INSTALLATION PROCEDURES FOR HAMPTON ROADS HYDROGEN GENERATORS

IMPORTANT NOTES: 1. WINTER OPERATION - Hydrogen Generators®, like any other pieces of equipment exposed to the elements, must be protected from freezing during cold weather. This can be accomplished by adding denatured alcohol in order to achieve a 20% alcohol solution. Initial cell fillup would require the addition of no more than 1/2 liter of alcohol. Proper Generator working capacity is about 2 and 1/2 liters so, 2 liters of distilled water added to 1/2 liter of alcohol equals an initial fillup. When a Generator requires additional water for continued winter operation, be sure to include enough denatured alcohol to maintain the 20% alcohol solution.

NOTE: The above information refers to the automobile/small truck generator, not the big-rig unit. That unit is typically installed with a water reservoir containing many gallons. Simply maintain a 20% alcohol solution as required by the actual gallonage contained in the reservoir.

2. CAUTION: This system should be installed by an authorized installer or a person totally versed in automotive circuitry, otherwise damage to Hydrogen Generator® components and/or the vehicle can occur.

3. The Hydrogen Generator® circuit should be connected to a 12 volt, 30 amp circuit at the Ignition Switch or a suitable alternate electrical source that is activated and deactivated when the engine is turned on and off. This prevents the Hydrogen Generator® from operating while the engine is turned off, as a safety precaution. For safety reasons, all necessary wiring not supplied with the unit, should have a 30 amp automotive rating.

4. The following instructions and procedures are for illustration ONLY and should not be used to actually install or operate a Hydrogen Generator®. Actual instructions and procedures are included with each Generator kit and may not follow these directions precisely.

UNIT PLACEMENT AND MOUNTING

1. The most common place for mounting the Generator Canister Assembly is under the hood, however, alternate locations are acceptable. The unit must be mounted in an upright position with the outlet slightly below the intake of the air filter connection source with appropriate bottom support or proper strapping.

2. The supplied AIR FILTER and its hose assembly are attached to the Hydrogen Generator® unit and the hydrogen supply hose is to be attached using supplied fittings to the intake system, after the (Mass Air Flow) Sensor and before the Throttle Plate, with standard ½ inch vacuum hose. It is not required to clamp hoses to fittings as long as hoses are sufficiently pushed onto fitting barbs.

3. The Air Resources Board E. O. No.supplied with the system, must be placed on or near the Generator. This is a requirement for passing Smog Check inspection.

4. It is assumed that the Ammeter Panel will be installed on the vehicle dashboard or other suitable location where it can be seen and monitored by the vehicle driver.

WARNING: DO NOT TAP HOSE FITTING HOLES IN AIR INTAKE PARTS WHILE STILL
ATTACHED TO THE ENGINE. THE AIR INTAKE ENGINE AIR SUPPLY SYSTEM MUST BE REMOVED THEN THOUROUGHLY CLEANED OUT AFTER TAPPING TO PREVENT SHAVINGS AND OTHER PARTICLES FROM ENTERING THE ENGINE.

SYSTEM WIRING

(Refer to drawing 101035-System Wiring Diagram-with Relay)

1. For safety reasons, be sure the ignition switch is “OFF” and battery is disconnected.

2. Wire the Ammeter Panel “HOT” wire (Inline 30 amp fuse) to supplied 30 amp relay, terminal #30.

3. The Ammeter Panel “GROUND” wire should be attached to a suitable ground source under the dashboard or other suitable location.

4. Connect the Ammeter Panel (RED) “GENERATOR” wire to the (RED) “GENERATOR” wire from the Hydrogen Generator canister.

5. Connect the Ammeter Panel “SENSOR” wire to the “SENSOR” on the Hydrogen Generator®.

6. Wire 30 amp relay, terminal #87, to Positive battery terminal.

7. Wire 30 amp relay terminal #86 to ground.

8. Wire 30 amp relay terminal #85 to “switched” 12 volt source (i.e., fuel pump).
NOTE: “Switched” 12 volt source refers to power that is “ON” when engine is running and “OFF” when engine is turned off.

INSTALLATION NOTES

There should be three wires leaving the vehicle cab from the Ammeter Panel through a 1/4” rubber grommeted hole at the bulkhead (SENSOR, GENERATOR and HOT wires). This hole must be drilled away from any exhaust manifold location to prevent possibly overheating of wiring. If required, a variety of commercially available heatsink materials can be used.to protect wiring that cannot be located away from the exhaust manifold.

SYSTEM CHARGING AND STARTUP

After installation of all wiring, the Hydrogen Generator® Canister and supply hoses, the system must be charged.

1. At the Hydrogen Generator® unit, remove the FILLER CAP on top of the unit. Fill canister with approximately 1 ½ liters of mineral drinking water. Reconnect the vehicle battery, turn ignition “ON” and turn power switch at Ammeter Panel “ON.”

2. With someone to assist, slowly fill the canister with water until the “GREEN” LED on the Ammeter Panel starts to glow. At this point, the canister needs only an additional 1 ½ cups of water to complete the filling process. “DO NOT OVER FILL THE CANISTER.”

3. Turn the Ammeter Panel switch to “OFF” and start the engine. Turn the Ammeter Panel switch to “ON" and the ammeter should read between 3 and 7 amps. NOTE: As a safety measure, “Never Operate the Hydrogen Generator® without the Engine Running.”

4. After the initial filling with mineral drinking water, the canister should be topped off periodically with distilled water unless the amperage reading drops below 4 amps. At that point, the canister should be topped off with mineral water again until the amperage settles into an average operating range of 4 to 10 amps. CAUTION: if you add too much water, the system might need to be drained off (using drain cap at bottom-side of canister unit) until the level is just visible approximately ½ inch below the FILLER CAP fitting on top of the unit. BE SURE to tighten filler cap and drain cap securely. If these caps are not tightened securely, the intake vacuum system may be adversely effected possibly causing the engine to operate inefficiently.

5. After a few minutes of operation with the engine running, the amperage reading will settle to an ideal operating range of 4 to 10 amps.

6. The GREEN LED indicator on the Ammeter Panel will begin to dim and eventually go off when the system needs more water. This will generally occur once between or at fuel tank fill-ups, depending on gas tank size, engine displacement, ambient temperatures, etc.

FINAL NOTE: In General, these installation procedures apply for both Hampton Roads Hydrogen Generator® products UBC 9075100100 and UBC 890751011-6. The main difference is the physical size of the units. Both products have the same external fittings and connections for installation.