A Home-made Dew Destroyer

Walter Dutchak (Submitted: 2014.08.12)

I needed a Dew Buter! "#r m$ 8%inch &'(. Dew wa ruinin) *iewin) ei#n c#nitentl$.
+#r th#e #" $#u wh# ha*e a bit #" interet in electr#nic and #me kn#wh#w in #lderin) electr#nic
c#m,#nent t#)ether- I hare thi little ,r#.ect #" buildin) $#ur #wn Dew /eater "#r $#ur telec#,e.
(he c#t i *er$ l#w i" $#u are intereted in thi #rt #" thin).
't m$ l#cal branch #" the 0#$al 'tr#n#mical S#ciet$ #" &anada- 1reident Da*e 2c&arter had
,r#*ided a *er$ e""icient dei)n "#r a ,ule m#dulated circuit t# c#ntr#l a 123 dew buter $tem. /e
e*en ,r#*ided u))eti#n #n h#w t# make the heater element uin) reit#r.
(he circuit l##ked like a )reat dei)n- but I ,re"erred a li)htl$ di""erent a,,r#ach t# makin) the heater
element.
(he heater element were #" a ,arallel reit#r ladder dei)n which wa ab#ut 1! t# 1.4! wide and
w#uld re5uire #methin) like 3elcr# tri, t# "aten t# the telec#,e and e$e,iece. What I wanted wa
a rin)%ha,ed! heater element that w#uld tuck in a)aint the )aket that c#*ered the c#rrectin) len.
+#r the #ther heater I ,re"erred t# dei)n a erie reitance l##, that I c#uld c#il ar#und the e$e,iece
and "inder c#,e.
/a*in) limited a*ailabilit$ #" reit#r *alue that I c#uld #btain I tarted t# w#rk #ut a dei)n "irtl$ "#r
the c#rrectin) len heater. +#r the heater t# ,ut #ut u, t# 6 #r 10 watt #" heat I needed mall *alue #"
reitance and $et t# dii,ate the hi)her *alue #" heat the reit#r w#uld ha*e t# be lar)er- lar)e
en#u)h t# handle the e7tra heat with#ut c##kin) themel*e t# cinder. B$ buildin) mall ,arallel
)r#u, #" 8 reit#r each I decided that I c#uld trin) 6 uch )r#u, in erie "#r a t#tal reitance #"
ab#ut 14 9hm "#r ab#ut 10 Watt #" heat ,#wer #ut,ut at 12 3#lt D&. ((hi wa all r#u)h etimatin)
in the head. 'ctual buildin) and meaurement #" the *ari#u *alue ,r#*ed t# be li)htl$ di""erent- a
$#u will ##n "ind #ut b$ readin) #n).
(he ,r#blem I had t# #l*e in*#l*ed the "act that it w#uld be unlikel$ that I c#uld tu"" each )r#u, #" 8
,arallel reit#r int# ab#ut a :! diameter tube which w#uld make the heatin) rin). It wa a ,r#blem
#" t#,#l#)$. /#w t# rec#n"i)ure the ,h$ical ha,e #" the 8 reit#r in ,arallel # that the$ c#uld
bec#me a narr#w and len)thened ,acka)e.
;*entuall$ the #luti#n ,reented itel" t# me and the tretched #ut la$#ut (ee +i)ure B < D bel#w)
had the ad*anta)e #" ditributin) the heat #*er r#u)hl$ a 8! len)th (time 6) within the heatin) rin).
It wa till n#t # ea$ t# h#*e int# the :! diameter tubin) #" the rin) # I cut a lit al#n) the hidden
ed)e #" the rin) and that acc#mm#dated the reit#r nu)l$ a the ketch bel#w h#w.
+I=>0; % '
Page 1 of 11
When tu""in)! the reit#r int# the rin) #" tubin) it i im,#rtant that wire d# n#t make h#rt
circuitin) c#ntact. Small tri, #" tandard *in$l inulati#n ta,e can be ued at critical ,#int. D9
?9(- h#we*er- ue cellul#e ta,e ince it w#uld melt under increaed heat and a h#rt circuit w#uld be
ine*itable.
+I=>0; @ B
+i)ure%B h#w h#w each )r#u, #" three 4.A 9hm reit#r in ,arallel are c#nnected in erie a 1.4B
9hm )r#u, (6 )r#u, 7 1.4B 9hm C ab#ut 14 9hm t#tal reitance). 12 3#lt acr# 14 9hm
w#uld ,r#duce heat dem#ntrated b$ the "#rmula "#r 1#wer a (3#lt S5uare di*ided b$ 0eitance)-
i.e. V
2

/R C 12712D14 C 144/14 C about 10 Watts #" heat ,#wer.
+I=>0; @ &
(he ,h$ical c#n"i)urati#n (&#n"i)urati#n ') #" three 4.A 9hm reit#r in ,arallel h#wn in +i)ure B
ab#*e i e5ui*alent t# the c#n"i)urati#n h#wn bel#w (&#n"i)urati#n B) in +i)ure D . In b#th cae
(&#n"i)urati#n ' and &#n"i)urati#n B) the t#tal reitance in ,arallel i ab#ut 1.4B 9hm.
&#n"i)urati#n B i arri*ed at b$ bendin) &#n"i)urati#n ' int# an in%line! ha,e- makin) ure that
n#ne #" the interc#nnectin) wire t#uch t# create a h#rt circuit.
+I=>0; @ D
(he 8!EF60 ha a circum"erence #" a,,r#7imatel$ 28 inche at the c#rrect#r ,late. >in)
c#n"i)urati#n B- i" each ,arallel )r#u, #" reit#r i ,aced e*enl$ # that it ,an ab#ut 8.01!- a t#tal
#" 6 uch )r#u, can be c#nnected in erie ,r#*idin) a t#tal e""ecti*e reitance #" a,,r#7imatel$14.06
9hm. which w#uld ,r#duce a calculated ma7imum #" ab#ut 10.2 Watt #" heatin) ,#wer "r#m a 123
D& u,,l$.
(# c#ntruct the heatin) rin) w#uld ue a t#tal #" 27 4.A 9hm reit#r and each reit#r w#uld
dii,ate a ma7imum #" .88 Watt #" heat when the ma7imum current thr#u)h the reiti*e dew
heater i at a ma7imum #" a,,r#7imatel$ 0.84 am,ere. (hi wa the the#retical dei)n that I tarted
with t# build a dew heater rin) "#r the EF60 8! Schmidt c#rrectin) len (c#rrect#r ,late).
A detailed description of the project follows.
(he ab#*e c#n"i)urati#n wa built- ,laced inide a "ire% retardant lee*e (1D4! diameter electrical
inulati#n tubin)) and teted with the ,ule width m#dulated c#ntr#ller circuit dei)ned b$ Da*e
Page 2 of 11
2c&arter- at that time ,reident #" the 0'S& E#nd#n (0#$al 'tr#n#mical S#ciet$ #" &anada @
E#nd#n branch atr#n#m$ club).
;ach #" the three reit#r in ,arallel wa aembled- and then each tri,le )r#u, wa #ldered in erie.
(here were 6 )r#u, alt#)ether "#r a t#tal #" 2A 4.A 9hm reit#r ued. ' menti#ned ab#*e- the
calculated reitance #" each 8 reit#r ,arallel )r#u, i 1.4BB 9hm and the t#tal calculated reitance
#" 6 uch )r#u, i 14.064 9hm.
(he aembled c#rrectin) len heater wa meaured with tw# di""erent di)ital multi%meter and the$
a)reed #n a t#tal reitance #" 18 9hm. ((hi )#e t# h#w that the#retical and meaured *alue are
#"ten di""erent becaue #" l#wer t#lerance #" chea,er c#m,#nent). G
H Watt rated reit#r were ued. I" thee reit#r are #nl$ rated at : Watt each- then the heater can
till a"el$ #,erate at B Watt #" ,#wer (which w#uld be ab#ut 8.8 *#lt a,,lied t# the heater (ab#ut
80I #" the 11 *#lt that )et deli*ered t# the heater at the ma7imum ,#tenti#meter ettin) ).
+#ll#win) are the meaurement d#ne durin) tetin) #" the heater and c#ntr#ller unit:
Measurements
(in all "#ll#win) e7am,le the $mb#l J tranlate a i a,,r#7imatel$ e5ual t#!)
In,ut 3#lta)e et at J 12.8 3 ( 'll *#lta)e are D& )
2a7. /eater 3#lta)e J 11 3#lt
/eater 0eitance J 13 Ohms
(here"#re the (he#retical 1#wer J 11
2
D18 J 9.4 Watts
TABLE - 1
't the ma7imum ,#tenti#meter ettin) 6.4 Watt #" ,#wer i ,r#duced. (hi ,#wer i dii,ated
thr#u)h 2A reit#r a heat. &#n"i)urati#n B (+i)ure%D) a h#wn ab#*e (al# ee +i)ure @ B)- wa
h#w thee reit#r were arran)ed @ 6 )r#u, #" three reit#r in ,arallel. (hu at the ma7imum
ettin) each reit#r will dii,ate ab#ut 6.4D2A J 0.84 Watt #" ,#wer a heat. (hi h#uld be n#
,r#blem i" the 4.A 9hm reit#r ued are actuall$ rated a H Watt reit#r. /#we*er- i" the$ indeed
are #nl$ : Watt reit#r then the heater will a"el$ ,r#duce ab#ut B Watt #" heat a e7,lained ab#*e.
(he c#ntr#l unit wa built with 4 0&' ,h#n# ,lu) #utlet t# c#nnect heater # that 8 m#re heater can
be c#nnected. (he c#ntr#ller c#ntr#l the #ut,ut t# all 4 heater in e7actl$ the ame wa$. In #ther
w#rd- i" the ,#tenti#meter i et at A4I #" ma7imum then each heater will deli*er #nl$ A4I #" it
ma7imum heatin) ca,abilit$.
Page 3 of 11
'll heater mut be dei)ned t# w#rk "r#m the c#ntr#ller 12 3#lt D& in,ut (#r a wa meaured ab#ut
11 3#lt acr# each heater). (he reitance #" each heater h#uld be dei)ned t# ,r#duce the re5uired
ma7imum heat #ut,ut "#r the #,tic #n which it will be ued. (+#r e7am,le- the heater "#r the "inder
c#,e #r "#r an e$e,iece need #nl$ deli*er a ma7imum #" ab#ut 4 Watt and at m#t time #nl$ ab#ut
1.4 Watt will u""ice t# maintain e$e,iece and mall "inder c#,e "ree "r#m dew).
Figure E. DE !EATER R"#$
FOR T!E %ORRE%T"#$ LE#&'
(he rin) i attached t# the c#rrectin) len )aket b$ d#uble ided "#am ta,e- the kind ued "#r attachin)
maller ,icture "rame t# wall. 2an$ S&( #wner ha*e re,laced the c#llimati#n crew eem in
+i)ure%; with B#bK Ln#b. In the cae #" the 8! EF60- the ,latic len c#*er till "it- alth#u)h n#t all
the wa$ in- and a mall n#tch wa cut #ut t# all#w the wire lead "r#m the heat rin) t# ,a thr#u)h t#
the t#, #" the telec#,e tube. M#u ma$ n#tice that the lead e7itin) the heater c#il are at the b#tt#m #"
the heater rin) in thi #ld ,icture- but I later turned in ar#und # that the lead c#uld e7it at the t#,
where the$ are ta,ed t# the tube.
(he heater wire are terminated with a mall tw#%,r#n)ed "emale ,lu). (he cable "r#m the c#ntr#ller
unit ha a matchin) male tw#%,r#n)ed ,lu). M#u can arran)e the c#nnecti#n the wa$ it uit $#u bet.
DESIG !"# !IDE#S$"%E &E'E%IE$E HEA(E#S
')ain uin) 4.A 9hm- H Watt reit#r- the "#ll#win) erie c#n"i)urati#n #" A reit#r wa ued t#
,r#duce a l##el$ c#iled heater (c#*ered b$ a wire inulat#r) which w#uld ,r#dWatt #" heat ,#wer at
the ma7imum heater c#ntr#ller ettin). (he return wire (bel#w the reit#r) wa le"t inulated
(inulati#n i n#t h#wn in thi dia)ram).
F"$(RE ) F' E*e+ie,e - Fin.er s,/+e !eater %/n0igurati/n 1A2/3e4
"#&(LAT"#$ the heater' 9n *er$ c#ld ni)ht the heater c#il can be wra,,ed with an$ inulatin)
material t# ,re*ent heat "r#m eca,in) int# the c#ld ni)ht air. 9r,haned w##l t#ckin) will "ind a ue
here.
Page 4 of 11
5u6se m/.u6ate. !eater %/ntr/66er %ir,uit
(hi circuit wa dei)ned b$ Da*e 2c&arter- 1at 1reident #" the 0'S& E#nd#n (0#$al
'tr#n#mical S#ciet$ #" &anada @ E#nd#n Branch). (here are e*eral imilar circuit dei)n #n
*ari#u atr#n#m$ ite that c#uld be ued "#r $#ur ,er#nal circuit #r #ne c#uld ,urchae a
c#mmerciall$ made circuit- uch a the Lendrick unit. (he 0>;400 c#m,#nent bel#w i a el"%
reettin) ,latic "ue. 0>;800 can be ued al#. 0&'%t$,e "emale ,h#n# .ack are ued t# c#nnect
,#wer t# the heater
+I=>0; @ =
/eater cable with 0&'%t$,e male ,lu) ,lu) int# thee .ack % #nl$ 4 h#wn at the b#tt#m #" +i)ure%
=. 'n$ number #" #ut,ut i ,#ible limited #nl$ b$ the 10 'm, current ratin) #" the 29S+;(
(1#wer (ranit#r).
TE&T MEA&(REME#T& /0 %/rre,ting Lens !eater %ir,uit
'll tetin) meaurement were d#ne with the "#ll#win) c#mm#n ,arameter:
S#urce ,#wer u,,l$ wa et t#: 12.3 V D% (>in) a *ariable D& ,#wer u,,l$).
(he /eater &#ntr#ller &ircuit wa the 1ule 2#dulated c#ntr#l circuit dei)ned b$ Da*e 2c&arter.
%ORRE%T"#$ LE#& !EATER'
!eating L//+ "#r the Schmidt c#rrect#r ,late #" the 8! EF60 telec#,e.
(he l##, wa c#ntructed #" 2A 4.A 9hm- H Watt reit#r arran)ed in 6 ,arallel )r#u, c#nnected in
erie (decribed ab#*e). ;ach ,arallel )r#u, c#ntain 8 reit#r #" 4.A 9hm each- "#r a t#tal
e5ui*alent reitance #" ab#ut 1.4B 9hm. (hu 6 uch )r#u, in erie t#tal ab#ut 14 9hm
(he actual 2;'S>0;D E991 0;SIS('?&; wa 13 Ohms. (able%2 h#w the reult:
(he +/tenti/meter ha"t wa turned t# l#wer the reitance in r#u)hl$ 1D10th te, @ a *er$
r#u)h etimate t# )et a )eneral *iew #" the ,#wer #ut,ut ,r#duced #*er the ran)e #" the 40 L
#hm ,#tenti#meter.
(he +/tenti/meter i a 40 L 9hm *ariable linear reitance c#ntr#l @ like a *#lume c#ntr#l @
identi"ied a 5/t. setting in (able%2 bel#w. ' the ,#tenti#meter i et t# a l#wer reitance the
,ule tream c#min) #ut #" the 444 (imer chi, caue the 29S+;( (2etal 97ide +ield ;""ect
(ranit#r) t# ,a m#re current t# the heater and thu the heater )et h#tter. 'l#- a the
,#tenti#meter reitance i l#wered the Ei)ht ;mittin) Di#de (E;D) in the c#ntr#ller circuit
)et bri)hter t# indicate that the heater are at a h#tter ettin).
Page 5 of 11
('EB; @ 2
TE&T MEA&(REME#T& /0 0in.er s,/+e - E*e+ie,e !eater %ir,uits
')ain- the #urce ,#wer u,,l$: (>in) a *ariable D& ,#wer u,,l$) wa et t# 12.3 V D%.
!eating %/i6s @ a trin) #" A reit#r in erie w#und ar#und #cular c#ntainer (c#iled).
+#r the 40mm #b.ecti*e len < e$e,iece end #" the EF60 +inder c#,e- and "#r all #ther e$e,iece.
+I=>0; @ /
The return wire below the resistors is electrically insulated (This insulation is not shown in Figure-H).
thee heater tri, were c#iled ar#und the "inder c#,e and e$e,iece
e*en 4.A 9hm reit#r were linked in erie "#r a t#tal reitance #" 82.6 9hm #" reitance.
the entire trin) wa encaed in an inulati#n c#*erin) tri,,ed "r#m a ,air #" inulated 18
)au)e wire and then l##,ed t# "it ar#und the A1D4! circum"erence #" the "inder c#,e dew
hield at the #b.ecti*e len end #" the "inder c#,e. /ere a)ain- the electrical inulati#n wa lit
al#n) #ne ide t# "acilitate tu""in)! in the trin) #" heater reit#r. (he A reit#r in erie
actuall$ meaured at 33.3 Ohms. (he ame wa d#ne "#r the "inder c#,e e$e,iece end and "#r
the heater t# be ued with all interchan)eable e$e,iece.
(able%8 h#w the reult meaured at r#u)hl$ 1D10th ,#tenti#meter ettin) inter*al:
Page 6 of 11
('BE; @ 8
%/i6e. E*e+ie,e !eater
+i)ure%I h#w h#w the c#iled erie heater l##k ar#und an e$e,iece. (he ,h#n# ,lu) i actuall$ at
the end #" a much l#n)er cable which e7tend be$#nd the c#iled ,art h#wn in the ,icture. (he ,icture
h#w the ,lu) at the end #" the c#il .ut t# let $#u kn#w where the ,lu) c#nnecti#n i.
+I=>0; @ I: ;$e,iece /eater &#il
HEA(E# (ES(IG )sin* a +,- .attery %ower %ac/
(he #urce wa the ;liminat#r! ,#wer ,ack "r#m &anadian (ire (an aut# ,art and h#me hardware
t$,e #" t#re). (he meaured D& *#lta)e #ut,ut wa 12.B4 3 D& (uin) the D& Batter$ E#ad (et
cale! #n a di)ital multi%meter. ((hi meaure the actual D& 3#lta)e when the batter$ i c#nnected t#
a l#ad % uch a dew heater in thi cae). 9n the re)ular D& cale the readin) wa 18.08 3 D&.
(he heater c#il were teted uin) the ab#*e batter$ ,#wer ,ack and )a*e reult *er$ imilar t# the
tet d#ne ab#*e (uin) a D& ,#wer u,,l$).
Page 7 of 11
The LADDER .esign
+I=>0;%N: Eadder Dei)n
(he ladder dei)n c#nit #" hi)her *alue reit#r arran)ed in ,arallel % like te, in a ladder. /i)her
*alue reit#r are al# uuall$ much le e7,eni*e than *er$ l#w *alue reit#r.
'"ter $#u #lder t#)ether the ladder #" reit#r $#u c#*er them with a thin la$er #" warm inulati#n-
uch a #ld #ck cl#th and then wra, the wh#le thin) ar#und the tube #" an e$e,iece #r near the
#b.ecti*e len #" $#ur "inder c#,e #r telec#,e.
E5"LO$
(he heater and c#ntr#ller w#rk *er$ well. Se*eral ,e#,le in #ur 'tr#n#m$ '#ciati#n ha*e ued the
c#ntr#ller dei)ned b$ Da*e 2c&arter and the$ attet t# it u,erb "uncti#nin). (he heater dei)n
decribed in thi article can be ued with an$ 12 *#lt c#ntr#ller unit. (he main ad*anta)e #" the erial
reit#r dei)n #*er the ladder! reit#r dei)n i that "ewer reit#r are ued. (he diad*anta)e i
that l#wer *alue reitance mut be ued in erie- that i wh$ I ued #me hi)her *alue in ,arallel
()r#u, #" 8) t# create an #*erall l#wer reitance be"#re c#nnectin) the )r#u, in erie. 9" c#ure
there are #ther ,r# and c#n n#t dicued here.
I ha*e .,e) #" the c#,,er "#il ide ,attern that I ued t# make m$ circuit b#ard. It i rather ,rimiti*e
ince I d# n#t ha*e the ,r#,er etchin) e5ui,ment and chemical. I im,l$ car*ed the ,attern with an
;7act#! kni"e blade. (he ,art lit i bel#w.
% See ,art lit @ ne7t ,a)e:
Page 8 of 11
LIST of parts for Dew Heater Controller Unit
(CB) - Circuit board (From 2 1/2x4 down to 1 x 2)
* 555 timer IC. may be marked C1455!" #$555#" %&555! etc.
' IC (ocket )or 555 timer IC
* I*F5+,& or (imi-ar # c.anne- !ower /0F$1" 5,2 31,& or
better" e45 01612#,5" 1!+,55$
* 47,uF 182 e-ectro-ytic ca9acitor.
* 1#4,,1 (i-icon diode.
* 1#:14 or 1#414; (i-icon diode.
* *ed <$6 -i4.t emittin4 diode.
* 5,= > -inear 9otentiometer e.4.5 !.$.C. ty9e 28%5,+1
+ o) 22,, > 1/4? re(i(tor(.
2 o) ,.1uF 5, @o-t ono-it.ic ceramic ca9acitor(.
*%$4,, *ayc.em !o-y(witc. Fu(e.
ay u(e *%$+,, in(tead
15:1& or 15:1< Aammond 9-a(tic ca(e
!-a(tic knob e.4.5 &u4at !=$0-8,B-1/4
4 c.a((i( 9.ono Back( e.4.5 0witc.cra)t +5,1F*.
4 9.ono 9-u4( e.4.5 0witc.cra)t +5,7.
1;C two-wire cord" -on4 enou4. to 4o )rom .eater contro- to
9ower (u99-y" and )rom eac. 9.ono 9-u4 to .eater e-ement(
(coi-().
* Orientation of component on circuit board is important!

Page 9 of 11
DE DE&TRO7ER %"R%("T BOARD DE&"$# 18ni0e-Et,he.4
$. 0 .ottom or !oil Side 1.lac/ areas are $opper !oil left after etchin* o)t white areas2
$. 0 (op or $omponents Side 1showin* placement of components2
Page 10 of 11
(he Dew /eater &ircuit wa h#ued in a ,latic b#7 that had c#ntained nail ,urchaed at /#me
/ardware. Bel#w are tw# ,icture h#win) the "inihed ,r#duct with #ne heatin) c#il wra,,ed ar#und
an e$e,iece. 9n the ri)ht%hand ide in the ,icture $#u can ee the &ir)arette Ei)hter!%t$le c#nnect#r
that ,lu) int# a batter$ ,ack that ha the "emale #cket #" thi c#nnect#r. It can al# ,lu) int# the 123
#utlet in $#ur car.
9n the le"t%hand ide in the ,icture there are "#ur "emale%0&' c#nnect#r "r#m which the #ut,ut ,#wer
"#r the heater i #urced. 2#re c#nnect#r can be added b$ im,l$ ,lu))in) in 2%wa$ ,litter int# the
e7itin) c#nnecti#n. (he heater c#iled ar#und the e$e,iece i ,lu))ed int# #ne #" the heater "emale
0&' c#nnect#r.
(hi i h#w I did it- n#thin) "anc$- but it w#rk )reatO I built the unit in thee ,icture A $ear a)#.
2a$be $#u will )i*e it a tr$ i" $#ur kill include electr#nic. WePd l#*e t# ee $#ur "inal ,r#duct and
c#mment.
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Page 11 of 11