STAFOR HHO PWM pulse width modulator Installation manual.

Transcription

STAFOR HHO PWM pulse width modulator.
Installation manual.
HHO hydrogen on demand dual fuel systems
Ecologically clean – lowers CO and CO2 emissions
HHO hydrogen generators for fuel saving
STAFOR HHO PWM pulse width modulator
HHO hydrogen on demand dual fuel systems.
Safety precautions
Disclaimer
Important information
Safety equipment
Enjoy your new system
Technical specifications
STAFOR HHO PWM LED displays (indicators) schema
Internal regulators (inside the box) and connection points location
STAFOR HHO regulation instruction
STAFOR HHO PWM typical connection schema
Installation examples of STAFOR HHO PWM
Pulse width modulation
Main features of the STAFOR HHO PWM
Electrical connections
Amperage control
Water level sensor
Additional information
STAFOR HHO PWM working principles
Thermal runaway
Electrolyte concentration indicator
Troubleshooting
Warranty
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STAFOR HHO PWM pulse width modulator.
HHO hydrogen on demand dual fuel systems
Safety Precautions
Disclaimer
When purchasing this device, you are held responsible for any damage that may occurs during installation or
operation of this device. The manufacturer or seller are not held liable and holds no responsibility for any personal
harm or property damage. Thank you for purchasing Revolutionary STAFOR HHO PWM. Please read contents
below carefully to understand the installing and operation procedures before getting started.
Important Information
Read and follow these safety precautions to avoid hazards. If you do not understand these instructions or do not
like to work on vehicles, please have a qualified mechanic do the installation for you. Incorrectly installing or using
the HHO System may result in serious damage to you and/or your vehicle.
It should take approximately 3 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.
STAFOR HHO System does not store hydrogen, subsequently there is no fire hazard when installed properly.
However water electrolysis generates Hydrogen, an explosive gas, which means that you should never light a
match or smoke near or in front of the generators output - the water tank could blow up!
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 carried out on automotive installations and maintenance.
Enjoy your new 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.
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Technical Specifications
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Compact size, black plastic box 90*70*24mm
Power switch engine sensor ON or OFF of engine
Constant current automatic holding (regardless to work temperature or electrolyte concentration)
Changeable frequency from 30Hz to 30000Hz
Frequency measure feature
Short circuit protection
Newest electronics used in construction
Detailed manufacturing control
PWM trimmer, from 0% to 100% HHO cell power out
LED amperage (current) indicator on PWM case
Indicator for electrolyte concentration in HHO system
Inside the box the adjust power ampere trimmer
Delayed start up for car engine, car battery and alternator protection
External fan for cooling PWM in heavy duty cycles
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STAFOR HHO PWM LED displays (indicators) schema:
Amperage (30.0) – Showing amperage of HHO
system. STAFOR HHO PWM is automatically holding
constant amperage (max +/- 1A).
Electrolyte concentration – Electrical pulses width
for installed amperage, showing concentration of
electrolyte.
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Optimal concentration is 50% (five blocks).
 MIN shows that you need to add
electrolyte (for example STAFOR HHO
KOH).
 MAX shows that there are too much
electrolyte in water and you need to dilute
it with distilled water.
 WATER LOW shows that there are low
water levels in HHO system.
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Internal regulators (inside the box) and connection points location
1. Amperage regulation trimmer (potentiometer) –
must be tuned only one time.
2. Frequency regulator (regulated at factory to
optimal frequency for STAFOR HHO generators)
3. Frequency measurement point (can be
measured with almost any kind of frequency
meters). Impulse signal with amplitude in 5V
between point F and -IN terminal.
4. Jumper for switching between Low (30Hz3000Hz) and High (3kHz-30kHz) frequency
5. -IN terminal - GND battery Input
6. -OUT terminal - PWM power supply to HHO CELL
negative line
7. +OUT terminal - PWM power supply to HHO
CELL positive line
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8. +IN terminal - +12/24V Battery Input
STAFOR HHO regulation instruction
Regulation using PWM amperage trimmer must be done in accordance with HHO generator regulation table. After
first regulation car must drive at least 70km or work idle at least 30min. Then you must do fine tuning of amperage
for correct results.
If you are not able to rise amperage or electrolyte concentration indicator is showing MIN you must add
electrolyte (for example STAFOR HHO KOH).
After regulation is finished STAFOR HHO PWM will hold installed amperage regardless to work temperature or
electrolyte concentration (if not lower than MIN or greater than MAX on indicator).
STAFOR HHO PWM typical connection schema
For connection use built in PWM 4 way 60A MAX connector: +12/24V and GND Battery Input, +12/24V and GND to
HHO CELL power out.
IMPORTANT
You must install a circuit breaker or fuse between PWN and car battery! Place it as close to
battery as possible!
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*Single wire + positive (0.5 mm²) should be connected from ignition source to relay (standard car relay to 40A or 60A). This is the correct
method of connecting the HHO system for long term/everyday use.
*For short term use or testing the ignition source and relay is not needed. The PWM will detect automatically when the car engine is switched
ON (higher than 13.5V in 12V models or 27.6V in 24V models) or OFF (lower than 13.4V in 12V models and 27.5V in 24V models) . This is
however an extra safety features.
*Ignition source - Check engine light (the best source we've found).
*HHO system must only work when engine is running.
*It must not work when the key is turned to ignition, but the engine is off.
Installation examples of STAFOR HHO PWM
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Pulse width modulation
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 to HHO system.
PWM amperage adjustment (Trimmer) and built-in ammeter will make that controlling easy.
This ability keeps the cell running at cool operating temperatures and prolongs the life of the cell while increasing
the HHO output.
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.
Main Features of the STAFOR HHO PWM
The PWM is an electronic device designed for making the automatic power supply of the HHO System without the
need for relays or picking up the signal from the alternator/ignition key, making the system safer to use and easier
to install, keeping constant current. In general the new STAFOR HHO PWM will work based on the voltage of the
car/truck:
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Engine is stopped – voltage in car/truck is 12V or 24V – PWM is not working
Engine is working – voltage in car/truck is more than 13,5V or 27,6V – PWM is working
The STAFOR HHO PWM auto detect when the car engine is running and automatically switches ON the HHO
system, without any additional requirements. The device will automatically power OFF when the car engine is
turned OFF or not running.
The PWM is also capable to indicate on LCD display electrolyte concentration for regulated amperage.
PWM have option for adjustable frequency for optimal work of any construction HHO cell.
Electrical Connections
The PWM device is spited in 2 different work zones:
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PWM power supply to HHO CELL
Battery power supply to PWM
Important notices:
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The cables for the Battery power supply must always be connected directly to the battery terminals using
the two 4 mm² wires.
The distance between the STAFOR HHO PWM and car Battery, HHO Dry Cell must be the shortest possible
in order not to have voltage losses in the circuit that could compromise the engine START detection (car
Engine ON). Make sure your connections are tight and try to keep wires as short as possible.
If you're using over 25 amps double up on the wires!
Make sure that there is no contact between wires in the PWM to avoid HHO system working when car
engine is OFF.
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Please refer to the illustration below for typical configuration of the electrical connections of the STAFOR HHO
PWM:
-IN terminal - GND Battery Input
*Single wire (4 mm²) to terminal and the other
end fastened to chassis.
*Fastening the aluminum enclosure to the
vehicles chassis.
+IN terminal - +12/24V Battery Input
-OUT terminal - PWM power supply to
HHO CELL negative line
+OUT terminal - PWM power supply to
HHO CELL positive line
IMPORTANT
Be careful not to reverse polarity, otherwise you can burn STAFOR HHO PWM!
Amperage Control
Electrolysis of water is the decomposition of water molecule (H2O) into oxygen (O2) and hydrogen (H2) gases due
to an electric current passing in the water. Electrolysis of pure water requires excess energy in the form of
potential 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.
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The special STAFOR HHO KOH electrolyte should be added to the water the first time that you use the system, and
also when refilling, but in lower quantities and ONLY if STAFOR HHO PWM electrolyte concentration indicator is
lower than 50% (five blocks). Optimal concentration for already regulated amperage is 50% (five blocks).
Water Level Sensor
During HHO production in HHO generator water level drops down and concentration of electrolyte rises. On
STAFOR HHO PWM you will see when electrolyte level reach MAX, that can mean that water level is very low.
Additional water level should be placed in a way that, when the water level is above the minimum value.
Additional water level (floater) must be connected thru relay in accordance with schema provided by floater
manufacturer.
IMPORTANT
Double check all your connection!
If you make a mistake you may burn out the PWM, car electronics or HHO system.
Things you should know about your alternator:
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Alternators have a maximum rating anything from 35 amps to 200+ amps.
This is the maximum amps your alternator can give you.
It means it can give you those maximum amps momentarily at about 3500 RPM.
Continuously it can give you at least half those amps without suffering any damage.
If you draw more than half the maximum rating you will eventually burn out the regulator on the
alternator and perhaps the alternator itself.
Common-sense says, that a 200amp alternator could give you 60%+ continuously.
Whereas a 35 amp alternator even 40% continuously could be a strain on it.
Knowing all of this, it is not wise purchasing a HHO system that runs at 60amps when your 1964 model VW beetle
has a 35amp alternator. Balance is the key to success with HHO.
IMPORTANT
Before charging your car DC Battery or using external power source for cars engine start disconnect
fuse for HHO system. If you will not disconnect fuse there is possibility that HHO system will start to
work when engine is OFF!
STAFOR HHO PWM working principles
Most car alternators put out 14 to 14.4 volts and this is controlled by the alternators regulator.
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The PWM is designed to protect your alternator and your battery.
It does this by dropping back the amperage automatically when the car puts out lower volts.
Most cars while idling and under the added strain of a HHO generator, air-condition, headlights or any
other current drawing appliances fitted to your car, will put out less volts and amps.
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Thermal runaway
The PWM will protect your HHO cell from "Thermal Runaway" by keeping the amps of your HHO Cell at the figure
you have PRESET. It will not pass that amount no matter how many amps are requested by your HHO Cell while it
heats up. Make sure your HHO system regulation is in accordance with regulation table or you will burn out the
HHO Cell or PWM.
IMPORTANT
STAFOR HHO PWM effectively stops the vicious cycle of Thermal Runaway in its tracks.
Electrolyte concentration indicator
Work principle of electrolyte concentration indicator:
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It shows how much current is being stopped by the PWM as a percentage (by 10%) to keep constant
regulated amperage. For example 50% (five blocks) is optimal work mode for PWM and HHO generator. It
will provide best possible HHO gas production.
90% (nine blocks) most of the current is being stopped.
10% (one block) very little or no current is being pulsed or stopped.
Troubleshooting
PWM will not switch ON:
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Check your fuse or circuit breaker from car battery.
If you are using fluid level sensor check that water (electrolyte and water mixture) is at the correct levels.
Too low means auto shut down of HHO system.
Amperage indicators shows 00.0 and no indication on electrolyte concentration – check if there is no
short circuit and all wiring is done properly.
Check your cars Volts. If they are too low go to auto electrician, your car electrical system may be
malfunctioning or your cars alternator is too small for the size of HHO system you are running.
PWM indication:
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Amperage or electrolyte concentrator indicator parameters are not stable – check hoses for blockages or
kinks, make sure that water mixture is getting in HHO cell.
Cannot regulate Amps on PWM:
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You may need a higher concentration of electrolyte.
You may have set the amperage too low or too high. Check the regulation table.
Wires from battery to PWM or from PWM to HHO Cell are hot to the touch:
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Use thicker wire or double up wiring.
Make sure your connections are tight to avoid heating of connection points.
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WARRANTY
Name
Data
Model
Serial number
Work current, А
Car model
Engine, type/volume
Reg.number of car
Name, surname/Client
Client phone number
Date of installation
Installation made by
1.
SAFETY PRECAUTIONS
a. The nominal operating temperature, -40 ° C to +200 ° C.
b. The nominal value of the fuse 25A.
c. Prohibited any interference with the electrical control circuit of PWM.
d. Recommended to install PWM in the car interior for work conditions safety.
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Type
1500km
10000km/1 year
20000km/2 years
Visual inspection
Electrical connection
inspection
PWM are sold in accordance that the client understands and assumes full responsibility for the safety and
understands the warnings associated with the installation of a STAFOR HHO PWM and using it in the car. Customer
agrees to comply with all safety regulations to avoid potential risks. Seller shall not be liable for any loss or damage
caused by improper installation and/or operation of the PWM. WARNING! It is forbidden to use open flame near
the HHO generator - hydrogen is a flammable gas!
2.
GUARANTEE
a. The guarantee for the hydrogen generator is 24 months from moment of sale.
b. During the warranty, never make any interference in the PWM circuit. All work on the STAFOR
HHO PWM must be performed by certified car service.
c. If there was any interference with any of the PWM part, the user loses the warranty.
I have no claims and objections:
(signature)
(name, surname)
Installation made by:
(signature)
(name, surname)
Z.v.
STAFORHHO.com
E-mail: [email protected]
Phone: +371 27124103
Phone: +371 28444384
Address: 45/47 Mukusalas street,
Riga, Latvia, LV1046
Fax: +371 67603399
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STAFOR HHO PWM pulse width modulator Installation manual.

Transcription

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