifthepumpwasnotinstalled
inthetrunk.Slidetwosmallstainlesssteelhoseclampsontothehighlowtemptubing.
Installtubingontothepumpinletfittingandfirmlytightenthehoseclamps.
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HyTronicsModule
MaterialsList:
PurchasespecificelectroniccomponentsascalledforinschematicdiagramsFigure5,
Figure6,andFigure7(availableatRadioShack).
Two12PositionMaleInterlockingConnectors(RadioShackPart#:274232).
Two12PostionFemaleInterlockingConnectors(RadioShackPart#:274242).
OneUniversalComponentBoard(RadioShackPart#:276168).
OnePCBoardKit(RadioShackPart#:2671576).
OneEnclosure8x6x3(RadioShackPart#:2701809).
MaterialsSource:

RadioShack(Nationwidestores).

Directions:
1. ReferringtoFigure5,buildtheelectrodecircuitusingcomponentsasdetailed.

2. ReferringtoFigure6,buildthecoilcircuitusingcomponentsasdetailed.

3. ReferringtoFigure7,buildtheindicatorscircuitusingcomponentsasdetailed.
Note
Sinceboththeelectrodecircuit(Figure5)andcoilcircuit(Figure6)operateat
relativelylowfrequencies,physicallayoutoftheHyTronicsmodulecomponentsis
notcritical.MountcomponentsusingtheUniversalComponentBoard,ordesign
andcreateyourownPCBoardlayoutusingthePCBoardKit(evenincludesneeded
chemicalsolutions).TherecommendedEnclosureprovidesprotectionforthe
HyTronicscircuitsandisattractiveandeasytomount.
Theelectrode,coil,andindicatorcircuitsmaybebuiltonthesameboardoron
separateboards,usingthesideboardmountingfeatureoftherecommended
Enclosure.
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4. Drillaholeintheenclosureandinstalla3/8IDgrommet.Cuteight(8)1footlengthsof
hookupwireandstripofinsulationfromoneendofeachwire.Routeonewirethrough
thegrommetandsolderittotheHyTronicsGround()bus(seeFigure5)andlabelthe
wire.RefertothefollowingFigurestosolderthesevenremainingLEDandbulbsocketwires
(besuretolabeleachwire).
PWRONFigure5
AllOtherLEDsFigure7.
Positive(+)bulbsocketcenterconnectorwireFigure7

5. Cuttheeightwirestoequallengthandstripofinsulationfromtheendofeachwire.
Connectthewirestothe9positionfemaleinterlockingconnector.Besurethewirelabelat
eachpositioncorrespondstothewirelabelandeachpositionofthemale9position
connector.Afterconnectingwires,removealllabels.Securethewireswithatiewrap
placedaboutevery3alongthelengthofthebundle.

6. DrillanotherholeintheenclosureandinstallaIDgrommet.Cutnineteen(19)1foot
lengthsofhookupwireandstripofinsulationfromoneendofeachwire.Soldertwo
wirestotheappropriateterminalsfortheGeneratorelectrodes(Figure5),andtwowiresto
theappropriateterminalsfortheGeneratorcoil(Figure6).Solderonewiretothe
appropriateterminalofthepumpcircuit(Figure7).Solderonewiretotheappropriate
terminalfortheGeneratorwaterlevelswitch(Figure7).Solderfivewiresbeforethefuse
connection(battery+sideofpowerbus,seeFigure5)andfivewirestothenegative()bus.
Solderonewiretothethrottle10Kresistor(Figure5).Soldertwowiresforthetankwater
levelswitch(Figure7).Besuretoappropriatelylabeleachwire.
Note
AholemustbedrilledintheHyTronicsmoduleenclosureforroutingwirestothe9
positionindicatorspanelconnector.Asecondholemustalsobedrilledforroutingwiresto
two12positionconnectorsforalothersystemcomponents.Besuretoinstallan
appropriatelysizedgrommetineachhole.
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7. Cutthenineteenwirestoequallengthandstripofinsulationfromtheendofeachwire.
Connectanyninewirestoa12posiotnmaleinterlockingconnector.Connecttheremaining
ninewirestoa12positionfemaleinterlockingconnector.Securethewireswithatiewrap
placedaboutevery3alongthelengthofthebundle.

8. AttachtheHyTronicsmoduleunderthedashpanelandasfarforwardaspractical.Connect
the9positioninterlockingconnectorsofthemoduleanddashindicators.
Note
Twoconnectorsareusedtoprovideextrapositionsforfutureexpansion,modifications,
anddesignimprovement.Besuretouseamale12positioninterlockingconnectoranda
female12positioninterlockingconnectortopreventaccidentalconnections.
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FuelInjectororCarburetorAdaptor

1. Installanappropriateadapteronyourengine.Contactacompanyexperiencedingasoline
conversionsystems,explainingthattheWaterhybridsystemisdesignedforswitchingback
andforthbetweenhydrogenandgasolinefuels.
Note
Sincehundredsofvariousfuelflowsystemsexist,werecommendcontactingacompany
experiencedwithgasolineenginefuelconversionsystems.Describeyourvehiclesengine
andtheWaterhybridsystem,andaskforthecompanysrecommendations.Inparticular,
inquireaboutthepossibilityofinstallingaBeamGarretsonAdapter.

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ThrottleAssembly

ListofMaterials:
OnePrecisionPot,Series578,100K(ClarostatPart#:578X1G32P104SW).
One1footlengthCPVCRod,diameter(USPlasticPart#:43182).
MaterialsSource:
StateElectronics
36Route10
EastHanover,NJ07936
Phone:19738872550TollFree:18006318083
Fax:19738871940

UnitedStatesPlasticCorp

Directions:
1. Determinethebestlocationintheenginecompartmentforinstallingthesleeveandarm
assemblyandpotmountingbracket.

2. FabricateapotmountingbracketwithdimensionsindicatedinFigure21from1/8CPVC
sheet.Ifnecessary,modifythebracketsizeandattachmentpointstosuityourvehicle.Do
notcutthe3/32slotuntilinstructedtodosoinstep6.

Note
Figure21depictsatypicalHyTronicsthrottleassembly.Sincehundredofvarious
throttlelinkagesareinuse,thefollowingprocedureisofferedasageneral
guideline.
Thepotmountingbracketisdesignedtoallowpotcentering(housingrotation)and
preciseadjustmentofthrottlesensitivity(bracketrotation).Thethrottlelinkage
sleeveallowsprecisepotrotationlimitadjustments(idletofullthrottle)when
combinedwithbracketrotation.
Note
TheHyTronicsthrottleusesahighqualityprecisionpot(potentiometer)designedfor
reliabilityanddurability(over5millioncompleterevolutions).Cheappotswillsoonfailor
causeproblems;donotsubstituteacheappot.
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3. Cuta11/2lengthodiameterCPVCrod.Locateaconvenientspot.Measurethe
diameteroftheexistingthrottlelinkage.Drillaholewiththemeasureddiameterlengthwise
throughtherod.Usingathinbladesaw,cuttherodinhalflengthwise.Usingabeltsander,
sandaflatsurfaceatleastwideontoonerodhalf.

4. Cutax11/4sleevearmfrom1/8CPVCsheet.Drilla7/64holeinoneendofthearm
aboutfromtheend.Usingadrillorcountersinktool,beveleachendoftheholeabout
1/16deep.Applyprimer,andthencement,tothematingsurfacesofthearmandsleeve
andjointheparts.Allowthepartstoairdryforatleast2hoursandthendresscutedgesof
allthrottlepartswithsandpaper.

5. ReferringtoFigure5,positiontheshaftofthe100Kthrottlepotentiometer(pot)atthe
midpointofitsrangeofrotation.Usingamarkingpen,markanalignmentlinebetweenthe
potshaftandbushingatthepointshowninFigure21.Usinga#41drillbit,drillaholein
theshaftatapointinlinewiththeshaftalignmentmark,and3/16infromtheshaftend.

6. Cuta6lengthof3/32stainlesssteelweldingrod.Temporarilyinstallthepotintothe3/8
holeinthemountingbracket.Slidetheweldingrodintotheshafthole.Aligntheshaftand
busingmarksandrotatethepotbodysothattherodpointsdirectlyupward(parallelwith
thefrontedgeofthebracket).Placeamarkatthepointwheretheantirotationpin
contactsthebracket.Removethepotandrodfromthebracket.AsshowninFigure21,cut
acurved3/32wideslotextendingfromeachsideofthemarkedpoint.Temporarily
installthepotontothebracketandcheckthattheantirotationpinfitsintotheslotand
doesnotbindintheslotasthepotbodyisrotated.Ifnecessary,andusingasmallfinetoo
file,filetheslotuntilthepotbodyrotatesfreely.Dresstheslotedgeswithsandpaper.
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Figure21:ThrottleAssemblyDetails
7. Attachthepottothebracketwiththefurnishednutandlockwasher.Temporarilyinstall
therodintotheshafthole.Rotatethepotbodytoaligntherodparallelwiththefrontedge
ofthebracketandfirmlytightenthemountingnut.Usingafile,squareoffbothendsofthe
rodandDeburrwithsandpaperorafinetoothfile.UsingMEKoracetoneandasoftclean
cloth,cleanthepotshaftandrod.FlushtheholeinshaftwithMEKoracetone.

8. MixasmallquantityofhighqualityepoxysuchasJBWELD.Usingaprecisioninstrument
suchasatoothpick,coattheshaftholewithathinlayerofepoxy.Applyathinlayerof
epoxytooneendoftherodandinsertitintotheshafthole,allowingittoextendabout
1/8beyondtheendofthehole.Formasmallfilletofepoxyaroundthejunctionoftherod
andshaftatbothsidesoftheshaft.Allowtheepoxytocureforatleast24hoursbefore
goingtostep33.

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9. ReferringtoFigure21,attachthesleeveandarmassemblytothethrottlelinkageusinga
smallhoseclampateachend.Locatethepotdirectlybelowthearmwiththerod
protrudingthroughtheholeinthearm.Positionthebracketforeoraftandsidewaysuntil
therodissquarewiththesleevearmandparallelwiththefrontedgeofthebracketwith
thethrottlelinkageisapproximatelyatitmidpointoftravel.Positionthebracketupor
downuntiltherodrotatesthroughanangleofapproximately60degreeseachsideof
centerasthethrottlelinkagemovesthroughitsfullrange.

10. Usingtwobolts,washers,andlocknuts,attachthebrackettotheenginestructure.
Positiontheboltintheslotatapproximatelytheslotmidpointtoallowthepottomoveup
ordownforpreciseadjustment.Loosentheboltsslightlyandpivotthebracketupand
down.Checkthattheboltdoesnotbindintheslotatanypoint.Ifnecessary,andusinga
smallfinetoothfile,filetheslotuntilthepotbodyrotatesfreely.Dresstheslotedgeswith
sandpaper.

11. Checkthatthepotroddoesnotbindinthearmholeasthethrottlelinkageismoved
throughitsfullrangeoftravel.Ifnecessarytoeliminatebinding,rotatethepotslightlyupor
downand/orslidethesleeveassemblyslightlyforeoraft.Firmlytightenthebracketbolts
andsleevehoseclamps.
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PreliminaryAssemblyandTesting

1. Installamalecrimponsnapconnectoroneachofthefourelectrodeandcoilpinsofthe
Generator.SecurelyinstalltheGeneratorintheenginecompartmentusingbolts,
washers,andlocknuts.BesuretheGeneratorislevelwiththevehicleframe.Ifthewater
pumpisinstalledinthetruck,gotostep3.Ifinstalledintheenginecompartment,goto
step2.

2. Cutalengthofsiliconebraidtubingtoconnectthewaterpumpoutlettothe3/8fittingon
thesideoftheGeneratorhousingnearthebottom.Allowsomeslackinthetubing.Goto
step3.

3. Ifthewaterpumphasaninternalcheckvalve,slidetwosmallhoseclampsontothewater
tubingandinstallontothe3/8barbfittingtonthesideoftheGeneratorhousingnearthe
bottom.Allowsomeslackinthetubingandfirmlytightentheclamps.Ifthepumpdoesnot
haveaninternalcheckvalve,installacheckvalveinthetubingafewinchesfromthebarb
bitinginthesideoftheGenerator.Allowsomeslackinthetubing.Usetwosmallhose
clampsoneachbarbfittingadtightenfirmly.Besuretoinstallthecheckvalvesothatthe
flowdirectionarrowonthevalvepointstowardtheGenerator.

4. Cuttwo(2)3lengthsofbraidtubingandattachthemtoeachendofacheckvalvewith
smallhoseclamps.Tightentheclampsfirmly.Usingtwosmallhoseclamps,attachavalve
hosetothecarbadapterontheenginewiththevalvearrowpointingtowardtheadapter.
Tightentheclampsfirmly.

5. Usingtwohoseclamps,attachtheflamearrestortothecheckvalvehose.Firmlytightenthe
clamps.Cutalengthofbraidtubingtoconnectthe3/8barbfittingontopoftheGenerator
totheflamearrestor.Slidefoursmallhoseclampsontothetubingandconnectthetubing
betweentheGeneratorandflamearrestor.Allowsomeslackinthetubingandfirmly
tightentheclamps.

Caution
Donotattempttosolderwiresdirectlytothefourgeneratorelectrodeandcoilpins.
Excessheatwilldamagetheepoxybond,possiblycausinggasand/orwaterleakage.
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6. Usingtwosmallhoseclamps,attachthepressuregaugetubingtothe1/8fittingontopof
theGenerator.Allowsomeslackinthetubingandfirmlytightentheclamps.

7. Cutfour(4)5footlengthsofhookupwireandstripofinsulationfromoneendofeach
wire.Twistthestrandedendsoftwowirestogetherandtrimtheendstoalengthof3/8.
CrimparingterminaltothesplicedwiresandattachtheterminaltotheHyTronicspower
switch.Repeattheprocedurefortheothertwowires.Mounttheswitchataconvenient
pointonthedash.Routeonepairofswitchwirestothevehiclepositive(+)powerbusthat
isalwayshot(thebatterysideofthebusasshowninFigure5).Cutthewirestolength
andstripofinsulationfromthewireends.Twistthewirestogether,trimto3/8,and
crimparingterminal(orotherappropriateconnector)tothewireends.Donotattachthe
terminal,orotherconnector,tothebusuntilinstructedtodosoinstep16.

8. Cuttwo(2)5footlengthsofhookupwireandsplicetogetherwitharingterminalaswas
doneinstep7.Locateaconvenientspotintheenginecompartmenttoattachthering
terminaltothevehiclechassis.Drilla3/32holeatthatlocationandattachtheterminal
followingtheprocedureofsteps11and15.

9. Routethetwowiresthroughthegrommetinstalledintheenginecompartmentfirewall.
Allowingslackinthewires,cutthewirestolengthtoreachthetwo12positionconnectors
oftheHyTronicsmodule.Trimofinsulationfromtheendofeachwireandconnecteach
wiretoanegative()buspositionofeitherofthe12positioninterlockingconnectors(see
step6).

10. Routetheremainingpairofswitchwirestotheconnectorsandcutthewirestolength,
allowingsomeslackinthewires.Connectthewirestotheconnectorsattwoofthebattery
positive(+)powerbuspositionsinthesamemanneraswasdoneinstep9.

11. Cutfour(4)wiresofappropriatelengthtoconnecttheGeneratorcoilandelectrodepinsto
theconnectors.Stripofinsulationfromeachwireandinstallafemalecrimponsnap
connectortoeachwire.AttachtheconnectorstotheGeneratorterminals.Routethewires
totheHyTronicsconnectorsandcutthewireendstoequallength.Stripofinsulation
fromeachwireendandconnecteachwiretotheappropriatepositionoftheHyTronics
connectors.

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12. ReferringtoFigure7,connectthetankwaterlevelandGeneratorwaterlevelswitchwires
totheappropriatepositionsoftheHyTronicsconnectors.Usingbuttconnectors,splice
hookupwirestotheswitchwiresasrequiredtoreachtheHyTronicsconnectors.

13. CuttwolengthsofhookupwiretoconnectthethrottlepottotheHyTronicsconnectors.
Stripofinsulationfromoneendofeachwireandsoldereachwiretothepotterminals.
Slidea1lengthofheatshrinktubingontoeachwireandoverthesolderedterminalsand
shrinkthetubing.

14. RoutethepotleadstotheHyTronicsconnectorsandcuttheirendstoequallength.Strip
ofinsulationfromtheendofeachwire.Connectonepotleadtoabatterypositive(+)
powerbusconnectorposition.Connecttheotherleadtotheconnectorpositionleadingto
the10Kresistorlead(seeFigure5).Rotatethepotshafttoitsmidpointposition.

15. Usinganohmmeter,verifythattheHyTronicspowerswitchisintheOFFposition.Ifnot,
placetheswitchintheOFFposition.

16. Connecttheswitchringterminal,orotherconnector,tothebatterypositive(+)powerbus.

17. DoublecheckallelectricalandelectronicconnectionsoftheWaterhybridsystem.Correct
anyconnectionerrorsasrequired.Connectthetwo12positioninterlockingconnectorsof
theHyTronicsmoduletothematchingsystemconnectors.Verifythatallsystemconnectors
areproperlyengaged.Ifstillinplace,removetheHyTronicsmoduleenclosurecover.
Caution
PowerwillbeappliedtotheWaterhybridsysteminstep18.Anyincorrectelectricalor
electronicconnectioncanleadtosystemorcomponentfailureand/ordamage.Besureto
doublecheckallelectricalandelectronicconnectionsbeforeapplyingpower.
Caution
Donotconnectthewaterpumpleadsnoraddwatertothetankuntilinstructedtodoso
instep1ofFinalAssemblyandTesting.
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18. Immediatelyafterapplyingpower,checkforthefollowingsystemresponsesintheorder
noted.Ifanyproblemexist,shutpowerOFFimmediately.
Smokeand/orelectricalsparkingdoesnotoccur.
Electricaloverheatingofanysystemcomponentdoesnotoccur.
Ontheindicatorpanel,checkthattheLEDsfunctionasfollows:
PWRON,PUMPON,andGENWATERLOWLEDsarelit.
TANKWATERLOWLEDisblinking.
Ontheindicatorpanel,checkthatthegaugelightsarelit.

PlacethewaterhybridsystempowerswitchtotheONposition.Verifythatnoproblem
exists.Ifaproblemexists,turnpowerOFFimmediately.

19. Ifnoproblemexists,gotostep20.Ifaproblemexists,troubleshoottolocateandrepair(or
replace)thefailedcomponent.Afterreplacementorrepairisaccomplished,gobacktostep
18.

20. Usingyourfingerssheatsensors,checkthatnosystemcomponentisoverheating.If
overheatinghasnotoccurred,gottostep21.Ifoverheatingoccurred,turnpowerOFFand
returntostep19.

21. Checkthatthevehiclegaspedalisinthefullidleposition.Ifnot,placeitistheidleposition.
Connectadigitalvoltmetertopin6ofamplifierLM741(refertoFigure5)andrecordthe
voltagelevelthere.Ifvoltageispresent,gotostep22.Ifnovoltageexists,acomponentis
defectiveandmustbereplaced.Afterreplacingthecomponent,gobacktostep18.

Note
Asthegaspedalismovedfromidletofullpower,thevoltagelevelatpin6ofamplifier
LM741shouldincreaseslightly.Expectanincreaseofapproximately1VDCto4VDC.
Caution
Donotattempttostarttheengineuntilinstructedtodoso.Thisisapreliminarytestto
verifybasicsystemfunctioning.Ifanyproblemexists,shutoffpowerimmediately.
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22. Movethegaspedaltofullpower.Recordthevoltagelevelatpin6.Comparethevoltage
withthatrecordedinstep21.Ifthevoltagelevelhasincreasedbyatleast1VDC,gotostep
23.Ifthevoltagelevelhasnotchangedatall,acomponentisdefectiveandmustbe
replaced.Afterreplacingthecomponent,gobacktostep21.

23. Rotatethe20KThrottleAdjustpotfromstoptostop.Verifythatvoltageatpin6variesas
thepotisrotated.Ifvoltagevaries,gotostep24.Ifvoltagedoesnotvary,acomponentis
defectiveandmustbereplaced.Afterreplacingthecomponent,repeatthisprocedure.

24. SettheThrottleAdjustpottoitsmidpointofrotation.

25. Connectanoscilloscopeleadtopin3oftheNE555controller.Verifythatasquarewave
pulseexistsandthatthepulsewidthratioincreasesasthegaspedalismovedfromfullidle
tofullpower.Ifasquarewaveexistsandthepulsewidthratioincreases,gotostep26.Ifa
pulsedoesnotexist,orthepulsewidthratiodoesnotincreaseasagaspedalismoved,a
componentisdefectiveandmustbereplaced.Afterreplacingthecomponent,repeatthis
procedure.

26. Rotatethe2Kpulsewidthadjusttrimpotfromstoptostop.Verifythatthepulsewidth
changesasthepotisrotated.Ifthepulsewidthchanges,gotostep27.Ifthepulsewidth
doesnotchange,acomponentisdefectiveandmustbereplaced.Afterreplacingthe
component,repeatthisprocedure.

27. Setthe2Ktrimpottoitsmidpointofrotations.

Note
AhighlystablesquarewavepulseiscreatedbytheNE555controller.Asthegaspedalis
movedtowardfullpower,theinputvoltagetothecontrollerfromtheLM741amplifier
increases,increasingthepulsewidthratioofthecontrollersquarewaveoutputatpin3.
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28. Connecttheoscilloscopeleadtopin3oftheNE555controller.Verifythatsquarewave
frequencychangesastheoscillator2Kpotisrotated.Ifthefrequencychanges,gotostep
29.Ifthefrequencydoesnotchange,acomponentisdefectiveandmustbereplaced.After
replacingthecomponent,repeatthisprocedure.

29. Settheoscillatorpottoitsmidpointofrotation.

30. Connectanoscilloscopeleadtopin8oftheNE555controller.RotatethePulseWidth
Adjustpotfromstoptostop.Verifythatthepulsewidthchangesasthepotisrotated.If
thepulsewidthchanges,gotostep31.Ifthepulsewidthdoesnotchange,acomponentis
defectiveandmustbereplaced.Afterreplacingthecomponent,repeatthisstep.

31. SetthePulseWidthAdjustpottoitsmidpointofrotation.

32. Connectadigitalvoltmeterleadtopin8oftheNE555controller.Rotatethe10KStrength
Adjustpotfromstoptostop.Verifythatthevoltagelevelchangesasthepotisrotated.If
thevoltagelevelchanges,gotostep33.Ifthevoltageleveldoesnotchange,acomponent
isdefectiveandmustbereplaced.Afterreplacingthecomponent,repeatthisstep.

33. SettheStrengthAdjustpottoitsmidpointofrotation.
Note
Thefrequencyofthesquarewavepulsefallsintherangeof15KHzto20KHz.Thetrigger
oscillatorcircuitprovidesvariablefrequencyinputpulsestotheNE55controllerin
responsetoadjustmenttothe2Ktrimpotanddipswitchsettings.
Note
ReferringtoFigure5,ThefrequencyofthecoilcircuitiscontrolledbytheCD4059ADivide
byNCounter,andfallsintherangeof15Hzto20Hz.Inputtothecounterisreceived
fromtheelectrodecircuit(Figure5).Whenthefrequencyoftheelectrodecircuitis
changed,thefrequencyofthecoilcircuitchangesaccordingly.Pulsewidthofthecoil
circuitisadjustedwiththe10KPulseWidthAdjustpot.
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34. ReferringtoFigure5,setthedipswitchesaccordingtooscillatorDC4069manufacturer
instructionstoobtainafrequencybetween15KHzand20KHz.

Connectanoscilloscopeorfrequencymeterleadtopin6ofoscillatorCD4069.Verifythat
theoscillatorfrequencyisbetween15KHzand20KHz.Ifthefrequencyisnotbetween15
KHzand20KHz,adjustthe2KFrequencyAdjustpottoobtainafrequencywithinthat
range.Ifthecorrectfrequencycannotbeobtained,thereisadefectivecomponent(most
likelyCD4069)intheoscillatorcircuit.Locateandreplacethedefectivecomponentand
returntothisstep.

35. ReferringtoFigure6,andusinganoscilloscopeorfrequencymeter,verifythatthe
frequencyofthepulseappearingatthecollectorofcomponent2N3055isfrom15Hzto20
Hz.Ifthefrequencyiswithinthatrange,gotostep37.Ifthefrequencyisnotwithinthat
range,gotostep36.

36. SettheDividebyNcounterforanNfactorof1,000accordingtothemanufacturers
instructions.Verifyafrequencyof15Hzto20Hzatthecollectorofcomponent2N3055.If
thefrequencyiswithinthatrange,gotostep37.Ifthefrequencyisnotwithinthatrange,a
componentisdefectiveandmustbereplaced.Afterreplacingthecomponent,gobackto
step35.

37. ShutpowerOFF.
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CylinderHeadTemperature

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

1. Ifthewaterpumpisinstalledinthetrunk,connectitspositive(+)powerleadtoabattery
positive(+)powerbusconnectorposition.Ifthepumpisinstalledintheengine
compartment,spliceahookupwiretitspositive(+)powerleawithabuttconnectorand
connectittoabatterypositive(+)powerbusconnectorposition.Inlikemanner,connect
thepumpnegative()powerleadtotheconnectorpositionleadingtothecollectorleadof
theE3055TswitchasshownonFigure7.

2. Fillthewaterhybridsystemtankwithwater.Checkthatnowaterleaksfromthetankor
anyofitstubingconnections.Ifnecessary,correctorrepairanyleaks.

3. Parkyourvehicleonalevelsurfacewithparkingbrakeengagedandtransmissioninneutral.
Liftthetrunklidifthewaterpumpisinstalledinthetrunk.Liftthehood,orengine
compartmentcover.

4. Followingmanufacturersinstructions,settheengineadapterforhydrogenoperation.

Caution
Closelymonitorthepressuregauge.ifgeneratorgaspressureexceeds70psi,shut
poweroffimmediately.Asasafetyprecaution,pressureexceeding85psiisvented
bythepressurereliefvalve.Donotdependonthereliefvalvetorelieveexcess
pressure.
Ifanysystemproblemexists,shutoffpowerimmediately.
Note
Yourvehicleisnowreadytorunwithsupplementalwaterforthefirsttimewiththe
Waterhybridsystem.Forinitialoperation,itsbestthattheengineisalreadywarmedup
tonormaloperatingtemperature.Ifnotuptothetemperature,driveonsolelygasoline
power for at least 15 minutes.
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5. ReferringtoFigure5andFigure6,settheThrottleAdjust,PulseWidthAdjust(onein
eachcircuit),FrequencyAdjust,andStrengthAdjustpotstotheirmidpointofrotation.
Immediatelyafterapplyingpower,checkforthepossibilityofanyofthefollowing
problems.Ifanyproblemexists,immediatelyshutpowerOFF.
Smokeand/orelectricalsparking.
Generatorpressureexceeds70PSI.
Electricaloverheatingofanysystemcomponent.
Gasand/orwaterleakagefromtheGenerator.
Waterleakagefromthetubes,fittings,andothercomponents.

TurnpowerON.WaitforGeneratorpressuretoreachatleast25PSI.IfGeneratorpressure
willnotreachatleast25PSI,gotostep7.Whenpressurereachesatleast25PSI,startthe
engine.Runtheengineatidlespeeduntilinstructedtodootherwise.Checkthatnoneof
theproblemsnotedaboveexists.Ifanyproblemexists,immediatelyshutpowerOFFandgo
tostep6.
CheckthefollowingIfconditions:
o Iftheenginestarts,gotostep26.
o Iftheenginewillnotstart,gotostep7.
o Ifanyproblemnotedatthebeginningofthisstepexists,gotostep6.

6. VerifythatpowerisOFF.Asystemcomponenthaseitherfailedorisdefective.Troubleshoot
tolocatethecomponent.Repairorreplacethecomponentandgobacktostep5.

7. ShutpowerOFF.Obtainasmallbucketorlargecontainer.OpentheGeneratordraincock
anddrainuntilempty.Closethedraincock.Ifnowaterdrained,gotostep8.Ifatleast
somewaterdrained,gotostep14.

8. TurnpowerON.Verifythatthewaterpumpruns.Ifthepumpruns,gotostep9.Ifthe
pumpdoesnotrun,turnpowerOFFandgotostep25.
Note
Atidle,gaspressureshouldbeintherangeofabout12psito28psi.ATfullpower,about
28psito62psi.
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9. Verifythatwaterisreachingthepumpinlet.Ifwaterreachestheinlet,gotostep13.If
waterdoesnotreachtheinlet,gotostep10.

10. Disconnectthetubingfromthepumpoutlet.Verifythatwaternowreachesthepumpinlet.
Ifwaterreachestheinlet,gotostep12.Ifwaterdoestoreachtheinlet,gotostep11.

11. TurnpowerOFF.Checkforrestrictionsonthetubingleadingtothepumpinlet.Ifa
restrictionislocated,repairasnecessary,reconnecttubing,andgobacktostep5.Ifno
restrictionexists,thepumpisdefectiveandmustberepairedorreplaced.Afterpump
repairorreplacement,reconnectthepumpandgobacktostep5.

12. VerifythatwaterisflowingfromthepumpoutletandturnpowerOFF.Ifwaterwasflowing,
thecheckvalveiseitherdefectiveorhasbeeninstalledbackward.Replacethecheckvalve
orreinstallitwiththeflowarrowpointingtowardstheGenerator,reconnecttubing,andgo
backtostep5.Ifwaterwasnotflowing,thepumpisdefectiveandmustberepairedor
replaced.Afterpumprepairorreplacement,reconnectthepumpandgobacktostep5.

13. Disconnectthetubingfromthepumpoutlet.Verifythatwaternowflowsfromthepump
outletandturnpowerOFF.Ifwaterwasflowing,thecheckvalveiseitherdefectiveorhas
beeninstalledbackwards.Replacethecheckvalveorreinstallitwiththearrowpointing
towardstheGeneratorandgobacktostep5.Ifwaterwasnotflowing,thepumpis
defectiveandmustberepairedorreplaced.Afterpumprepairorreplacement,reconnect
thepumpandgobacktostep5.

14. TurnpowerON.VerifythatnowaterispresentinthetubingleadingfromtheGeneratorto
theflamearrestor.TurnpowerOFF.Ifwaterwaspresent,gotostep15.Ifwaterwasnot
present,gotostep17.

15. RefertoFigure7.CuttheGeneratorwaterlevelswitchwireconnectedtotheHyTronics
positive(+)powerbuswithinabout6oftheGenerator.Stripfromeachendofthecut
lead.ConnectasohmmeterleadtothewireexitingtheGeneratorandtheotherleadto
vehicleground().Verifythattheohmmeterindicatesthattheswitchcontactsareopen.If
theswitchcontactsareopen,gotostep16.Iftheswitchcontactsareclosed,theswitch
sloshshieldhasbeenincorrectlyinstalled.Removethesloshshieldandreinstallit.Besure
theshieldisaccuratelycenteredaroundtheswitchfloat.Reconnecttheswitchwireswitha
buttconnectorandgobacktostep5.
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RunaCaronWater

16. Reconnecttheswitchwireswithabuttconnector.Adefectivecomponentexistsinthe
pumpcontrolcircuit.Replacethedefectivecomponentandgobacktostep5.

17. Verifythatthecheckvalveinthetubingleadingtotheengineisinstalledwiththeflow
arrowpointingtowardtheengine.Ifthecheckvalveisinstalledcorrectly,gotostep18.If
thecheckvalveisnotinstalledcorrectly,removeitfromthetubingandreinstallitcorrectly.
Gobacktostep5.

18. Setthewatercontaineronalevelsurface,markthewaterlevelonthesideofthe
container,anddisposeofwater.ClosetheGeneratordraincock.

19. DisconnectthegasoutlethosefromthetopoftheGenerator.TurnpowerON,waitforthe
waterpumptostoprunning,andshutpowerOFF.Openthedraincockanddrainwaterinto
thecontaineruntiltheGeneratorisempty.Closethedraincock.Checkthewaterleveland
disposeofwater.Ifthewaterlevelwashigherthanthelevelmarkedinstep18,gotostep
20.Ifthewaterlevelwasaboutthesame,gotostep26.

20. Reconnectthetubinganddisconnectthetubingfromthecarburetoradapter.Turnpower
ON,waitforthewaterpumptostoprunning,andshutpowerOFF.Openthedraincockand
drainwaterintothecontaineruntiltheGeneratorisempty.Closethedraincock.Checkthe
waterlevelanddisposeofwater.Ifthewaterlevelwashigherthanthelevelmarkedinstep
18,gotostep21.Ifthewaterlevelwasaboutthesame,gotostep22.

21. Theadaptor(oritsassociatedparts)iseitherdefectiveorrequiresadjustment.Following
themanufacturersinstructions,eitheradjusttheadapterorreturnittothemanufacturer
foradjustmentorrepair.Afteradjustmentorrepair,reconnectthetubingandgobackto
step5.

22. Reconnectthetubinganddisconnectthetubingbetweentheflamearrestorandcheck
valve.TurnpowerON,waitforthewaterpumptostoprunning,andshutpowerOFF.Open
thedraincockanddrainwaterintothecontaineruntiltheGeneratorisempty.Closethe
draincock.Checkthewaterlevelanddisposeofwater.Ifthewaterlevelwashigherthan
thelevelmarkedinstep18,gotostep23.Ifthewaterlevelwasaboutthesame,gotostep
24.

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RunaCaronWater

23. Thecheckvalveisdefective.Replacethevalve,reconnectthetubing,andgobacktostep5.

24. Theflamearrestorhasbeenconstructedincorrectly.Removetheflamearrestorfromthe
tubing,removeitsendfittings,anddisposeoftheflamearrestor.ReturntotheFlame
Arrestorprocedure.Followingtheinstructionsthere,constructanewflamearrestor.Allow
theCPVCcementtoairdryforatlest24hours.Applyathincoatingforpipejoint
compoundtothetappedthreadsintheendsoftheflamearrestorandfittings.Threadthe
fittingsintotheflamearrestorandtightenfirmly.Installthenewflamearrestorintothe
tubingandgobacktostep5.

25. TurnpowerOff.Themostlikelycandidateforpumpfailureisthepumpitself.Cutthepump
negative()buswireandcheckpumpoperationwhiledisconnectedfromtheHyTronics
module.Ifthepumpstilldoesnotrun,ordrawscurrentinexcessof15ampsduringstart
up,repairorreplaceitandreconnectthepumpwiresusingbuttconnectors.Alsocheckto
seeifthemainfusehasblown(refertoFigure5).Ifthefusehasblown,replaceitandgo
backtostep5.

Ifthepumpoperatesnormally,reconnectthewirewithabuttconnector.Checktoverify
thattheE30556Tswitch(refertoFigure7)hasnotfailedduetopumpcurrentoverload.If
theswitchhasfailed,replaceitwithaswitchofhighercurrentcapacityandgobacktostep
5.Iftheswitchhasnotfailed,cuttheGeneratorwaterlevelswitchwireconnectedtothe
HyTronicspositive(+)powerbuswithinabout6oftheGenerator.Stripfromeachend
ofthecutlead.ConnectanohmmeterleadtothewireexitingtheGeneratorandtheother
leadtovehicleground().Verifythattheohmmeterindicatesthattheswitchcontactsare
closed.Iftheswitchcontactsareclosed,eitherthepumpisdefective,apumpcircuit
componentisdefective(refertoFigure7),orwiringerrorsexist.Troubleshoottolocatethe
problemandrepairorreplaceasnecessary.Aftercorrectingtheproblem,gobacktostep5.

Iftheswitchcontactsareopen,theswitchsloshshieldhasbeenincorrectlyinstalled.
Removethesloshshieldandreinstallit.Besuretheshieldisaccuratelycenteredaroundthe
switchfloat.Reconnecttheswitchwireswithabuttconnectorandgobacktostep.

26. VerifythatnowaterispresentinthetubingleadingfromtheGeneratortotheflame
arrestor.Ifwaterispresent,turnpowerOFFandgobacktostep15.Ifwaterisnotpresent,
readthefollowingnotesbeforegoingtostep27.
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Herearesomegeneralguidelinesforgainingoptimalperformancebytheveryeffective
methodknownastweaking:
Atidle,Generatorpressureshouldbe12PSIto28PSI.
Atfullpower,Generatorpressureshouldbe28PSIto62PSI.
Foreachdriving(oridle)condition,besureCHTneverexceeds40degreesmorethanthe
valuerecordedinstep1.
BesureCHTneverexceeds400degrees.

27. Parkyourvehiclewiththeengineatidle,transmissioninneutral,andparkingbrakeset.
WaituntilGeneratorpressurestabilizesandgotostep30.

28. Driveyourvehicleat25MPHinresidentialareas.IftheFrequencyAdjustpotisrotated
CWtoincreaseGeneratorpressure,gotostep30.

IftheFrequencyAdjustpotisrotatedCCWtoincreaseGeneratorpressure,gotostep37.

29. Driveyourvehicleat60MPH(orfullpower)onasteepgrade.IftheFrequencyAdjustpot
isrotatedCWtoincreaseGeneratorpressure,gotostep30.

IftheFrequencyAdjustpotisrotatedCCWtoincreaseGeneratorpressure,gotostep37.

Note
Tweakingthewaterhybridsystemiseasier,safer,andfasterifanotherpersondoesthe
drivingwhileyoudothetweaking.
Note
Thewaterhybridsystemisdesignedtooperatewelloverawiderangeofdifferent
electronicsettingsandadjustment.Itistolerantofjustaboutanythingshortofgross
adjustmenterrors.However,sinceeachenginehasuniquerequirements,obtaining
optimalperformanceismostlyamatterofmakingsimpletrialanderroradjustment.
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30. ReferringtoFigure5,rotatetheFrequencyAdjusttrimpotfullycounterclockwise(CCW).
Slowlyrotateclockwise(CW).IfGeneratorpressurestartstoincreasebeforerotatingabout
90%oftotalrotation,gotostep31.Ifpressuredoesnotincrease,gotostep37.

31. RotateslowlyCWuntilpressurestopsincreasing.Rotateanadditional10degrees.Wait
untilpressurestabilizesandrecordpressure.SlowlyrotateCCWuntilpressurestartsto
drop.SlowlyrotateCWuntilpressureincreasestotherecordedvalue.Recordthatthe
FrequencyAdjustpotisrotatedCWtoincreasepressure.IfyourWaterhybridisbeing
tunedwhileidling,gotostep32.Ifyourvehicleisbeingtunedwhiledriving,gotostep43.

32. RotatethePulseWidthAdjusttrimpotfullCCW.SlowlyrotateCW.Ifpressurestartsto
increasebeforerotatingabout90%oftotalrotation,gotostep33.Ifpressuredoesnot
increase,gotostep39.

33. RotateslowlyCWuntilpressurestopsincreasing.Rotateanadditional10degrees.Wait
untilpressurestabilizesandrecordpressure.SlowlyrotateCCWuntilpressurestartsto
drop.SlowlyrotateCWuntilpressureincreasestotherecordedvalue.Recordthatthe
PulseWidthAdjustpotisrotatedCWtoincreasepressure.Gotostep34.

34. IfyouaretweakingyourWaterhybridwiththeengineatidle,gotostep35.Ifyouare
tweakingyourWaterhybridwhiledriving,gotostep36.

35. RefertoFigure21.Ifnecessary,adjustengineidlespeedbylooseninghoseclampsand
slidingthearmandsleeveassemblyeitherforeoraft.Tightenhoseclampsfirmly.If
pressureexceeds28PSI,gotostep41.Ifpressureis28PSIorless,gobacktostep28.

36. Ifpressureexceeds62PSI,gotostep42.Ifpressureis62PSIorless,gotostep44.

37. RotatetheFrequencyAdjustpotfullyCW.SlowlyrotateCCW.Ifpressurestartsto
increasebeforerotatingabout90%oftotalrotation,gotostep38.Ifpressuredoesnot
increase,rotatethepotCWtoitsmidpointandgobacktostep32.

38. RotateslowlyCCWuntilpressurestopsincreasing.Rotateanadditional10degrees.Wait
untilpressurestabilizesandrecordpressure.SlowlyrotateCWuntilpressurestartstodrop.
SlowlyrotateCCWuntilpressureincreasestotherecordedvalue.Recordthatthe
FrequencyAdjustpotisrotatedCCWtoincreasepressure.IfyourWaterhybridisbeing
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RunaCaronWater

tunedwhileidling,gobacktostep32.IfyourWaterhybridisbeingtunedwhiledriving,go
tostep43.

39. RotatethePulseWidthAdjustpotfullyCW.SlowlyrotateCCW.Ifpressurestartsto
increasebeforerotatingabout90%oftotalrotation,gotostep40.Ifpressuredoesnot
increase,rotatethepotCWtoitsmidpointandgobacktostep34.

40. RotateslowlyCCWuntilpressurestopsincreasing.Rotateanadditional10degrees.Wait
untilpressurestabilizesandrecordpressure.SlowlyrotateCWuntilpressurestartstodrop.
SlowlyrotateCCWuntilpressureincreasestotherecordedvalue.RecordthatthePulse
WidthAdjustpotisrotatedCCWtoincreasepressure.Gobacktostep34.

41. Usingamarkingpen,placeanalignmentmarkontheFrequencyAdjustandPulseWidth
Adjustpots.Determinetheamountofpressureexceeding28PSI.(Forexample,ifpressure
is32PSI,excesspressureis4PSI).Reducepressureto28PSIbyalternatelyrotatingeach
potinthecorrectdirectionafewdegreesatatime.Attempttodividetheexcesspressure
equallybetweenthetwopots.(Forexample:ifexcesspressureis4PSI,attempttoreduce
pressure2PSIwitheachpot).Gobacktostep28.

42. Usingamarkingpen,placeanalignmentmarkontheFrequencyAdjustandPulseWidth
Adjustpots.Determinetheamountofpressureexceeding62PSI.(Forexample,ifpressure
is70PSI,excesspressureis8PSI)Reducepressureto62PSIbyalternatelyrotatingeachpot
inthecorrectdirectionafewdegreesatatime.Attempttodividetheexcesspressure
equallybetweenthetwopots.(Forexample,ifexcesspressureis8PSI,attempttoreduce
pressure4PSIwitheachpot.)Gotostep44.

43. IfthePulseWidthAdjustpotisrotatedCWtoincreaseGeneratorpressure,gobackto
step32.

IfthePulseWidthAdjustpotisrotatedCCWtoincreaseGeneratorpressure,gobackto
step39.

44. IfyoujustcompletedWaterhybridtuningafterdriving25MPHinresidentialareas,goto
step45.IfyoujustcompletedWaterhybridtuningafterdriving60MPH(orfullpower)ona
steepgrade,gotostep67.

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RunaCaronWater

45. ReferringtoFigure21,besurethethrottlelinkagemovesthroughitsfullrangeoftravel
fromidletofullpowerwithoutbindingoftherodwithinthearm.Performtheprocedureof
step66beforeproceeding.

Driveyourvehicleat60MPH(orfullpower)onasteepgrade.Listencloselyforthesoundof
engineprecombustion(ping).Iftheenginepings,gotostep46.Iftheenginedoesnot
ping,gotostep56.

Optimalmixtureisachievedbyleaningparahydrogentothepointofcreatingpingandthen
slightlyricheninguntilpingdisappears.Youwillbesequentiallyfinetuningtwodifferent
pots.ItsveryimportanttocloselymonitorCHTwhileleaningtopreventexcessivelyhigh
CHT;refertoCHTrecordedinstep1fordriving60MPH(orfullpower)onasteepgrade.Be
sureCHTdoesnotexceedtherecordedvaluebymorethan40degrees.NeverallowCHTto
exceed400degrees.

46. ReferringtoFigure6,rotatethePulseWidthAdjustpotfullycounterclockwise(CCW).If
theenginepings,gotostep47.Iftheenginedoesnotping,gotostep53.

47. Rotatefullyclockwise(CW).Iftheenginepings,gotostep48.Iftheenginedoesnotping,
gotostep53.

48. SlowlyrotateCCW.IfCHTdecreases,continuerotatingCCWuntilCHTstopsdecreasing.Go
tostep49.IfCHTincreaseswhilerotatingCCW,rotatefullyCCW.SlowlyrotateCWuntil
CHTstopsdecreasing.Gotostep49.

49. RotatetheStrengthAdjustpotfullyCCW.Iftheenginepings,gotostep50.Iftheengine
doesnotping,gotostep54.
Note
Theproceduresofsteps45through65tunethecoilcircuittocreateanidealmixtureof
parahydrogen(createdbythecoil)andorthohydrogen(createdbytheelectrodes).Low
levelsofparahydrogen(toolean)canresultinexcessivelyhighcylinderheadtemperature
(CHT),acommoncauseofengineprecombustion(ping).Highlevelsofparahydrogen
(toorich)resultinlowCHT;coolingcombustion,decreasingefficiency,andpossibly
causingengineroughness.
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RunaCaronWater

50. RotatefullyCW.Iftheenginepings,rotateeachpottoitsmidpointandgotostep51.Ifthe
enginedoesnotping,gotostep55.

51. TurnpowerOFF.ReferringtoFigure6,thecoilcircuitisnotproducingenough
parahydrogen.Replacethe10Kresistorconnectingpin3ofcomponentNE555tothebase
ofcomponent2N3055witha10Kpot.Adjustthepotforabout9Kresistance.Gobackto
step45.Ifyoureachthisstepagain,adjustthepotforabout8Kandgobacktostep45.If
necessary,eachtimeyoureachthisstep,adjustthepotforabout1Klessandgobackto
step45.Ifthepotiseventuallyadjustedfor2Korless,acircuitcomponentisdefective.
Locateandreplacethedefectivecomponent.Adjustthepotfor10K.TurnpowerONandgo
backtostep45.

52. Slowlyrotateclockwise(CW)untilpingstarts.SlowlyrotateCCWuntilpingstopsand
continuetorotateCCWabout5moredegrees.IfCHTismorethan40degreeshigherthan
thevaluerecordedinstep1,continueslowlyrotatingCCWuntilCHTdecreasesto40
degreesabovetherecordedvalue.Gobacktostep29.

53. SlowlyrotateCCWuntilpingstarts.SlowlyrotateCWuntilpingstopsandcontinuetorotate
CWabout5moredegrees.IfCHTismorethan40degreeshigherthanthevaluerecordedin
step1,continueslowlyrotatingCWuntilCHTdecreasesto40degreesabovetherecorded
value.Gobacktostep29.]

54. SlowlyrotateCWuntilpingstarts.SlowlyrotateCCWuntilpingstopsandcontinuetorotate
CCWabout5moredegrees.IfCHTismorethan40degreeshigherthanthevaluerecorded
instep1,continueslowlyrotatingCCWuntilCHTdecreasesto40degreesabovethe
recordedvalue.Gobacktostep29.

55. SlowlyrotateCCWuntilpingstarts.SlowlyrotateCWuntilpingstopsandcontinuetorotate
CWabout5moredegrees.IfCHTismorethan40degreeshigherthanthevaluerecordedin
step1,continueslowlyrotatingCWuntilCHTdecreasesto40degreesabovetherecorded
value.Gobacktostep29.

56. ReferringtoFigure6,rotatethePulseWidthAdjustpotfullycounterclockwise(CCW).If
theenginepings,gotostep62.Iftheenginedoesnotping,gotostep57.

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RunaCaronWater

57. Rotatefullyclockwise(CW).Iftheenginepings,gotostep63.Iftheenginedoesnotping,
gotostep58.

58. SlowlyrotateCCW.IfCHTincreases,continuerotatingCCWuntilCHTstopsincreasing.Go
tostep59.IfCHTdecreaseswhilerotatingCCW,rotatefullyCCW.SlowlyrotateCWuntil
CHTstopsincreasing.Gotostep59.

59. RotatetheStrengthAdjustpotfullyCCW.Iftheenginepings,gotostep64.Iftheengine
doesnotping,gotostep60.

60. RotatefullyCW.Iftheenginepings,gotostep65.Iftheenginedoesnotping,rotateeach
pottoitsmidpointandgotostep61.

61. TurnpowerOFF.ReferringtoFigure6,thecoilcircuitisproducingexcessiveparahydrogen.
Replacethe10Kresistorconnectingpin3ofcomponentNE555tothebaseofcomponent
2N3055witha20Kpot.Adjustthepotforabout11Kresistance.Gobacktostep45.Ifyou
reachthisstepagain,adjustthepotforabout12Kresistanceandgobacktostep45.If
necessary,eachtimeyoureachthisstep,adjustthepotforabout1Kmoreresistanceand
gobacktostep45.Ifthepotiseventuallyadjustedforabout18Kresistanceormore,a
circuitcomponentisdefective.Locateandreplacethedefectivecomponent.Adjustthepot
for10K.TurnpowerONandgobacktostep45.

62. Slowlyrotateclockwise(CW)untilpingstopsandcontinuetorotateCWabout5more
degrees.IfCHTismorethan40degreeshigherthanthevaluerecordedinstep1,continue
slowlyrotatingCWuntilCHTdecreasesto40degreesabovetherecordedvalue.Gotostep
66.

63. SlowlyrotateCCWuntilpingstopsandcontinuetorotateCWabout5moredegrees.IfCHT
ismorethan40degreeshigherthanthevaluerecordedinstep1,continueslowlyrotating
CWuntilCHTdecreasesto40degreesabovetherecordedvalue.Gotostep66.

64. Slowlyrotateclockwise(CW)untilpingstopsandcontinuetorotateCWabout5more
degrees.IfCHTismorethan40degreeshigherthanthevaluerecordedinstep1,continue
slowlyrotatingCWuntilCHTdecreasesto40degreesabovetherecordedvalue.Gotostep
66.

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RunaCaronWater

65. SlowlyrotateCCWuntilpingstopsandcontinuetorotateCWabout5moredegrees.IfCHT
ismorethan40degreeshigherthanthevaluerecordedinstep1,continueslowlyrotating
CWuntilCHTdecreasesto40degreesabovetherecordedvalue.Gobacktostep29.

66. Precisethrottleadjustmentiseasyusingthespecialfeatureofthewaterhybridsystem
throttleassembly(RefertoFigure21).Herestherecommendedmethod:
a. Disengagethearmfromthethrottlerod.Rotatethepotshaftthroughthetotal
rangeofrotationrequiredtogofromidletofullpower.Usingaruler,measureand
recordthetotaldistancetraveledbythetipofthethrottlerodasthepotisrotated.
b. Rotatethepotshafttoitsmidpointofrotationandpositionthethrottlelinkageat
itsmidpointoftravel.Slidethearmontothethrottlerodandattachthearmand
sleeveontothethrottlelinkagewithhoseclamps.
c. Raiseorlowerthepotbyrotatingitsmountingbracketaboutboltuntilthrottle
linkagemovesthroughitsfullrangeoftravel.Ifnecessary,toobtainaddeddistance
betweenthepotandarm,thearmandsleeveassemblycanbeinvertedtoposition
thearmabovethelinkage.
d. Toassuresmoothoperationwithoutbinding,besurethethrottlerodissquared
withthesurfaceofthearmwhenthelinkageisatitsmidpointoftravel.Ifnecessary,
rotatethepotbodywithinthelimitsofthe3/32slotandrotatethesleeveabout
theaxisofthelinkageuntilthethrottlerodissquarewiththearm.
e. Adjustidletodesiredspeed.Operatethethrottlethroughseveralcyclestoverify
smoothoperationwithoutbinding.
f. Firmlytightenmountingbolts,hoseclamps,andthepotretainingnut.Withthe
throttleatidleposition,trimthethrottlerodtolengthsothatitprotrudesabout
abovethearm.SquaretherodendwithafileandDeburrwithsandpaper.Mixa
smallquantityofepoxy,suchasJBWELD,andapplyintothe3/32slotinthearea
oftheantirotationpintosecurethepotagainstrotation.

67. Whiledriving,verifythatthefourLEDsoperateasfollows:
GreenPWRONlightswhenpowerisONandisnotlitwhenpowerisOFF.
GreenPUMPONandyellowGENWATERLOWbothlightwhenthewaterpumpis
runningandarenotlitatallothertimes.
RedTANKWATERLOWisnotlitwhentankwaterlevelismorethanabout1/3full,and
blinkswhenwaterfallsbelowthatlevel.

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IfallfourLEDsoperateproperly,gotostep68.Ifnotoperatingproperly,refertoFigures5,
6and7andtroubleshoottolocatethedefectivecomponentorwiringerror.Repairor
replaceasnecessaryandgotostep68.

68. Congratulations,yourWaterhybridsystemisworkingperfectly!Afterabout25hoursof
driving,firmlytightenhoseclampsonallfittings.Happydriving!
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RunaCaronWater

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

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RunaCaronWater

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

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

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


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RunaCaronWater

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

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

GarrettsGauge
Heresacompletehydrogen/oxygensystem(refertoFigure22)allwrappedupinaneatlittle
package.Itwasaningeniousconcept,allthebasicelementsarethere.Butitwentthewayof
countlessotherinventorsdreams,doomedtofailonlybecauseoflackofvitaltechnology.
CharlesGarrettoriginallypatentedthisgadgetbackin1932(USPatent2,006,676),termingitan
ElectrolyticCarburetor.Heproposedchargingtheelectrodeswithastoragebattery,a
hopelesslyinadequatepowersource.
Leadplatesservedasthewatercapacitorandweaksulfuricacidaselectrolyte.Sincethewater
chamberhastobeelectricallynonconductive,itwasconstructedofbakelite(anearlydayform
ofplastic).Anelectricmotordroveagearwithanoffsetpinandlinkage,actuatingaswitchto
reversebatterypolaritytotheplates.(Mechanicallycreatingaverylowfrequency,lowvoltage,
pulse).Waterlevelwasmechanicallycontrolledbymeansofafloatandneedlevalveassembly
designedtorestrictthewaterinletport.
LookingattheGarrettGadget,wecanseethatthebasicconceptofawaterpoweredengineis
notanewideabyanymeans.Hewasontherighttrack:allheneededwas70moreyearsof
evolvingtechnology.
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Figure22:Garrett'sGadget

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Reference
StephenChambers,ApparatusforProducingOrthohydrogenand/orParahydrogenUSPatent
6,126,794andPrototypeVaporFuelSystem.
StanleyMeyer,MethodforProductionofaFuelGasUSPatent4,936,961.
CarlCella,AWaterFueledCarNexusMagazine,OctNov1996.
PeterLindemann,WhereintheWorldisAlltheFreeEnergy.
WilliamS.Power,TheHydrostar
GeorgeWiseman,TheGasSaverandHyCoSeries.
C.MichaelHoller,TheDromedaryNewsletterandSuperCarbTechniques.
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AThoughtorTwo
Duringcountlesshoursspentresearchingandcompilingmaterialforthisbook,Iwasconstantly
amazedattheingenuityofthehundredsofpatentedinventionsIhappenedupon.
Ihopeyouenjoythisbook.Itwasarealchallengeforme,butIhadagreattimeputtingit
together.DontforgettoletmeknowaboutyourexperienceswithyourownWater
hybridand,
Happy Driving!!