Les Banki Circuit

Updated Version
August 16, 2007

Synchronized 3 Frequency PWM circuit & cell drivers

(for ‘resonance’ electrolysis of water)

Background

The basic idea for this design is based on information published by Bob Boyce.
(He is a member of several ‘free energy’ discussion groups/forums on Internet.)
Amongst many other very useful bits of information, he has revealed the frequencies, the ‘feed’ method to the
electrolyzer cell & other important electronic details.

Having been heavily involved in the “water fuel” technology (about 13 years ago) I can easily tell if published
information bits are dis-information or REAL.
I have collected some of Bob’s most important postings and put them in a file (about 78 pages, at present) I
simply named ‘Bob Boyce’.
I am convinced that he is possibly the most knowledgeable man (alive), with practical knowledge, on the
subject of using water as the ONLY fuel.

This also happens to be my goal. (NO mixing with any other type of fuel to buy!)

Introduction

In more than one posting, Bob has stated that there should (ideally) be 3 frequencies, harmonically related, to
obtain optimum results.
These centre frequencies are: 10.7kHz – 21.4kHz – 42.8kHz
They should NOT be in phase but very, very close (slight phase delay between them).
These frequencies could/should be mixed (‘modulated’) in a transformer which feeds the electrolyzer cell from
its secondary winding.
(However, he added that tuning 3 independent frequencies simultaneously is not an easy task. The details above
may explain why so many experimenters in the past have failed to obtain results in their quest of finding the
“resonance” frequency of water.)

Brief technical description

My basic idea is as follows: Since the frequencies: 10.7kHz – 21.4kHz – 42.8kHz are harmonically related, only
ONE needs to be tuned.
Either frequency multiplication or division can be performed to obtain the other two. (Using flip-flops, digital
division is very simple.)

Using division, we start with the highest frequency, 42.8kHz.

Divide by two gives 21.4kHz. Divide that by two gives 10.7kHz.
There are two remaining tasks to be performed:
Synchronizing the 3 independent PWM oscillators running at F, F/2, F/4) and,
provide adjustable phase delays between them.

My design is based on the SG3525A, (a regulating PWM chip) because of its following features:
* Oscillator frequency range: 100Hz – 400kHz
* It has an ‘oscillator output’ terminal
* Separate ‘sync’ terminal [multiple units can be ‘slaved’ (synchronized)]
* Internal ‘soft start’
* Pulse-by-pulse ‘shut down’
* Adjustable dead-time control
* Latching PWM to prevent multiple pulses
* Totem-pole, dual source/sink output drivers
* Input under voltage lockout with hysteresis
* Its outputs can be configured as single-ended OR push-pull

The SG3525A is also cheap and readily available.

Further, it should be obvious to the technical reader, that any other group of frequencies can be used by the
appropriate choice of time constants for the oscillators, phase delays and sync pulses – within the limits of the
SG3525’s oscillator frequency range.

A single 4013 (CMOS, dual D-type flip-flop IC) performs the 2 frequency divisions.
Two 4538 (CMOS, dual monostable multivibrator, in non-retriggerable modes),
act as phase delays and sync pulse generators at the same time.

With this arrangement, adjustments have been greatly simplified:

* Only ONE (the highest) frequency is ‘tuned’.

(The other two are automatically ‘locked’ to be F/2 and F/4.)
* Duty Cycle for all 3 Pulse Width Modulators can be set independently or, with a common control to the same
value – as desired.
* The two phase delays can be independently adjusted between pre-determined limits.
* All 3 PWM outputs can be configured as single-ended OR push-pull drive, as desired.
(Note: transformer windings needs to match - single-ended OR push-pull- respectively.)

Detailed technical description:

I will not describe/explain the internal circuitry of the SG3525 PWM as it is well covered by Application Note
AN250/1188 by SGS-THOMSON MICROELECTRONICS.
I will only deal with the chip’s important features and how they are used in this design.

The main feature for this application is the ability to ‘synchronize’ multiple chips.
The ‘twist’ here is that the two ‘slave’ units are tuned/synchronized to generate
F/2 and F/4 sub-harmonics.
This is the way its done:
IC1’s ‘oscillator output’ (pin 4) signal is amplified by a single transistor TR4 (BC547) since its amplitude is too
low for driving the CMOS IC’s input.
(this single transistor stage inverts the pulses but that does not matter here)
This amplified oscillator output signal is fed to the clock input (pin 3) of IC4A (4013).
The F/2 output (now a ‘square wave’ with ~ 50% duty cycle) from pin 1 (Q output) is fed to the clock input (pin
11) of the second flip-flop (IC4B) and also to the “A”
(rising edge input, pin 4) of IC5A (4538)

IC5A generates the ‘phase delay’ pulses.

The R-C time constant is determined by C22 (1n), R18 (12k) and P5 (10k)
[Note: the specified minimum output pulse width for the 4538 is 1 s. Therefore, a small (say 1 or 2 phase
shift at the frequencies involved here) can not be generated directly.]
So, the phase is delayed by around 180 which can then be fine tuned to the required amount. Note also that
with this method not only phase ‘lag’ but also phase ‘lead’ can be easily set within very wide limits!
Needless to say that since the phase shift is naturally frequency dependent, altering the frequency will (slightly)
alter the phase shift.

The ‘Q’ output of IC5A (pin 6) is connected to the second non-retriggerable monostable’s (IC5B) “B” input (pin
11, falling edge trigger).

IC5B is the sync pulse generator.

The R-C time constant C23 (100p) and R19 (3.9k) set the pulse width to about 390ns.
From the ‘Q’ output (pin 10) these pulses are fed to the ‘sync’ input (pin3) of IC2 (second PWM IC, SG3525A)
Its oscillator time constant [C17 (10n), R7 (8.2k) & R9 (33ohm)] is set to be about 10% longer than the
minimum expected frequency.
It should be noted here that the oscillator timing capacitors C17 & C21 do not begin to recharge as long as their
sync pins are high.
In other words, these oscillators do not start before the sync pulses are terminated.

The second ‘divider/phase delay/sync pulse generator’ stage for the 3rd PWM (IC3) is identical to the first one,
with the addition of IC6 (A & B)
The only difference is that the F/2 pulses are taken from the ‘Q’ output (pin 1) of IC4A and fed to the clock
input (pin 11) of the second divider flip-flop, IC4B.

P1 is the ONLY frequency control. With the component values shown in the diagram, it has a range of approx.
+7.5% to -6.5% from the centre frequency of 42.8kHz. The other two PWM oscillators are in sync, giving
EXACTLY F/2 and F/4.

Pulse Width Modulation (Duty Cycle) is either adjusted individually with P2, P3 and P4, or collectively, by P2
(50k), connecting the slider (through 10k resistors) to pin 2 of IC1, IC2 and IC3. (In that case, P3 and P4 are
omitted.)
The SG3525A’s control voltage (for duty cycle adjustment) ranges from about 0.9V to 3.3V (typical).
Setting this control voltage range minimizes the ‘dead band’ of the potentiometer.

The 1V – 3.3V range is set by the bias network [D4, D5, D6, D7, R1 (39k) - P1 (50k) - P2 (50k) – P3 (50k) –
D8, D9] between the 5.1V reference voltage (pin 16 of IC1) and ground.
The outputs of the 3 Pulse Width Modulators [IC1, IC2 & IC3 (SG3525)] are arranged as single ended outputs
by connecting their A & B outputs (pins 11 & 14) to ground and using the ‘Vc’ (pin 13) as output with pull-up
resistors R4, R8 & R12 (1k) to the positive supply rail.

Using a dedicated MOSFET driver have some advantages compared to the use of complementary discrete
transistors.
First of all, the TC 4420 MOSFET driver can supply peak currents of up to 6A! to the gate of the MOSFET
switch.
Second, when using this driver, there is no need for level shifting.
Since it has a ‘Schmitt trigger’ input, it also acts as a ‘wave shaper’.
But perhaps most importantly, there is no need to amplify the pulses.
(That would involve yet another IC, a wide band OP. To fully turn on most power MOSFETS, a drive voltage of
at least 10 – 12V is needed.)

TVS diodes D1, D2 and D3 (1.5KE18A) are protecting the MOSFETS.

They are SUPER FAST devices, working in the sub-nanosecond (pico) range!

[Users of the TC4420/TC4429 Universal Power MOSFET Interface Ic’s should be aware that for trouble free
performance, a careful printed circuit board layout is essential, especially de-coupling and grounding.
See AN-28 (Application Notes) by “TelCom Semiconductor, Inc.”]

[If TC4420’s cannot be obtained, they can be substituted with medium power complementary NPN/PNP
transistor pairs. The Collector of the NPN transistor must be connected to the 14V supply line. ( NOT to the
+8V!)]

As even most non-technical readers probably know, the 12V supply line in a car is anything but ‘12V’!! (It can
be anywhere from about 10.5V to 15V, under certain conditions, depending on several things.)
To minimize drift (due to voltage & temperature variations) a +8V regulator is used to supply all ICs.

[+8V was chosen since under certain conditions battery voltage may be as low as 10.5V and most ‘normal’
regulators need a voltage ‘overhead’ of at least 2.5V before ‘dropping out’ (stop regulating)].

Les Banki
(Electronic Design Engineer)
Water Fuel & LBE Technologies

Parts list for Synchronized 3 Frequency PWM circuit:

C1 (0.1u) C2 (1uF) C3 (100uF)
C4 (2200uF) C5 (2200uF) C6 (0.1u)
C7 (1uF) C8 (0.1u) C9 (1uF)
C10 (10uF) C11 (0.1u) C12 (0.1u)
C13 (4n7) C14 (0.1u) C15 (0.1u)
C16 (0.1u) C17 (10n) C19 (0.1u)
C20 (0.1u) C21 (22n) C22 (1n)
C23 (100p) C24 (1n) C25 (100p)
C26 (0.1u) C27 (0.1u) C28 (0.1u)
C29 (0.1u) C30 (0.1u) C31 (0.1u)
CN1 () CN2 () CN3 ()
CN4 () D1 (1.5KE18A) D2 (1.5KE18A)
D3 (1.5KE18A) D4 (4148) D5 (4148)
D6 (4148) D7 (4148) D8 (4148)
D9 (4148) IC1 (SG3525) IC2 (SG3525)
IC3 (SG3525) IC4 (4013) IC5 (4538)
IC6 (4538) IC7 (TC4420) IC8 (TC4420)
IC9 (TC4420) MOV1 (15V) P1 (1k)
P2 (50k) P3 (50k) P4 (50k)
P5 (10k) P6 (10k) R1 (39k)
R2 (2K2) R3A (3K3) R3B (3k3)
R4 (1k) R5 (47R) R6 (2k2)
R7 (8k2) R8 (1k) R9 (33R)
R10 (2k2) R11 (8k2) R12 (1k)
R13 (33R) R14 (4k7) R15 (1k)
R16 (10k) R17 (10k) R18 (12k)
R19 (3k9) R20 (10k) R21 (10k)
R22 (10k) R23 (4k7) REG1 (+8V)
TR1 (80A) TR2 (80A) TR3 (80A)
TR4 (BC547)
------------------------------------------------
Summary of parts list

Capacitors:

16 x 0.1 uF
3 x 1uF
1 x 10uF
1 x 100uF
2 x 2200uF
2 x 1nF
1 x 4n7
1 x 10nF
1 x 22nF
2 x 100pF

Diodes:

3 x 1.5KE18A
6 x 4148

IC's

3 x SG3525A-2
1 x 4013
2 x 4538
3 x TC4420 mosfet driver

Potentiometers:

1 x 1k
3 x 50k
2 x 10k

Resistors:

1 x 39k
1 x 2K2
2 x 3K3
4 x 1k
1 x 47R
2 x 2k2
2 x 8k2
2 x 33R
2 x 4k7
5 x 10k
1 x 12k
1 x 3k9

1 x BC547
Mosfets should be able to handle up to 60V and 80 Amps
Phase delays in multi-frequency Pulse Width Modulators
Since the release of my “Synchronized 3 frequency PWM” design into the public domain, I have received
several requests for further explanation of phase delays in PWMs.
The phase delay issue has also generated some controversy, which further reveals that this subject is not well
understood by most experimenters.

I will attempt to explain it in a way which (hopefully) can be understood by most.

However, some knowledge of electronics is required for gaining proper understanding.

To aid the understanding, I will make a direct comparison between Bob’s PWM3 series and my design of the
“Synchronized 3 frequency PWM”.
(I feel it is appropriate to do so since it was Bob’s design which inspired me to design mine, in order to greatly
simplify tuning.)

As Bob has already explained (several times) most of the points (like: why 3 frequencies, the role of phase
delays, why a toroidal transformer is used, etc., etc.) there is no point repeating it all.

First of all, please note:

Phase delays (shifts) are expressed in degrees (°), NOT percentage (%).

Bob’s PWM3 design uses 3 independent, FREE RUNNING oscillators.

These 3 frequencies are then tuned independently to be exactly F, F/2 and F/4, for resonance.
This design, by its very nature, does NOT need an added phase delay, for the following reasons:
Since these 3 oscillators are NOT synchronized, even if the second and third frequencies are tuned VERY close
to, or even EXACTLY F/2 and F/4, A RANDOM, CONTINUOUSLY CHANGING PHASE SHIFT WILL
STILL EXIST.

Needless to say, this drifting phase shift will also pass the ‘dreaded’ 120° regularly but briefly. At times it may
even be EXACTLY 120° for a cycle or two. This, however, will be mostly imperceptible to the circuitry,
transformer and particularly the observer.
As I understand it, possible dangers may arise (according to Bob) ONLY when the phase delays are FIXED at
120°!

My “Synchronized 3 frequency PWM” is very different.

Not only are the second (F/2) and third (F/4) frequencies are digitally divided down
from F, they are not only SYNCHRONIZED with F but also PHASE LOCKED.

[Oscillators can be synchronized in several ways. However, with some of the methods one can only achieve a
‘frequency lock’ condition. Others can do both frequency AND phase lock. For example: have a look at “Phase
Locked Loops” (as building blocks)]

Again, that means F, F/2 and F/4 are EXACTLY in phase!

Since there is no random phase delay drift, this design NEEDS added phase delays.
The advantage is that these added delays are predictable and adjustable.
Keep in mind that since these delays are just simple pulse timers, they are frequency dependent. (As I indicated
in the circuit description.)
If needed, they COULD be made frequency independent with a little more circuit complexity.
Originally, I allowed a 0 - 360° adjustment range but if desired, this can easily be restricted to a much narrower
range. (by changing a couple of component values)
However, even this should not normally be necessary.
To those who wish to experiment with this circuit and want to avoid the possibility of getting close to the 120°
phase delay point, I suggest you do the following:

Set up the circuit WITHOUT any kind of load connected.

(Or, leave the output stages out for the time being.)
With an oscilloscope, adjust the frequency, Duty Cycles (on all 3 PWMs) and adjust the two phase delays to say,
within 5 - 10°, initially.
Then, when you set up the rest and connect your load, DO NOT stray too far off the initial phase delay settings.
[While I cannot give you exact figures, (that’s what experimentation is about!) my guess is that it will be much
less than the figures indicated above!)
Don’t even be surprised if it turns out to be less than 1°!]

120 cell plate design

Please do not rush into it.
To make a 120 cell unit is not a small job and if you make a mistake it will cost you heaps.
There are a few more practical points to be aware of before you decide on the material you will buy.
Normally I use 15mm Acrylic but you can go to 20mm if you don't mind the extra cost.
(Another option could be to fit some angle iron (or aluminium) frame on the corners to reinforce the structure.)

Consider also the following points:

1. The two (2) end plates are 110x110x2mm and MUST be fitted first. (with the bolts already welded on)
Counter sink the Acrylic (on the inside wall) to make room for the head of the bolt & weld.

2. The "neutral" plates are 119x185x0.5mm (I will be using 0.5mm plates.)

They are cut 1mm shorter than the distance between the bottom of the grooves. (on the sides)
This is to avoid trouble with tight fit.
Remember, there is 119 of them, should you need to trim them!

3. Use the correct EXCEL list for the plate thickness of your choice. (or generate your own list)
With the exception of the total width and height of the cell, all other dimensions depend on the plate thickness.

4. If you wish to alter the dimensions of the cell plates, you ought to consider that stainless steel sheets come in
standard sizes, usually 4'x8' (1220x2440mm).
I took this into consideration to avoid waste (off cuts).
With the dimensions indicated in the drawings, I can cut all 120 plates out of one sheet with almost no waste.

5. The 'formula' for generating new EXCEL lists is: thickness of end plate (say 2mm) + gap distance (3mm) +
1/2 plate thickness (1/2 of 0.5mm is 0.25mm) = 2+3+0.25=5.25mm.
This is the position of the first groove from the edge of the board.
Then, add 3.5mm (which is the sum of the gap distance + plate thickness)
You only need to calculate ONE. EXCEL will do the rest. The last groove number will be the same as the
number of gaps (cells) and you once again add the same figure as above (5.25mm) to get the total dimension of
the board.

6. Depending on the method of machining the grooves, extra length may have to be added for mounting holes
at both ends. (these will be cut off later)
When cutting the board, take the saw blade thickness into account.
First, cut out the bottom (from the middle, see drawing) and then trim the remaining two sides to the correct
sizes.
Refill is the undisputed biggest challenge of the series cell system! Over the years I had many different ideas
but rejected them all, for various reasons. (as had some other experimenters, they didn't get it right either!)
I know that some experimenters actually gave up on the series cell design altogether mainly because they did
not know how to make them properly and the refill presented an 'engineering' challenge!
However, I think my latest idea (which I had for several years now), while not cheap, should solve the problem.
(it has not yet been tried - lack of time!)
I will try to describe it and perhaps you can try it and fine tune it. (it would save me doing it!!)
During the next few days I will make a drawing of it so it will be easier to understand.

The idea is to use two containers. The electrolyzer will be made the same as before but without a lid. Open.
It will be placed into another, larger container which will have a lid/gasket and be pressurized.
(The gas output port will be on this lid.)
This container will be filled with electrolyte to the exact level as desired in the electrolyzer itself.

A narrow and relatively thin strip of plastic (Acrylic) is clamped to the bottom plate of the electrolyzer (for the
purpose of drilling them together) and small holes (say, 1.5mm diam.) are drilled under each and every cell, in
the middle of the 3mm gaps.
(If faster fill is needed, more than one row of holes could be drilled.)
Since the two pieces are drilled together, perfect line up of all holes is obtained.
This strip is then mounted on a spring loaded slide arrangement under the cell and off-set slightly to cover ALL
holes.

When the electrolyzer needs to be filled, the strip is moved slightly (2 - 2.5mm) to line up the holes!
If a piece of epoxy resin coated mild steel (or magnet) is attached to this strip, it could be operated by an
electro-magnet (solenoid) from the outside of the container!
This solenoid is then turned on/off as required with some sort of electronic control. (yet to be decided)
Remember, the gas pressure also acts on the electrolyte in all directions and therefore the
electrolyte will be forced through all the holes until the levels are EXACTLY the same as in the main container.

The water level sensors will be in the main container (NOT in the electrolyzer) and water will be pumped from
the purified water storage container. (the "fuel tank" Cool )

Acrylic Slot Cutting Information

A slitting saw does not break easily, unless you are grossly abusing it!
With a large CNC milling machine, a job like this is "a piece of cake".

SLITTING SAWS are available in every imaginable diameter and blade thickness!

Here is just one of many web sites you should look at (British quality):

http://www.tapdie.com/html/slitting_saws__slitting_saws_i.html

Further, here is an idea if you don’t have access to a milling machine:

Get a sturdy table (for this purpose) and mount the saw under the table with only a few millimeters of the blade
sticking up through a slot in the table top.

(You can fix the saw arrangement to a permanent 5mm or make it adjustable.)

Your “saw” can simply be a cheap disc grinder with a saw blade fitted, instead of the usual stone disk. Support
the saw blade on both sides with rigid metal disks.

Leave no more than about 8-10mm of saw’s edge exposed.

(In other words, the diameter of the two supporting discs will be about 15-20mm less than the diameter of the
thin slitting saw.)

Next, mount some accurate guide arrangement on the top of your table where you can push the work piece
along by hand!

As for disc grinders, some even have electronic speed control and smooth start-up for a little extra cost.
(I got one, its great!)

It does not need to be very powerful. Remember, you are only cutting plastic, not metal.

I think we will end up making our own purpose built 'router table', specifically for this job.
Plans for such a table are offered for sale on Internet. Have a look at: http://www.solsylva.com/

As for my complete power supply design, it is almost done. Only some minor details need to be worked out
and the necessary parts to be obtained since I am going to use the latest technology available.
[I have been trying to obtain some samples for at least 6 months. My efforts are finally paying off. I am
chasing the last (I hope) part, a 20A Hall effect sensor for the 240VAC power control.]

Best Regards

Les Banki

P.S.: DON'T use Polycarbonate (Lexan) with KOH (Potassium Hydroxide). They are NOT compatible.
Use Acrylic (Plexiglass) with KOH. [I won't suggest NaOH (Sodium Hydroxide) as it is not as good as
KOH]

Ignition system for small engines running on Hydroxy ONLY

It should be obvious that with Hydroxy as the ONLY fuel, the use of 2 stroke engines are ruled out since they
require oil to be mixed with their fuel for lubrication.

Therefore, only 4 stroke engines will be considered in this brief.

First, some engine data.

The crank shaft on a 4 stroke engine turns twice (720º) for every ‘work’ cycle.
Since most (if not all) small engine designs use a magnet on the fly wheel (which is mounted on the crankshaft)
to generate the ignition sparks,
2 sparks are delivered for every work cycle.
The second spark (which is delivered during the exhaust stroke) is NOT needed and so it is called “waste
spark”. With hydrocarbon fuels it is harmless.

However, with Hydroxy ONLY, this “waste spark” MUST be eliminated.

With hydrocarbon fuels, ignition usually takes place around 8º before TDC to allow some atomization of the
fuel before the actual ‘explosion’, which occurs approximately 10º after TDC.

If Hydroxy is ignited at ANY point before the piston has reached TDC, the explosion takes place at that
INSTANT.
(There is NO delay or atomization here since it ‘burns’ about 1000 times faster than hydrocarbon fuels and it
could be said that it is not ‘burning’ but exploding!)
The force of the explosion instantly tries to push the piston DOWN when it is still trying to come to the top to
complete its compression stroke!
That is most undesirable!
When the ignition is delayed (retarded) to the point where the explosion usually occurs with hydrocarbon fuels
(around 10º after TDC) then the piston’s downward movement is reinforced and useful work is gained.

Now, consider what would happen if the waste spark was NOT eliminated.
As stated above, the crankshaft revolves twice for every ‘work’ cycle.
(The first revolution covers the intake and compression stroke and the second one the power and exhaust
stroke.)
Thus, the second spark (‘waste spark’) occurs just before (the same degree of advance as the wanted spark,
about 8º) before TDC at the end of the exhaust stroke.
But when the ignition pulse is delayed to be after TDC, the waste spark will occur at the beginning of a new
‘cycle’, where the intake valve has just started to open.
So now, with a slightly open valve there is an open path to the fuel line (Hydroxy), and there comes a spark!
Guess what happens… Guaranteed back fire!

And I can assure you that even the most minute opening will allow the ‘flame front’ to propagate back to the
supply line. How do I know? Experience. Lots of it.
Further, let me tell you that I have personally not found ANY method of stopping back fires to propagate back
to the electrolyzer, EXCEPT water. While most people call them bubblers, I prefer the name “flash-back
arrestor”, since that is their true role.
If you doubt the above statements about stopping flash backs traveling back to your electrolyser and DESTROY
it, by all means, ignore the advice.
Not only will you DESTROY your electrolyser but very likely injure or even KILL yourself and/or others!

An example of engine calculations:

I bought a new, 118cc, one cylinder, 4 stroke petrol engine for Hydroxy experiments.
Its rated max. output is 4 horsepower (2960W) at 3600RPM.
For the ease of calculations, lets round up the capacity to 120cc (0.12L)
This is the maximum volume of air/fuel mixture it can suck in during its intake cycle.
As stated before, the engine’s ‘work’ cycle number is half the crankshaft revolution.
Thus, at 3600RPM, the number of fuel intakes is 1800/minute.
1800 x 0.12L = 216L/minute
However, as only 1% of QUALITY Hydroxy (mixed with 99% of air) is needed to obtain the same power as
petrol, this 120cc engine should require only 2.16L/minute of Hydroxy to run at 3600RPM!!
(Naturally, it would require less at lower speeds. It remains to be seen if it will require more under full load
than this calculated volume.)

Now a few notes about the necessary ignition delay and how to achieve it.

In one article it was suggested that one could use a 555 IC to delay the ignition pulse.
Yes, that could be done but it would only be correct at ONE speed.
The reason is obvious:
Ignition advance/delay is related to piston position, NOT time.
It is expressed in ‘degrees’ but for hydrocarbon fuels it is varied slightly with engine speed. (due to its relatively
slow burning)
With Hydroxy, ignition will take place at the same ‘degree’, (same position of the piston) regardless of engine
speed.
At this stage, a couple of things are clear already:

One: on my test engine (and I dare say on most, it not all, small engines) it is not possible (meaning: NOT
practical) to eliminate the ‘waste sparks’.
Two, there is NO provision for ignition timing adjustments, neither mechanical, nor electronic.
In other words, the existing ignition systems used on small engines are USELESS for Hydroxy.
We need a NEW electronic ignition system, complete with ADJUSTABLE delay.
So how can that be done?

Again, two revolutions of the crankshaft is 720º (two circles but one ‘work cycle’).
The camshaft, (controlling the valves) however, turns only ONCE, which is 360º.
In electronic terms, that is 100%.
We want to delay the ignition timing from where it is now, say, from 8º before TDC to 10º after TDC. That is a
delay of 18º.
The equation is: 360 : 100 = 18 : X Re-arranging it: 360X = 1800, X = 5
In other words, 18º is 5% of 360º.
We need to delay our original ignition pulse by 5%, irrespective of frequency.
(the ‘frequency’ here is the engine’s revolution)
The above example serves to illustrate the difference between the ‘old’ and the ‘new’ settings, assuming that the
degree settings relate to the camshaft revolution, 360º.
However, as I understand it, the ignition advance/retard degrees are usually expressed in terms of crankshaft
degrees (720 - two revolutions of the crankshaft)
In that case, the above percentage of 5% is halved.
Then, 18º is 2.5% of 720º

Since we need a NEW ignition system, this ‘delay’ will no longer relate to the ‘old’ setting. A new signal is
taken from a sensor (Hall switch) mounted on the engine, detecting the intake (or exhaust) valve’s position.
Using the signal from this sensor, the ignition spark could be made to occur anywhere but we want it approx.
10º (or more) after TDC (adjustable within a few degrees)
Of course, our reference is still TDC.
When we express all that in electronic signal terms, the intake stroke (piston travels from TDC to BDC) is ¼ of
the engine’s work cycle, which is 25% of our wave form.
(90º of the work cycle and 180º of crankshaft rotation)

If we transform the delays from degrees to percentage, we get the following figures:
10º ATDC is a delay of ~1.39%
25º “ ~3.47%
So, if we want the adjustment range of 10º - 25º, the percentage difference is 2.08%.
[We can also calculate the elapsed time this translates to, for any given speed.
For example: at 3600RPM, the ‘frequency’ is 30Hz. One period is 1/30 = 0.0333sec.
Thus, a 1.39% delay means that the piston has traveled (from TDC) for 463.3s to reach the position of 10º
ATDC (relating to crankshaft revolution)]

One simple way to implement these delays is to use a PWM (Pulse Width Modulator) circuit, which is my
preferred choice.
(How this is done will be described in detail in a technical “circuit description”.)

It needs to be pointed out that the ignition system for Hydroxy ONLY (not just a booster) will be very different
from ignition systems for hydrocarbon fuels.
It will be significantly simpler.
There will be NO “speed mapping”, NO “load mapping”, NO retard/advance change with engine RPM, NO
rich/lean mixture setting, NO cold start setting, NO “knock sensor”, NO fuel/air temperature sensor, NO
Oxygen sensor, etc., etc.,
(“modern” engines are full of all that rubbish!)
There will be NO need for high energy sparks, multiple sparks, etc.
Further, there will be NO such thing as UNBURNED fuel remaining in the cylinders!!

In short; when we get to the larger engines (cars), the first thing we have to do is to rip out the “computer” and
install our own system, incorporating electronic injection as well.
(Perhaps another option could be to completely re-program the ‘computer’, provided that one could obtain the
original programming software from the manufacturer, which, I would say, is HIGHLY unlikely!)
I am in favor of electronic injection (but ONLY for Hydroxy) for two reasons:
1. I reason that if we allow Hydroxy to flow continuously, some of it may disappear during the other ¾ of the
engine’s work cycle. (the intake stroke is only ¼ cycle)
2. If Hydroxy is ALWAYS present in the intake manifold, we may risk a damaging back fire.

No, the new ignition system will NOT use a microprocessor (the modern “buzz-word”)!
NO fancy software, NO programming.
It will be a mainly analog design, using parts available everywhere and are dirt cheap!
Should a fault occur, it will be quick, easy and cheap to repair.

Les Banki
(electronic design engineer)
Water Fuel & LBE Technologies