Water Injection Manual (Preview)
Water Injection Manual (Preview)
Water Injection Manual (Preview)
019.84 $6.6
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George Wiseman
Eagle-Research
Energy Solutions
since 1984
www.eagle-research.com
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Water Injection
by George Wiseman
Eagle-Research
Energy Solutions
since 1984
Copyright March 2002, August 2009 by George Wiseman WATER INJECTION ISBN 1-895882-37-0 ALL RIGHTS RESERVED No part of this publication may be reproduced in any form or by any means, electronic or mechanical, including photocopying and recording, or by any information storage or retrieval system without written permission from the author, except for brief passages quoted in a review. Desktop Publishing by: SPACE 2001 / Penticton, BC Printed by: Kootenay Kwik Print / Cranbrook, BC
Wiseman, George, 1958Water injection : how to supplement fuel with water / by George Wiseman
TABLE OF CONTENTS
INTRODUCTION ........................................ 1 MYTHS VS FACTS OF WATER INJECTION ............................. 1 WATER STATES .......................................... 3 Vapor; Water; Steam DESIGNING A WATER INJECTION SYSTEM .................................................. 4 Anti-freeze Techniques; Heating the water; Pressurize the water; Component choice and placement; Automatic operation; Safety Features; Shutoff valves; Add water in a direct ratio to the fuel; Water Shutoff; Startup delay; Cold temperature shutoff; Monitor liquid level; Deceleration water shutoff; Ease of Operation ANTI-FREEZE TECHNIQUES ................. 5 Alcohol; Engine coolant; Gravity purge; Air purge; Take the system inside; Electric Heaters PRESSURIZE THE WATER ...................... 6 Pressurize with a water pump; Pressurize with compressed air; Air Compressor; Smog Pump; High Pressure Air Tank WATER FILL TUBE AND VENTING ...... 9 Water fill cap PRESSURE HOSE CONSIDERATIONS .. 9 WATER INJECTOR .................................. 10 INJECTOR (OR SPRAY NOZZLE) POSITION ............................................. 10 ADDING A LARGE WATER TANK ....... 10 ELECTRONIC CIRCUIT DESIGN ........ 11 Circuit design recommendations; Electrical and Electronic parts list / descriptions; Capacitors; Switches; Light Emitting Diodes (LED); Diodes; Resistors; Potentiometers; 358 operational amplifier; Mosfets; Understanding Mosfets; P-channel vs N-channel Mosfets WATER INJECTOR CIRCUIT FOR NON-EFI ................................................ 14
continued on reverse
has read a collection of applicable books has working knowledge knows subject well enough to teach an entry-level person Bachelor level
has own collection of 'tools of the trade' works 'in trade' for family & friends has full set of tools; is paid as a semi-professional 3 yr. Apprentice level 4-5 year training and experience in applicable trade
RESOURCES .............................................. 26 Helpful Products; Helpful Books & Literature; Links Index of Figures Fig. 1: Water Injection (WI) / water pump .... 6 Fig. 2: Simplest Water Injection ..................... 7 Fig. 3: WI using air compressor ..................... 8 Fig. 4: WI using high pressure compressed air tank ................................................ 9 Fig. 5: Parallel Mosfets ................................ 14 Fig. 6: Water Injection for non-EFI .............. 15 Fig. 7: Simplest EFI Circuit ......................... 15 Fig. 8: EFI with LEDs & SO options .......... 16 Fig. 9: High Pressure Shutoff/water pump ... 16 Fig. 9a: /compressor ..................................... 16 Fig. 10: Electronic Pressure Regulator ........ 17 Fig. 11: Electronic Over-Pressure Regulator ......................................... 17 Fig. 12: Alternator Power ............................. 18 Fig. 13: Startup Delay .................................. 18 Fig. 14: 555 Frequency Chart ...................... 19 Fig. 15: Deceleration water shutoff .............. 19 Fig. 16: Low Level ....................................... 20 Fig. 17: Low Water Warning ........................ 20 Fig. 18: High Water ...................................... 20 Fig. 19: Automatic Water-Fill ...................... 21 Fig. 20: Cold Engine SO .............................. 21 Fig. 21: Polarity Reversal (negative) ............ 21 Fig. 22: Polarity Reversal (positive) ............. 21 Fig. 23: Thermistor Switch .......................... 22 Fig. 24: High-Low Setpoint ......................... 22 Fig. 25: Water Heating ................................. 25
TOOLS
This book is at the How-To (8) stage. A standard.set of mechanics tools is applicable for most project options. Recommendations for specialized tools are included with option instructions.
PARTS
This book is at the How-To (8) stage. Recommendations for specific parts are included with option instructions. A list of Electronic parts can be found in Electronic Circuit Design.
Costs quoted, throughout this book, are based on year of publication rates.
INTRODUCTION
Using water to directly replace a portion of the fuel is a technology that has been around as long as there have been engines powered by fossil-fuel. When extra performance was needed, like in WW2 aircraft or in farm tractors, the technology was applied on an OEM level Racing is a common aftermarket water injection application. Installed properly, water injection increases power and performance. The basic concept of Water Injection is simple: Have a water tank and spray the water into the engine in a controlled manner. The problem is the details that can make it work well, or be a minor disaster. We outline some options, using low cost components and simple techniques, and give details that will guide you toward the work well scenario. There are several methods to pressurize the water so that it will spray into the engine. The simplest methods use the pressure difference between atmospheric pressure and intake manifold pressure. We call this passive water injection. Passive systems are simple and effective, but tend to give most water during idle and least water when the engine is under load. This is because they depend on the engines intake manifold vacuum to suck in the water. Intake manifold vacuum is highest at deceleration (you need no water); still high at idle (you need very little water); about medium during light load on the engine (you need more water) and very low during
high load on the engine (you need the most water). Passive Water Injection systems, with ways to add more water as the vacuum decreases,.are described in Super Gas Saver Secrets. For best results, you want the water to be injected into the engine in an exact ratio to the actual fuel going into the engine. Advanced Water Injection systems use an alternate source of pressure (or a venturi system) to inject the water. We call these active Water Injection systems. In this book we detail options to help you build your own practical, active Water Injection system. Buying an effective Water Injection system can be pricey, running between $300-$1000 US. Using this book, you can custom-build your own basic or full feature version for a fraction of that price. All the Water Injection systems mentioned in this book add the water to the engine independently of the fuel. Although there are methods of mixing water and fuel, that is not the subject of this book. There have been successful experiments where water has been exclusively used as the fuel for internal combustion engines. Several of these technologies are covered in Water as Fuel, Book 1. (see Resources) You will get a gain just with the simplest Water Injection system. We recommend starting with the simplest system and adding features at your convenience.
Stage one occurs when the spark plug fires. It ignites the fuel that has managed to turn to vapor before ignition. Fossil-fuel can only burn when it is in a vapor state and mixed with oxygen. Stage two follows the first so closely that it seems like one explosion. As the initial vapor explodes, the explosion creates enough heat and pressure to vaporize the portion of the fuel that was still liquid when the spark plug fired. Most of this second explosion does not actually power your vehicle! The time it takes to turn to vapor, then mix with oxygen and then combust is too long. Gasoline engines actually pump large quantities of extra fuel into the engine for no other reason than to quench (as in put out the fire) the explosion in the cylinders.
Traditionally, if you lean the vehicles mixture, using the idle-mixture screws on your carburetor, the engine and exhaust temperatures will rise. This is what causes the myth that leaning the mixture will damage the engine. The reason for the traditional excess heating is the time required for combustion and the time the engine allows for combustion. The liquid fuel charge provided by conventional fuel systems requires about 25 milliseconds to combust. So even though ignition takes place before top dead center, the fuel would still be burning as it goes out the exhaust (about 7 milliseconds later). This overheats the engine, burns exhaust valves and wastes potential heat energy. At 2000 RPM, a 292ci engine has a piston stroke time from top dead center to exhaust valve open of about 5 milliseconds. The 292ci is a long stroke engine, most V8 engines only have about 3 milliseconds to exhaust valve open. The traditional solution, for preventing this overheating problem, is to add extra fuel (in liquid form) to quench the explosion shortly after its begun. The
spark plug fires the small amount of fuel that has managed to vaporize. As the initial charge explodes, it vaporizes the additional liquid fuel. The combustion then dies because the mixture is now too rich to burn. Keeping the engine cool can be accomplished by turning the fuel completely to a vapor and mixing it with oxygen before the spark plug fires. Vapor fuel takes 3 to 7 milliseconds to combust completely. This is exactly the right amount of time to convert most of the fuels potential heat energy into mechanical energy. The burning can be completed before the exhaust valve opens.
to steam soaks up some of the heat and lowers the combustion temperatures. The resulting steam separates the fuel and oxygen and the explosion is quenched. Water Injection produces cooler engine and exhaust temperatures with a performance increase. When the water turns to steam, it expands 1500 times, increasing the compression and driving the piston down. Water Injection also promotes less or no carbon buildup in the cylinders. Carbon buildups are caused by burning excessive fuel. The traditional fuel cooling technique burns huge amounts of excess fuel.
Carbon buildup causes engine damage by preventing engine components from cooling by acting as an excellent insulator. Hot engine components expand more, get lubricated less and wear faster. Carbon buildups cause burned valves by preventing them from cooling and closing properly. Carbon buildups cause preignition and detonation by creating constriction areas and hot spots. Carbon deposits can suddenly become detached and bounce around in the cylinder, causing mechanical damage. Carbon deposits build up in engine components (like rings) preventing them from moving properly and decreasing efficiency. Excess carbon particles get into the oil and act like a sandblaster, destroying the wear surfaces inside of the engine. Carbon buildups are good for people making money rebuilding engines, but bad for you and the environment.
The incompletely burned fuel is now ejected from the engine, to be pollution or to be burned in a catalytic converter. This excess cooling fuel has been partially combusted (turned to carbon monoxide and excess hydrocarbons) and is still enough fuel to run another engine. (Weve done it.) FACT: Leaning the mixture will damage the engine only if other means are not used to keep the engine cool. Using excess fuel to cool the engine is only good for vested interest who want us to use lots of fuel. FACT: You can keep your engine cool, increase power and reduce pollution with a method that has been used for over a hundred years! Water Injection works. If you apply it, you will prove it to yourself. Then, youll want to ask the car companies: Why isnt it being used? When using Water Injection, the spark plug fires the vapor gasoline after the initial explosion. The heat of the explosion turns the water to steam. Water requires large quantities of latent heat to turn to steam. The conversion from water
Water Injection allows you to cut back on fuel flow while increasing engine performance and engine life.
Water as liquid causes the carbon deposits to flake off the hot components in your engine, because
the cold drop of water causes the red hot carbon to suddenly contract as it cools, causing the deposit to break away from the engine and fly out the exhaust. There is a water carbon cleaning technique that can help carbureted and throttle body fuel injected engines. Warm up the engine. Rev it to 1500 rpm. Slowly pour a pop bottle of warm water down each venturi. Do not pour so fast that the engine rpm drops. Clean and gap the spark plugs. An atomized water mixture (mist) or water as steam applied to the intake air in a manner that applies the water evenly to all cylinders will increase power, clean carbon deposits, stabilize the combustion (higher octane rating) lower pollution and give better fuel economy.
universally applied. We think it is simple economics. It is cheaper to build vehicles without it and vehicles are less apt to have problems because no one has to remember to put water in them. Another reason may be because vested interest WANTS you to burn as much fuel as possible. It puts more money in their pockets. And then there is the planned obsolescence the automotive industry actually wants your vehicle to wear out because they make more money repairing vehicles than selling them. Technology exists today to make vehicles run a million miles with practically zero maintenance and require NO fuel fillups for the life of the vehicle. Such vehicles could be built at about the same cost as vehicles sold now. In any case, dont ask us why Water Injection isnt applied. We put it on our vehicles and we wrote this book so that you can too. Water in itself will not hurt your engine in any way. Improper application of water will damage engines, just as an improper application of fuel. OEM do not use stainless steel exhaust systems because it costs more and because the automotive industry makes so much money in the replacements.
Vapor Water vapor injection is usually achieved by bubbling some of the engines intake air through a water bath. This saturates the incoming air with water moisture in a vapor form. This is simple evaporation technique is quite effective for a small performance improvement and to help keep the engine clean. We have long recommended this technique for carbureted fuel systems. The techniques for water vapor injection are covered in our Super Gas Saver Secrets book. We do NOT recommend vapor injection for fuel injection systems that use a MAP sensor.
For EFI systems that use a MAP sensor, go directly to water liquid injection for best results. Water vapor injection acts like an air leak in the intake manifold. The air leak causes a slight drop in manifold vacuum (a rise in absolute pressure). The computer thinks you need more power and adds fuel. This is because the computer assumes that when the absolute pressure rises, the engine is under load and adds fuel to give you the power it thinks you need. Avoid this by going with water liquid injection.
Steam caused by vaporizing the water speeds up the combustion of the fuel with a catalytic action, resulting in a faster burn of the mixture. A faster burn is more efficient, transferring more of the fuels potential energy into mechanical energy. Steam causes the fuel to combust more completely in the cylinder, so exhaust levels of hydrocarbons, carbon monoxide and oxides of nitrogen drop dramatically. Level of carbon dioxide raises a bit (which shows more complete combustion). And, interestingly, oxygen levels increase, typically about 2%. Water as liquid can also replace the extra fuel used to quench the secondary flame. This allows up to 50% of the fuel to be replaced by water with no loss in engine performance or power. Harmful exhaust emissions of hydrocarbons and oxides of nitrogen drop to near zero.
Water Injection technology is well known to vehicle manufacturers and since it is well proven to be beneficial, one would wonder why it isnt
FACT: Advancing timing has long been known to increase power, efficiency and performance, but advancing timing also increases the risk of engine knock. Water injection reduces engine knock, allowing significantly advanced timing. All internal combustion engines should be using Water Injection. Since the OEM is not providing it, you must buy or build your own.
WATER STATES
There are three states that water can be in when it is injected into the engine; vapor, liquid and steam.
Water Water liquid injection is best applied using a spray nozzle of some type. The liquid water needs to be sprayed into the vehicles air intake as tiny droplets. The water needs to partially evaporate and mix well with the air. Water Injection in liquid form works well in all internal (and external) combustion engines. The gains in economy, performance and pollution reduction can be dramatic. Steam Water steam injection is the optimum method of Water Injection and will be the subject of another book. Steam injection allows you
to recycle some of the vehicles waste heat back into the combustion process; at the same time as having the water enter the cylinder prepared for maximum combustion enhancement.
system needs to be optimized for application, skills and parts available to you. You will spend some time finding your components and figuring out how and where to place them. e Automatic operation You will want to keep your controls and maintenance to a minimum. Basic simplicity of operation will most likely get the Water Injection used, both by yourself and any other driver(s). f Safety Features The design should be automated to prevent damage if the system is abused. Example: running out of water may damage pumps or injectors. As a safety feature, the electronics could be made to shut off the Water Injection if the water is low. g Shutoff valves Use solenoids to prevent pressurized fuel or air from going where we dont want it during engine shutoff or water fill situations. We use manual shutoff valves to assist maintenance. h Add water in a direct ratio to the fuel Use active systems that are controlled to inject water only as it is needed. i Water Shutoff You will want your Water Injection to be shut off anytime the engine is not actually turning over. j Startup delay Some engines will startup smoother if water is not being sprayed into the air as they are trying to start. Quite often, a short delay is all that is needed to assure smooth performance. Try this before the cold temperature shutoff option because it gets water into your engine sooner, maximizing gains.
One way to delay Water Injection is to use an oil pressure switch to a shut-off option. The Water Injection will not start til the oil pressure builds up. Obviously, this is only a short delay. If you need more delay, or if you have an oil pre-pressurization system (which gives oil pressure before the engine starts turning over), you can add a few components to your electronic circuit. This delays the Water Injection startup each time you start the vehicle. (see the appropriate schematic.) k Cold temperature shutoff This can prevent flooding, by excess water, before the engine has a chance to warm up. It allows time for the water to heat if you are using that option. It also allows time for the water to thaw if frozen. l Monitor liquid level This will help you and any other driver(s) keep water in the system. m Deceleration water shutoff Your engine needs water when it is using fuel, not during deceleration when your engine is not working. At this time, the engine is running cool anyway and should have the fuel shut off. There is no reason to have water flowing into your engine when the vehicle is decelerating. We design the deceleration shut-off to shut off the Water Injection, the regular fuel system, HyZor (if used), the HyCO 2A (if used) and any other incidental fuel supply.
If using deceleration shutoff to shut off fuel, youll want to put in overrides that turn the fuel back on when the vehicles clutch or brake is applied, to prevent the engine from stalling. See Super Gas Saver Secrets and HyZor Technology for the details.
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Water Injection
#3 in the Water As Fuel series
Another Eagle-Research winner! In Water Injection, George Wiseman continues his mission: to share patent-free energy solutions that help people get further on a tank of gas. Learn how-to design, build, install and operate a low cost, simple, effective 'active' water injection system.
A Water Injection installation also requires the Carburetor Enhancer (Carbureted vehicles) or the EFIE (fuel injected vehicles), so that the fuel from the regular fuel system is reduced when adding water.
Replace some Fuel with Water Increase Power And MPG Remove carbon Engine runs Cooler Increase Engine Life Cleans carbon out of engine Decreases NOx, CO, HC
"I am very impressed with the results I have had from adding a simple water injector, more power, no more knocks or pings, and my engine runs 60 degrees cooler no matter how hard I drive it. Thanks for your efforts. I look foreward to applying more of your ideas as soon a I can build them!"
- James Grudzinski, USA -
ISBN 1-895882-37-0