Brown's Gas: - B - O - O - KT - W - O - ")
Brown's Gas: - B - O - O - KT - W - O - ")
Brown's Gas: - B - O - O - KT - W - O - ")
---------J,
'I,
George Wiseman •
L....---
./
_
DISCLAIMER
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We define practical as simple, inexpensive,
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presented herein.
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Although care is taken to present accurate information:
We gather information from diverse sources, perform
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PRINTED IN CANADA
Table of Contents • Through bolts 17
• Drill and tap shell 17
INTRODUCTION 1 • Mixing electrolyte 18
• Fill electrolyzer with electrolyte 18
DESIGNING A BG ELECTROLYZER 2
•A " ' S>peclifi'
ppIIcatlOn IcatlOns 2 DESIGNING ELECTROLYZER POWER SUPPLY 19
• Series-cell 2 • Power supply considerations ..........................•....... 19
• Transformer-less design 3 • J0ltage measurements 19
• Simple power supply 3 • Number of cells in series 19
• Power supply options 4 • Frequency across the electrolyzer 19
• Electrolyte 4 • Voltage threshold 20
• Sealing between cells 5 • Pressure switch 20
• Plate masking 5 • DC power circuit 20
• Plate degreasing 5 1. Capacitor amperage limiting 20
• Plate texturing 5 2. Voltage doubler 21
• Plate material 5 3. J0ltage doubler with capacitive limiting 22
• Plate thickness 5 • Main power circuit 22
• Plate spacing 5
• Number ofcells 6 LIQUID LEVEL & TEMPERATURE CONTROLS 23
• Pure water 6 1. The 12 VDC power supply 23
• Fail-safe features 6 2. Second circuit group; liquid level and
• Bubbler tank 7 temperature processing 24
• Liquid-vapor separator 7 3. The signaled mosfets, relay and buzzer 26
• Assembly hints 26
SIZING A BG ELECTROLYZER 7 • Circuit adjustments (tuning) 28
• Gas volume needed 7 • 'Balance' the op-amps , 28
• Available power 8 • Set the circuit temperature 28
• Electrolyzer diameter 9 • Circuit tests 28
• Plate spacing 9 • Circuit component list 30
• Kind ofelectrolyte 9
• Electrolyte concentration 9 BUILDING A CONTROL BOX 30
• Power supply option 10 • List of components and materials 30
• Pressure relief valve 31
BUILDING A BG ELECTROLYZER 10 • Pressure switch 31
• Safety tips 10 • Automatic electronic liquid level and
• Electrolyzer list of materials 10 temperature controls 31
• Cut rings from tube 11 • Install gauges 32
• Size rings 11 • On/offswitch 32
• Mark out plates 11 • Indicator lights 32
• Cut plates 12 • Full-wave bridge rectifier 32
• Straighten plates 12 • Main relay 32
• Degrease Plates 12 • Terminal strips 33
• Holes in plates 13 • Duplex receptacle 33
• End plates 13 • Hook main power inlet cord to enclosure box 33
• Liquid level tube 16 • Enclosure box 33
• End gaskets 16 • Install capacitors 33
• End plate assembling... 16 • JVzre control box 34
• Plastic cap on SS bolt 16 • JVzres from enclosure to electrolyzer 34
• Initial cut long shell 16 • Gas pressure hose from liquid-vapor separator 34
• Assemble rings & plates into tube 17
• Final long shell cut 17 DESIGNING AND BUILDING A BUBBLER 34
• Put end caps on 17
continued...
OUR EXPERIMENTAL USE OF BROWN'S GAS 42 The circuit has been added at the back of the book and
• Modifier tank 42 appears on pg. 59.
• Welding glass 43
• Welding iron 43
• Cutting cast iron 43
• Welding cast iron 43
• Cutting iron , 43
• Welding copper 44
• Welding aluminum 44
• Brazing 44
• Cost to operate compared to oxy.lacet 44
OVER-UNITY HEAT 48
!
Valve 1
anything goes wrong. Water fill to torch )"
In addition, Eagle-
Research is happy to offer
technical advise to people Bubbler
building electrolyzers of tank
any design. We welcome
suggestions for /' Liquid-vapor
separator
improvements of our Sensor shroud ---!+--!t:>-,
design.
Application specifications
liquid level sensors --~~ /
Components not shown
The particular BG relative to size, only
electrolyzer design Water level tube ~ to existence and
outlined in this Book is placement
designed to be applied
using ordinary oxy.fact. Fig. 1
Diffuser plate ~ ~.~ ..~;.>~. "~;'>~'.~
welding tips and/or cutting . .. . .. .... ... .... .. ... ...
torch.
Ifyou don't have time to do it right In some cases, a liquid-vapor separator SIZING A BG ELECTROLYZER
now, when will you have time to do it (I-v s) arrangement is still needed. (I
over? use one as a matter of course), because Gas volume needed
liquid can be carried by the gas coming
from the e1ectrolyzer. You need to decide how much gas
Bubbler tank
volume you need for your applications.
The bubbler tank prevents a backfire The I-v s is simply a wide spot in the
going to the electrolyzer, by separating For jewelers'-work and electronics,
hose going from the electrolyzer to the
the gas flow into very small bubbles bubbler. We make it out of ordinary you only need a very small flame.
that are each completely surrounded by schedule 40 clear PVC pipe and caps, This is the size of torch that the BN
water. The gas may explode (and 2" diameter X a foot high. 200 was designed to operate. We think
implode) but the explosion WILL NOT the BN 200 was a bit small. An
travel through the water. The bubbler Locate the I-v s above the electrolyzer electrolyzer with less than a 500 liter
tank, as designed here, will contain the so that any liquid it contains can drain per hour capability is not
explosion. back to the electrolyzer. recommended.
Use at least a 1/2 inch inside diameter
The Bubbler is needed. It is the only hose from the electrolyzer to the I-v s , We size our electrolyzers as ER XXXX
thing we've discovered, so far, that will (Eagle-Research). So,an (Eagle-
to allow for easy draining. Don't allow
operate on a continuous basis, any dips in this hose, or the 'liquid Research) electrolyzers ratedfor 1,000
absolutely trouble free, AND reliably puddle'that forms in the dip will Liters per hour would be an ER1000.
stop a backfire (explosion). prevent the liquid-vapor separator from
draining. The series-cell design will operate
Design it properly and maintain a efficiently at any volume up to its total
certain water level in it (about six The hose from the top of the liquid- capacity. If you need only 400 liters
inches above the diffuser). If you vapor separator to the Bubbler can be per hour (LIh), you could use a 2400
don't design it properly, it will explode 3/8". Check-valve and valve #2 can be Lih electrolyzer, but you'll be paying
(killing you or worse). If you don't 3/8". We like to use gate valves. Ball more money than you have to, to build
maintain a proper bubbler liquid level, valves are unreliable for this service. the electrolyzer. In addition, you'd
your e1ectrolyzer will explode (killing Get a high quality check-valve. (see need a 60 amp breaker.
you and blowing your shop into the Resources)
surrounding area). The operating expense would be the
same if you take 400 Lih from a
You want a through-bolt to go through I advise to use a drill-press whenever The a-rings around the center bolts
about every 2.5 inches on your possible. Remember to wear gloves can be compressed to 113 of their
through-bolt circumference. We put and goggles. Always clamp your work diameter. Use about 50 hardness
several bolts around the circumference to the press before drilling. Make sure EPDM material for the a-ring. Drill
to have an even pressure on the gasket the drill bit won't drill into your press- the appropriate sized counter-sink in
(helps to seal) and to spread the end table. Set the press to the appropriate both sides of the plastic endplates. The
plate pressure to several points (helps speed for the bit you are using. a-ring will make an oval, about 113
prevent warping). wider than it's original diameter; so
Assembly Tip: Pre-drill all your holes you need to make the counter-sink a bit
The 'cage'of bolts also breaks up the with a smaller drill bit that is about the deeper than that; NO MORE!!!!!. The
plastic pieces if you happen to burst size of the web on the tip of your washer on one side and the plastic
your electrolyzer, thus only smaller larger drill bits. Holes up to 114 inch spacer on the other will hold the 0-
pieces of plastic fly. They still hurt don't require pre-drilling. rings in place.
when they hit you.
Drill the center hole for your power- To give an example of the countersink
You do NOT want a through-bolt to go bolt size. Drill the through-bolt holes. hole size: Assuming a 5/16 SS bolt that
through dead center of the top (12: we are sealing with 118" O-rings. The
o'clock position) because this is where Note: I recommend two 3/8" power- O-ring is normally a fraction less than
your gas-out tube will go (in about the bolts through each endplate for any 5/16" ID (0.309"). 118" (0.130) less
middle of the shell, not the end plate). amperage greater than 30 amps. Or the 30% equals 0.09. 0.309 + 0.09 + 0.09
bolt will get too hot and melt your = 0.48 inches. Find a drill bit
Take Care to get the angles cut into 3/4" CPVC plastic end-plate
the appropriate comers of the steel
(and plastic). If you accidentally flip
l!i!]~!OO~~!f"f;""~"~"f;""~"~"<E-- 9/16" iron through-bolt
1/2" Iron II- <E-- CPVC schedule 80 pipe
the plates, your through-bolt holes end-plate
won't line up anymore. <E-- 1/8" EPDM gasket
1/8" x 1" SS washer under
As you cut the steel, think how much SS electrolyzer plate
easier it'll be with the Brown's Gas. I 3/8" Stainless ~ mm~~~1 ~ Thick plastic cover over SS bolt
do not use oxy.lacet. to cut with any Steel bolt Silver- solder bolt to plate
more. BG cuts iron so fast and clean.
Plastic electrical / 1/8" EPDM O-rings around SS bolt
Now, you'll drill out the IRON (not insulating ring
plastic) end plates to allow room for <E-- SS electrolyzer plate
the insulating spacer around the
power-input bolts (Drill so that you
have about 1/4 clearance around the
Fig. 5
Brown's Gas, Book 2/ www.eagle-research.com15
Uquid level tube End gaskets commercial BG electrolyzer would
have automatic liquid level monitor
Notice that the liquid level tube is 'off- Note: if you are not clean about and shut down. It can be built on
set', meaning that the two holes going building and filling the electrolyzer exactly the same circuit design as the
into the electrolyzer end-plate are not and/or if you use components or automatic liquid level control for the
on the center line. This is to sealing materials that are not bubbler, shown elsewhere.
accommodate the length of the copper compatible with the sodium hydroxide,
fittings and still allow the liquid level then you'll get FOAMING. The foam The SS plate on the 'sight tube' end-
to be visible. is un-desirable because it 'shorts out' plate assembly needs an additional hole
the plates as the electricity travels on drilled in the stainless steel plate.
We fasten Tees (liS" FNPT to FNPT to the foam instead of through the plate-
MNPT on run) on the copper tubes pack (causing wasted electricity). And Plastic cap on SS bolt
(liS" NPT) coming through the the gas flow carries the foam up into
electrolyzer end-plate. Then we put the Bubbler, through the bubbler and The stainless steel bolt head is covered
barbed fittings (liS" MNPT to 114" out to the torch, where it contaminates by a piece of plastic to prevent the bolt
barbed) on the Tee's to install the level the flame (causes it to tum yellow). from participating in the electrolysis.
tube. We put liS" valves sticking The piece of plastic covering the bolt is
straight out on the 'run'of the Tee. We cut a round circle of lISth inch just thick enough to just reach the next
These valves assist filling and draining thick Neoprene or EPDM 'rubber'. plate, which holds the plastic cover in
of the electrolyzer. The circle to fit past the edges of the place (the plastic cover is there to
shell. We cut the holes for the center prevent the bolt from participating in
This arrangement allows us to position washer, fittings and (if we make it that the electrolysis process). Make the
the clear hose in a 'C'(or reverse C) wide) through-bolts with regular gasket plastic bolt covers from CPVC scrap.
around the center bolt. Allowing us a hole punches.
clear reading of the electrolyte level in Initial cut long shell
the smaller electrolyzers. Otherwise End Plate Assembling
the barbed hose fitting would be For the electrolyzer shell; I've used
covering the spot where the liquid level Note that in this sketch I've shown PVC pipe and been happy with it, it's
should be. how to get the power into and out of less expensive, more readily available,
the series cell. I put the electrical input comes in all the same sizes as CPVC;
Note that I use clear braided PVC hose under the electrolyte. You can put the BUT it can only go to 120°F before it
for the sight tube. I choose this bolt anywhere under the electrolyte; I is too hot to handle the pressure in the
because it is compatible with the just find it convenient to put it in the electrolyzer. CPVC can go to 160°F
sodium hydroxide and has a reasonable center of the electrolyzer. before it is too hot.
pressure rating. The hose does need to
be replaced every so often, you'll The two end plates have a hole in them I choose schedule SO CPVC pipe for
know when. to accept a stainless steel bolt. We the outer wall of the electrolyzer
then silver solder the SS bolt to the SS because I want the strength and the
We have found it extremely helpful to plate to assure a long term sure ability to handle a higher temperature
put a small dark plastic floating ball contact. than regular PVC pipe.
inside the PVC sight tubes
(electrolyzer and bubbler). We make The stainless steel bolt extends through Cut the pipe on the same jig you built
our own ball by heating a bit of dark the electrolyzer end plates and the to cut the rings. When cutting the
HDPE (hot air gun) and rolling it into a electrical wires are attached to them. electrolyzer pipe to length, cut it a little
ball. The ball must be big enough to long at first; because your rings and
not go through the copper fittings but Stack SS washer/s between the SS plates may not measure EXACTLY as
small enough to travel easily through plate and the plastic end-plate; the SS you figure and even a small error adds
the hose. washers to be the same thickness as the up when multiplied over a hundred
liS" thick end-gasket. This will times.
In the larger electrolyzers (ten and prevent the SS plate from becoming
twelve), you can just run the sight tube warped as it is bolted. Later you'll finish trim the shell after
straight down. This is helpful to the the plates and rings are inserted into
floating ball, because there won't be a The two electrolyzer end-plates are the shell.
bend (kink or flattened spot) that tends totally assembled before they are
to catch the ball. bolted onto the CPVC pipe. Note: Instead of cutting the shell, you
can just add or subtract a ring/plate
You can use a sight tube to monitor the combination or two, it will make little
liquid level in the electrolyzer. A difference to the actual result. Don't
~
Volts per cell Plate Spacinl:
2.0 112 inch
1.9 3/8 inch
" Nega'we output 1.75 1/4 inch
Put extra capacitance in parallel with first capacitor; which is NOTE: these 'rules of thumb' are
in series with the load on the AC POWER line. Fig. 6 generated from extensive testing of
actual electrolyzers using different
Note, I've reached as high as 500 hertz high to most efficiently make Brown's numbers of cells, types of electrolyte,
(pulses per second) using this method. Gas. Then use a voltage doubler to electrolyte concentrations, power
The capacitance is raised or lowered bring the voltage (and thus the supplies, etc. These 'rules of thumb'
'til there is a 'resonance'effect. amperage) up to whatever I require. will get you into the 'ball park'and
give you an operational electrolyzer. I
Voltage threshold Pressure switch can't guarantee any particular
performance. You will notice slight
Most of the time the AC voltage is A pressure set-point switch differences.
below the 120 volts needed to push any (mechanical or electronic) on the
current across the 60 series-cell. The electrolyzer will operate a relay-switch 1. Capacitor amperage limiting
brief moments that the sine wave goes (mechanical or electronic) to tum on
above 120 volts, reaching about 170 and off the power to the electrolyzer Note that this is the 'basic'power
peak volts, is the only time amperage when needed. supply circuit for the e1ectrolyzer only,
actually goes through the 60 series- without all the controls that tum the
cell. Assuming that your electrolyzer can main relay on and off. This is the
make more gas than your torch needs circuit starting from the output side of
The amperage that can travel in a 60 (which MUST be the case), this the main relay.
series-cell is limited by the 'voltage pressure set-point switch prevents gas
threshold'potential of the cell. After loss out the pressure relief valve. You use capacitive amperage limiting
that threshold is reached, the amperage if you have too few cells to use Voltage
more or less just shorts across the Gas loss out the valve is bad because Doubler.
electrolyzer. of inefficiency (you paid for the
electricity to make the gas and you are Capacitive Limiting is also used if you
With sodium hydroxide, at 1.8 volts throwing the gas away) but also simply want to reduce the amperage
per cell, the amperage can barely flow; because it could cause wild pressure through any electrolyzer at any time
at 2.4 volts per cell, a lot of amperage fluctuations in the pressure of the gas (even if you have a voltage doubler).
can flow. in the bubbler tank, which is likely to For example, if you have a heating
cause backfire from your torch. problem (and/or amperage runaway),
The voltage 'threshold'can be raised you can limit the amperage through
by adding more cells in series, which DC power supply your electrolyzer.
would further limit amperage through
the electrolyzer. Or the 'voltage It is possible to make Brown's Gas When an electrolyzer gets too warm,
threshold'can be lowered by using from a DC voltage source, such as a the warm electrolyte allows more
fewer cells in series, which would battery, but you must pulse the current amperage flow and may cause too
cause more amperage to flow from the battery. much amperage to flow. Too much
Amperage is then limited by the amperage could over-heat your
capacitive limiting type power If we apply straight DC current to the electrolyzer and/or toss electrolyte
supplies. e1ectrolyzer, we find the oxygen and right out of your e1ectrolyzer and/or
hydrogen always devolving to their di- 'pop' your fuse or breaker.
Generally speaking I recommend atomic state. And your electrolyzer
keeping the 'voltage threshold'fairly will heat up.
Fig. 8
N--------- ..
P-----------+< ~
,...--,1
...- ....------4l,..- Positive
output
Cf ~ V DC Voltmeter
~4 t
Fig. 9
t Pressure shut-off
Electronic shut-off
Main shut-off
L..---------.--(A'm
Negative
output
DC Ampmeter
capacitance to the 'legs'of your without all the controls that tum the side of your transformer that provides
voltage doubler. As you add main relay on and off. This is the the low voltage for the electronics,
capacitance on each leg of the voltage circuit starting from the output side of gauges, buzzer and relays.
doubler (equal on each leg): the main relay.
You'll note that the DC ammeter is on
You'll note that the amperage will rise Same as Voltage Doubler, only you the line going into the electrolyzer; it
at the rate of one amp per 50 uF per have capacitive limiting in series on doesn't matter which one, just so you
leg with 120 VAC RMS. the input common with the center of get the polarity correct. Although I
the voltage doubler capacitors. depict a capacitive limited, voltage
And the amperage will rise at one amp doubler power supply here, the
per 11 uF per leg with 240 VAC RMS. Main Power Circuit ammeter is installed in the same place
on all the power supplies.
IMPORTANT NOTE: 'There ain't We have the main power coming in on
no such thing as a free lunch'. When an ordinary 240 Volt cord, using You'll note that the DC voltmeter is
you increase the voltage using a properly rated receptacles, wire sizes mounted between the lines going into
voltage doubler, the 'extra power' and plugs. The 'P'is power or hot; the the electrolyzer, you have to get the
comes from AMPERAGE from your 'N'is neutral, where you wire to when polarity correct. Although I depict a
RMS source. you want 120 VAC. capacitive limited, voltage doubler
power supply here, the voltmeter is
When using a voltage doubler circuit, Note that our electrolyzer draws about installed in the same place on all the
the amperage being drawn from the 50 amps, so I use a main relay rated at power supplies.
wall is about TWICE the amperage 90 amps. The relay is normally open,
you see across your electrolyzer. You three pole, single throw. The relay has There are any number of 'extras'that
must be sure your wall fuse or breaker a 120 volt coil to activate it. can be applied to this circuit, like
can handle the amperage you will be indicator lights and receptacles (120
adding. Remember that the Note the three shut-off switches wired volt and 240 volt); but I left them out
MAXIMUM continuous operating in series, in series with the main relay of this schematic because I'm trying to
amperage of your breaker or fuse will coil. This is so that if anyone of the keep it seriously simple. What you see
be only 80% of the 'rated'amperage. switches is open (off) then the main will work just great! The electronics
For example; a 20 amp breaker should relay has no power and is off! The has status indicator lights and you can
hold 16 amps. Pressure switch is normally closed, see when the power is on (to the
open on pressure rise (could be a
Further Note: When a breaker 'trips', it relay). The Electronic switch is a
will not again hold as much amperage relay that is normally open, held
Low voltage
o
as before. After each 'trip'the actual closed by the electronic circuit. Power Supply
amperage that the breaker will hold is a The Main switch is normally 7812
bit less. open, closed only when you want
the electrolyzer operational (this
3. Voltage Doubler with capacitive could be a relay too), I usually
limiting just use an ordinary light switch.
Note that this is the 'basic'power The points marked 'a'and 'b' are ~
supply circuit for the electrolyzer only, where you connect the primary Fig. 10
22 www.eagle-research.com/Brown.s Gas, Book 2
electrolyzer) by looking at the volt and 'til the electrolyzer either has water The electronics are arranged in three
amp gauges. added or cools down. groups to make it easier to understand.
Power supply, electronic processing,
I have designed a simple circuit that and signaled mosfets.
UQUID LEVEL AND TEMPERATURE even a novice can build. Novices have
CONTROLS already built my circuits using my 1. The 12 VDC power supply
instructions. Don't be concerned if
I designed electronic circuits to act as you don't know how to do it now; you The low voltage, 12 VDC power
sentinels, monitoring critical CAN learn how. You can buy all of supply is for the electronics, the buzzer
parameters of the electrolyzer 's the electronics at your local Radio and the relay. It could also be for 12
performance. The electrolyzer can Shack and the peripherals at local volt electric or electronic gauges if you
work quite adequately without these hardware and automotive stores. use them. The low voltage could also
circuits but I don't recommend that be used across a pressure switch to
you do so. I have these controls on my power a relay instead of
the pressure switch having
to take the full amperage
Bubbler liquid (the amperage would then
level control go across the relay).
circuit
J a) We have a transformer
to step the voltage down
from 120 VAC to 12.6
VAC. The transformer
LL
~
must be rated about 50%
above the actual amperage
you'll be using. You can
get a good idea of the
• D J amperage by hooking up
your circuits to a 12 Volt
battery and measuring
(with an ammeter) your
Fig. 11 amperage flow with
everything turned on.
own electrolyzers, because I often I sincerely recommend that you buy b) Then we add a full wave bridge
don't pay enough attention to the Getting Started in Electronics by rectifier, which is just four diodes
operation of the electrolyzer; my Forrest M. Mims, III. I and many arranged in a square (note that the band
attention gets concentrated on the job others have self-taught ourselves on the diode is the negative end, diodes
at hand. electronics from this simple book. are polarity sensitive). The full wave
What the book will tell you is how to bridge rectifier turns the AC
The two most critical things to monitor get 'in the ballpark'on simple (alternating current) into DC (direct
are liquid level in the bubbler tank electronic circuit design and to current) needed by the electronics.
(backfire arrester) and the temperature understand the electronic language.
of the electrolyzer itself. You will have You will learn how to put electronic c) Then we add an electrolytic
sight tube and a temperature gauge but components together to make circuits capacitor, rated at least 35 VDC (50
that is not enough, you must remember do what you want them to do. VDC is better) and 1000 uF (uF is
to look at them. The electronics are a micro-Farad) for each amp that will
fail safe for those people, including Next, I recommend that you get the flow through the transformer; in this
me, who fail to ALWAYS check the 'data sheets'on any electronic case about 1,000 uFo The capacitor
bubbler liquid level and watch the component (particularly the chips) that allows voltage to be 'stored'in the
e1ectrolyzer temperature. you buy, so you will understand their circuit, which smoothes out the pulses
working parameters. Since (in this that would otherwise occur direct from
The electronics are designed to be two- circuit) I use all electronics from Radio a full wave bridge rectifier.
step. First, you'll get a warning Shack, they'll be able to make you
buzzer, then if the problem gets worse, copies from their Semiconductor d) Then we add a 7812 (in a TO-220
the electronics will actually shut off the Reference Guide. During this chapter, case) voltage regulator, for those parts
electrolyzer and will not allow a restart I will be assuming that you have this of the circuit that the voltage must stay
information. very stable. You will want to put a
!
circuit the positive voltage is 'grounded'
Bubbler liquid
Circuit
R1<
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ElectrolyzerTe
mperature
control circuit
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Fig. 14
Bubbler liquid
level control
circuit
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Electrolyzer
Temperature
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R5 R5
Fig. 15
1/S" SS Pipe
4" diameter
20" high
ea-- Sensor
1/S FPT shroud
<I- 1/4" (nominal)
1/S FPT jJ SS Tubing
6" above 20.5" long,
diffuser extending
plate 0.25" below
1/S" hole
diffuser plate.
Diffuser plate;
16 gauge SS plate,
with 3/32 holes
about every 1/4";
fastened 1" above 1/8 FPT
3/S" SS Plate
Fig. 16
Control circuit
DZ ":...
T1 gree~
SZ
Copyright George Wiseman February ZOOO. I consider this to be the absolute bare bones simplest circuit.
The control circuit tells the Mosfet when to feed power to the electrolyzer in the main circuit.
See Brown's Gas Book Z for specifications not mentioned here. Main current is limited by C1. Rate C1 as
per Brown's Gas Book Z. Main Bridge Rectifier should have an amperage rating as per Brown's Gas Book Z;
use a heat sink and thermal paste.
Mosfet M1 0 is rated at higher than the main power supply peak voltage. Be sure to use a heat sink with
thermal paste and voltage isolator kit (if needed). If one mosfet has too low of an amperage rating, mosfets
can be placed in parrallel to increase amperage rating of the circuit, all Gates connected to DZ with ZO ohm
resistors. Note that the Source of the mosfet needs to be connected to the negative of the control circuit.
S1 is simply to manually shut off the electrical circuit. Mosfet turns on when voltage is applied to it's Gate.
SZ (mounted off board) is a normally closed (open on pressure rise), direct acting pressure switch, made of
stainless steel with a teflon diaphram. It should have at least a ZO watt rating and either be adjustable or
factory set at your desired electrolyzer pressure.
Add an S3 (mounted off board), temperature switch (not shown above) if you need to limit the electrolyzer
temperature. Make the switch normally closed (open on temperature rise) and pre-set at your maximum
temperature. I'd put the switch between SZ and DZ.
The T1 needs to be 10 volts (rated) on the secondary. The voltage can go up to 15 volts with no damage to
the mosfet; which is very likely to happen because it may be hard for you to find a transformer small
enough for this circuit's requirements, so the secondary voltage will rise above it's specified rating. The
primary of T1 should be rated for whatever the main circuit voltage is.
The control circuit bridge rectifier can be tiny, half amp at SO volts is more than needed. CZ is an
electrolytic capacitor minimum rating 100 uF and SO volts. D1 is a red LED, to indicate when the control
circuit is turned on. DZ is a green LED, put there to see when the power is being fed to turn on the mosfet;
it will flash very quickly as the SZ keeps the pressure to within 0.001 psi. R1 and R2 are liZ watt 400
ohm resistors.
T1, CZ and the control circuit bridge rectifier can be replaced with a 1Z VDC battery.
NI--------- ..
p---------~ . . .r. .- - , I
...._ .... .... Positive
output
cp (§
V DC Voltmeter
~~ t
Fig. 9
t Pressure shut-off
Electronic shut-off
Main shut-off
Negative
output
DC Ampmeter
capacitance to the 'Iegs'of your without all the controls that tum the side of your transformer that provides
voltage doubler. As you add main relay on and off. This is the the low voltage for the electronics,
capacitance on each leg of the voltage circuit starting from the output side of gauges, buzzer and relays.
doubler (equal on each leg): the main relay.
You'll note that the DC ammeter is on
You'll note that the amperage will rise Same as Voltage Doubler, only you the line going into the electrolyzer; it
at the rate of one amp per 50 uF per have capacitive limiting in series on doesn't matter which one, just so you
leg with 120 VAC RMS. the input common with the center of get the polarity correct. Although I
the voltage doubler capacitors. depict a capacitive limited, voltage
And the amperage will rise at one amp doubler power supply here, the
per 11 uF per leg with 240 VAC RMS. Main Power Circuit ammeter is installed in the same place
on all the power supplies.
IMPORTANT NOTE: 'There ain't We have the main power coming in on
no such thing as a free lunch'. When an ordinary 240 Volt cord, using You'll note that the DC voltmeter is
you increase the voltage using a properly rated receptacles, wire sizes mounted between the lines going into
voltage doubler, the 'extra power' and plugs. The 'P'is power or hot; the the electrolyzer, you have to get the
comes from AMPERAGE from your 'N'is neutral, where you wire to when polarity correct. Although I depict a
RMSsource. you want 120 VAC. capacitive limited, voltage doubler
power supply here, the voltmeter is
When using a voltage doubler circuit, Note that our electrolyzer draws about installed in the same place on all the
the amperage being drawn from the 50 amps, so I use a main relay rated at power supplies.
wall is about TWICE the amperage 90 amps. The relay is normally open,
you see across your electrolyzer. You three pole, single throw. The relay has There are any number of 'extras'that
must be sure your wall fuse or breaker a 120 volt coil to activate it. can be applied to this circuit, like
can handle the amperage you will be indicator lights and receptacles (120
adding. Remember that the Note the three shut-off switches wired volt and 240 volt); but I left them out
MAXIMUM continuous operating in series, in series with the main relay of this schematic because I'm trying to
amperage of your breaker or fuse will coil. This is so that if anyone of the keep it seriously simple. What you see
be only 80% of the 'rated'amperage. switches is open (off) then the main will work just great! The electronics
For example; a 20 amp breaker should relay has no power and is off! The has status indicator lights and you can
hold 16 amps. Pressure switch is normally closed, see when the power is on (to the
open on pressure rise (could be a
Further Note: When a breaker 'trips', it relay). The Electronic switch is a
will not again hold as much amperage relay that is normally open, held
Low voltage
o
as before. After each 'trip'the actual closed by the electronic circuit. Power Supply
amperage that the breaker will hold is a The Main switch is normally 7812
bit less. open, closed only when you want
the electrolyzer operational (this
3. Voltoge Doubler with capacitive could be a relay too), I usually
limiting just use an ordinary light switch.
Note that this is the 'basic'power The points marked 'a'and 'b' are
supply circuit for the e1ectrolyzer only, where you connect the primary Fig. 10
22 www.eagle-research.com/Brown·s Gas, Book 2