Congratulationsonpurchasing your veryown instructions for converting yourmotorvehicleintoawaterburninghybrid!Wefeelfortunateinbeinggiventheopportunity tobring thisvaluable informationyourway.Now,youtoocanbeinvolved in efforts to help utilize an incredible and priceless technology;harnessingwaterasasourceofenergyforyourvehicle!

Weencourageyou toalsoexploreourdownload section forFREEbonusesandsupplementalplansanddocumentstogiveyouthewidestvarietyofoptionsandresourcesavailableasyoubeginthewaterhybridconversionprocess.

Copyright2008ALLRIGHTSRESERVED

2 RunaCaronWater

LEGALDISCLAIMER:Thisbookhasbeeneditedandrevisedforcontentclarity,textreadability,andtechnologicalsuitabilityformodernfuelinjectionandoldercarburetorbasedvehicles,andisinspiredbytheoriginal,publicdomain,Hydrostarconversionplans.

Pleasebeadvised that thisconversionmaymeasurablymodify theexhaustcharacteristicsofyourvehicle. Therefore,westronglyadviseyoutocontactyour localornationalgoverningbodyorregulatorstoverifycompliancewithexistingemissionsrequirementsandstandards.Wealsoencourageyoutoverifythatyourvehiclepassesstateorgovernmentemissionstestsaftercompletingtheconversion.

Althoughtheseplansaredesignedtobe100%reversibleandtoworkwiththevastmajorityofmotorvehicles,youacknowledgeandunderstand thatbycarryingout theseplans,youareassuming responsibility for all potential risks and damages, both incidental andconsequential,relatingtoorresultingfromuseormisuseoftheseplans. Furthermore,youunderstand that there are inherent risks relating to any exploratory and pioneeringmechanicaltechnology.

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PrefaceThisbookpresentscompleteplansanddetaileddescriptionssufficienttobuildaworkablewaterhybridsystemforyourfuelinjectedorcarburetedmotorvehicle.Thetechnologycontainedhereinhasnotbeenpatentedandhasbeenplacedinthepublicdomain.

Thishasbeendoneinhopesofdiscouragingsuppressionofthisknowledgebut,evenmoreimportantly,toencouragetheopenflowofinformationrelatingtowaterhybrids.Weencourageyoutohelpyourfriendsandfamilywiththeirownconversionsonceyouhavegraspedtheprinciplesandtechniquesyourself.

WealsourgeyoutoexploretheFREEresourceswehaveprovidedtoyouonourdownloadpage,asthesemaygiveyouadditionalideas,particularlyifyouseekamorecustomsolutionorwanttoexploreadditionalwaystoaccomplishyourwaterhybridgoals.

Ifyoudecidetobecomeinvolvedwithyourownconversionproject,orjustwanttoofferadvise,anopinion,orconstructivecriticismonhowtoimprovetheseconcepts,pleasefeelfreetocontact,WilliamS.Power,thearchitectoftheoriginalplansthisbookisbasedon.

Hewilldohisbesttogetbackwithyou,buthecantguaranteeaninstantresponse.Sometimeshesawayfromtheofficeweeksatatime;testingandperfectingnewconcepts,orjustchasingdownparts.Hereswhereyoucanwritehim:

PowerProducts,7017NLinchfieldRd.#388,Glendale,AZ85307.

Havefunwithyourwaterhybridproject,andhappydriving!

WilliamS.Power

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ContentsPreface ............................................................................................................................................ 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,aswecannotguaranteethesesourceswillofferthebestpricesoralwaysbeavailable: .................. 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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BasicQuestionsandAnswersAgoodstartingpointforunderstandingthewaterhybridtechnologyistoansweravarietyoffrequentlyaskedquestionsyoumayhave.Sohereitgoes:

WhatistheWaterhybridsystem?Thesewaterhybridplansessentiallyconvertyourvehicletousewaterasasourceofsupplementaloreven(theoretically)primaryfuel.Theenginederivesfuelfromhydrogenandoxygen,generatedbytheelectrolysisofwater.Althoughpetroleumderivedfuelandanexternalelectricalgeneratingsystemisnottheoreticallyrequired,inmostcircumstancesitisapracticalnecessity.Theonlybyproductresultingfromthehydrogenandoxygencomponentsofcombustionwithintheengineiswatervapor.Therefore,emissionsareusuallycleaner,emittingfewerpollutingparticles.Inshort,theWaterhybridsystemisacleanersystem;onethatderivessupplementalfuelfromafreeandinexhaustibleresource;WATER!Ithastheuniqueadvantageofbeingabletoremovepollutantsfromtheairduringcombustion,andevenreducesthecarbonresiduewithintheengine(similartotheeffectofhigheroctanefuels).

TheWaterhybridsystemisprovenandhasbeenimplementedinvariousformsandvarietiesbyengineers,mechanics,andhobbyistsaroundtheworld.Itistheendresultofmanyyearsoftestingandexperimentationwithamultitudeofhydrogengeneratingsystemsbasedontheprincipleofelectrolysisofwater.

Waterelectrolysisissimplythebreakingdownofwaterintoitsbasichydrogenandoxygenatomsbypassinganelectroniccurrentthroughit.Youdontevenhavetoaddanelectrolyte(suchasacid)tothewatertoassureelectricalconductivity,asisrequiredwithabattery;plainoldtapwaterworksfinebecauseitcontainsnaturalelectrolytessuchasminerals,andalsomunicipaladditivessuchaschlorinewhichalsoaidinelectricalconductivity.Infact,electrolysisisinmanywayssimilartothereactionwhichoccurswithinyourvehiclesbattery.Electrolysisofwaterusnothingnew;itwasfirstaccomplishednearlyacenturyago.But,untiltechnologieslikethewaterhybridsystemweredeveloped,itrequiredahighvoltagepowersupplyandconsumedvastamountsofelectricalenergy.Itactuallyrequiredmuchmoreelectricalenergythantheenergyderivedfromthecombustionoftheresultinghydrogenandoxygen.Inotherwords,itwasanextremelyinefficientprocessthathadlimitedpracticaluse.

Thewaterhybridsystemisapracticalsolutiondevelopedforuseinfuelinjectedandcarburetedmotorvehicles.ThesecretofthewaterhybridsystemlieswithinitsHyTronicmodule.Itproducedrelativelylowvoltage,butuniquelyshapedelectronicpulsesofprecise

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frequencyandduration.TheoverallpowerconsumptionoftheHyTronicmoduleandtheentirewaterhybridsystemisfairlylow;actuallylowenoughtobeeasilypoweredbyyourvehiclesexcesselectricalandheatoutput,andwithenoughreservepowerlefttohelprunallyourvehiclesotherelectricaldevices.

Isthewaterhybridsystemaperpetualmotionmachine?Thewaterhybridsystemisnotaperpetualmotionmachine.Itisahighefficiency,waterfueled,electromechanicalsystemcapableofproducinghydrogenandoxygeninsufficientquantitytoimprovetheoverallfuelefficiencyofinternalcombustionengines.

Isthewaterhybridsystemsafe?Vehiclespoweredbythewaterhybridsystemareinherentlysaferthanhydrogenpoweredvehicleswhichrequirehydrogentanks.Insteadofhydrogentanks,thewaterhybridsystemextractscombustiblehydrogenasneededfromthewater,andthissteadyreleaseofhydrogenisburnedcontinuously,therebypreventinglargeraccumulationsofhydrogengas.

Whyisthewaterhybridsystemiscalledaconversionsystem?Thewaterhybridsystemiscalledaconversionsystembecauseitdoesntrequireremoval,modification,ordisablingofanyofyourvehiclesexistingsystems.Therefore,itallowsyoutorunyourvehicleoneither100%gasolinesystemsorthewaterhybridsystem.IntheunlikelyeventthatyourWaterhybridfails,youcaneasilyswitchbacktosolelyusinggasolinepower.But,youllsoonbegettingyourwaterhybridbackintoworkingorder.Onceyouvedrivenwiththewaterhybridsystemyoullneverbehappywithanythingelse!

Howwelldoesthewaterhybridsystemperform?Avehiclepoweredbythewaterhybridsystemistheoreticallycapableoftravelingfrom50to300milesoneachgallonofsupplementalwater,whileimprovingoverallfuelefficiencyupto45%.However,asistrueforanyengine,actualefficiencydependsonmanyfactorssuchas;drivinghabits,terrain,vehicleweightandshape,andabilitytotweakandoptimizethesystem.

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CantheWaterhybridsystembeusedinotherways?Yes,theWaterhybridsystemcanprovidefuelfromwaterforjustaboutanyhomeappliancerequiringnaturalgasorpropaneasasourceofheat;therebysavingvaluableanddiminishingnaturalresources.Spaceheatersandfurnacesareexcellentcandidates.Stovesandothercookingunitssuchasbarbecuegrillscanalsobefueledbythewaterhybridsystem.Suchapplicationsrequireaseparatepowersupplytoconvertyourhomes120voltACpowerintothe12voltDCpowerrequiredbythewaterhybridsystem.YoucanpurchaseaninexpensivepowersupplyatanyelectronicsstoresuchasRadioShack,orhavesomeonefamiliarwithelectronicsbuildoneforyousincethedesignisverysimple.Thecostofhomeelectricityusedbythewaterhybridsystemisinsignificant,probablylessthan$3permonthinmostcases.

IstheWaterhybridsystemdifficulttobuild?No,thewaterhybridsystemisrelativelyeasytoassembleandveryeasytoinstall,especiallycomparedwithotherconversionplansonthemarket.Nospecialtoolsarerequired.Theusualtoolandequipmentfoundinatypicalhomeworkshopwilldothejob.AssemblingtheHyTronicmoduletoachieveitsinherenthighlevelofreliabilityrequirescareandattentiontodetails,alongwithaverageelectronicsskills.Theonlyspecialpieceoftestequipmentyoumaywanttohaveaccesstouseisanoscilloscope.ItISNOTnecessary,butmayhelpyouobtainpeakefficiencyfromtheHyTronicsmodule.But,youshouldnthaveanyproblemgettinghelpfromalocalelectronicsguruifyoudonthaveanoscilloscope.MostfolksaresofascinatedbyunusualelectronicsystemsanddevicesthattheywouldalmostbewillingtopayyoufortheprivilegeoftweakingyourHyTronicsmodule!

CanIbuyareadytoinstallWaterhybridsystem?Rightnow,thisspecificwaterhybridsystemisnotbeingcommerciallymanufactured,buttherearevariousdistributorsaroundthecountrywhoofferDIY(Doityourself)partsorfullyassembledkitsutilizingsimilartechnologiesandprinciples.

PlanningisintheinitialstagesforproducingWaterhybridconversionkitsformostvehiclesandeventuallymanufacturingtheentiresystem,oratleastitsmajorcomponents.Werehopingtohavesomeprototypekitstestedsoonanddeliveryofreadytoinstallkitsshouldbeginsometimebeforetheendof2008.However,youllsoonbebuildingyourown!

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TheWaterhybridsystem!Figure18inthisbookdepictsthecoreoftheWaterhybridsystem.Whileeachcomponentisessentialtoitsoperation,theheartofthesystemistheHydrogen/OxygenGeneratorsinceitconvertswaterintocombustiblegaseousfueltopoweryourengine.Awatertankandpumpstoreandsupplywaterforthegenerator.SimpleelectronicsignalsfromtheHyTronicsModuleinitiateandsustainthecreationofhydrogenandoxygenwithintheGenerator.AnInDashGaugeandIndicatorAssemblyallowsyoutoaccuratelymonitorallaspectsoftheWaterhybridsystem.EverypartoftheWaterhybridsystemisruggedlydesigned,forreliableoperationandlonglife.

Letstakeacloserlookateachpartofthesystemtogetabasicunderstandingofhoweverythingworksandinteracts.

Hydrogen/OxygenGeneratorReferringtoFigure1onthefollowingpage,theHydrogen/OxygengeneratorhousingisaroundcylinderconstructedwithhightemperatureCPVCpipe,amaterialwidelyusedbythebuildingindustryinplumbingsystems.CPVCpipeisextremelydurableandtemperaturetolerant.Itsalsoaveryfriendlymaterialinthatitseasytoworkwithandcanbeusedtofabricateotherthingssuchasfurniture,planters,andhousingsforjustaboutanything.

TheGeneratorhousingcontainsabasiccoilandtwocylindricalelectrodes;usedtogeneratebothhydrogenandoxygen.Eachcanbemadefromavarietyofmaterialssuchasstainlesssteeland/orceramic,alsoverydurablematerials.However,twoatomicallydifferentformsofhydrogenareproducedwithintheGenerator.Mostofthegeneratedhydrogenisorthohydrogen,averypowerfulandfastburninggascreatedbythetwoelectrodes.Apreciselycontrolled,highfrequencyelectronicsignalfromtheHyTronicsModuleactivatesandcontrolstheelectrodes.

Theotherformofhydrogen,parahydrogen,iscreatedbythecoil,butinmuchlessquantitythanorthohydrogen.Apreciselycontrolled,verylowfrequencyelectronicsignalfromaseparatecircuitwithintheHyTronicsModuleactivatesandcontrolsthecoil.Parahydrogenisalesspowerfulandslowerburninggas,butisnecessarytopreventprecombustion(commonlycalledknocking)withinyourengine.Parahydrogenslowstheburningrateofthehydrogenmix,thusboostingitsoctanelevel.Suchprecisecontrolallowsyoutoexactlymatchyourenginesoctanerequirements.Toraiseoctanelevelsingasoline,specificadditivesmustbeused

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toslowitsburningrate.Atbestthisisaninexactsciencesinceitdependsupontryingtoaveragetheoctanerequirementsformillionsofengines.

Technicallyspeaking,theHydrogen/OxygenGeneratoritselfisanelectronicbasedunit.Thetwoelectrodesformabasiccapacitor,thousandsoftimeslargerthancapacitorsusedintypicalcircuits,withwateractingasitsdielectric.Theinnerelectrodeisnegativelycharged,andtheouterelectrodeispositivelycharged,bythehighfrequencyHyTronicssignal.Chemically,eachwatermolecule(H20)iscomposedoftwopositivelychargedatomsofhydrogenandonenegativelychargedatomofoxygen.Sinceoppositechargesattract,thepositivelychargedhydrogenatomsarepulledtowardtheinnerelectrode.But,atthesameinstant,thenegativelychargedoxygenatomsarepulledtowardtheouterelectrode.Thisactionalignseverywatermoleculebetweentheelectrodes,withtheendsofeachmoleculebeingpulledinoppositedirections.Inanutshell,thisisthehydrolysisprocesscentraltohydrogenextraction.

Figure1:Hydrogen/OxygenGenerator

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Forafewbriefmoments,onlymoreaccuratealignmentandincreasedpullingactionuponthewatermoleculesoccurs.But,theHyTronicssignalpulseskeepchargingthewatercapacitortohigherandhighervoltagelevels;actuallyseveralthousandvolts.Suddenlytheelectricalforcesbecomesogreatthatthewatermoleculesburstapart(scientistscallthisactiondisassociation)intotheirgaseousformsofhydrogenandoxygen.IfyouwereabletolookintotheGenerator,thisactionwouldbeobviousbecauseoftheformationofmillionsoftinyhydrogenandoxygengasbubbles.AslongastheHyTronicssignalisapplied,thewatercapacitorremainsfullycharged;continuouslycreatingorthohydrogenandoxygen.

Anotherelectroniccircuitisformedbythegeneratorcoil.Thisisaninductivecircuit,meaningitcreatesamagneticfieldasopposedtothechargedfieldcreatedbythewatercapacitor.TheverylowfrequencyHyTronicssignal(actuallyashortpulse)activatesthemagneticfieldofthecoil.Assoonasthepulsestops,themagneticfieldcollapses.Thiscreatesanevenstrongermagneticfield,butafieldofoppositepolarity.Thatishowaninductivecircuitworks,anactioncommonlycalledinductivekick.Eachpulseispreciselytimedsothatalmostimmediatelyafterthemagneticfieldreverses,anothershortpulsearrives.Onceagainthecoilischargedanditsmagneticfieldcollapses.Butnowthecontinuallyreversingmagneticfieldbecomesevenstrongerduetoaddedenergyofeachnewpulse.Eventually(actuallywithinjustafewseconds)thecoilreachesitsmaximummagneticstrength,calleditssaturationpoint.

Mostmoleculesareeffectedbymagneticfields.Thecoilsreversingmagneticfieldsvibratethewatermoleculessovigorouslythattheydisassociateintogaseousformsofparahydrogenandoxygen.Disassociationobservablyoccurs,asseenbythecreationofmillionsoftinyhydrogenandoxygengasbubblesaroundthecoil.

Atthispoint,wevecoveredtheconceptsneededtounderstandthebasicfunctioningofthegenerator.EveryothercomponentoftheWaterhybridsystemissimplyusedtopreciselycontroltheactionofthegenerator.ByvaryingthestrengthandfrequencyoftheHyTronicsignals,theratebywhichhydrogenandoxygenarecreatedcanbevariedtomatchenginerequirementsatanyparticularmoment.Waterissuppliedbythetankandpump,whilewaterlevelwithintheGeneratoriscontrolledbyalevelsensorandswitch.Forsafetypurposes,areliefvalveprotectsagainstexcesspressurebuildupwithinthegenerator.Separateportsareprovidedforattachinghosestoroutegastotheengineandtoanoptionalgaugetomonitorgaspressurebuildupwithinthegenerator.Adrainvalveisinstalledtoallowperiodicflushingofaccumulatedmineralsandcontaminants.ThebottomendcapisthreadedsothattheGeneratorcaneasilybeopenedupforinspectionorrepairandforoccasionalcleaningoftheelectrodesandcoil.Twopairsofstainlesssteel(copper,oranyconductivemetal)rodends

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protrudefromtheGeneratorbodytoprovideelectricalconnectionoftheelectrodesandcoiltotheHyTronicsModule.

AsshowninFigure18,thegeneratorgasoutputhoseconnectstoaflamearrestor,whichinturnconnectstopressurefittingsattachedtotheengine.TheflamearrestorprovidesprotectionagainstcombustionflashbackintotheGeneratorintheeventthatenginebackfiringoccurs.AswiththeGenerator,thearrestorbodyisconstructedfromCPVCpipe.Itsasimpleunitusingsmalldiameterpipe,endcapswithhosefittings,andstuffedwithstainlesssteelwool.Pressurefittingkitsarereadilyavailableatengineshops.Theyredesignedforconvertingenginestorunonpropane,sotheyareperfectlyadaptabletotheWaterhybridsystem.

Itisrecommendedtoinstallthegeneratorintheenginecompartment.Itcanbeinstalledjustaboutanywherespacepermitsinthevehicle,eveninthetrunk.But,everythingissimplifiedbyplacingitneartheenginesincethatminimizesroutingofhoses,gaugelines,andelectricalwiring.

WaterTankandPumpObviouslythisisthesimplestpartofthewholesystem.Justaboutanylargecontainerwillholdwater,butwellrecommendaparticulartankwhenwegetintotheconstructionphase.Thereareendlesswaystosaveafewbuckshereandtherewhilebuildingthewaterhybridsystem,butIdontrecommendcuttingcornersattheexpenseofquality.Theentiresystemisdesignedtobehighlyreliable,sowhytakeachanceonmessingthingsupbygoingcheap?Forexample,Irecommendinstallingawaterlevelsensorinthewatertanksoyoucaneasilymonitorwaterquantity,andsensorsarerelativelyexpensive.Otherwiseyoullhavetooccasionallycomparethemilesyouvedrivenversusthequantityofwater;withallthatbasedupontheMPGofwaterconsumption.Theotheralternativeistocheckthewaterlevelfairlyoften,butsomedayyoullrunthetankdryandwishyouhadspenttheextramoneyforasensorandindicator.

Itsbesttouseagenerouslysizedwatertankof.5to1.5gallonscapacity.ThetankIllberecommendingholdsover2gallonsandhastranslucentlevelmarkings,soitseasytoseehowmuchwaterremains.Theextraofcapacityofwatertakesupverylittlespace,butleavesagoodreserveforlessfrequentrefilling.Irecommendinstallinga6inchventtubeintothetankcaptopreventspillagefromsloshingwater.

Youllalsohavetodecideonpumplocation.IfyouusetheselfprimingpumpIrecommend,youcanmountitintheenginecompartment.Ifyoudontuseaselfprimingpump,youllhavetomountthepumpdirectlyontothetank,orcloseby,andatalevelnearthebottomofthetank.

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Also,ifyoudontuseaselfprimingpump,thewaterhosegoingfromthepumptotheHydrogen/OxygenGeneratorwillhavetobecapableofwithstandingatleast66PSIwaterpressure.Thatstheminimumrecommendedpumppressurecapacityrequiredtoovercomemaximumgaspressuresof65PSIwithinthegenerator,withanadditional1PSIneededtoactivatetheonewayvalveinstalledonthegeneratorhousing.Also,ifyoudontuseaselfprimer,youllhavetorunanextrapowerleadbacktothetrunk.Forthesakeofsimplicityandreliabilityaselfprimingpumpisthebestwaytogo.

InDashIndicators[OPTIONAL]ReferringtothefollowingFigure2;topermiteasymonitoringofWaterhybridfunctions,Irecommendtwogauges:Generatorpressure(GENPRESS)andenginecylinderheadtemperature(CHT).Ialsorecommendfourindicatorlights:GENWATERLOW,PUMPON,TANKWATERLOW,andPWRON.Thesecanbeinstalledintoyourvehicledash,ormountedinanearbyconsole.PLEASENOTE:TheInDashIndicatorsARENOTrequired,butareaniceperkifwithinyourbudgetandtechnicalexpertise.

Figure2:InDashIndicators

MonitoringtheGENPRESSandCHTgaugesallowsyoutodevelopafeelforhowthesystemrespondstovariousdrivingconditions.Theycanalsobeofhelpintweakingthesystemtoobtainmaximumperformanceandeconomy.

TheGENWATERLOWlightnormallyremainsunlit.Asfuel(water)isconsumed,theGeneratorwaterlevelgraduallydropsuntiltheGENWATERLOWlightilluminates.Atthatpointthewaterpumpshouldstartpumpingwater,illuminatingthePUMPONlight.WhenGeneratorwaterhas

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risenbacktoitsnormallevel,theGENWATERLOWlightshouldgobackout.Atthesametime,thepumpshouldstoprunning,turningoutthePUMPONlight.So,undernormaloperatingconditions,bothlightsshouldbeilluminatedatthesametime,andbothlightsshouldgooutatthesametime.Anyotherlightcombinationindicatesamalfunction.

TheTANKWATERLOWlightilluminateswhentankwaterleveldropstoits1/3fullpoint,indicatingthatyoushouldthinkaboutfillingthetankbeforelong.ThePWRON(PowerON)lightshouldlight,andremainlit,aslongastheWaterhybridsystemisoperatingnormally.ThesignalforthislightcomesfromtheHyTronicsModule.So,ifthePWRONlightevergoesout(exceptwhenthesystemisintentionallyturnedoff),orbecomesintermittent,theHyTronicsModuleismalfunctioning.

HyTronicsModuleTheHyTronicsModulecontainselectronicscircuitsforcontrollingand/orprovidingpowertoallthewaterhybridsystemselectricallyoperateddevices.Separatecircuitsexisttoperformeachofthefollowingfunctions:

ProvidepowertotheGeneratorelectrodesintheformofahighfrequencysignal,creatingorthohydrogenandoxygen.

ProvidepowertotheGeneratorcoilintheformofaverylowfrequencysignal,creatingparahydrogenandoxygen.

ControlpowertothewatertankpumpviasignalsreceivedfromtheGeneratorwaterlevelsensor.

Providebusingandterminalpointsfordistributingpowertosystemgauges,indicators,andsensors.

GeneratorElectrodeCircuitSchematicFigure5depictstheschematicdiagramfortheGeneratorelectrodecircuit.ItsoutputisasquarewavepulsewhichisappliedtothecylindricalelectrodesoftheHydrogen/OxygenGeneratorshowninfigure18.

ReferringtothefollowingFigure3,thissquarewavepulsehasanON:OFFratioof1:1.Thatis,thepulseisturnedONforaslongasitsturnedOFF.ThesquarewavepulseshowninthefollowingFigure4hasanON:OFFrationof3:1.Thatis,thepulseisturnedONforthreetimesaslongasitsturnedOFF.TheGeneratorelectrodecircuitofFigure5iscapableofvaryingitssquarewavepulseratiobetween1:1and10:1.

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Figure3:SquareWaveON:OFFRatio1:1

Figure4:SquareWaveON:OFFRATIO3:1

EachON:OFFpulsesequenceisreferredtoasacyclesinceeachnewpulsesequencekeepscyclingONandOFFinanidenticalway.Figure3showsthreecyclesofON:OFFpulsesequences.Ifthesecycleswerealltooccurwithinatimespanofonesecond,wewouldrefertothepulseashavingafrequencyof3cps(cyclespersecond).If127cycleswerealltooccurwithinatimespanofonesecond,wewouldrefertothepulseashavingafrequencyof127cps.Signalfrequenciesusedtobereferredtoinexactlythatmanner(3cps,127cps,etc.).However,becausesomefolkslovetochangethings,thetermsusedtodaywouldbe3Hzand127Hz.TheabbreviationHzisusedtohonorMr.Hertz,ascientistwhohelpedpioneerthetheoriesandpracticalusesofelectricalsignals.ThesymbolKisusedtodenoteunitsof1,000.Thus3,000Hzwouldbe3KHz,and127,000Hzwouldbe127KHz.ThesquarewavecreatedbythecircuitofFigure5canbevariedinfrequencyfromapproximately8KHzto260KHz.

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Figure5:GeneratorElectrodeCircuitSchematic

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ThesquarewavepulseratiodeterminestheamountofcurrentsenttotheGeneratorelectrodesbythecircuitoffigure5.Iftheratioislow(1:1),verylittlecurrentarrivesattheelectrodes.So,verylittlehydrogenandoxygenareproducedbytheGenerator.Iftheratioishigh(10:1),maximumcurrentreachestheelectrodesandtheGeneratorproducesmaximumgasvolume.Varyingvoltageinputfromapotentiometerconnectedviaa10Kresistortopin3ofcomponentLM741causesthecircuittovarythepulseratio,andthereforecontrolstheamountofgasesproduced.Thepotentiometershaftconnectstothevehiclethrottlelinkage,enablingcontrolofgasvolumeindirectresponsetovoltagechangescorrelatingwithrotationofthepotentiometershaftinrelationtothrottlepositioning.Atrimmingpotentiometerconnectspins2and6ofcomponentLM741,enablingpreciseadjustmentofthethrottleinputsignal.Asecondtrimmingpotentiometerconnectspins4and7ofcomponentNE555,enablingprecisepulsewidthadjustment.

TheelectrodepairsofeachGeneratorexhibitauniquefrequencyofelectricalresonanceatwhichoptimumgasvolumeiscreated.ThisfrequencyoftenvariesconsiderablyamongdifferentGenerators.Severalfactorsdetermineresonancefrequencysuchas:electrodesizeandshape,Generatorchambersizeandshape,spacingbetweenelectrodes,coilparametersandrelativepositioning,andpulseamplitude(voltagelevel).Atrimmingpotentiometerconnectedbetweenpins1and2ofcomponentCD4069allowstheprecisefrequencytobeobtained.Byselectingvariouscombinationsofdipswitchconnectionstoabankoffourcapacitors,pulsefrequencycanbevariedbetweenapproximately8KHzand260KHz.

GeneratorCoilCircuitSchematicThefollowingFigure6depictstheschematicdiagramforthegeneratorcoilcircuit.ItsoutputisasquarewavepulsewhichisappliedtothecoiloftheHydrogen/OxygenGeneratorshowninfigure18.

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Figure6:GeneratorCoilCircuitSchematic

TheGeneratorcoilcircuitcreatesapulsedsignalverymuchsimilartothatoftheelectrodecircuitoffigure5;but,productionofparahydrogenandoxygenbythecoilentailstotallydifferentoperatingparametersthandoesorthohydrogenandoxygenproductionbytheelectrodes.Optimumoperatingfrequencyforthecoilismuchlower,withintherangeofapproximately16Hzto25Hz.Coilfrequencydirectlycorrelatestotheoptimumoperatingfrequencyoftheelectrodecircuitsinceitsinputsignalisreceiveddirectlyfrompin3ofelectrodecircuitcomponentNE555.TheelectrodecircuitsignalisreceivedviatheDividebyNlogiccircuitwhichproducesoneoutputsignalinresponsetoaspecificnumberofinputsignals.Forexample,iftheoptimalfrequencyoftheelectrodecircuitis19KHzandtheDividebyNlogiccircuitcreatesoneoutputpulseforevery1,000inputpulses,theoutputfrequencyoftheDividebyNlogiccircuitwouldbe19Hz.Thatsignalisreceivedviapin2ofcomponentNE555,whichcreatestherequiredsquarewavepulses.Thosepulsesaresentviapin3tothebaseoftransistor2N3055,wheretheyareamplifiedandtransmittedtothecoil.

20 RunaCaronWater

Thevolumeofparahydrogenandoxygencreatedbythecoilcanbepreciselyregulatedbyadjustingthepulsewidthandamplitudetrimmerpotentiometersofitsassociatedcircuit.Parahydrogenactsasanoctanebooster.Therefore,thevolumerequireddependsentirelyupontheoperatingdemandsofyourengine.Sinceparahydrogencoolsthecombustionprocess,excessvolumetendstoreduceengineefficiency.Withthatinmind,thecoilcircuitshouldbeadjustedsuchthatonlyenoughparahydrogeniscreatedtopreventengineprecombustion(knocking).However,ifengineoperatingtemperatureisrunningonthehighside(asdeterminedbytheCHTgauge)increasingparahydrogenvolumeisaneffectivewaytolowerthetemperature.

InDashIndicatorsCircuitSchematicTheoptionalInDashIndicatorsCircuitschematicisdepictedbyfigure7.Twogaugesandfourlightemittingdiodes(LEDs)comprisetheInDashIndicatorsassembly.TheGeneratorpressure(GENPRESS)gaugeconnectsviaahosetoitsrespectivefittingontheGeneratoritself(refertofigure13).Thecylinderheadtemperature(CHT)gaugeelectricallyconnectstoasensorplacedunderanenginesparkplug.

WhentheGeneratorwaterlevelsensorisactivatedbylowwaterlevel,its12VDCsignalissenttopin2ofdetectorLM741viaa10Kresistor.Detectoroutputfrompin6triggersthebaseofpowertransistorE3055T,completingthecircuittoactivatethewaterpumpandilluminatethePUMPONLED.The12VDCsensorsignalalsoilluminatestheGENWATERLOWLED.WhenGeneratorwaterrisestoitsnormallevel,thelevelsensoropens;turningoffthepumpandbothLEDs.

Whenthetankwaterlevelsensorisactivatedbylowwaterlevel(at1/3tanklevel),its12VDCoutputsignalilluminatestheWATERLOWLED.Afterrefueling(addingwater),thelevelsensoropens,turningofftheLED.

21 RunaCaronWater

Figure7:InDashIndicatorsCircuitSchematic

WhentheWaterhybridsystemisturnedon,thePWRONLEDilluminates.TheGeneratorelectrodecircuit(Figure5)activatestheLED.FailureoftheLEDtoilluminateusuallyindicatesanelectrodecircuitmalfunction.

22 RunaCaronWater

LetsBuildthewaterhybridsystem!:GeneratorConstruction

ElectrodesSinceenginerequirementsdictatethevolumeofhydrogenandoxygengasesthatthegeneratormustcreate,andgasvolumeisvariable,Irecommendsizingitaslargeasispracticaltoallowreservecapacity.Maximumoutsidediameterof4.5isalreadydeterminedbytheconstructionmaterialusedfortheGeneratorhousing:4CPVCSchedule80pipe.Irecommendaminimumheightof10.Maximumheightdependsuponavailablespacewithintheenginecompartmentbut,forstructuralintegrity,limitheightto18.Carefullychecktheenginecompartmentofyourvehicletoensurethatadequatespaceexistsforgeneratorinstallation.Ifadequatespacedoesnotexisteitherlimitthegeneratorheight(butnotlessthan10),orlocatethegeneratorwithinthetrunk,orasfarforwardaspossibleunderthedash.

1. AfterdeterminingGeneratorheight,obtaina31/2(3.50)outsidediameterstainlesssteeltubewithwallthicknessof.040to.063andlength5shorterthanthedeterminedheightoftheGenerator.AstandardalloyofT304stainlesssteelisrecommendedfortheelectrodes.Thistubewillbeusedtoconstructtheouterelectrode.RefertotheGeneratorexplodedviewofFigure9asanaidtocorrectconstruction.

NOTE

Thefollowingsteps2through4willbeusedtodeterminetheoutsidediameterfortheinnerelectrode.Thisprocedurewillcreatea.045gapbetweentheinsidewalloftheouterelectrodeandtheoutsidewalloftheinnerelectrode.ThisvalueisanidealgapformaximumandmostefficientproductionofhydrogenandoxygengaseswiththeWaterhybridsystem.

Caution

Itmaybepossibletoobtain31/2outsidediameterstainlesssteeltubingwithawallthicknessof.040to.063andt304alloyatalocalshopthatmanufacturesexhaustand/ormufflersystems.Alltubedimensions,includingroundness,mustbeheldwithin.005throughoutitsentirelength.Donotuselowqualitytubing.Ifyoudo,theefficiencyofthewaterhybridsystemwillbeseverelydegraded.

23 RunaCaronWater

2. Multiplythewallthicknessoftheouterelectrodebyafactorof2andrecordtheresultasdimensionA.Forexample,ifthewallthicknessis.050,dimensionAwouldbe.100.

3. Addavalueof.090tothevalueofdimensionAandrecordtheresultasdimensionB.Forexample,ifdimensionAis.100,dimensionBwouldbe.190.

4. SubtractthevalueofrecordeddimensionBfrom3.50.RecordthisvalueasdimensionC.

Forexample,ifdimensionBis.190,dimensionCwouldbe3.31.

5. Toconstructtheinnerelectrode,obtainastainlesssteeltubewithanoutsidediameterequaltotherecordeddimensionC,withwallthicknessof.40to.063,T304alloy,andlengthequaltothatoftheouterelectrode.

6. ReferringtothefollowingFigure8,drilleight(8)holes,spacedat45degreeintervals,aroundthediameterofoneendoftheouterelectrodetube.Locatetheholecenters11/32fromthetubeedge.Clampalargediameterwooddowelorrodinavisetobackuptheelectrodewhiledrilling.Deburrtheholesafterdrilling.

NOTE

Forbestresults,drillingstainlesssteelrequiresacarbidetippeddrillbitandlightlubricatingoil.Takeyourtimedrillingsoasnottooverheattheelectrode.

NOTE

TheCAUTIONalsoappliestotheinnerelectrode.

24 RunaCaronWater

Figure8:ElectrodeDetails

7. Repeattheprocedureofstep6todrilleight(8)holesatthesamedistancefromtheendoftheinnerelectrodetube.

8. ReferringagaintoFigure8,drill1/8holesaroundtheendoftheouterelectrodeclosesttotheholes.Locatetheholecenters3/32fromthetubeedge,withholdcentersspacedat3/8intervalsaroundtheentirediameter.Deburrtheholesafterdrilling.

9. Repeattheprocedureofstep8todrill1/8holesaroundtheentirediameteroftheendof

theinnerelectrode.Deburrtheholesafterdrilling.Thoroughlycleanalloilresiduefrombothelectrodesusingasoftcleancloth,andMEKoracetoneasacleaningsolvent.

10. ReferringtoFigure8,cuttwo(2)3rodlengthsfrom3/32diameterbarestainlesssteelweldingrod,alloyT304.Usingafile,squareoffanddeburrtherodends.

NOTE

Barestainlesssteelweldingrod,T304alloy,canbeobtainedatanyweldingsupplystore.

25 RunaCaronWater

11. ReferringtoFigure8,solderoneoftherodstotheoutsidesurfaceoftheouterelectrode.Positiontherodparalleltothelengthoftheelectrodewith2protrudingpasttheendofthetube.Usesilverbearingsolderandfluxappropriateforsolderingstainlesssteel.

12. Repeattheprocedureofstep11tosoldertheotherrodtotheinsidesurfaceoftheinnerelectrode.

13. Aftertheelectrodeshavecooled,thoroughlyscrubthesolderjointswithwarmsoapywater

usingastiffbristlebrush.Thoroughlyrinsetheelectrodeswithwarmwateranddrywithasoftcleancloth.

NOTE

Silverbearingsolderandfluxcanbepurchasedatanylargehardwareorelectricalsupplystore.

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

AnylargeplumbingsupplyorplasticssuppliermaybeabletosupplyCPVCSchedule80pipe,fittings,andaccessoriesrequiredtoconstructthewaterhybridgenerator.IhighlyrecommendUnitedStatesPlasticCorporationasanexcellentsource;theyhavealwaysprovidedfriendlyanddependableservice.

MailOrders:UnitedStatesPlasticCorp1390NeubrechtRdLima,OH458013196PhoneOrders:18005379724(7:30am7pmEST,MonFri)FAXOrders:18008545498(24/7)TechnicalService:18008210349(8am5pmEST,MonFri)CustomerService:1+8007691157(8am6pmEST,MonFri)

Caution

Usecpvcpipe(schedule80)toconstructthegeneratorhousing.Donotusepvcpipe,orcpvcschedule40,sinceitwillnotwithstandhightemperatureorpressureaswell.

Donotusecpvcpipeofsizegreaterthan4:sinceitdoesnotofferanadequatesafetymarginagainstrupturewhensubjectedtohighpressureandtemperature.

Carefulattentiontocraftsmanshipanddetailduringgeneratorconstructionisessentialtoensuresafeandreliableoperation.

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,Irecommendpurchasinga12threadedpipenippleratherthanthreadapipeyourself.RefertotheGeneratorDetailsviewofFigure10asanaidtoconstruction.

2. Usingamiterboxortablesawtoassuresquareness,cutoffoneofthe12pipenipplethreadedends23/4fromtheend.Dressthecutedgeswithsandpaperorafinetoothfile.Gotostep8.

3. Usingamiterboxortablesawtoassuresquareness,cutthethreadedpipenipple51/2fromoneofitsthreadedends.Dressthecutedgeswithsandpaperorafinetoothroundfile.

Caution

Readdirectionsprintedontheprimerandcementcanlabelsforproperuseoftheproducts.Afterpriming,applycementassoonaspossible,toobtainsafeandreliablebonding.Donotlettheprimerdrybeforeapplyingcement.

Note

CPVC4Schedule80pipehasanoutsidediameterof4.5.

Iftheheightofthehousingwillbe10,asdeterminedduringtheprocedureatthebeginningoftheElectrodessection,followthedirectionsofstep2,thengotostep8.Iftheheightwillbegreaterthan10,gotostep3.

28 RunaCaronWater

4. Primetheoutsidematingsurfaceofthecutendofthe51/2pipenippleandoneoftheinsidematingsurfacesofthecoupling.Applyanevenlayerofcementtotheprimedsurfacesandassembletheparts.Allowthepartstoairdryforatleast10minutesbeforegoingtostep5.

5. Primetheoutsidematingsurfaceofthe12pipeandinsidematingsurfaceofthecouplingattachedtothepipenipple.Applyanevenlayerofcementtotheprimedsurfacesandassembletheparts.Allowthepartstoairdryforatleast30minutesbeforegoingtostep6.

6. Iftheheightofthehousingistobe18,gotostep8.Iftheheightistobelessthan18,go

tostep7.

7. Usingamiterboxortablesawtoassuresquareness,cutthepipeassemblyneartheunthreadedendtoformatotalpipelengthequaltolessthanthehousingheight.Dressthecutedgeswithsandpaperorafinetoothroundfile.

8. Measuretheinsidediameterofthethreadedendcap.Securelyclamp1/8thickCPVCsheet

toadrillpressbed.Drilladiameterholethroughthesheet.Usingaflycutter,cutadiskwiththemeasureddiameter.Checkthatthediskfitssnuglyintotheendcap.Ifloose,replacewithaslightlylargerdisk.Iftight,replacewithaslightlysmallerdisk.Besuretodrillaholdfirstifanewdiskiscut.Cutaseconddisktothecorrectdiameterwithcenterhole.

9. Applyprimer,andthencement,toonesurfaceofeachdiskandjointhediskstogether.

Alignthediskedgesandwipeexcesscementfromtheedges.Allowthediskstoairdryforanhourbeforegoingtostep10.

10. Referringtofigure9,beveltheedgesofthedisktofitthecurvedcontourofthebottomof

theendcap.Besuretheouteredgeofthediskmeasuresbetween1/32and1/16afterbeveling.

Caution

Theelectrodeswillbeattachedtothecontoureddisk.Formthecontouraccuratelytoassurestructuralintegrityofthewaterhybrid.

29 RunaCaronWater

Figure9:DiskContour

11. Lightlycoatthethreadsofthehousingendcap,andbottomedgeofthehousing,withpetroleumjelly.Applyprimertothematingsurfacesofthediskandendcap.Applycementtotheprimedareaoftheendcaponlyandinstallthedisk,seatingitfirmlyandevenly.Removeanycementthatoozesfrombetweenthepartswithcottonswabs.

12. Temporarilythreadtheendcapontothehousing,seatingitslowly,butfirmly.Waitabout15minutesforthecementtopartiallydryandthenremovetheendcap.

13. Repeattheprocedureoftheprecedingsteps8through10fortheunthreadedendcap.Theresnoneedtoapplypetroleumjellytoanyareasoftheunthreadedendcap.Applyprimertothematingsurfacesofthediskandendcap.Applycementtotheprimedareaoftheendcaponlyandinstallthedisk,seatingitfirmlyandevenly.Removeanycementthatoozesfrombetweenthepartswithcottonswabs.

Caution

Besuretomeasuretheinsidediameteroftheunthreadedendcapbeforecuttingdisks.

Caution

Theendcapwillbetemporarilythreadedontothehousingtoassureaccuratealignmentofthedisk.Donotuseexcessivecementwheninstallingthedisktopreventbondingofthehousingandendcapthreads.

Besurepetroleumjellycoatsonlytheendcapthreads.

30 RunaCaronWater

14. Sealtheholeinthethreadedendcapdiskwithelectricaltape.Usingastiffbristlebrushandwarmsoapywater,thoroughlycleanpetroleumjellyfromthethreadsandallotherareasoftheendcapandhousing.Rinseallpartswithwarmwater.

15. Repeatstep14,andthenwipethepartsdrywithasoftcleancloth.

16. Removetheelectricaltapefromthethreadedendcap.Allowtheendcapstoairdryforat

least8hoursbeforegoingtostep17.

17. Completelycovertheinsidesurfacesofbothendcapswithstripsofelectricaltape.Cutawaytapetoopenuptheholdineachdisk.

18. Purchaseahighquality,hightemperature,andwaterproofepoxycementtofilltheendcapcavities.IhighlyrecommendJBWELD,whichcanbepurchasedatanylargehardwareorautosupplystore.Itcomespackagedintwo2ouncetubes(onetuberesinandonetubehardener).Youwillprobablyneedatleastonepackagetofilleachendcap.IfyouhavequestionsaboutJBWELD,theycanbecontactedat:

JBWELDPOBox483SulphurSprings,TX75483Phone:19038857696TollFree:18005293530Fax:19038855911

Caution

Useonlyhighquality,hightemperatureandwaterproofepoxycementtofilltheendcapcavities.Usinganyothercementmayleadtoeventualfailureofthegenerator.

Note

Thecavityineachendcapwillbefilledwithepoxycement.Topreventtrappingairbubbles,thecapsmustremainlevelwhiletheepoxycures.Centeringandlevelingthecurvedcapsontheinnercoresoflargerollsoftapeworkwell.

31 RunaCaronWater

Figure10:GeneratorDetails

Note

Allepoxycementscurebychemicalreaction(afterthehardenerismixedwithresin).JBWELDremainspliableforabout30minutes.Theresnoneedtorushfillingtheendcapcavities,butbeawarethatoncethecementismixed,theresnostoppingitfromcuring.Ifyouhavetoremoveoradjustanythingafteritcures,youllneeddynamitetogetthingsapart.

Besuretomixequalamountsofresinandhardener(ifusingJBWELD).Theresinandhardeneraredifferentcolors;oneblackandonewhitetoavoidconfusion.Whenmixedproperly,youendupwithanicedarkgraycement.Ifyouaccidentallymixresinwithresin,orhardenerwithhardener,youendupwithnothingbutabigmess.

32 RunaCaronWater

19. Mixabouta4ouncebatchofepoxyinadisposablecontainersuchasasmallpapercup.Slowlyfillthecavity(toavoidtrappingairbubbles)tothetopoftheholeinoneoftheendcaps.Ifnecessary,mixmoreepoxy.

20. Repeatstep19tofilltheremainingendcapcavity.

21. Allowtheepoxytocureforatleast24hours.Removeallelectricaltapefromtheendcaps.Removeanyepoxyfromabovethetopoftheholeuntilflushwiththedisksurfacebygrinding,scraping,sanding,ordoingwhateverisrequired.

22. Measuretheinsidediameteroftheinnerelectrode.Recordthismeasurementasdimension

D.

23. Securelyclamp1/8thickCPVCsheettoadrillpressbed.Usingaflycutter,cutadiskwithdiameterequaltodimensionDfromthesheet.Checkthatthediskslideseasilyintotheendoftheinnerelectrodeoppositethesolderedrod,beingneitherloosenortight.Ifloose,replace3withaslightlylargerdisk.Iftight,replacewithaslightlysmallerdisk.

24. Subtractthevalueof.250fromtherecordeddimensionD.Recordthisnewvalueas

dimensionE.Forexample,ifdimensionDis3.21,dimensionEwouldbe2.96.

25. Securelyclamp1/8thickCPVCsheettothedrillpressbed.Usingaflycutter,cutanotherdiskwithdiameterequaltodimensionE.

Caution

Readdirectionsprintedontheprimerandcementcanlabelsforproperuseoftheproducts.Afterpriming,applycementassoonaspossible.Toobtainsafeandreliablebonding,donotlettheprimerdrybeforeapplyingcement.

Note

Besureyouhaveenoughepoxyonhandtototallyfilltheremainingcavity.Ifnot,purchasemorebeforestarting.Afterepoxycures,ithasverypooradhesionwithnewlymixedepoxy.

33 RunaCaronWater

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

27. Securelyclamp1/8CPVCsheettothedrillpressbed,centeringthecutteratleast3fromanyedgeofthesheet.Cuta31/2holeinthesheet.

28. Adjustthecuttertocutaringwithanoutsidediameterof315/16.

29. Checkthattheringslideseasilyontotheendoftheouterelectrodeoppositethesolderedrod,beingneitherloosenortight.Ifloose,replacewitharingofslightlysmallerinsidediameter.Iftight,replacewitharingofslightlylargerinsidediameter.

30. Repeattheprocedureofstep27tocuta35/8holdinto1/8thickCPVCsheet.

31. Repeatexactlytheprocedureofstep28.

32. Applytheprimer,andthencement,tooneoftheflatsurfacesofeachring.Jointherings,

aligningtheouteredges.Wipeanyexcesscementfromtheouteredges.Allowtheringstoairdryatleast30minutesbeforegoingtostep33.

33. Grindasmallnotchintotheinneredgeoftheringsjustlargeenoughtoallowtheringsto

clearthesolderedrodandsolderwhenslidontotherodendoftheouterelectrode.

Note

Theprocedureofstep34centerstheringswithinthethreadedendcap.Besurethewrappingtapedoesnotprotrudebelowtheedgeofthesmallerringatanypoint.Donotoverlaptapeendsifmoretapeisadded;simplybuttthetapeendsbeforecontinuingtowrap.

Note

Theprocedureofsteps27and28willbeusedtocutaflatringfromCPVCsheet.Donotunclampthesheetfromthedrillpressbeduntilstep28hasbeencompleted.

34 RunaCaronWater

34. Usingplasticelectricaltape,wraptheouteredgesoftheringsuntiltheyslideeasilyintothethreadedendcap.Iftheringsfitloosely,addmoretape.Iftheringsfittightly,removetape.

35. Applyprimertotheflatsurfaceofthesmallerring.Usingacottonswab,applyprimertotheflatsurfaceofthethreadedendcapcontactedbythesmallerring.Applyathin,evenlayerofcementtotheprimedsurfacesandinstalltheringassemblyintotheendcap.Allowthepartstoairdrybeforegoingtostep36.

Figure11:ThreadedEndCapDetails

Note

Theprocedureofstep36centersthediskscompletedinstep26withinthethreadedendcap.Besurethewrappingtapedoesnotprotrudebelowthesurfaceofthesmalldiskatanypoint.Donotoverlaptapeendsifmoretapeisadded;simplybuttthetapeendsbeforecontinuingtowrap.RefertoFigure11fordetailsrelatedtoinstallingthedisksintothethreadedendcap.

Note

RefertothefollowingFigure11fordetailsrelatedtoinstallingtheringsintothethreadedendcap.Applyprimeronlytotheflatsurfaceofthethreadedendcapcontactedbythesmallerring.Donotremovethetapeuntilinstructedtodoso.

35 RunaCaronWater

36. Usingplasticelectricaltape,wraptheedgeofthelargediskuntilthetapecreatesasnugfitwiththeinsideedgeoftheringassembly.

37. Applyprimertotheflatsurfaceofthesmalldiskandtheflatinsidesurfaceofthethreadedendcap.Applyanevenlayerofcementtotheprimedsurfacesandinstallthediskassemblyintotheendcap.Alignthediskswiththeirnotchoffsetatleastfromtheringnotch,asshowninFigure11.UsingalargeCclamp,lightlyclampthedisksandendcap.Allowthepartstoairdryatleast8hoursbeforegoingtostep38.

38. Removeallelectricaltapefromthethreadedendcapassembly.Scrapeawayanyexcesscementthatmayhaveoozedontotheflatinsidesurfaceoftheendcapinthoseareasthatwillcontactthebottomedgesoftheelectrodesandthreadedendofthehousing.

39. Drilla37/64holethroughthecenterofthethreadedendcapasshowninFigure11.

40. Temporarilyaligneachelectrodeandrodwithitsrespectiveholedrilledinstep39.Check

thateachelectrodeandrodcanbeinstalledintothethreadedendcapandseatedfirmlyonthecapsurface.Makeadjustmentsasnecessarytoachievecorrectseatingoftheelectrodes.Usingamarkingpen,markashortreferencelinenearthetopinsideoftheinnerelectrode.Markanothershortreferencelinenearthetopinsideoftheouterelectrode,aligningitwiththemarkontheinnerelectrode.Removetheelectrodesfromtheendcap.

Note

Threadswillbetappedlaterintotheholedrilledthroughthecenteroftheendcaptoattachthedraincock.

Usinga#41bit,drilltwoholesthroughthebottomofthethreadedendcapatthelocationsshowninFigure11.

Note

Besuretoalignthediskswiththeirnotchoffsetatleastfromtheringnotch,asshowninFigure11.

36 RunaCaronWater

41. Usingplasticelectricaltape,wrapthetopendoftheinnerelectrodeuntilitfitssnuglyintotheouterelectrode.Allowaboutofthetapetoprotrudeabovetheedgeoftheelectrodetofacilitateeasyremoval.Donotremovethetapeuntilinstructedtodoso.

42. Arrangeawaytosolidlysupportthethreadedendcapwhileinstallingtheelectrodesandwhiletheepoxycures(takesabout8hours).Centeringandlevelingthecurvedcaponthecurvedcapontheinnercoreofalargerolloftapeworkswell.

43. Onceagain,cleanthebottomendsoftheelectrodeswithMEKoracetoneusingasoftclean

cloth.

44. Sealthebottomsofthetwoholesintheendcapwithshortstripsofelectricaltapetopreventepoxyfromdrippingout.Thetapeswillbepushedasideastheelectroderodspokethrough,afterwhichthetapescanberemoved.

45. Mixupabouta2ouncebatchofepoxyinadisposablecontainersuchasasmallpapercup.

Filltheslotintheendcap(wheretheelectrodesareinstalled)allthewayaroundtoaboutitshalffulllevel.

46. Usingyourfinger,applyaverythin,butunbroken,coatofepoxycompletelyaroundthebottomedge(rodend)oftheouterelectrode.Formabandexte4ndingabouthighfromthebottomedge,coatingboththeinsideandoutsidesurfacesoftheelectrode.

Note

Besuretoinstalltheouterelectrodefirst.

Note

Theprocedureofstep41centerstheinnerelectrodewithintheouterelectrode.Donotoverlaptapeendsifmoretapeisadded;simplybuttthetapeendsbeforecontinuingtowrap.

37 RunaCaronWater

47. Installtheouterelectrodeintotheendcap.Astheelectrodestartstoentertheslot,loweritveryslowlysothattheepoxyhassufficienttimetoflowintothesmallholesdrilledaroundthebottomedgewithouttrappingairbubbles.Aftertheelectrodeisfirmlyseatedontotheendcapsurface,removethetapefromthebottomoftheendcap.

48. Applyathinfilmofpetroleumjellytothesurfaceofthetapewrappedaroundthetopoftheinnerelectrode.

49. Repeattheproceduresofsteps46through48toinstalltheinnerelectrodeintotheend

cap.Usethealignmentmarksonthetopsoftheelectrodesasanaidinlocatingtherodholdintheendcap.

50. Placeaboutfivepoundsofweightontopoftheelectrodestohelpkeepthemfirmlyseated

againsttheendcap.Foldingatowelortwointoseveralfoldsandplacingthemontopoftheelectrodes,withastackofhardcoverbooksontop,workswell.Thatmethoddistributestheweightevenly,whichcanotherwisebedifficultbecauseofthetapeprotrudingfromthetopoftheinnerelectrode.

51. Usingcottonswabs,removeanyexcessepoxyoozingfromtheeightholesaroundthe

bottomsoftheelectrodes.Ifnecessary,continuetodothisuntiltheepoxybeginstothicken(inabout3045minutes).Usinghouseholdtissuesordisposablerags,cleanepoxyfromtherodendsprotrudingthroughtheendcap,andfromthesurroundingsurfaceoftheendcap.

Caution

ALLOWTHEEPOXYTOCUREFORATLEAST24HOURSATTEMPERATURESOF70DEGREESORHIGHERBEFOREREMOVINGTHEELECTRODEWEIGHTSOROTHERWISEDISTRUBINGTHEELECTRODEASSEMBLY.FORLOWERTEMPERATURESALLOWEVENLONGERCURETIME.

Caution

Thesmallholesaroundthebottomedgesoftheelectrodeshelpsecuretheelectrodestotheendcapbecauseepoxyfillstheholes.Installtheelectrodesslowlyintotheendcapslotsoasnottotrapairbubbleswithintheholes.

38 RunaCaronWater

52. Removetheweightsfromtheelectrodeassemblyaftertheepoxyhascuredforatleast24hours,andremovethetapefromtheinnerelectrode.

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

39 RunaCaronWater

HousingAttachments1. Temporarilythreadtheelectrodeassemblyontothegeneratorhousing,tighteningitfirmly.

Supporttheentireassemblyontheinnercoreofalargerolloftapeaswasdoneintheprecedingstep42.

2. ReferringtothefollowingFigure12,fabricate3coilsupportbrackets(withtheindicateddimensions)from1/8thickCPVCsheet.

3. Usescrappiecesof1/8thickCPVCsheetasshimsbetweenthetopsoftheelectrodesandthebrackets.Applyprimer,andthencement,tothebracketsandtheinsidewallofthehousingat120degreeintervalsasshowninFigure11.Attachthebracketsandallowcementtoairdryforatleast30minutesbeforegoingtostep4.

Figure12:CoilMountingBrackets

4. Removetheelectrodeassemblyfromthehousing.

Note

Formostefficientoperation,thecoilmustbelocatedapproximatelyabovethetopsoftheelectrodes.Ashimisplacedbetweentheelectrodesandeachbrackettoachievecorrectclearance.Exercisecaretoavoidcementingshimstothebrackets.

40 RunaCaronWater

5. Cutfour11/2x6mountingbracketstripsfrom1/8thickCPVCsheet,asshownFigure13.Dresstheedgesofeachstripusingsandpaperorafinetoothfile.Formeachofthetwobracketsbyapplyingprimer,andthencement,tothematingsurfacesofeachoftwostripsandjoiningthemtogether.Aligntheedgesofeachstripandwipeexcesscementfromtheedges.

6. Cuta11/2wideringfromtheendofthecoupling.ReferringtoFigure14,andusingabandsander,sandthesideoftheringtoformaflatsurfaceapproximately11/4wide.Sandthesideoftheringatanotherpointtoformasimilarsurface.Cuteachoftwoflatsurfacesectionsfromtheringbycuttingatbothendsofeachflatsurface.AsshowninFigure14,thiswillformtwosectionsfromthering,eachwithflatoutsidesurfaces11/2byapproximately11/4.Dresstheedgesofeachsectionandroundthecornersslightlyusingsandpaperorafinetoothfile.

7. AsshowninFigure14,attachapipesectiontoeachofthetwobracketsattheirmidpoints,applyingprimertotheflatsurfaceofeachsectionanditsmatingsurfaceonthebracket,andthenapplyingcement.Besuretosquarethecurvedsurfaceofeachsectionwiththelengthofthebracket.

8. Makeadoublerbycuttingasection11/2widefromtheringasshowninFigure14.Dress

theedgesandroundthecornersslightlyusingsandpaperorafinetoothfile.

Note

MaterialfromaringcutfromthestraightcouplingwillbeusedtomakepartoftheGeneratorhousingbrackets.Itwillalsobeusedtomakeadoublertoincreasewallthicknessofthehousingwhereahosefittingisinstalled.

Note

BracketarrangementsformountingtheGeneratoraredictatedbytherequirementsofeachsysteminstallation.Figure13showsoneofthesimplestandmostcommonlyusedarrangements.Otherarrangementscanbeeasilyconstructedwith1/8CPVCsheet.

Bracketsthickareconstructedfromtwolayersof1/8thickCPVCsheet.

41 RunaCaronWater

Temporarilythreadtheendcapontothehousing,seatingitfirmly.ChooseapointanywherearoundthehousingasshowninFigure14,andmarkaspotupfromtheedgeoftheendcap.Removetheendcap.Applyprimer,andthencement,tothematingsurfacesofthedoublerandhousingandattachthedoublertothehousingwithitsloweredgeatthemarkedspot.Aligntheedgeparalleltothehousingbottomedge.Allowthecementtoairdryforatleast8hoursbeforegoingtostep9.

Figure13:HousingAttachmentDetails

9. Drilla37/64holethroughthecenterofthe11/2x11/2doublerandhousingwallasshowninFigure14.Besuretokeeptheholesquarewiththehousingwall.

10. Drillafastenerholeneartheendofeachbracket(totalof4holes)atthelocationsshowninFigure14.Slightlyroundthecornersofeachbracketusingsandpaperorafinetoothfile.

Note

Threadswilllaterbetappedintotheholetoinstallabarbedhosefittingtoconnecttothecheckvalve.

42 RunaCaronWater

11. PositionthebracketsasshowninFigure13,andclampthemtoaflatsurface.Checkthatthehousingseatsevenlyintothecurvedsectionofeachbracketwithnogapsbetweenthehousingandcurvedsection.Ifnecessary,loosentheclampstorepositionthebrackets.

Figure14:MoreHousingAttachmentDetails

12. Applyprimer,andthencement,tothematingsurfacesofthebracketsandhousing.Attachthehousingtothebrackets.Placesupportingblocksoneachsideofthehousingtokeepitfromrotatingorshiftingduringassembly.Waitatleast8hoursbeforelooseningtheclampsandmovingthehousingassembly.

Note

Thecheckvalvehoseattachestoabarbedfittingtobeinstalledlaterintotheholedrilledinstep9.Determinethedirectioninwhichyoupreferthefittingtopointinrelationtothemountingbrackets.Irecommendhavingthefittingpointdirectlyleft(asshowninFigure13)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,aswecannotguaranteethesesourceswillofferthebestpricesoralwaysbeavailable:CuttingToolSupply(CTS)340WGerriLaAddison,IL60101Phone:16305437171Fax:16305436906TheSpecialtyMfgCo(SMC)5858CentervilleRd.St.Paul,MN55127Phone:16516530599Fax:16526530989Generant1865Route23S,POBox768Butler,NJ07405Phone:1973886500Fax:19738384888StraVal21ColumbusAve.Garfield,NJ07026Phone:19733409258TollFree:1888380966Fax:19733409933FastenerHutInc.3781GlengarryWayNERoswell,GA300752615Phone:17704804617Fax:1+7709982721

44 RunaCaronWater

Norgren,c/oKipFluidControls,Inc72SpringLnFarmington,CT06032Phone,TollFree:18007225547Fax:18606774999

Directions:1. Usingamiterboxortablesawtoassuresquareness,cutaspacerapproximately2long

from1diameterCPVCrod.UsinganRsizedrillbit,drillaholethroughthecenteroftheroditsentirelength,andparalleltoitslength.AlsodrillaholdthroughthecenteroftheendcapwiththeRdrill,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.Besuretokeepthetapalignedparalleltothesidesofthespacerandtotaptothecorrectdepthof12threadsfromtheendofthetap.

3. Temporarilythreadthe35SSwaterlevelswitchintothetappedhole,seatingitfirmly.Inserttheswitchpowerleadsfrominsidetheendcapthroughthedrilledhole.Measureandrecordthedistancefromtheinsidesurfaceoftheendcap,asshowninFigure15.

4. Applyprimer,andthencement,totheuntappedendofthespaceranditsmatingsurface

insidetheendcap.Installthespacer,beingcertaintoaligntheholesinthespacerandendcap.Usingacottonswab,removeanyexcessgluethatmayhaveoozedintothehole.

Caution

BesuretouseonlyNPTFtaps.topreventpossiblewaterandgasleakage,donotuseNPTtaps.bothNPTandNPTFthreadswillsealproperlyinNPTFtappedholes.

Besuretotaptothecorrectdepthbyturningthetapuntilthe12ththreadfromthefrontofthetapfullyentersthehole.

Besuretoalwayskeepthetapalignedparalleltothesidesofthespacer.

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SloshShield1. Usingamiterboxortablesawtoassuresquareness,cuta31/16longsectionfrom11/2

CVPCpipe.Drillfour(4)1/8holesintothesidesofthepipe,spacedat90degreeintervalsandfromtheedgeasshowninFigure16.

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

3. Applyprimer,andthencement,tothematingsurfacesofthedrilleddiskandtheendofthepipeoppositethefourholes.Attachthedisktothepipe,beingsuretocenterthediskonthepipe.

Note

Sixofthesevendiskscutwillbeusedfortheflamearrestor.

47 RunaCaronWater

FlameArrestor1. Usingamiterboxortablesawtoassuresquareness,cuta3longsectionfrom11/2CVPC

pipe.

2. Usingaflycutter,cuta11/2diskfrom1/8thickCPVCsheet.Checkthatthediskfitssnuglyinsidethepipecutinstep1.Ifitdoesntfitsnugly,adjustthecutterasrequiredandcutatotaloffour(4)disks.

Figure16:SloshShieldDetails

3. Applyprimer,andthencement,tothesurfaceofeachoftwodisksandjointhediskstogether.Alignthediskedgesandwipeexcessgluefromtheedgeofthejoineddisks.Repeattheprocedureforthetworemainingdisks.

4. Inthesamemannerasinstep3,make2stacksof3diskseachfromthesixdiskscutinstep2oftheSloshShieldprocedure.Allowthediskstoairdryforatleastanhourandthendrilla37/64holethroughthecenterofeachofthetwostackeddisks.

5. ReferringtothefollowingFigure17,drillatotalofthirteen(13)1/8holesthrougheachof

thetwo11/2disksattheindicatedlocations.

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Figure17:FlameArrestorDetails

6. Applyprimertotheedgeofoneofthe11/2disksandabout3/8intoeitherrendofthe3pipebore.Applycementtotheprimedsurfacesandslidethediskintothepipebore,creatinga1/8gapbetweenthediskandthepipeendasshowninFigure17.Formasmallfilletofcementaroundtheouterjunctionofthediskandpipebore.Standthepipeonendfor5or10minutes(untilthecementwontrun)topreventpluggingtheholeswithcement.Ifanyholeisplugged,useashortlengthofstainlesssteelrodtoopenitbackup.Allowthecementtoairdryforaboutanhourbeforegoingtostep7.

7. Packtheinsideoftheflasharrestorwithcoarsestainlesssteelwool.Repeattheprocedureofstep6toinstalltheremaining11/2disk.

Note

Stainlesssteelwoolisavailableatsomelargesupermarkets,oryoucanpurchaseitfromthefollowingsource:

JWP2575WLemoyneMelrosePark,IL60160TollFree:18007329336FAX:170834580810

49 RunaCaronWater

8. ReferringtoFigure15,drilltwo37/64holesthroughthetopoftheunthreadedendcap,eachlocated13/4fromthecenterholeinthecap.Besuretokeepthedrillbitsquaredwiththecurvedoutersurfaceoftheendcap.UsingandRsizebit,drillaholethroughthetopoftheendcap13/4fromthecenterholeinthecapasshowninFigure15.

9. Tap3/818threadsinto37/64holesatthefollowinglocations: Twoholesontopofunthreadedendcap. Oneholeonbottomofthreadedendcap.

Note

Besuretokeepthetapsalignedsquarelywiththesurfacearoundtheholes.Taptothecorrectdepthof12threadsfromtheendofeachtap.

Note

Besurethetwostacksofthreedisksjoinedintheprecedingstep4haveairdriedforatleast24hours.

Whendrillingholesinthefollowingstep8,besuretokeepthedrillbitssquaredwiththecurvedoutersurfaceoftheunthreadedendcap.ThisplacestheaxisofeachofthethreeholesatanangletotheaxisofthecenterholeasshownFigure15.

Caution

BesuretouseonlyNPTFtaps.topreventpossiblewaterandgasleakage.donotuseNPTtaps.bothNPTandNPTFthreadswillsealproperlyinNPTFtappedholes.

Besuretotaptothecorrectdepthbyturningthetapuntilthe12ththreadfromthefrontofthetapfullyentersthehole.

Besuretoalwayskeepthetapalignedsquarelywiththesurfacearoundthedrilledhole.

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Oneholeindoubleronhousingwall. Oneholeineachoftwoflamearrestorendcaps.

10. Tap1/827threadsintotheRsizeholeclosesttotheedgeontopoftheunthreadedend

cap.

11. Usinga3/818tap,tapthreadsintothe37/64holeineachofthetwostacksofthreedisksjoinedintheprecedingstep4.Applyprimer,andthencement,tothematingsurfacesofoneofthestacksofdisksandthe3flamearrestorpipe.Attachthediskstothepipe,beingsurethetappedendoftheholefacesoutward.Repeattheprocedurefortheremainingstackofdisks.

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WaterLevelSwitchTest

1. Connecttheohmmeterleadstotheswitchpowerleads.Suspendtheswitchfromitspowerleadsandverifythattheohmmeterindicatesclosedswitchcontacts.Ifthecontactsarenotclosed,gotostep3.

2. Slowlyslidetheswitchfloatupward.Verifythatitscontactsopenatapproximatelythemidpointoffloattravel.Ifthecontactsopenproperly,gotostep4.Ifthecontactsdonotopenproperly,theswitchisdefectiveandmustbereplaced.

3. Usingamarkingpen,markasmalldotontopoftheswitchfloat.

Note

TheswitchprobablyhasNO(normallyopen)contactconfiguration.InvertingthefloatchangesittotherequiredNCconfiguration.

Note

Thewaterlevelswitchcontainsveryhighqualitymagneticreedcontacts.Itwillreliablyoperatethroughmillionsofcycleswhenconnectedtoaproperlydesignedelectroniccircuit.

ThewaterlevelswitchisusuallysuppliedwithNC(normallyclosed)contactconfiguration.Step1verifiestheNCconfiguration.

Caution

Neverattempttocontrolpowertoanyelectricaldevicedirectlythroughthewaterlevelswitch.Doingsowilldamageordestroytheswitch.

Note

Itisimportanttoverifycorrectoperationofthewaterlevelswitchbeforeinstallingitssloshshield.

52 RunaCaronWater

Carefullyremovethefloatretainingclipatthebottomofthecentertube.Removethefloat,invertitandreinstall.Reinstalltheretainingclip.Verifythatthedotonthefloatisnowatthebottomandrepeattheprocedureoftheprecedingsteps1and2.

4. Usingacountersinktool,orlargedrillbit,formasmallbevelintheouterendofthecenterholeintheunthreadedendcapthroughwhichtheswitchleadspass.

5. Applyalightcoatingofpipejointcompoundtothethreadsoftheswitchandmountingspaceraccordingtodirectionsontheproductlabel.Inserttheswitchpowerleadsthroughthespacerholeandthreadtheswitchintoplace,seatingitfirmly.

6. Obtainatransparentcontainer(suchasalargeglassjar)withanoutsidediameterofapproximately21/2to33/4andinsidedepthofatleast31/2.Placetheunthreadedendcapontopofthecontainerwiththeswitchinside.Besurethebottomsurfaceoftheendcapseatsevenlyontopofthecontainer.Positiontheendcapsothatatleastoneofthelargetappedholesprojectsinsidethecontainerandtheswitchfloatisatleastawayfromthecontainerwall.

Note

Thefollowingstepsareusedtoverifycorrectswitchoperationinresponsetowaterlevelchanges.

Caution

Donotapplyexcessivetorquetothewaterlevelswitchthreadswhileinstlalingtheswitchintoitsmountingspacer.Excessivetorquecandamagethespacerthreads,causingwaterand/orgasleakage,andpossiblesystemfailure.

Note

Asanaddedprecautionagainstpossiblewaterand/orgasleakage,IrecommendusingpipejointcompoundonallthreadedGeneratorhousingcomponents.

53 RunaCaronWater

7. Connecttheohmmeterleadstotheswitchleads.Checkthattheswitchcontactsareclosed.Veryslowlypourwaterthroughthelargetappedholeuntiltheswitchcontactsjustopen,andremainopen.Ifthecontactscloseagain,addaslightamountofwaterandwaitseveralsecondsbeforecheckingagain.Keeprepeatingthisprocessuntiltheswitchremainsopen.Checkthatthewaterlevelisatleast2fromthetopedgeofthejar.Ifthewaterlevelislessthan2fromthetop,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:NationalMagneticsGroup1210WinDr.Bethlehem,PA180177061Phone:16108677600FAX:16108670200MWSWireIndustries31200CedarValleyDr.WestlakeVillage,CA91362Phone:18189918553Fax:18187060911ActonTechnologies100ThompsonSt.POBox726Pittston,PA18640Phone:15706540612Fax:15706542810RadioShack(Nationwidestores)

55 RunaCaronWater

Directions:Afterthecoiliscompleted,itshouldbecoatedwithafewthinlayersofCPVCcement.Thatwayyouendupwithsomethingthatwilllastforever,ispracticallybombproof,andiseasytosolidlyattachinsidethehousingwithCPVCcement.But,gettinganythingtosticktoTeflontakesspecialchemicaletching(thatswhyTefloncookwareissopopular).Itscommerciallydonebyetchingwithsomeprettynastystuff.Severalcompaniesspecializeintheprocess,butyoudontwanttoknowthecost.Asafeandeasyetchingprocessthatcanbedoneathome,yetgivesgreatresults,hasrecentlybeendevelopedusingaproductcalledFluoroEtch.YousimplywarmFluoroEtchtoabout130degrees,sloshthecoilaroundinitforaboutaminute,sloshinisopropylormethylalcohol(sadly,thekindsyoucantdrink)foraminuteorso,washinwarmsoapywater,rinsewithwarmwater,andletairdry.Afterdoingthat,justaboutanythingwillsticktotheTefloncoatedcoilwire.Imtellingyou

Note

Thewaterhybridcoilishandwoundaroundaferritetoroidcorewithinsulated,hightemperaturecopperwire.Closeattentiontodetailandcraftsmanshipisessentialtobuildinganefficientandreliablecoil.Thereareliterallymillionsofdifferentcoilconfigurationsinexistence.Itsagreatareaforexperimentingsincecoildesignisasmuchartasitisscience.Believeitornot,theresactuallyanorganizationdedicatedtothecraft,theInternationalCoilWindingAssociation,basedinEngland.

Beforewarnedthatwindinganycoil,especiallyatoroidcoil,isatediousaffair,butIlldomybesttomakethejobaseasyaspossible.Thecoiliscreatedfrom2,000turnsofinsulatedcopperwirewrappedaroundacircularmagneticallysensitivecore.Thatmeansyouhavetodrageachwirewrapthroughthetoriodcorejustasmanytimes.

Tefloninsulatedcoppermagnetwireistheonlywaytogo.Ithandlesheatextremesverywellandisimpervioustojustaboutanythingyoucanthrowatit.Itisntcheap,butwellworththeinvestment.

CustomorderitfromMWSWireIndustries.Theycarryover25,000differentmagnetandspecialtyapplicationwires.BesuretoorderDoubleBuild(extraheavy)insulation,23AWG.Youllneedabout500to550feet,soitsprobablybesttoorder550feet.

56 RunaCaronWater

allthissothatwhenyoucallthenicefolksatActonTechnologiesyoullsoundknowledgeableenoughthattheywonthesitatesellingyouFluoroEtch.

1. Irecommendcuttingthemagnetwireintofour(4)100lengthsandone(1)150length.Otherwise,youhavetodrag550ofwirethroughthecore2,000times.Usingmath,thatworksouttojustover104milesofwiredragging(averagedover550feet),oronesorearmandatangledmess!Byworkingwith100and150lengths,youhavetomakefoursoldersplicestothewire,butyoucutyourwiredraggingdowntolessthan22miles.Youcouldevengowitheleven(11)50lengths;cuttingitto91/2milesand10soldersplices.Or,carriedtotheextreme,550onefootlengthscutsittolessthanmile(1,001feet),butyouhavetomake549soldersplices!Donttryshortcuttingthingsbywrappingthewirearoundthecoreseveraltimesandpullingtherestofthewireonthrough.Thecontinualbendingandstraighteningwilldestroythewirelongbeforeyoureachitsend.Amodifiedversionofthatmethodworks,buttakesafairamountofskillandexperiencetomaster(orrequiresspecialequipment).

57 RunaCaronWater

Figure18:TheIncredibleWaterhybridsystem!

Forminga3.5ODx2IDx.50toroidcoilfrom23AWGwirerequiresabout250turnsofwireperwrappedlayer.Sincethecoilbuildsinsizeasitswrapped,eachwrapusesanaverageofabout3ofwire.So,each100wireprovidesabout400wraps,orslightlyover11/2layers.Therefore,four(4)100footlengthsandone(1)150footlengthwillbuildan8layercoilofatleast2,000turns.

58 RunaCaronWater

2. ReferringtoFigure19,slipa1lengthofsmallheatshrinktubingabout4ontothemagnetwireandapplyheattoshrinkitinplace.Ifyouarerighthanded,youllprobablychoosetowrapthecoilinaclockwisedirection,holdingthecorewithyourlefthand.Inthatcase,laytheshrinktubingontopofthecore,angledofftotheleftatabout30degreesfromstraightoutasshown.Startthefirstwirewrapoverthetubingataboutitsmidpoint.Thiswillbethestartoflayer#1fortheinnercore.Besuretokeepthewirewrapstightsagainsteachotherontheinsideedgeofthecore,withnooverlapping.Keeptensiononthewire,withthewirealwayspointingstraightoutfromthecore.Precisewirepositioninghaslittletonoeffectonoverallcoilperformance.But,thefirstwrapdictatesthewirepositionsofeachsubsequentwrapsinceeachwirewillfallintothedepressionformedbetweenthetwowiresoftheprecedingwrap.Inshort,ifyoudoasloppyjobonthefirstlayer,youllendupwithasloppycoil.So,takeyourtimetodothejobright.Continuewrappinguntilyouhavecompletedafullturn(completingcoilinnerlayer#1).Tightlywrapastripofplasticelectricaltapearoundthewireandthecoilentrywireattheendoflayer#1.

3. Checkthepositionofeachwireontheoutsideedgeofthecore.Ifwrappedperfectly(which,ofcourse,isimpossible)therewillbea.019gapbetweenanytwowires.But,youcanpositioneachwirecloseenoughbyusingashortpieceofcoilwireasafeelergauge.Ifthefeelergaugewiretouchesthecoresurfacebetweenanytwowires,thegapistoowide,soatleastoneofthewiresisoutofposition.Usingyourfingernail,orotherbluntendedinstrumentthatwontdamagethewires,slightlyshiftwirestoclosethegapenoughtokeepthefeelergaugefromcontactingthecoresurface.Anygapthatistoowideindicatesanadjacentgapistoonarrow,sothosewiresshouldbemovedfurtherapart.Aftergoingaroundthecoilafewtimes,youwillalsobeabletovisuallydetectwiresoutofposition.

Note

Savethe150wireforthelastlayerincaseyouneedextrawiretocompletethe8thlayerwithoutsplicingnearthecoilentrywire.Anytimeyouinterruptwrapping,besuretotightlywrapastripofplasticelectricaltapecompletelyaroundthecoiltosecurethelastwrap.Teflonisextremelyslipperystuff;youdontwanttocomebackonlytofindthatallyourcoilwrapsareloose.Itwillhappenifyoudontusetape!

Thefirstcompletewrappingoftheentirecoildiameterformslayer#1fortheinnercore.Thisistheonlycriticallayersinceeachsubsequentlayerwillautomaticallypositionitselfbynestingbetweenthewiresofthepreviouswrap.

59 RunaCaronWater

Figure19:ToroidCoilDetails

4. Mixaboutaouncebatchofepoxy(suchasJBWELD).Usingasmallbrush,carefullyapplyathinlayerofepoxyaroundtheouteredgeofthecoil.Applywithamotionparalleltothewirestopreventwiremovement,beingsureepoxycontactsthecoiledsurfacebetweenwires.Suspendthecoilfromitswiresandallowtheepoxytocureforatleast8hoursbeforegoingtostep5.

5. Startwrappingcoillayer#2,exercisingcaretopositioneachwireintothegapformedbetweenthewiresoflayer#1ontheinnerandouteredgesofthecoil.Countandrecordthenumberofturns.Continuewrappinguntilyougetwithinaboutonefootofthewireend.Securethewirebytightlywrappingplasticelectricaltapearoundthewireandcoil.

Note

Whilewrappingcoillayer#2,besuretocountandrecordthenumberofturns.

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6. Temporarilywrapthewirefortwoorthreemoreturnsandcutitaboutshortoftheouteredge.Tosplicetothenextwirelength,unwrapthewireanduseasharpknifetoscrapetheTefloncoatingfromaboutofeachwireend.Alwayskeeptheknifebladeperpendiculartothewiretopreventdamage.

7. Slidealengthofheatshrinktubingovertheendofthenextlengthofcoilwire.Besurethetubingislargeenoughtofitoverawiresplice.Twistthewireendstogetherfor7or8turnstoformasplice.Cutthesplicetoalengthofaboutandbenditbacktowardthecoiluntilitlaysflushagainstthecoilwire.Solderthesplice,slidetheshrinktubinguntilitscenteredoverthesplice,andapplyheattoshrinkthetubing.Waitaminuteortwoforthetubingandsplicetocoolandgoontostep8.

8. Removetheelectricaltapefromthecoilandcontinuewrappinguntillayer#2iscompleted.

Recordthetotalnumberofturnsrequiredtocompletelayer#2.

9. Referringtotherecordednumberofcoilturnsneededtocompletelayer#2,determinethenumberofcoillayersrequiredtocompletethecoilwithatotalnumberof1,800to2,100turns.

Note

Besuretoendthelastcoillayernearthebeginningoflayer#1.Donotfinishthecoilwithapartiallastlayer.

Note

Althoughthetotalnumberofcoilturnsisnotcritical,almostallcoilsrequireatotalof8wirelayers.

Note

Coilthicknesstapersdownbetweentheinnerandouteredges.Tominimizeinnercoilthickness,positionwiresplicesonthetoporbottomofthecoil,midwaybetweentheedgesasshowninFigure19.

61 RunaCaronWater

10. Repeattheprocedureoftheprecedingsteps5through7untilthelastlayerhasbeencompleted.Besurethelastturnendswithinaturnortwoofthecoilentrywire.Cutthelastwiretoalengthofabout12.

11. ReferringtoFigure19,temporarilyslidea5lengthofheatshrinktubingovertheendsofthecoilwires.Drawthetubingsnuglyupagainsttheoutercoiledgeandbendthecoilleadsbacktowardthecoilattheouterendofthetubing.Tightlywrapeachcoilwire4to5turnsaroundthetubingabout1fromtheend,andtwistthewirestogetherforatleast5or6turns.

12. UsingFluoroEtch,whilesuspendingthecoilbytheheatshrinktubing,etchthesurfacesoftheTefloncoatedcoilwires.Closelyfollowthedirectionsontheproductlabel.Ifnecessaryasanaidtoetching,refertothegeneraldescriptionoftheetchingprocedurecalledoutlaterinthisdocument.Alwayshandlethecoilbysuspendingitfromthetubingduringeachphase,frometchingthroughfinalwarmwaterrinse.Usecleanpapertowelstoabsorbwaterdripsfromthebottomofthecoiluntildrippingceases.Allowthecoiltoairdryforatleast4to5hoursbeforegoingtostep13.

13. Usingasoftbristlebrush,coattheentiresurfaceofthecoilwithathinandevenlayerofCPVCcement.Usecottonswabstowipeawayexcesscementthatmaybedrippingfromthebottomofthecoiluntildrippingceases.AllowthecementtoairdryforatleastanhourandthenapplyasecondthinandevenlayerofCPVCcementinthesamemanner.

Caution

Exerciseextremecaretopreventdamagingthecoilwiresduringthefollowingprocedures.

ToassureproperbondingofCPVCcementtothecoilafteretching,donothandlethecoilwithbarehands.Ifthecoilmustbehandled,wearcleancottongloves.

Note

Donotshrinktheheatshrinktubinginthefollowingstep11.Itwillbeusedonlytemporarilytosecurethecoilwires.

62 RunaCaronWater

14. Repeattheprocedureoftheprecedingstep13untilatotalof5or6layersofCPVCcementhavebeenappliedtothecoil,allowingatleastonehourdryingtimebetweeneachlayer.Allowthefinallayerofcementtoairdryforatleast8hoursbeforegoingtostep15.

15. Unwrapthecoilwiresfromtheheatshrinktubingandremovethetubingfromthewires.Cuta1lengthofheatshrinktubinglargeenoughtoslipsnuglyoverthecoilwiresandtheshrinktubingofthecoilentrywire.Drawthetubingtightlyupagainstthecoilouteredgeandapplyheattoshrinkthetubing.

16. Usingasoftbristlebrush,applyathinbeadofCPVCcementaboutwidearoundthecoilendofthetubingandsurfaceoftheoutercoiledge.Allowthecementtoairdryforaboutanhourandthenapplyasecondbeadofcementoverthefirstbead.

17. Suspendthecoilfromtheendofitswiresandallowittoairdryforatleast24hoursbefore

goingtostep18.

18. Cutthecoilwirestoalengthof3fromthecoil.

Caution

Exercisecarenottopullthecoilexitwireawayfromthecoilwhileremovingtheheatshrinktubing.

63 RunaCaronWater

ToroidCoilInstallation

1. Usinga#41drillbit,drilltwoholesinthehousingwallatthelocationsshownFigure20.

2. Cuttwo(2)4lengthsof3/32barestainlesssteelweldingrod.Createa90degreebendinoneendofeachrodtoformalegapproximately11/2long,asshowninFigure20.Cuttheotherlegtoalengthof.Usingafile,squareofftheendsofeachrodanddeburrtheedges.

3. UseasharpknifetoscrapetheTefloncoatingfromaboutofeachcoilwireend.Always

keeptheknifebladeperpendiculartothewiretopreventdamage.

4. Wrapeachcoilwireendaroundthetopofa11/2rodlegforatleast4or5turns.Usingsilverbearingelectricalsolder,soldereachwiretoitsrodleg.Trimawayanyexcesswire.Formawirestrainreliefatthelegbottombywrappingheavythreadatleast2or3turnsaroundthelegandwire.Securethethreadwithaknotplacedontheoutsideoftherodbend.

Note

Irecommendlocatingthecoilelectricalconnectionsonthesideofthehousingdirectlyoppositethewaterpumpinletport.Thislocationminimizespossiblecoilwireconnectorfatigueduetotheeffectsofwaterturbulenceathighpumppressure.

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Figure20:ToroidCoilInstallation

5. Usingasoftbristlebrushandwarmsoapywater,cleanthesolderedareasoftherodandwire.Rinsewithwarmwaterandallowthethreadtoairdryforatleastanhourbeforegoingtostep6.

6. CoattheentirelengthofthelongrodlegwithathinevenlayerofCPVCcement.Allowthecementtodryforabout15minutesandapplyasecondthincoatofCPVCcement.Allowthecementtoairdryforabout15minutesbeforegoingtostep7.

7. Temporarilyinstallthecoilontopofitsthreesupportbracketswithinthehousing.Position

thecoilwiththewiresandrodspointingtowardtheholesdrilledintheprecedingstep1.Temporarilyattachthreesmallstripsofelectricaltapeontopofthecoiltomarkthelocationofeachsupportbracket.

8. Removethecoilfromthehousingandapplyprimertothebottomofthecoilatthethree

markedlocationsandthetopsurfaceofallthreesupportbrackets.CoatthetopofeachsupportbracketwithaheavylayerofCPVCcement.Installthecoilontothesupportbrackets,positioningitwiththewiresandrodspointingtowardthetwo#41drilledholes.If

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necessary,shiftthecoilslightlytocenteritsoutsideedgeswithinthehousing.Allowthecementedrodsandwirestoairdryatleastanhourbeforegoingtostep9.

9. Removethethreetapestripsfromthetopofthecoil.Usingacountersinktoolorlargedrillbit,Deburrtheinsideendsofthe#41holes.Inserttherodendsintotheholesandcheckthattheinsidebendradiusclearstheedgeofeachhole.Ifnot,countersinkslightlydeeperuntilthedesiredclearanceisobtained.

10. Using#400gritorfinersandpaper,polishthesurfaceoftheunsolderedlegofeachrod.MixasmallquantityofepoxysuchasJBWELD.Applyathincoatofepoxytotheunsolderedlegofeachrod.Usingatoothpick,orotherprecisetool,applyathincoatofepoxytotheinsideofeach#41hole.

11. ApplyaheavylayerofCPVCcementtothesoldere4dlegofonerod.Fullyinserttherodinto

the#41holdwiththesolderedlegpointingdirectlyupward.Holdtherodinplaceforabout5minutesuntilthecementdriessufficientlytoholditinplace.Whilewaitingforthecementtopartiallydry,cleanepoxyfromtherodendusingasoftcleanclothandsolventsuchasMEKoracetone.Repeatthisprocedurefortheremainingrod.Allowtheepoxytocureforabout8hoursbeforegoingtostep12.

12. Arrangethecoilwiressotheycontactthehousingwallasmuchaspossible.LaythehousingonitssideandapplyathicklayerofCPVCcementoverthewiresandsolderedlegofeachrod.Extendthecementlayeraroundtheholewhereeachrodentersthehousingwall,

Note

SeverallayersofCPVCcementareusedtosecurethecoiltothehousingbrackets,rodsandwirestothehousingwall,andtosealtherodsagainstpossiblegasand/orwaterleakagethroughtheholesinthehousing.

Note

Thetwo#41holesintheinsidehousingwallmustbecountersunktoadepthsufficienttocleartheradiusoftheinsidebendofeachrod,allowingthesolderedlegofeachrodtolayflushagainstthehousingwallwiththesolderedlegpointingupward.

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formingaboutadiameterpuddlearoundeachhole.Allowthecementtoairdryforatleast15minutesbeforegoingtostep13.

13. Standthehousingonend.Usingasoftbristlebrush,applyathicklayerofCPVCcementoverandaroundthecoilsurfaceabovewhereitcontactseachofthethreesupportbrackets.Besurethelayerextendsthewidthofeachbracket.Allowthecementtoairdryforatleast15minutesbeforegoingtostep14.

14. Repeattheprocedureoftheprecedingsteps12and13atleast4or5timestoobtainthe

desiredthicklayerofcement.Allowthecementtoairdryforatleastanhourbetweensuccessivelayers.

15. Aftertheepoxyhascuredforatleast24hours,use#400gritorfinersandpapertoremove

epoxyresiduefromtherodends.

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UnthreadedEndCapInstallation

1. Checkthatthematingsurfacesoftheendcapandtopofthehousingarecleanandfreeofdebrisofanykind.Cleanthematingsurfacesifnecessaryusingasoftcleanclothandmildsolventsuchasisopropylalcohol.

2. Afterdeterminingthedesiredpositionoftheendcap,applyprimertothematingsurfacesoftheendcapandtopoftheGeneratorhousing.ApplyathinlayerofCPVCcementtotheprimedareasandslidethepartstogether,seatingthemfirmly.

3. Standthehousingonendtopreventthepossibilityofexcesscementrunningintothreaded

holesintheendcap,allowingittoremaininthatpositionforatleastanhourwhilethecementairdries.

Note

Generatorfunctionandefficiencyisnotaffectedinanywaybytherotationalpositionoftheunthreadedendcap.

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GeneratorFinalAssembly

1. Cutthetworodendsprotrudingthroughthebottomofthethreadedendcaptoalengthof.Usingafile,squaretheendofeachrodanddeburrtheedges.

2. ApplyalightcoatingofpipejointcompoundtoallthreadedholesintheGeneratorhousingandendcapsaccordingtodirectionsontheproductlabel.

3. Applyalightcoatingofpipejointcompoundtothethreadsofthedraincock.Threadthedraincockintothe37/64threadedholeinthebottomofthethreadedendcap,seatingitfirmly.Repeatthisproceduretoinstalltheremainingcomponents: One3/8BarbedHoseFittinginto37/64holeinhousingdoubler. One3/8BarbedHoseFittinginto37/64holeontopofhousing. One1/8BarbedHoseFittingintoRsizeholeontopofhousing. OnePressureReliefValveinto37/64holeontopofhousing.

4. Usingatoothpick,orsimilarprecisetool,forceasmallquantityofSiliconeSealant(RTV

Cement)intotheholeintheendcapthroughwhichthewaterlevelswitchleadspass.Formasmallandsmoothfilletofsealantaroundtheleadsandendofthehole.Allowthesealanttocureforatleast24hoursbeforegoingtostep5.

5. Visuallyinspectallsurfacesandcomponentsofthehousingandendcaptoverifytheirintegrity.Correctpossibledefectsasrequired.

Caution

TopreventdamagetothreadedholesinCPVCmaterial,donotapplyexcessivetorquetocomponentswhileinstalling.Threaddamagecancausewaterand/orgasleakage,andpossiblesystemfailure.

Note