Kit DC8OOO Installation Manual - Smart
Contents
1. generator working only when the engine is also working Identify a point in your vehicle s electrical system which has 12 24 Volts positive present only when the engine is running circuit controlled by the ignition key position 2 The most secure connection is to excitement signal of the alternator If you do not know pRY CEL A hd m how to do this connection please ask you usual mechanic to do it for you Connect this electric source to the Relay Switch position 85 This circuit will control the HHO production Ground Dry Cell electric connections Inside each one of the Dry Cells we have 45 plates with a configuration that allows the insertion of yellow female spade connectors Not all of them should be connected because electrolysis would in this case be very intense and damage the surface of the plates We have to leave between the positive and the negative some plates without connections Neutral plates in order to break the voltage and increase the electrolysis efficie ncy with less heat production The neutral plates without any connections should be the following 12 V 3 neutral plates 24 V 10 neutral plates Please refer to the picture below for typical wiring connection of the dry cells using 24v The positive circuit red wire should be connected to the Relay Switch position 87 Connect the negative circuit black wire of the Generator to a2. Enjoy your System Be safe and enjoy your new Hydrogen on Demand Dual Fuel Generator System read and understand these instructions before and during the installation and you will benefit from your new system for years to come SiL CE HHO Plus AL T ERNA TIYe cANcaGizs KIT DC8000 INSTALLATION MANUAL OCTOBER 2011 Installation of the hydraulic components General configuration Your system is composed of the two individual drycells to be con nected in parallel to the water tank according to the illustration below HHO Tank HHO Gas jr upwards or in a vertical position Please remember that the water tank should be placed at least 30 cm above the generator Dry Cells in order to guarantee a sufficient water head for the water to flow Make sure to install the Dry Cells in a place Air Intake Manifold can easily be accessed and cleaned It should be mounted and Water or inspected from time to time secured in such a manner as to In the end pages of this manual you will be able to check each one of the individual connections to be made and parts to be used regarding the installation of the hydraulic We will now only focus on the main aspects of the installation now Positioning the Generator Dry Cells You will need to find a good place in the back of the driver s cabin to mount your new HHO system The dry cells can be mounted in a horizontal position upright an
3. an engine control unit ECU because the fuel burned inside the cylinders has significantly improved but the sensors continue expecting the same amount of un burnt oxygen to come out of the exhaust of the engine This causes a signal to be fed back to the ECU that give order to inject more fuel increasing the Wish trucks we need to make changes in the sensors Normaly the only trucks that need some modifications in order to increase fuel savings are modern diesels with Euro module IV and V air fuel mixture Richer which counter acts the fuel gains you may be expectecting Components An Electronic Control Unit ECU controls the internal combustion operation of the engine The simplest ECUs only control the quantity of fuel injected into each cylinder per engine cycle The more advanced ECUs also control the ignition timing variable valve timing VVT the level of boost maintained by the turbocharger and other engine peripherals ECUs determine the quantity of fuel ignition timing and other parameters by monitoring the engine through sensors In trucks the most important sensors are the MAP MAF airflow and tem perature sensors Mass Air Flow Sensor For an engine with fuel injection the ECU will set the quantity of fuel to inject based on a number of parameters For example If the accelerator pedal is pressed further down this will open the throttle body and allow more air to be pulle
4. good ground source KIT DC8000 INSTALLATION MANUAL OCTOBER 2011 5 internal combustions engines The system should provide around 0 3 liter min of HHO per each 1000 cm3 of engine displacement ex a 12000 cm3 engine will need around 3 60 Water and electrolyte setup Principles of the Electrolyte liter minute You will be meeting water electrolysis concentration this standard running your generator with 30A 24V Electrolysis of water is the The electrolyte should be decomposition of water molecule H2O into oxygen O2 and hydrogen H2 gases due to an electric current passing in the water added to the water only the first time that you use the system After for refilling we only use distilled water Water is getting a brown color after only a few hours working You have a too high electrolyte The electrolyte concentration to jn the system that is eating use in the HHO system depends on the type of electrolyte and the purity of the product The An electrical power source is connected to two electrodes or two plates typically made from the generator plates too fast Remove the water immediately and start all over again some inert metal such as stainless steel which are placed in the water In a properly designed cell hydrogen will appear at the cathode the negatively charged electrode where electrons enter the water and oxygen will appear at the anode the positively charged electrode Th
5. KIT DC8000 INSTALLATION MANUAL Safety Precautions Basic Information Read and follow these safety precautions to avoid hazards If you do not understand these instructions or do not like know to work on vehicles please have a qualified mechanic do the installation for you Incorrectly installing or using the HHO Hydrogen System may result in serious damage to you and or your vehicle It should take approximately 2 5 hours to install this unit so ensure that you have enough time to complete the installation Be sure to work outside no smoking at any time during the installation make sure the engine is off and very importantly NOT HOT Your HHO Generator System does not store hydrogen and subsequently there is no fire hazard when installed properly However water electrolysis generates Hydrogen an explosive gas which means that never light a match or smoke near or in front of the generators output the generator could explode Be careful with the generator working when the car is not moving A small amount of hydrogen can accumulate in the air intake of the motor and could explode if you smoke or use an open flame near it Safety Equipment Be sure to wear goggles and rubber gloves and only use professional tools use common sense and general safety procedures used for any work October 2012 Kit DC8000 Installation Manual October 2011 carried out on automotive installations and maintenance
6. You can now use your truck whenever you feel like ECU resetting is over Euro IV and V trucks Besides reseting the onboard computer In these modern trucks we have to make changes in the signal coming from the MAF For that we use a small electronic box called the MAF Enhancer that is basically a potentiometer variable resistor which varies its value by turning the knob according to the next picture 50K Pot 47K Ohms Signal Ground 5 Volts The Mass Air flow Sensor is a little though expensive device installed in your intake manifold It has 5 Volts or 12 Volts coming in and it simply senses the vacuum in the manifold and reduces this incoming voltage by a certain factor In other words it reduces the supply voltage to a direct current voltage in the range of 15 to 60 of the supply voltage depending on the design these numbers will vary and this varying but non pulsing signal is then sent back to the computer The arrangement of resistors simply takes this already reduced signal and reduces it further Linear Taper Ground Resistor 1 4 watt Too much reduction kills the engine it will simply shut off Yet if you control it correctly you can lean down the mixture from the balance of ingredients which is factory set at 14 7 1 14 7 parts of air to 1 part petrol down to 20 1 maybe even 50 1 INSTALLING AND TUNING The tuning procedure calls for clockwise and count
7. ch The Dial should point to minimum on the scale or all the DO THE NEXT STEP WITH CARE JUST IN CASE YOUR ENGINE STOPS UNEXPECTEDLY way anticlockwise Make sure your HHO Generator IS operational Warm up the engine and drive a while before experimenting with the knob 1 Now start turning the knob clockwise the mixture will turn leaner and leaner until the car stalls or bucks as you drive Back the knob off slightly after the bucking and chuoging 2 Keep the danger of overheating in mind If your HHO Plus Generator device is non operational temporarily set the enhancer at or near original factory setting rich 3 Set points can change from one petrol station s fuel to another weather conditions cold engine etc The differences are not large but if you re on the edge then the car will buck or vibrate and you ll need to change the set point a bit Remember that this is a simple device NOTE When this device turns on for the first time sometimes the check engine light comes on and this needs resetting with a ScanGauge Il or an OBD 2 Connector 1996 cars or newer When this has been done if your connections are correct it will stop off MAXIMIZE BENEFITS You will get improved reductions straight away How much is dependant on your HHO generator performance The better performance you get from this the more lean your truck but don t overwork the engine by leaning it too much play ar
8. d into the engine The ECU will inject more fuel according to how much air is passing into the engine A mass air flow sensor MAP or MAF is used to find out the mass of air entering a fuel injected internal combustion engine The mass air flow information is the most important one and necessary for the engine control unit ECU to balance and deliver the correct fuel mass to the engine Older Trucks Before electronics most engine parameters were fixed A carburetor or injector pump determined the quantity of fuel per cylinder per engine cycle Like mentioned before when adding a HHO gas to these trucks we will see immediate improvements in fuel consumption There are no special devices or requirements to fit the HHO System to these trucks but to improve the fuel savings the injection rate of the fuel pump should be tuned to the new air fuel mixture conditions Euro I Il and III trucks The ECU of your truck is like its brain using mapped data to work out the optimum control conditions for the engine According to the day to day driving conditions the ECU builds a memory data base that helps it to decide the course of action that should be taken by the engine to ensure an ideal drive Even though you have made modifications in your car with the HHO system the ECU still continues to get an input of the old data which is stored in its memory This old data is no longer credible as it pertains to conditions t
9. d level to the ground with the tube fittings facing directly ensure it does not move or bounce around while the vehicle is in motion even over rough terrain Securing it with a permanent bracket should be sufficient to secure it to the engine chassis and to operate perfectly Important Information When making the installa tion never make changes in the generator dry cell for mounting purposes Never open it loosen tighten the nuts or cut the screws You will damage the generator and it will not work properly after Positioning the Water Tank Make sure that water tank is installed with the same care as described for the generator As mentioned before the tank needs to be placed higher than the HHO dry cell to accomplish the gravity head needed for the water to flow into the generator Positioning the water and HHO hoses Please refer to the illustration below for typical installation of the hoses coming and going from the water tank qu KIT DC8000 INSTALLATION MANUAL Please verify that the bottom of the water tank is connected to the lower entry in the drycell and the upper connection to the higher entry in the drycell HHO injection point Please verify that the bottom of the water tank is connected to the lower entry in the drycell and the upper connection to the higher entry in the drycell The system is operated by vacuum suction from your truck s air intake which takes the HHO dir
10. displacement test Remember that the system should provide 0 3 liters min of HHO per each 1000 cc in the engine See if you are meeting that standard 2 Is the HHO gas getting into the engine We have seen cases where a leak in the system was keeping the hydrogen from getting into the engine A split hose can cause this or one that is not attached at all A check valve oriented in the wrong direction can block the HHO from getting to the engine One time we found that the lid to a dry cell s reservoir had a leak and when this was fixed the situation resolved completely Spray your hoses and connections with soapy water to expose any leaks in your system Fix any that you find 3 Is the amperage on your generator to high Another thing that should be checked here is whether your unit is making HHO or steam Some of the early cell developers would run their units with so much amperage that the unit was producing more steam than anything else If your unit runs hot to the touch you must suspect that at least part of your output is steam 4 Have you changed the electronic injection Vehicles with carburetors and some diesels Euros modules I Il and III do not require any changes But all other fuel injected engines will need to have its electronics handled to get the gains of an HHO system installation Usually the only sensors that require handling in trucks are the MAF Mass Air Flow Sensor 5 Have you tuned the f
11. e amount of hydrogen generated is twice the number of moles of oxygen and both are proportion nal to the total electrical charge Electrolysis of pure water requires excess energy in the form of overpotential to overcome various activation barriers Without the excess energy the electrolysis of pure water occurs very slowly or not at all This is in part due to the limited self ionization of water The efficacy of electrolysis is increased through the addition of an electrolyte such as a salt an acid or a base best electrolytes are KOH Potassium hydroxide and NaOH caustic soda Using KOH as electrolyte with a 98 purity we should start using a concentration around 0 012 in the water solution 12 g liter Then you should measure the current intensity going into the generator and increase slowly the concentration until you reach the standard operation amperage 30A 24V or 60A 12V Warning Do not fall in the temptation of not measuring the current or increase the electrolyte concentration more than is advised in this manual because in long term the generator will not work properly and you will not save any fuel Also it is false to assume that a higher HHO gas production will mean a higher fuel saving There is an optimum point for all Another thing that should consider is steam Some of the early cell developers would run their units with so much amperage that the unit was producing more steam than a
12. ectly to the combustion chamber mixing it with the air fuel The injection point must be done right after the air filter box and in modern trucks after the MAF sensor that measures the air flow going into the engine s chamber October 2012 You will need to remove the air duct to ensure that you do not leave any residue from the drilling you are about to do Drill a 19 mm hole close to the intake manifold Clean out any drill shavings insert the high pressure fitting using goop glue or teflon tape and tighten Connect the high pressure hose KIT DC8000 INSTALLATION MANUAL OCTOBER 2011 Installation of the electrical components General configuration Please refer to the illustration below for typical wiring configu retion for powering the system Electrics Ignition Source 5 ai gt Ground DC Battery In the end pages of this manual you will be able to check each one of the individual connections to be made regarding the install lation of the electrical circuits We will now only focus on the main aspects of the installation now Battery The system is powered by the 12 24V battery and controlled by the relay switch The system will only work if there is a signal from the ignition source The positive circuit red wire should be connected to the Relay Switch position 30 Identifying the ignition source This is an important connection to be made in order to have the
13. er clockwise rotation of the knob The idea is that turning knob will enhance or reduce the voltage The Enhancer can be installed on the dashboard or sit on the console or Under the bonnet if it can be fitted in a dry position To elimina te the work and MAF possible damage to MAP the dashboard and to enable better control place the box beside the driver s seat This makes tuning quite effortless Locate the wires connected to the MAF sensor There will be one for the positive supply voltage usually 5 or 12 volts The signal will be the wire with the weaker voltage and will change witth RPM when the engine is started There will also be a ground wire You can solder or crimp these with electrical wire connectors If you cannot locate the sensor or the wires or you re not sure please find a auto electrician to install it DO NOT IMPROVISE OR KIT DC8000 INSTALLATION MANUAL OCTOBER 2011 GUESS you may damage your computer To find the MAF Sensor Signal Wire use a Circuit Tester Use the Tester to locate the ground with o volts and the supply voltage of 5 volts The remaining wire is the MAF Signal wire Now cut the wire and join the 2 red cables from the enhancer The third connection the black cable with the earth lug already attached needs attaching to bodywork to make the earth Secure cables with cable ties supplied TUNING ON THE ROAD Turn the knob all the way to ri
14. hat existed before the modification This is the reason why ECU resetting is essential for KIT DC8000 INSTALLATION MANUAL OCTOBER 2011 optimum performance after any modification has been carried out in your truck The ECU has to operate on the newly acquired data as this new data reflects the true conditions post modification Resetting the ECU is important because it has a memory bank for octane This means that if you ve been using lower octane fuel the response of ECU will correspond to lower octane with the booster matching lower octane performance The ECU response will continue to correspond to lower octane even though you have started using higher octane fuel This is because the ECU has not been reset for higher octane Thus even though higher octane is in actual use the data in ECU memory still corresponds to that of lower octane This mismatch affects performance To reset the ECU you simply have to unplug the negative battery cable connection Theoretically it is best to leave it in this disconnected condition for as long as you can Practically leaving it disconnected overnight is more than enough After having left the cable disconnected for sufficient time you have to connect back the cable Start the car and keep it running so that it warms up This would not take more than 10 minutes at the most in summers Once you have done this you have accomplished the ECU resetting Shut off the engine
15. in level This electric signal will be connected to an alarm indicator light and to a 5 pin relay that will stop the HHO system from working Please check the illustrative diagrams above for more information The indicator light can be installed in the Interior of your vehicle allowing you to see immediately when the water Level gets Low Now you don t have to stop at all the times to check the water level in your hydrogen generator The amperage in the HHO Generator system will remain stable and with a small variation of value Amperage variation un the system When operating the system the water molecule will be brocken into HHO gas to be used by the engine The water level in the tank will slowly go down but the electrolyte will continue in the system with an increase of the concentration and therefore amperage being drawn into the generator This means that when you start using the system with the tank full Max level you have 30A and after some time when the tank is at the lower point Min level you will have 35A If you put too much electrolyte there are a combination of heating factors at work and can cause a situation called Thermal Runaway where an increase in ambient temperature combined with excess electrolyte mix leads to a overheating in the generator shortneting the life of system When applying a direct current to the HHO generator a high resistance will be present in the water electrolyte
16. mixture High resistance generates heat causing the water to heat up As the temperature rises the resistance in the water goes down allowing more current to pass through the fuel cell By the end of the day the current will be higher than the value you started with at the beginning of the day One way to control this is using a PWM PULSE WIDTH MODULATOR Pulse Width Modulation is a method of transmitting information on a series of pulses changing the frequency rather than a continuously varying analog signal It will allow you to control the amperage going into the generator in a very easy way This ability keeps the cell running at cool operating temperatures and prolongs the life of the cell while increasing the HHO output Main advantages Efficiency HHO generators will run cooler than standard linear power amps requiring substantially less heat sink mass Amperage control the control of the amperage going into the generator will be very easy to control The ability to control the amperage keeps the cell running at cool operating temperatures and prolongs the life of the cell while increasing the HHO output KIT DC8000 INSTALLATION MANUAL OCTOBER 2011 Electronic fuel injection Basic Information When adding a HHO gas to the engine of an older carbureted truck we will see immediate economies in fuel consumption However this is not the case for some electronic fuel injected vehicles equipped with
17. nything else If your unit runs hot to the touch you must suspect that at least part of your output is steam One way to test for steam is to run your gas outlet over some ice If you get significant amounts of fog forming water droplets you know that at least part of your output is steam Water levels in the tank Once you have your mixture ready pour it into the top of the water tank up to the water level line shown in the picture bellow Try to only fill your unit about 70 full This is imperative to allow the HHO produced to enter KIT DC8000 INSTALLATION MANUAL OCTOBER 2011 the gap left in the Tank and avoid any risks of some water getting into the engine The standard tank is a 6 liter unit which will provide you with approximately 1500 kilometers of driving Be sure to make your maintenance plan with that in mind and refill the tank when it is required In our store we have a new product that can help you to control better the water levels in the tank and reduce the problems regarding the management of the system It is called the WATER LEVEL CONTROL SWITCH HHO Tank Description The Water Level Control System Indicates and stops the HHO gas production when the Water Level gets low in the Dry Cell Tank How does the Water Level Control System Works In the water tank we will install a water level switch that will send an electric signal whenever the water drops below a certa
18. ound until you find the PERFECT BALANCE point The way you drive also has quite an influence if you need fast acceleration you will not be able to lean it out as much as driving normal KIT DC8000 INSTALLATION MANUAL OCTOBER 2011 Check list for HHO debugging Basic information HHO will improve combustion efficiency This is a scientific fact When introduced into the engine along with the petroleum based fuel it causes the flame speed to increase This allows more of the petrol to burn during the power stroke and it will be a dramatic increase over the combustion without the HHO After the combustion efficiency is improved the ECU is often fooled by the reduced quantity of unburned hydrocarbons and increased oxygen content and often will add fuel to compensate This can ruin your mileage gains The simplicity of a successful HHO installation is to get some HHO into the engine and adjust the sensor inputs as necessary so the ECU is not blocking the gains That s all If we can do those 2 things we will always get vastly improved fuel economy and vastly improved decreased emissions You should check out these items working from the top down Check List 1 Is your device making HHO The most common bug we encounter trying to debug systems is that HHO is not being produced or is not getting into the engine for some reason Check your system Measure the output of your HHO cell by doing a water
19. uctions Presented by HHO Plus Energias Alternativas Lda http www hho plus com Di C HHO Plus ALTERNATIVE cCNcAGIcS Travessa das Serras n 33 2430 720 Vieira de Leiria Portugal Tel 00 351 91 377 66 38 Email Sales hhoplusgas com
20. uel injection pump rate Vehicles with carburetors and some diesels Euros modules I Il and III do not require any changes except to tune the fuel injection rate to the new air fuel mixture 6 Have you reset your computer Some computers are able to learn and adapt to the conditions that exist in your engine Since you have made a major change by adding an HHO system and EFIEs you may need to reset the computer to erase what it learned about the system when it was inefficient and start over again with the new improvements installed You can reset your computer by disconnecting your battery ground wire and leaving it off overnight then reconnecting it again 7 Is there something else mechanically wrong with your engine If your engine is working properly adding an HHO system will not correct that You will often find that if your engine is not working properly just fixing it can give you a dramatic increase in fuel savings all by itself If you had any kind of check engine light before starting the project you should get this fault explored and handled If you re not sure reset your computer turn off all of your HHO and any other added modifications and see if you still get a fault code If so get it fixed 10 KIT DC8000 INSTALLATION MANUAL October 2012 KIT DC8000 INSTALLATION MANUAL OCTOBER 2011 12 Kit DC8000 Installation Manual HHO Hydrogen Generator Dry Cell DC8000 Installation Manual Instr
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