HHO Plus DC2000 Manual de usuario
DC2000 –Installation Manual
HHO Hydrogen on Demand Dual Fuel Generator Systems
HHO Plus, Alternative Energies, Ltd
Technical Department
Travessa das Serras 33, Vieira de Leiria, Portugal
T: 00 351 244 697 116 E: info@hhoplusgas.com
DC2000 –Installation Manual 2
HHO Plus, Alternative Energies, Lta –Travessa das Serras 33, Vieira de Leiria, Portugal –Tel. 00351244697116 –Email: [email protected]
CONTENTS
Safety Precautions 4
Important Information 4
Safety Equipment 4
Enjoy your new system 4
Installation of the hydraulic components 5
General configuration 5
Positioning the Dry-Cell 5
Positioning the Water Tank 8
Positioning the Bubbler 9
Positioning the water and HHO hoses 10
HHO injection point 11
Installation of the electrical components 13
General configuration 13
Battery 13
Identifying the ignition source 13
Dry-Cell electric connections 14
Water and electrolyte setup 16
Principles of the water electrolysis 16
Electrolyte concentration 16
Water levels in the tank 18
Amperage variation in the system 18
Electronic fuel injection 20
Basic Information 20
DC2000 –Installation Manual 3
HHO Plus, Alternative Energies, Lta –Travessa das Serras 33, Vieira de Leiria, Portugal –Tel. 00351244697116 –Email: [email protected]
Components of the electronic injection 21
MAP/MAF sensor 21
Lambda sensors 22
Resetting the ECU 23
Installing the lambda sensor extender –Pre-Cat Sensor 24
Isolating the lambda sensor body –Pre-Cat and Pos-Cat Sensors 26
Test run and checking your work 27
Maintenance 27
Check-list for HHO system debugging 28
Important information 28
Check-List 28
Parts positioning 30
HHO connection from the water tank to the bubbler 31
HHO connection from the bubbler to the air intake manifold 32
Water connections between the water tank and the dry-cell 33
Electric connection from the battery to the relay (Position 30) 34
Electric connection from the ignition source to the relay (Position 85) 35
Electric connection from the relay (Position 86) to the Ground 36
Electric connection from the relay (Position 87) to the dry cell 37
Electric connection from the dry cell to the ground 38
DC2000 –Installation Manual 4
HHO Plus, Alternative Energies, Lta –Travessa das Serras 33, Vieira de Leiria, Portugal –Tel. 00351244697116 –Email: [email protected]
Safety Precautions
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.
Your 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.
DC2000 –Installation Manual 5
HHO Plus, Alternative Energies, Lta –Travessa das Serras 33, Vieira de Leiria, Portugal –Tel. 00351244697116 –Email: [email protected]
Installation of the hydraulic components
General configuration
Please refer to the illustration below for typical configuration of the mechanical and hydraulic parts of the
HHO system. In the end pages of this manual you will be able to check each one of the individual connections
to be made regarding the installation of the components. We will now only focus on the main aspects of the
installation.
Positioning the Dry-Cell
You will need to find a good place in your engine compartment to mount your new HHO system. Please
remember that the water tank should preferably be placed at least 20 cm above the generator Dry-Cells in
order to guarantee a sufficient water head for the water/hydrogen to flow. But in some cases with not too
much space available to make the installation we just need to make sure that the bottom of the water tank is
a little bit higher than the top of the dry-cell.
Bubbler
Air Intake
Manifold
DC2000 –Installation Manual 6
HHO Plus, Alternative Energies, Lta –Travessa das Serras 33, Vieira de Leiria, Portugal –Tel. 00351244697116 –Email: [email protected]
Install your new HHO Dry-Cell as far away from the heat of your engine as possible. Normally the best place
to install the dry-cell is in the space between the front grill and the radiator as it is closest to the air entering
the engine compartment and often the largest space available.
DC2000 –Installation Manual 7
HHO Plus, Alternative Energies, Lta –Travessa das Serras 33, Vieira de Leiria, Portugal –Tel. 00351244697116 –Email: [email protected]
Make sure to install the Dry-Cell in a place that can easily be accessed
and cleaned or inspected from time to time. It should be mounted and
secured in such a manner as to ensure it does not move or bounce
around while the vehicle is in motion, even over rough terrain.
Securing it with a permanent metal bracket (see photos above –metal
bracket not included in the kit) should be sufficient to secure it to the
engine chassis and to operate perfectly.
The dry-cell can be mounted in horizontal
or vertical position.
The vertical position does not require any special remarks. The water
intake is connected in the bottom and HHO output will be in the top
of the cell. You just need to make sure that the HHO output hose is always above the top of the cell. If not the
HHO gas will have difficulties moving outside the cell and the production will be reduced.
The horizontal position requires more care in the installation. The cell has to be positioned upright and
leveled to the ground with the tube fittings facing directly to the sky. If you look carefully the cell has 2
openings, one higher than the other. The lower opening is for the water intake and the upper opening for
HHO gas output. We must make sure that the cell is not placed with an angle/rotation that reduces the
distance between the two openings. Please take a look at the pictures below.
If the Dry-Cell is placed as shown in the image on the right you will not use 100% capacity of the generator to
produce HHO gas. Also the HHO gas will have problems getting out of the cell being released gulps. You can
verify this problem if fluctuation of the amperage is very high.
Important Information:
When making the installation
never make any type of
changes in the dry-cell.
Never open it, loosen/tighten
the nuts or cut the screws.
You will damage the dry-
cell and it will not work
properly after. Changes
made in the cell are not
covered by the warranty.
DC2000 –Installation Manual 8
HHO Plus, Alternative Energies, Lta –Travessa das Serras 33, Vieira de Leiria, Portugal –Tel. 00351244697116 –Email: [email protected]
Positioning the Water Tank
Make sure that water tank is installed with the same care as described before for the generator. The water
tank needs preferably to be placed 20 cm above the HHO dry-cell to accomplish the gravity head needed for
the water/hydrogen to flow into the generator. But in some cases with not too much space available to make
the installation we just need to make sure that the bottom of the water tank is a little bit higher than the top
of the dry-cell. Please take a look at the pictures below:
DC2000 –Installation Manual 9
HHO Plus, Alternative Energies, Lta –Travessa das Serras 33, Vieira de Leiria, Portugal –Tel. 00351244697116 –Email: [email protected]
Positioning the Bubbler
The bubbler will serve two purposes: cleaning the HHO gas and act as a safety barrier. When HHO gas is
produced from the dry cell, some small water vapor is produced as well because the water will get a little bit
hot with the passage of current. This water vapor can
carry tiny particles of electrolyte which can cause
damaging corrosion. As the HHO bubbles rise up the
column of water inside the bubbler they are "scrubbed"
of any electrolyte particles that were attached to the
water vapor. The result is much cleaner HHO gas.
In the event of a flashback, the bubbler also acts as a
safety barrier. If a flame reaches the bubbler and ignites
the HHO that has accumulated at the top, the water
column will prevent the HHO from going on to the dry
cell because the flame cannot skip from bubble to
bubble.
Make sure that bubbler is installed above the water tank to accomplish the gravity head needed for a correct
“filtering” of the HHO gas. Please take a look at the pictures below:
EXAMPLE OF A COMPRESSED
INSTALLATION
DC2000 –Installation Manual 10
HHO Plus, Alternative Energies, Lta –Travessa das Serras 33, Vieira de Leiria, Portugal –Tel. 00351244697116 –Email: [email protected]
Positioning the water and HHO hoses
The hose connections on vertical position of the dry-cell do not require any special remarks. The water
intake is connected in the bottom and HHO output will be in the top of the cell. You just need to make sure
that the HHO output hose is always above the top of the cell. If not the HHO gas will have difficulties moving
outside the cell and the production will be reduced.
The hose connections on horizontal position of the dry-cell require only that the positioning of the HHO
output hose be made also always on an uprising position without ups and downs. If this happens, the HHO
gas will have problems moving into the water tank and will also be released gulps reducing the efficiency of
the system. You may verify this problem if fluctuation of the amperage on your system is very high. Please
refer to the illustration below for typical installation of the hoses coming and going from the water tank:
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