PWM (ver2)

Basically it's the same internal components as the PWM Cluster Box only a bit more compact and asthetically pleasing.
Another quick Video.

This box was made for my wife's car. In her car I will go more the OEM look. The gauges will be installed either in the dashboard or in pods on the A- pillar.

This is the dimensional drawing for building the PWM enclosure.

PWM Gauge Cluster

I finally got around to putting the cluster together. The PWM adjustment knob is at the lower left. Basically all the components were put into a Radio Shack project box. It works like a dream.

Here is a quick video

It shows the guts and the wiring. I used 8 & 10 AWG wire.

Unfortunately, all I had was red.

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This is the wiring diagram for the PWM with both the volt meter & the ammeter incorporated in it. This configuration will allow monitoring of the adjusted voltage being sent to the generator as well as the amount of amps the generator draws. By using a PWM you can make a heavy (28%) concentration of KOH electrolyte without drawing amperage which would normally fry your HHO generator.

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Pulse Width Modulator (PWM)

This is the completed PWM. It controls the amperage that the HHO generator will draw. Voltage is modulated as a series of pulses which results in a sine-like flux density waveform in the magnetic circuit of an electromagnetic actuator. The smoothness of the resultant waveform can be controlled by the width and number of modulated impulses per given cycle.

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By using this I can make a 10:1 electrolyte which as is would draw enormous amounts of amps, but I can now control just how much the HHO generator will get from my alternator.

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This is really not hard to build. You can get all the components at Radio Shack. All the schematics are included here. You can also buy a PWM like this for around $30. In retrospect, I have seen other PWMs which are far superior for about $120. Should this one fail in the future I think I will go that route.

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PWM (Pulse-Width Modulation) for controlling DC loads. This is the basic connections to the HHO generator.


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Fan Cooled 30 AMP PWM
TECHNICAL SPECIFICATIONS: Power supply 12/24 VDC via. jumper Load voltage 12/24 VDC 30A max Output: Output frequency : 100Hz. This will adjust the DC output range from 0% to 100% Board size is 3.9"L x 1.7" W x 1.6"H Fan is for a 12V systems

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Electrical Gauges

Amp Meter
I found a nice Centech 50 amp ammeter at Harbor Freight for $5.99
2-1/4" diameter bezel, 2-3/64" case.

Volt Meter
I also found a Centech volt meter at Harbor Freight for $5.99. It measures from 8 to 16 volts and has the same 2-1/4" diameter bezel, 2-3/64" case.
So both gauges for under $12 bucks!

The Water Pump

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This is a small 1GPM pump to help circulate the electrolyte. The system doesn't really need it but this gives me options as to where to locate the reservoir and the HHO generator since the system will no longer be gravity fed. Without the pump I would have to install the output of the reservoir slightly higher than the HHO Generator input.

The Dry Cell

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This is a much more cleaner & compact design. Designed and constructed from plates that are Precision cut 3" X 7" Corrosion Resistant High Moly Stainless Steel. The plates are cross hatch and rotary sanded to promote bubble release and then cleansed in an Ultrasonic cleaner at 40,000 Hz leaving them microscopically clean. The plates are sealed between high temperature 1/16" thick EPDM gaskets. No inferior automotive grade gaskets used. The end plates are manufactured from 1/2" high grade, high temperature Cast Acrylic. The end plates measure only 4-3/16" X 7-3/4" so the unit will fit anywhere. They are held in place with 1/4" X 20 Zink plated bolts. This cell has a configuration of

-NNNN+NNNN-NNNN+NNNN-

It is rated at a conservative 15 to 30 Amp's. At those amperages a Cell that will run without overheating. It won't melt wires or boil the Electrolyte Solution. It also won't overload your alternator.

The Wet Cell

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This is the original wet cell. It produced a nice amount of gas. It it very big and heavy. As you can see the original wiring had 12 volts going to each cell. Way to much amperage. This cell was rewired to a configuration of:

+NNNNNNNNNNNN-

Although it worked ok, it is bug & bulky. Very hard to work with. I will probably use it in an HHO Torch.