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Fuel Cell and Pulse-width modulator (PWM) Installation Guide, Facts & Figures & Parts List
Created By: Dennis R Peacock in affiliation with Rene Poyaoan
Initial setup
The PWM is capable of sustained current output far in excess of what can be delivered by most typical automotive alternators. Despite this fact, it's not impossible to exceed the 75 amp continuous, 250 amp peak impulse maximum limits of the device. It's easier than you may think. In the previous example I explained how the cell can draw as much as 3 times the amount of current if powered by straight DC once it gets hot. Let's say you set the PWM to regulate at 30 amps. If the cell wants to draw 60 amps from straight DC the PWM will throttle back to 50% duty cycle. If the cell wants to 120 amps the duty cycle drops to 25%. In all cases the average current remains at 30 amps, well below the 75 amp maximum. What changes is the peak impulse current. Even at 120 amps peak impulse, that too is also well within safe operational limits. However, many builders like to use parallel plate designs (+-+-+-+-+-). This puts the full input voltage between every plate. It's very easy to add too much electrolyte to this type of cell and create a virtual dead short. No matter what, the PWM will limit the average current. But 30 amps average into a nearly dead short is impulses of nearly infinite current. 600 amps peak is still 30 amps average at 5% duty cycle but well in excess of the 250 peak impulse maximum of the PWM. Get it? When you first get your PWM it will be calibrated for 20 amps at 2.5 Khz. This is a good baseline to start with for most installations. REMEMBER, IT IS VITALLY IMPORTANT to adjust your initial startup current with electrolyte
concentration first while the cell is cold from straight DC. Then use the PWM to limit current as the conditions of the cell changes with temp. Frequency can literally be adjusted by ear. It's not that critical. If you need to know what the exact frequency is you'll need a frequency counter or oscilloscope. The % adjustment is used as a manual HHO throttle and can be extended to a throttle pot if desired. Other uses for your CCPWM: Overload protected 12V EV motor speed controller High powered 12V Lamp Dimmer control Tesla Coil primary driver Warranty: This PWM is warranted against defects in materials and workmanship. It is guaranteed not to be dead on arrival and to meet or exceed the published specifications. Liability is limited to repair or replacement at our discretion. Warranty does not cover misuse including but not limited to miswiring, water damage or exceeding any published rating. Customer acknowledges that, as a still experimental field of study, devices such as this used in HHO experiments may be subjected to unexpected conditions causing premature failure for which the manufacturer will have no responsibility. Repair cost quotes based on time and materials plus return shipping. HHO can be a dangerous field of study if not treated with the utmost respect. We shall assume no responsibility for any harm to the customer, witnesses, neighbors or passersby, or any personal property owned by any of these, directly or indirectly through his/her use of this device. Customer warrants that he/she shall use this device in compliance with local, state and federal laws, regulations. One Large benefit to HHO is called heavy water, and the source of heavy water is electrolysis which is what we are doing. Heavy water has one more atom of hydrogen. So what we want to do is put a magnet in our overflow reservoir to collect the iron from the cell. Never drain the water from the cell as it is making heavy water , instead just wait tell the overflow reservoir is empty then clean it and the magnet. Heavy water will increase your production of HHO. If you plan on tearing your cell apart after one year for inspection make sure you keep the water and put it back into the cell when you are done. http://en.wikipedia.org/wiki/Heavy_water
Stainless Plates
12 Bolts 1/4x4 24 stainless washers. 12 nuts Buy one meter of 3/8 fuel hose and cut 12 pieces 2 for insulating bolts from steel plates.
Scan black image then print to 1.5 inches by 3inch. Place microchip on paper to make sure its the right size. Print onto transparent film using a laser printer and use as photo-mask along with photo-sensitized boards. You can put 4 pcbs on one 4x6 inch board, its best to print 2 copys so you can pace one on top of the other for better coverage. Place image face down on apiece glass and tape edges in place. Place 2nd print out on top of the first align and tape down for better coverage. Next in a dark place take the protective covering off your photo-sensitized board and lay it face down on the print out and tape in place. Now turn over the glass so you can see the image as seen in the picture below. Walk outside and place in direct sunlight for one min then go back to your dark place and take the board off the glass and rinse it in the developing solution (one liter of tap water with one pack of developing crystals provided with the sensitized board) tell the green comes off the board where you see the white traces on the picture below. Rinse in fresh water. Now wash it in warm ferric chloride until all the copper is gone from the unprotected area, rinse in tap water. Then take the pcb out to the sun unprotected for one more min then rinse in the developing solution one last time to remove the green from the board so you can solder to the board, rinse one last time. Now your ready to drill holes in the board so you can install the parts. The two large circles are for the grounding/mounting studs and must be mounted to the case (ie metal box). Wear rubber gloves and eye protection
There is only 6 electronic parts in the box that are not on the circuit board. 1LED, Amp meter(black)Mosfet,C5 & C7 & 12volt 30 amp car relay not shown. Part D1 attaches at the drain of the mosfet and goes to the positive cell connection blocking current going back to the mosfet. Mount car relay on pos battery stud inside the box. C5 connects between the terminals of C7. C7 grounds to the box and the other terminal goes to + Cell bolt.
Then run a wire from terminal 87 on the car relay to the positive on the amp meter. Then the neg amp meter connects to the +cell bolt. Terminal 86 to ground 85 to master switch bolt between the cell bolts.
RS Components Ltd http://philippines.rs-online.com/web/ 21/F Multinational Bancorporation Centre 6805 Ayala Avenue Makati City Philippines or mouser eletronics
PWM Parts List, v2 Unless noted, all resistors are in ohms, 1/4W, 5% tolerance. All capacitors are in uF, 16V minimum Designation P/N Qty Description Mouser Digi-Key LM324NFSND $0.42 ea Misc vendors
U1
LM324
Quad Op-Amp
512-LM324N $0.33 ea
RS
268-0002 (36p)
U2 7810 1 10V Regulator 512-LM7810ACT $0.31 ea 296-21622-5ND $0.84 ea
RS
661-6702 (61p)
Q1
IRFP064N
Power MOSFET
541-0008 (154p)
D1
MUR420G or equiv
863-MUR420G $0.42 ea
MUR420GOSND $0.53 ea RS
MUR420 (25p)
D2-D3-D4
DIODE
1N4001
L1
100uH
Inductor
RS#1910598(22p) RS 191-0598
R9
100
Resistor
R10, R13
1k
Resistor
R1, R7,
1.8k
Resistor
R6
3.9k
Resistor
660MF1/4LCT52R392J $0.05 ea 71CCF0710K0JKE36 $0.02 ea 71-CCF07-J-22K $0.02 ea 71-CCF07-J-100K $0.02 ea 71-CCF07-J-1M $0.02 ea
R3, R4, R5
10K
Resistor
R2
22k
Resistor
R8 R11,R14
100k 1M
1 1
Resistor Resistor
C1
0.022uF
598-DSF050J223 $0.19 ea RS
476-2572 (8p)
C3
0.047uF
140-100Z5-473ZTB-RC $0.16 ea
2508425618 (14p)
RS
C2, C4,C5
47uF
Electrolytic cap
RS
224-4268 (17p)
C5
4.7uF / 100V
Polyester film
5989-100V4.7-F $2.27 ea
RS 115-629 (68p)
C6
.001uF
140-50P2-102K-TBRC $0.08 ea
C7
12,000uF / 1 25V
35 volt RS 127-802
(246p)
RELAY
6 Volt 1amp
OUAZ-SS-106L
Relay 2
12 volt 30amp
Fuse holder
VR3
1K
522-0063 (140p)
VR1
10k
522-0079 (140p)
VR2
20K
522-0142 (140p)
GD234
532-4180, $0.70 ea
http://www.alexan.com.ph/
TO-247 insulators Heat sink compound CPU cooler PC Board Fibre shoulder washers For #10 screw 5C12B3
MCM 21-1170 $4.21/25 526-NTE303 1g $1.77 ea 345-1006-ND 4g $5.04 ea NewEgg $3.99 + S&H Directron $1.99 ea
RS 178-822
RS 528-176
15p ea 3p ea 1p ea
LET'S GET FAMILIAR WITH YOUR NEW H.O.G. FUEL CELL INSTALLATION:
The Dry Fuel Cell is the heart of the system that generates the HHO gas and cools down the engine. You will need to find a place in the engine compartment to mount your new HOG cell. It MUST BE MOUNTED as such & The fitting openings facing NORTH to the sky, and NOT side mounted or it will not work properly and you will have unstable amp draw that could blow the fuse. It should be mounted and secured in such a manner as to assure that it cannot bounce around when the vehicle hits bumps etc. Use the 4 longer bolts for mounting front and back make sure not to over tighten bolts when reinstalling. Make sure that your Reservoir/Bubbler is installed higher than the fuel cell as this would have a gravity fed system .. Furthermore, make sure all hoses connection to the fittings are
securely tightened with hose clamps and in the rare event there happens to be a fitting leaking at any of the threads, use Teflon tape or plumber's Goop to seal them according to the products instructions. There are no pumps involved with the circulation. This device needs to be installed upright as seen in the illustration. If you're not sure of something, tell us the problem by sending a message via email or posting your problems on HHO Philippines facebook account. Try to install your new Dry Fuel Cell as far away from the heat of your engine. Locate the coolest available place in the engine area. We cannot give you an exact number here for what is too hot, because there is a combination of heating factors here. There is a situation called Thermal Runaway, where an increase in ambient temperature combined with too high of electrolyte mix can lead to a destructive result to the Dry Fuel Cell. You can prevent this from happening by following instructions below and utilizing whats called a pulse width modulator (PWM) to keep a stable current draw to the HOG Fuel Cell.
Your new HOG Fuel Cell device is operated by vacuum pressure from your vehicles engine, plus a 12 Volt supply from your vehicles electrical system. The device is designed to operate on 12 Volts. Refer to the wiring diagram below. If youre not sure, consult with your auto mechanic, or contacting us for help.
Now it's time to connect the HHO gas output line to your vehicle so you go much further on a tank of gas. (Follow the diagram below).
How To Use Your Vacuum VACUUM Dry cell systems should be connected to the closest area to the throttle throat (throttle body), not directly to intake manifold vacuum. The idea is to suck the HHO gas into a place such as the carburetor throat or fuel injection throttle body, where it can be automatically mixed with the existing fuel/air mixture. Best connection spot on carburetors and injection systems is at the closest location to the throttle body throat. Connect the output hose on the air filter container right above the carburetor throat and on fuel injection system, right above the throttle body throat by means of a fitting. On rubber duct type hoses, you can use a soldier gun and melt a hole in the rubber duct closest to the throttle body and glue and screw the fitting into the hole with Goop glue. On metal or hard plastic ducts, remove and drill hole, thread it, install fitting, and then clean the metal shavings out of the duct before installing it. On diesel or gas engines with turbo charger(s), the HHO output hose goes into the intake system BEFORE the turbo charger. On twin turbo chargers you will have to use a 3/8 T fitting at the end of the HHO output hose to run 2 additional hoses, one each, to each intake system BEFORE each turbo charger. 2, 3/8 elbow fittings will be needed to tap into the intake system to connect the output hoses to. WARNING: If you put the HHO output hose into the intake AFTER the turbo charger(s), the HHO system will become pressurized, damaging the HHO system.
FINAL SETUP Filling the Reservoir/Bubbler with DISTILLED WATER & THE ELECTROLYTE: Electrolyte Mix: 13 cc of Potassium Hydroxide to 1 liter of Distilled water (recommended)
Once you have your mixture ready, pour it into the top of the Reservoir/Bubbler up to the water level line. (see sample diagram below) This is just a sample of a 2 quart Reservoir/Bubbler. Be sure to leave about 1/2 of the tank empty 50% full). What you decide to use is your decision. While you are filling the unit, you should be able to see water running down to your Dry Fuel Cell. If you don't see any water going down the tube, this could mean you don't have the Reservoir/Bubbler high enough above your HOG Cell. Always try to install your HOG Cell at the lowest level on your vehicle at least higher than the top of the cell. The HOG cell system should be bled of all air before operating or unstable amp draw will occur and may cause main power fuse to blow. It is not recommended to use your mouth to do any bleeding of lines.
TEST RUN:
1. Start by checking all your connections. Make sure your amp meter and inline fuse have been installed. 2. Now start your vehicle. While it's running, watch for bubbling action inside of your Reservoir/Bubbler. You should be able to see the gas entering the Reservoir/Bubbler tank. Initial use of the HOG cell shall result to a low ampere reading, which will produce less HHO output, This is normal, since the HOG cell is being conditioned and the electrolyte is still mixing with the water solution. 3. Check how many amps your dry cell is pulling. This cell was made to run at 20 amps without overheating at all. It will produce over 1 liter of HHO gas per minute (a liter in approximately 40 seconds) if you have everything hooked up according to the instructions (that's all the hydrogen your vehicle will need to see an improvement in fuel mileage). 4. If you have done everything right, within a short time, you will notice that the engine starts to sound dramatically different. It will sound smoother and quieter. Your RPM's may be unstable for a couple of minutes. This is normal. The HHO is starting to
change the combustion cycle and cancels the pinging and the engine is now adjusting to the changes. Your RPM's will normalize in a couple of minutes.
SAFETY FEATURES:
H.H.O. gas is colorless, odorless, tasteless, and noncorrosiveand it is nontoxic to humans. Hydrogen has the second widest flammability range in air of any gas, but leaking hydrogen gas rises and diffuses to a nonflammable mixture quickly. H.H.O. ignites very easily and burns hot, but tends to burn out quickly. A H.H.O. flame burns very cleanly, producing virtually no soot, which means that it is also virtually invisible. In some ways, a gaseous H.H.O. fuel leak is less dangerous than a leak of diesel fuel or gasoline. Leaking diesel fuel and gasoline can puddle and spread over a large area, and the puddles will persist because they evaporate slowly. H.H.O. leaks tend to be vertical, with only a relatively narrow area/volume in which a flammable mixture existsthe H.H.O. quickly rises and dissipates in open air to non hazardous levels. If designed properly, the most likely location of a major H.H.O. leak in the fuel cell is when the bolts that hold the fuel cell gets un tightened or the hoses connecting the fuel cell to the air intake gets punctured or loosed. Leaking H.H.O. can pool and spread, but will quickly evaporate as it is heated by the surrounding air. A leak on the fuel cell will register a low amperage on the Pulse Width Modulator as shown on the amp gauge attached to the PWM, a safety feature that can easily detect a leak or a low electrolyte on the water added to the fuel cell. The most important safety principle in any situation is educationmaking anyone who will come into contact with a vehicle aware of a potential hazard. For hydrogen and other alternative-fueled vehicles, this is done with appropriate labeling to let users, emergency responders, and the public know that hydrogen is present. Hydrogen Hydrogen Oxygen Fuel Cell A fuel cell is also a galvanic cell; the hydrogen and oxygen do not combust inside the device. Instead, H2O react electrochemically and produce a clean highly combustible gas that is a supplement to gasoline or diesel fuel used in an internal combustion engine Theoretically any typical spark-ignited engine, like the gasoline engines used in most cars, can operate on a range of liquid or gaseous fuels, including HHO. However, due to differences in the chemical properties of the various fuels, the designs of engines optimized for each are quite different. Because of the wide flammability range of hho, an internal combustion engine (ICE) operating on HHO can operate with a much leaner air/fuel mixture than a typical gasoline engine, which improves efficiency. Because HHO is a light gas, it displaces more volume in the combustion chamber than gasoline vapors, and super-charging is generally required to get equivalent power output as the same sized gasoline engine. HHO Injection Systems HHO injection system for a diesel engine produces small amounts of hydrogen and oxygen on demand by electrolyzing water carried on board the vehicle. The electricity required is supplied by the engines alternator or 12/24-volt electrical system The hydrogen and oxygen are injected into the engines air intake manifold, where they mix with the intake air. In theory, the combustion properties of the HHO result in more complete combustion of diesel fuel in the engine, reducing tailpipe emissions and improving fuel economy A HHO injection system for a diesel engine produces and uses significantly an amount of HHO that supplement an amount of HHO gas that lessens the use of diesel from 35% to 40%. The system is designed to produce HHO only when required, in response to driver throttle commands. When the system is shut-off, no HHO is present on the vehicle.
ELECTROLYSIS OF WATER The most abundant source of hydrogen on earth is waterevery molecule of water contains one oxygen atom and two hydrogen atoms. It is relatively simple to separate the hydrogen in water from the oxygen using electricity to run an electrolyzer. An electrolyzer is a galvanic cell composed of an anode and a cathode submerged in a water-based electrolyte. In many ways, the operation of an electrolyzer is the opposite of operating a hydrogen fuel cell. In a fuel cell, hydrogen and oxygen are supplied to the anode and the cathode, and they combine to form water while creating an electrical current that
can be put to use. In an electrolyzer, an electrical current is applied between the anode and the cathode, which causes the water in the electrolyte to break down, releasing oxygen gas at the anode and hydrogen gas at the cathode.
"HHO Philippines is a social networking group involved in the science of converting water (H2O) to HHO; through the process of brute force electrolysis; a highly combustible, environmentally clean gas that can help contribute in solving the current oil crisis, lessening air pollution and help deter global warming . The group offers free information from various HHO enthusiasts, world wide involved in the proliferation of this amazing work of man. Members contribute their knowledge on how HHO works and informing those who had long been misinformed about the true essence of this innovation. The Hydrogen Oxygen Generator (HOG) being featured in this group is the innovation of the creators of the group which is being shared to people who want to build their own. Its advertising purposes is to acquire funds for further research in other projects being undergone by the innovators. We are a non-profit organization. Payments are considered as donations. Our main objective is to teach people how to make their own. How to understand the benefits of this technology for use by the masses. This site has no intentions of going against the oil companies nor any entity that produces and market fossil fuels. In fact we are their allies in preserving fossil fuels for use by future generations. ". Join us in facebook HHO Philippines @ Facebook
http://www.facebook.com/groups/360232803470/?id=10150252365713471¬if_t=group_activity