The Karupika Solar Cooker
Contents
1. Q0 Leg No 3 1 pc G9 Knob Bolt D 1 pc Q9 Finger Nut K 1 pc AS i KS DOC he KI A ie y X A SN NI 17 Tripod Post 1 pc Hexagon head Bolts M4 18 mm with cross recess silvery 2 pcs 16 Spacer Sleeve 1 pc Flange Nuts large 4 pcs STAs 6 Grease 1 pack Q Center Mirror Box 1 pc Q2 Column base for assembling work 1 pc Grip of the Pan 1 pc O ring Pack aay 63 Glass Cover 1 pc Instant adhesive af Grip fixing Bolt 1 pc Documents e User Manual copy with the Diagrams for the Timing of the Solar Cooker Rearrangements Do it yourself Manual 1 copy xX Screws and nuts are supplied in somewhat extra quantities Keeping them in monkey dishes helps your works go well Your needful tools oe A Scotch tape scissors Phillips screwdriver and cutter knife The driver bit should be a Phillips 2 and a heavy duty grip required xX An electric driver helps your works go quite quick Avoid a windy place for your works Clip and paste the following labels on screw and nut bags and have smooth jobs a a AE AE ramp aw ap ay amy ami E m AN UE UN GF amm Aa 7 IE IE JE AE ES D GU GE A dd ES EE my ES ES SEU AES K EP GU li i in a N N N LI al i al N 63 50 pes N 42. Toothpick 65 Metal band amp Using a Toothpick 65 makes it easy to ply the band from the Center Mirror to make a space where a Mirror T3 cuum cnet RD is inserted g 5 Fix the Mirror 3 with the screw once Rear face loosen as shown in Step 4 3 and two sets of Machine Screws 4 and Flange Nuts 63 i ON Loose all the rest of screws on the rim and making spaces with the Toothpick 65 insert and fix loosely lall the rest of KARU Mirrors CO and 8 The arrangement is shown in Fig 30 N Check all the Mirror parts are Radially and properly arranged around the middle of the Center Mirror 3 and All the way seated inl X Mirror surface Then fully tighten all the screws A sticker on the rear surface Finished shape The Mirror is very FRAGILE at this stage Be careful in handling 8 Check again all the KARU Mirror parts CO and are arranged in right locations An error in assembling causes ill effects afterwards 9 Remove all the protective films from KARU Mirror parts CO and 1 Cut off four side boards of the Center Mirror Container Q2 and cut the basal plate along the black lines Bent side board cuttings and make triangles Fix triangles with Scotch tape 2 Bent side board cuttings at two lines as shown in Fig 35 to make four triangle shaped Pedestals L 11 3 Put Scotch
3. Fig 58 Fig 58 uus error Ignoring such a crisscross error and tightening the Knob Bolt C Q9 may cause the deformation of the Core Bar Extension 2 end 12 After tightening the Screw 64 fully tighten the Screws 49 13 Mount the Sighting Devise Q9 inside the Parabola o 7 Assembling the Pan 1 Mount the Grip on the Pan The thumb bent The hook hole comes upward comes upward Grip fixing Bolt 63 All the assembling works now have been completed a xk Now you start the next stage the adjustment of the main body Please refer to the User Manual o 8 Adjusting the Trivet 1 Assemble the equipment following instructions in the User Manual Your solar cooker assembled from the kit as it stands does not hold the pan in a perfectly horizontal position due to the following defects A Looseness in the structure and B Fudge factors in parts production and assembling In this step such defects are to be corrected A Correcting the tilt caused by looseness in the structure Due to a play between the Tripod Post and the Spacer Sleeve the Trivet is slightly leaning forward Hold the Pot Frame with your both hands and give it a twist to adjust the tilt See Fig 62 When the Core Bar Assy is in the or Position C see Figs 62 63 and 64 Tighten Finger Nut K Q9 slightly 16 Spacer Sleeve 2 m In the case of the twist the assy
4. 24 pcs A i ii i Flange Nuts i Machine Screws M3 6 mm p small sunny yellow p Sunny yellow i i i E a E it in a E e N ii 4 i i N N N i ii i ih i Machine Screws li i Hexagon head Bolts i i i N N E N M4 8 mm silver i M6 25 mm silver N li RSV ZO SES y SY y SUN y EY y EY y SUN y SUN y UNS li US 7 EY y SY y EY y EY y GUN y T y T y JUNO SUN y Sm N N N N 65 Tooth picks q 12 pes li li li x i P l i i Machine Screws X N 5 pcs N N MA 12 mm X i ii Q ii N N N sunny yellow X J P d y d d d P m P aN J pow p LO EJT ET EJT fF EJT ET EZT qr 8G L eee E ae L i q q N E N N al aj L N 2 pes N N 46 C 17 pcs N 1 S q i li N N E 1 Flange Nuts 1 Flange Nuts q N S N N large sunny yellow medium sunny yellow 1 Ls SEN SEN SEN GEN af R Las SEN SEN SES GEN lt a EV 7 SESUO SES AES A i i L 6 amp l6 pes 10 pes i N N N N Machine Screws 1 1 Machine Screws 1 N N N N 1 M3 8 mm 1 1 M3 6 mm 1 N i E il il N sunny yellow N N stainless steel N t 7 7 EY T S AEVO AES lt a lt a 7 ah P Ey SEV ED SEV EY ED SEN EY O SEN 7 SEW O du A o 2 Assembling the Outer Frame o An excessive torque deforms the setter metal True up the surfaces of handgrip ends and nuts flat 2 Put together by hand start KARU Flanges 53 and 69 to make a circular f
5. Notches ae i Mirror surface with a film Approx 45 Cut off a piece about 3 cm wide Bend it AGAINST Mirror surface Approx 45 2 Before starting next step please look at the rear face of the Center Mirror Assy 3 IMPORTANT Please do not pull out black screws on four hookups of the metal band as shown with marks on Fig 29 or the Center Mirror Assy loses its shape and it 1s difficult to regain it ie LY a Rear face of the Center Mirror Assy G Aluminum basis metal surface oress fitting nut Metal band 3 Lay down the Center Mirror Assy 3 on soft cloth the Parabola Cover may be used and loosen the screw as shown on Fig 30 If the Center Mirror Assy 1s set on a cloth covered bucket rather than a cloth covered flat surface you can make the assy more stable during your works Be careful not to spoil screw heads with the driver tip or the scratches on the heads cause poor results of mopping the mirror surface with fine and nasty fibers pulled out of a rag and left on screw heads Excessive pressure on the nut on metal band makes it drop off to the under side Be careful not to press the screw head too strongly with the driver tip Loosen this screw at first C 3 The Center Mirror Assy Hookups 4 Insert Mirror parts r3 between metal bands and the rear surface of the Center Mirror Assy 3 10
6. counter clockwise to correct a tilt as shown in Fig 65 B Correcting fudge factors in parts production and assembling Adjust the pan holding points of three trivet rods by bending them softly and gently with your fingers to make the position of the pod horizontal When the rubber tubes of trivet rods hold the pan at three points at the periphery of its bottom and pot 1s kept horizontal B you get the best result A rm Manufacturer and Seller Information Amane Studio 1138 1 Shionada Saku City Nagano 384 2102 Japan Phone 81 267 51 5430 Japanese only Fax 81 267 51 5431 e mail info amane studio jp http amane studio jp 18
7. half horizontally along the black line Then connect sections of two halves to make one large column LI 12 Place the cover over the large column and put the Parabola on it with the mirror surface upward 13 Insert Screws 42 to screw holes on inner two circles of the Mirror and loosely fix them with nuts 83 gt See Fig 48 Ten screws at the lower part MUST be the Stainless steel Screws 47 instead of Screws 42 to avoid erosion caused by spills and splashes of boiling liquid gt See Fig 48 14 Check the entire mirror carefully to see if there is any bending or warping of the surface 4 M The nice secret for this step to be done well is to tighten screws in the numerical order of the circuits EI D Q 3 and 4 driving a warp of the mirrors to the outer areas When still a warp remains loose some of nearby screws for adjustments and tighten them fully again Any of Incorrect bent lines mentioned as a in Step 4 1 Page 9 makes it impossible to avoid warping In that case you must adjust incorrect lines 1 Place one of the Bushes on the hole in the KARU Mirror at the Ga side gt See Figs 47 and 48 2 Insert the end of the Core Bar Assy into the hole edged with the bush on the mirror surface At first insert the end with a washer deep into the hole on the parabola and then move the assy horizontally to insert the end of 2 into another hole on the
8. opposite side Clicks of the Bush Q face outside Both of the Position A and B The concave Bar comes front Position B c DO NOT hit the Mirror surface d screws inside the dotted lines must be stainless steel made ones 4 The concave Bar comes front Fig 48 The Angle Setter faces the direction opposite w ud e to that of the Position and c NOTE Be careful not to hit the Mirror surface with the Spacer Sleeve 19 when inserting it 14 3 Set the Bush at the 43 side into the hole on the Mirror surface 4 Remove the washer tightening Screw from the end of the Core Bar Assy fig 49 side 5 Using a toothpick grease slightly the washer on the end of the Core Bar Assy at the side to prevent frictions Ga side upward 8 Replacing the Parabola inclined make the 43 side upward helps to make your job easy 9 Apply instant adhesive into the square hollow in the Bar end Washer 63 before fitting it to the end of the Core Bar Extension AN A r Insert Screws 45 to the holes of the Outer Frame TNE NS E IN azo a Be careful not to let the Washer 63 drop off during the work 15 10 Set Holder A 43 with two Flange Nuts loosely tighten 11 Tighten the Bar with Knob Bolt C 29 At this job check the square hollow of the Bar end Washer correctly covering the end of the Core Bar Extension 2
9. The Karupika Solar Cooker from the Kirapika Solar Cooker Series Do It Yourself Manual V3 I Model IPSE F Amane Studio O Oo o Contents ooo 1 Checking the Parts ccc t te 2 2 Assembling the Outer circumferential Frame 5 3 Assembling the Core Bar Assy e e 5 4 Assembling the Mirror s 9 5 Assembling the Parabola e e e eea 11 6 Mounting the Core Bar Assy s e eee 14 7 Assembling the Pans e se se 16 8 Adjusting the Angle of the Trivet e e eee 17 Thank you very much for purchasing the Karupika solar cooker x Please read carefully this do it yourself manual and assemble the kit properly x Please have this manual in your careful keeping and provide for a rainy day Please refer to the User Manual for handling the solar cooker We humbly ask you to understand that the do it yourself kit 1s not covered by our one year warrant o 1 Checking the Parts o Please check all the parts and their required quantities you have in the package 1 Core Bar 1 pc Knob Bolt C 1 pc 9 wing nuts 2 pcs Spring Washers 2 pcs A sticker attached 6a KARU Flanges 7 pcs Ga En Frame pc Ob Concave Pan Frame 1 pc O Trivet Rod E 1 pc pc 8 KARU s C 18 Leg No 1 1 pc Q5 Sighting Device Assy 1 set
10. le to the latitude of your area and then select La Or b shown below a I will rearrange the solar cooker to the appropriate position for each season because I want to be able to use the solar cooker all the time all year round b I will choose the position that enables me to use the solar cooker for the longest period of time in the year without rearranging it because itis a lot of work In this case please note that there will be some minutes of the day when you cannot align the solar cooker with the sun at certain periods of the year If you chose a above use the position applicable to each season shown in the large circle chart um oosely tighten the Spacer Sleeve on the Core Bar 1 The concave part comes at the back Fig 16 shows example of areas with latitudes between 25 Land 27 5 N in decimal degrees The period of use May 1 to Aug 10 gt E Aug 11 to Sep 10 and Apr 1 to Apr 30 O gt Sep 11 to Mar 31 gt If you chose b above use the position shown in the small circle chart at the top right of the large circle chart In this example M the suitable position is Position B gt AD A T T i i ie i ie he Position A Y i l i i l i i i i l i l i i i i l i i i i i l Loosely tighten the Sum
11. mer Angle Setter 13a on the Spacer Sleeve 16 Firmly tighten all the bolts and screws How it 1s mounted when looking from above 4 ANN Le a a a a a a a ee re Oy Nye Ey RS d C o Position B CY Loosely tighten the Spacer Sleeve on the Core Bar 1 The concave part should be at the front AI S A S A NEU a a a a GNU UNO UU 49 UV O UU NU Firmly tighten all the bolts and screws 19 l SN OS cipere YN TSPERIR mmm Position Cmm mmm Loosely tighten the Spacer Sleeve on the Core Bar 1 The concave part should be at the front The make up looked down 12 gae rer ee ee gp c rrr rc ydo een ee ee ee AE a he a a he a a a O CEU a ee NEG NV ee r ee ae a ee a MEN a yy Fan orae EE emen ops P AR enero REI Bolt and screw tend to loosen during usage Screw them in tightly a 4 Assembling the Mirror l Bent two ears on each of the KARU Mirrors and 8 on the right lines marked with notches at a 45 degree angle See Fig 27 It is highly recommended to bend them against a hard edge of a table or anything else to achieve sharp lines A round edge is NOT desired Get straight sharp bent lines Incorrect bent lines result in undesired finish Be aware of a slight difference between locations of notches on both sides Bent lines deer D I Notches A
12. orm See Figs 5 and 6 Fit the bosses into holes at their overlapping areas and hand tack them with the Screws 45 and Nuts 49 3 Tighten fully all the Screws 45 on the circular Flange Loose tightening causes the outer frame deformed into an ellipsoidal shape under the influence of the external pressure All the Screws 45 must be tighten firmly The hole for a boss to fit 9 2 Screw the Trivet Rod E D with the Nut 69 on its screwed part into a screwed hole on the Core Bar D 19 True up the male screw end and the bar surface flat 3 Mount the Pan Frame a on the Core Bar Q with two Bolts 42 4 Mount the Pan Frame on the Core Bar Q and tighten bolts with two Nuts Bd i On this area do not give an excessive torque Hold this part to tighten the screw A jog between surfaces does not matter 5 Screw fully the end of the Core Bar Extension into a hole at the Core Bar Q end As loosening of the link between two bars during usage makes the parabola unstable tighten the extension firmly A v4 4 gt 4 Y PAG Abas dum N For high solar altitudes For medium solar altitudes For low solar altitudes 1 Check the latitude of the area where you plan to use the solar cooker 2 Check the Diagrams for the Timing of the Solar Cooker Rearrangements at the end of the User Manual Select the set of circle charts applicab
13. tape over cut lines of the Column base for assembling work 4 Place the inter crossed plates prepared in Step 5 1 into a column to make a regular octagon Fig 38 5 Place a cloth the Parabola Cover over the column to protect the mirror surface The mirror on the right side overlaps the left one ii Hold the rubber edged mouth softly Bosses come up side Important The label with a mark must come onto the Handgrip 13 x2 6 Put four triangle pedestals around the Column Q2 7 Put the Frame on four Pedestals The workshop should be large enough for you to move around the Parabola rather than moving it around If such a place is not available and if you must move the Parabola around you have better to attach four Pedestals to the bottom of the Outer Frame with Scotch tape beforehand 8 Place the preliminarily assembled Mirror on the Frame 9 Tighten loosely the Mirror to the Frame in 16 places with Screws 6 and Nuts 63 The right one overlapping amp f In order to prevent the mirror assy warping upward 4 37 VN fix it temporarily on the outer frame with two 6 tooth picks inserted into the holes on both of holes next to the one to be screwed At this time check N 7 X the overlapping parts of the mirrors as shown in Fig 41 SS G3l Tooth picks 10 Tighten LOOSELY all of 16 Screws 6 on entire circumference H 11 Cut off the column vertically and divide it in
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