CC HHO-PWM User's Guide Software version 1.25
Contents
1. 12V or 24V purple ACC 12V or 24V after ignition green for current to 40A 10mm2 7 AWG for current to 30A 6mm2 9 AWG for current to 20A 4mm2 11 AWG Signal from MAP MAF or any different signal option MASA POJAZDU Controller HHO NOTEN your sensor MAP MAF It is only connection example You will need finding real connection on Controller pin nr description if RS TTL TxD RS TTL RxD SCL yellow SDA white temp sensor H20 analog input GND 5V 50mA LCD GND green LCD 5V brown Oo SIN OD A A D gt sa zl E temp sensor H20 12V ACC sig after ignition QE ee a N Alternator D H LCD display Q Q in nr description T 1 LCD 5V brown x 2 SCL gt a 3 SDA y Q 4 LCD GND green a TO AN r B B D a s ar INOTET 2 7 P D d lit is only connection fj lexample You will need option finding real connection on your sensor MAP MAF opd E IMPORTANT Additional connection to GND in car green Signal from MAP MAF or any different signal Analog output signal MAP MAF Lamp of charginig MASA POJAZDU a 7 Controller Additional switch d description E cl Controller HHO RS TTL TxD Temperature sensor i e Do n2. 2 auto Switch by pressing Wor A Work mode manual Work mode auto Setting mode manual allows operation independently of the battery voltage Fig 8 Menu Work mode Set the mode to auto causes dependence of the set current of the accumulator voltage As aresult the controller will automatically turn it on after the voltage exceeds approximately 13 2V ie after the engine firing and automatically turn it off after the battery voltage drops below 12 9V ie after the engine is turned off When connected to a 24V the controller automatically switches these levels to 26 4V and 25 8V Switch on of current is delayed by 10 seconds after exceeding the level of activation Switch off current takes place immediately 5 4 Menu 3 Analog input settings 3 Anal inp set Fig 9 The third point of the menu By pressing the ENT you can set the voltage to cell current supply characteristics On the main slot connector pin 6 there is the analog input cable green You can enter a voltage of 0 to 30V It allows control of the stabilized current of the cell in accordance with the characteristics shown in Figure 7 rev 14 z 17 05 2013 7 13 CC HHO PWM user s guide Cell current Imax D j 1 j U 4 1 j U i U j 1 H U H U H i H i U H U H D H D Imin Umin Umax Analog input voltage Fig 10 Voltage to cell current supply characteristics Umin 0 DN Fig 11
3. be red and the cable minus negative black For a current below 20A recommended are cables in insulation resistant to high temperatures with a cross section gt 4mm2 For current up to 30A gt 6mm2 and for 40A gt 10mm2 The fuse placed in the main power circuit supply for the controller and the cell Fece Should be set to match the current of the cell For Icel lt 15A Fea 20A for Icel lt 20A Fee 25 30A for Icel lt 30A Fea 35 40A 4 2 The LCD module Connect the gray four wire cable it s attached to the plug from the outlet of the implementing module to the LCD module This cable should be drag into the cabin at the shortest route In the back of the housing of the display there are four screws that need to be unscrew with a star screwdriver Then using a flat screwdriver about 2mm wide pull the back housing panel off Before attaching the ends of the cable to the socket drill a 5mm diameter hole in the back or side wall in a place convenient for you and drag the cable through it It s recommended to cut off the excess of the cable leaving only a few inches piece enabling free connection to the display How to connect the cable to the display is shown in the figure below Fig 3 How to connect the cable to the display rev 14 z 17 05 2013 5 13 CC HHO PWM user s guide 5 MENU 5 1 The main screen The main screen displays all of the values measured by the controller That is s
4. CC HHO PWM User s Guide Software version 1 25 CC HHO PWM user s guide Contents H Eeer 3 2 Resulatory capabilities cia i2csascaleacicdanca dead nisni ier aa eE eE uaes 3 W EE 4 A nistall ati Gis e eG AGES Cale GE BGR EG BE Lg 4 4 1 The mplementing Allee eer isda eee ee 4 42 Ae LCD mod le eege EE ege 5 5 M t eegene Allee Grete emt ele Goede Ee 6 5 1 WS main SCRE SN asi eae i Ba ee ys EE 6 5 2 Menu l Current regulator mode geet degen Seed 6 5 3 Menu 2 Work mode eege geed EEN 7 5 4 Menu 3 Analog input AEN 7 5 5 Menu A Water temperature settings sesesesesessseesseesseesseresseeesseessresseesseeesseee 9 5 6 Meng 5 reQucne y SELUIN ee leede 9 5 7 Menu 6 Factory default settings sccssssscssssscsssssesessccsenscceesscessnsecesacees 10 6 Default and recommended alarm levels w 12 sccstrn testa eiidn eesti DEENEN 11 T Wafanty e moinen sel ee te elated al ete ea enad 11 Designer Jerzy Hetmanski Phone 48 603 781 110 Email jerzy het z pl rev 14 z 17 05 2013 2 13 CC HHO PWM user s guide 1 THE PURPOSE The device purpose is to regulate an electrical current especially in a dry and wet cell to produce HHO It allows the user to set a direct current current source regardless of a voltage Wide Input Voltage Range The controller is designed to regulate the current in a cell the distance between the electrodes gt 1 8 mm the thickness of the isolating separ
5. The first point voltage Imin 10 0A Fig 12 The first point current Umax 4 2V Fig 13 The second point voltage Imax 33 3A Fig 14 The second point current To make changes press the keys Y or A To move to the next setting press the key ENT To go back to the main menu press the ESC rev 14 z 17 05 2013 8 13 CC HHO PWM user s guide NOTE In the submenu if no key is pressed for 20 seconds the driver himself will go to the main menu and after another 20 seconds to the main screen 5 5 Menu 4 Water temperature settings 4 Water temp Fig 15 The fourth point of the menu By pressing the ENT you can set the alarm temperature levels for water Fig 16 The fourth point of the menu If the water temperatures exceeds the TwH the alarm will be turned on turning off the current in the cell protecting it from damage Fig 17 The fourth point of the menu Water temperature drop below TfL will turn off the alarm and reconnect the current to the cell Changes are made using keys V or A To move to the next setting press the ENT and to exit to the main menu press the ESC If you don t want to use the temperature sensor you don t have to connect the temperature sensor The driver will automatically detect the absence of the measuring probe and will ignore this measurement In this case the screen will display the inscription Tw _np_ which means not connected
6. WARNING The temperature sensor should be mounted on the cable between the expansion tank and the cell or mounted outside in the bottom of the tank In any case it should not be put into the tank where the KOH solution could destroy it 5 6 Menu 5 Frequency settings 5 Frequency set Fig 18 The fifth point of the menu Here we can set the operating frequency of the PWM controller Changes are make in increments of 10 100 1000 and 10000 Hz rev 14 z 17 05 2013 9 13 CC HHO PWM user s guide ENT gt Fig 19 Switching and frequency change Currently the position change is indicated by an arrow Changes are made using the y or A WARNING It s not recommended to set a frequency less than 2000Hz Recommended frequency is 24000Hz The number you see on the screen after Hz is proportional to the duty cycle that is the average cell voltage It varies from 0 to 1000 filling of the PWM is in parts per thousand promiles This allows you to find the resonance of the cell You should find the frequency for which this number is as small as possible There the cell achieves the highest efficiency The resonance frequency depends on the cell construction and sometimes it is difficult to determine Some cell constructions may not show clear minimums Because of the power losses especially in the regulator it is important to provide the highest frequency preferably 24000Hz and PWM digit as large as possibl
7. ator layer is 2mm Installation of cables to screw terminals should be done using cable lugs for screw M5 which should be adjusted to a diameter of the wire The terminals should be tighten with the right tools for mounting lugs on the cable After tightening the cable to the terminal it s recommended to secure the bolts with a technical vaseline Minus power supply from accumulator Plus power supply from accumulator Plus to cell ee gn Minus to cell Fig 1 Description of the main terminals Recommended connectors for M5 screws KLAUKE NINGI or similar 2 REGULATORY CAPABILITIES gt Allowable supply voltage 8 to 32V gt Operating voltage range 9 to 30 V gt Stabilized current recommended no more than 35A above 25A it is necessary for the driver to be installed in a ventilated area eg near a radiator fan or an external mount fan or to install an additional external heat sink gt Current control rev 14 z 17 05 2013 3 13 CC HHO PWM user s guide 1 the keyboard every 1A 2 analog input every 0 1A gt The controller type PI gt Frequency 40 Hz 25kHz adjustable in increments of 10 Hz I do not recommend setting the frequency of less than 200Hz 3 ALARMS The regulator oversees the three main parameters of the system battery voltage water temperature and the temperature of the main transistor regulator Based on continuous
8. e Top like during normal operation after the warm electrolyte is not less than 700 see Chapter 6 5 7 Menu 6 Factory default settings 6 Default set Fig 20 The sixth point of the menu Here you can restore the factory settings for all parameters of the controller The string of characters located in the second line is the serial number of the controller NOTE IMPORTANT After the factory reset the measurement error may be up to 20 for the current measurement and 10 for the voltage measurement The driver should be re calibrated Without adequate instruments it s impossible ENT def set ESC lt cancel gt Fig 21 The screen rev 14 z 17 05 2013 10 13 CC HHO PWM user s guide Pressing the ENT key will set the factory settings Pressing the ESC key or not pressing any key for 20 seconds will exit from the sixth point of the menu without changing the settings 6 DEFAULT AND RECOMMENDED ALARM LEVELS Recommended settings of the alarm levels 1 Temperature of the cell electrolyte TwH 65 C turn off the current of the cell TwL 60 C turn on the current of the cell 2 Factory settings that can be changed only when the service code is given or by using the service program for the PC UbL 12 9 turn off voltage level V UbH 13 2 turn on voltage level V kP 200 proportional factor of the PI controller changes not recommended kI 75 inte
9. grating factor of the PI controller changes not recommended delON 10 time delay in seconds Imax 40 0 maximum current 40 0 A for digital security Do not increase This value can be reduced at most TrH 85 C the temperature of the heat sink which turns off the current of the cell TrL 75 C the temperature of the heat sink which turns on the current of the cell ATTENTION With these parameters it is NOT RECOMMANDED to change the setting Kp Ki and Imax This can lead to unstable operation or damage to the controller 7 WARRANTY If the user will use the device as intended device will be installed in accordance with manufacturer s instructions and in the right location specified in the manual the manufacturer watranties for a period of 12 months The warranty does not cover any mechanical or electrical damages resulting from wrong installation or misuse It does not cover a damage resulting from short circuits during installation or within the hydrogen generator rev 14 z 17 05 2013 11 13 Ha brow o yellow N LCD display keyboard A E y WW Temperature sensor Do not put into the electrolyte Attach this sensor to the delivery pipe to the cell electrolyte LCD display innr description LCD 5V brown SCL SDA LCD GND green Additional connection to GND in car Temperature sensor 30A 45A ll
10. measurement of these parameters the alarm is generated It is manifested by a short beep repeated approx every 0 5 seconds The alarm turns off the current stabilizer output current equals zero and it s maintained till the removal of the cause of the alarm eg low battery voltage or too high temperature of the main transistor of a regulator or water To turn off the beeping press any key During the alarm instead of the current displayed is the inscription I A before pressing any key CAR after pressing any key 4 INSTALLATION 4 1 The implementing module The controller must be installed in a ventilated area so as to eliminate direct flooding The good cooling of the bottom of the housing of the controller should be ensured on the upper side there are plastic stoppers because this is where all active components are the main control transistor and diode Bottom of the housing Keep cooled Fig 2 Housing Cooling To reduce the loss in the supply system of a cell power cables of the controller and the cell should be as thick and as short as possible The power cables a cable plus and a cable minus should be guide as close to each other in an one tube assembly as possible This applies to both the regulator and the power supply of the cell Cables colors should be chosen rev 14 z 17 05 2013 4 13 CC HHO PWM user s guide according to the standard ie the cable plus positive should
11. ot put into the electrolytell SCL yellow ttach this sensor to the delivery SDA white jipe to the cell electrolyte purple temp sensor H20 Temperature sensor SE GND 5V 50mA LCD GND green LCD 5V brown temp sensor H20 12V ACC sig after ignition 30A 45A ll 12V or 24V for current to 40A 10mm2 7 AWG for current to 30A 6mm2 9 AWG for current to 20A 4mm2 11 AWG Schemat of second variant of connection
12. tabilized current I supply voltage U water temperature Tw heat sink temperature Tr I 10 0A U 14 1V Tw 56C Tr 46C Fig 4 The main screen You can switch between the main screen and the menu by pressing the ESC The main menu contains 6 points which are described below 5 2 Menu 1 Current regulator mode 1 I Regul mode Fig 5 The first point of the menu By pressing ENT we can choose the setting method for the current 1 keyboard 2 analog input Switch by pressing VW or A I Regul mode keyboard I Regul mode anal input Fig 6 Menu Regulator mode Setting mode keyboard allows changing of the current with the keys Y or A Changes in the value of the current setting are possible after the return to the main screen This can be done by pressing twice the ESC button or waiting about 20 seconds after which the driver goes to the menu itself and after another 20 seconds to the main screen rev 14 z 17 05 2013 6 13 CC HHO PWM user s guide Setting mode anal input allows to change the current settings by connecting the voltage to the analog input with an external potentiometer or MAP MAF signal Voltage to current ratio is linear in characteristic which will be described in section 3 4 5 3 Menu 2 Work mode Fig 7 The second point of the menu By pressing ENT we can choose the setting method for the current 1 manual
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