Protect and repair your engine from hydrogen
embrittlement by using a ceramic treatment.

The 80% efficient hydrogen generator produces mixed hydrogen and oxygen gasses when powered by DC.  The oxyhydrogen gas is a stoichiometric mixture of hydrogen (2 parts vol.) and oxygen (1 part vol.).  The hydrogen generator uses KOH electrolyte to split distilled water into hydrogen and oxygen.  The series-cell is very efficient as it allows the cells to operate close to their optimal cell voltage (1.47V). The hydrogen generator runs fairly cool, at about 30-50 C depending on the current and electrolyte. The hydrogen generator has 6 cells with a target input voltage of about 12.9-14.1Vdc which makes the cell voltage about 2.0V.

Pulsing (PWM) or modulation of the input voltage waveform increases performance, as it is known that in the beginning of each pulse larger current flows than in the steady state condition, thus lowering the cell voltage needed to push thru a certain amount of current and increasing the efficiency slightly.

The seven electrolyzer plates are stainless steel (316L grade). A gas vent hole is drilled in each plate. The electrolyte level is always about 25mm below the gas vent hole. There are 3mm diameter liquid level equalization holes drilled in the bottom corner of each plate in such a way that adjacent plates have holes in opposite corners. Staggering and using small holes minimizes any efficiency loss due to current leakage between cells, but makes electrolyte refilling and level equalization significantly easier.  The two end plates (electrodes) have a small SS piece protruding at the top for electrical contact.

The finished hydrogen generator is equipped with a bubbler. The bubbler is absolutely essential to prevent backfires from blowing up the electrolyzer. The bubbler may be filled with 20% alcohol to prevent freezing of the bubbler water.  The KOH electrolyte does not freeze.

Gas production is directly proportional to the current draw only. You need approximately 12 Amps for each Liter Per Minute.

The ideal cell voltage would be about 1.48V, and anything above it is wasted efficiency. The lowest practical cell voltage seems to be around 1.8V-2.0V. The voltage is only needed to push the current thru the cell, it has no relation on the amount of gas produced. The cell overvoltage (above 1.48V) is determined by electrode materials, current density, electrode spacing and conductivity of electrolyte.

Power or total efficiency of the hydrogen generator is defined as the amount of watts needed to produce one LPH. Series-cell designs seem to have the best efficiency in the range of 2.5-3 Watts per LPH.

Many people build simple single-cell car hydro-booster type electrolyzers and control the amperage by using weak electrolyte. The cell voltage is often around 13V, and they put just enough electrolytes to pass 5A or so. 5A creates only 3.5 LPH of gas, so the efficiency is very bad at 18.5 Watts per LPH. Properly designed 6-cell series electrolyzer would produce 6 times that amount or 21 LPH gas at the same input power.

The cell voltage is also dependent on the current density (current / electrode area). Smaller cell area is less efficient because it requires higher voltage to pass the same amount of amps. Good practical current density is around 0.5A/Sq.inch or 0.1A/cm^2.

The smaller the electrode spacing the lower the cell voltage. In practice 3mm electrode spacing is good up to about 10A. At higher currents the electrolyte starts foaming and crawling up the plates (reduces efficiency) and the electrolyzer starts spitting electrolyte foam out. For 10-40A use 5mm-8mm spacing.

Best electrolyte is KOH (28% by wt). These give the lowest practical cell voltage.

The bubbler is absolutely essential to prevent backfires from having an explosion in the hydrogen generator.  Adding a flashback arrestor to the system as well as bubbling the gas thru a water bath is the only safe way to prevent backfires, provided that the bubbler is strong enough to contain any backfires and that the water level in the bubbler is high enough.

The hydrogen generator will not be able to take any pressure without leaking. For pressurized operation use a pressure-proof shell (metallic).  If you need to store oxyhydrogen gas for a short period of time, put a large balloon on the bubbler exit gas nozzle. The balloon will store the gas at atmospheric pressure and will not be very dangerous if it explodes due to a backfire. Remember to wear hearing and eye protection.

Caution:  Oxyhydrogen is a very explosive gas.  Do not store in any containers.  If the gas is stored and ignited, a “grenade” effect could be experienced in which the storage container is turned into shrapnel and shards of metal or plastic could cause harm or damage to a person or property.

The Hydrogen Generator (Electrolyzer) should be connected to a 12 or 24 volt 30 amp circuit at the ignition switch or a suitable source that is activated and deactivated when the engine is turned on or off. This will prevent the Electrolyzer from operating when the engine is turned off for safety concerns and prevent damage to the unit or components.

Installation Instructions:

1.      After opening and unpacking the box, check the generator and auxiliary components for damage or breakage.

2.      Read complete set of instructions before assembly and installation.

3.      Before handling the Potassium Hydroxide read the enclosed MSDS sheet and follow the recommended safety procedure.

4.      When mixing the electrolyte use “Distilled Water Only” – See Mixing Instructions.

5.      “Use Distilled Water Only” in the Bubbler.

6.      When filling the Electrolyte Reservoir and Bubbler, “Do Not Overfill”.

7.      Mount the Hydrogen Generator assembly as close to the power source and air intake as possible and in an upright position.

8.      Mount the Electrolyte Reservoir Tank as close as possible to the Generator and above it.

9.      Mount the Bubbler as close as possible to the Electrolyte tank at the same level and as close as possible to the air intake.

10.  Mount the relay, start switch and Pulse Width Modulator (DC Motor Control) in a suitable location. Cooling vents must be put in to the PWM control box. to avoid overheating and damage to the PWM.

11.  Before proceeding for safety reasons, make sure the ignition switch is in the “OFF” position and the battery is disconnected.

12.  Use only 30 amp rated automotive wire during installation.

13.  Find suitable power for the start relay (switched 12 volts) like the fuel pump so that the unit will only operate when the engine is running and connect it to terminal 85 on the relay.

14.  Run a red wire from the positive terminal on the battery to the start switch and connect the output of the switch to terminal 87 of the start relay.

15.  Connect terminal 86 of the relay to an engine ground.

16.  Connect a red wire from terminal 30 of the relay to the terminal marked “+12V” on the Pulse Width Modulator.

17.  Connect an engine ground to the terminal marked “G” on the Pulse Width Modulator.

18.  Connect the terminal Marked “+M” on the Pulse Width Modulator to one end of the fuse and the other end of the fuse to the terminal on the Electrolyzer stamped with a “P”.

19.  Connect the terminal marked “-M” on the Pulse Width Modulator to the terminal on the Electrolyzer marked “N”.

20.  Install the 90 degree fitting on the air intake as close as possible to the engine and before a turbo not after if equipped.

21.  Install tubing from Generator (top port) to the inlet port on the side of the electrolyte tank.

22.  Install tubing from the “Gas Out” port on the Electrolyte tank to the “Gas In” port on the Bubbler tank.

23.  Install tubing from “Gas Out” on Bubbler to air intake fitting from step20.

24.  Proceed to Mixing & Filling Instructions.

Electrolyte Mixing & Filling Instructions:

1.   Read MSDS sheet before opening Potassium Hydroxide-Follow handling                        

      procedures closely. Be sure to use gloves, apron and eye protection.

2.      Put half-gallon gallon of “DISTILLED WATER” in a glass container.

3.      Add two pounds Potassium Hydroxide slowly-Water will heat up as you add the Potassium Hydroxide.

4.      Wait for the mixed chemical to cool down before adding to the electrolyte reservoir tank.

5.      Once the chemical mix has cooled down (hand warm) add the mix to the Electrolyte tank until you reach the fill line. The hydrogen generator will fill as you fill the Electrolyte tank.

6.      The hydrogen generator will fill with electrolyte very slowly due to air trapping. If possible, tip the generator if possible to speed up the filling process.  As the generator operates, electrolyte will creep down to refill the generator.

7.      Do not overfill-Stop at the fill line on the Electrolyte tank.

8.      Fill the Bubbler tank with “Distilled Water” to the fill line.

9.      DO NOT USE REGULAR TAP WATER AT ANY TIME FOR REFILLING THE ELECTROLYTE OR BUBBLER RESERVOIRS.

Startup Instructions:

1.      Before starting the Generator ensure the PWM is fully counterclockwise-Min      

Gas Out.

2.   Generator will start producing gas as soon as the engine starts-To increase gas              

                  flow adjust PWM towards max.

            3.   Generator will create a lot of bubbles at first-turn up PWM slowly.

Maintenance Instructions:

1.      Check Bubbler level daily

2.      Check Electrolyte level daily

3.      Check all connections weekly

Protect and repair your engine from hydrogen
embrittlement by using a ceramic treatment.

Warranty Limitations
Your Hydrogen Generator has been designed and built with quality products and great care to ensure trouble free operation.

It is important that you analyze all aspects of your application and review the information concerning the product or system.

Due to the variety of operating conditions and applications for this product, the user through its own analysis and testing is solely responsible for making the final selection of the products and system and assuring that all performance, safety, and warning requirements of the application are met.

Failure or improper selection or improper use of the product and/or systems described herein or related items can cause personal injury, property damage or death.

The product described herein, including without limitation, product features, applications, designs, availability and pricing are subject to change by Umpqua Energy, Inc. at any time without notice.

Umpqua Energy Incorporated a corporation (Seller or UEI), warrants to the original purchaser that the products sold by UEI shall be free from defects in material and/or workmanship WHEN DELIVERED BUT NOT THEREAFTER. The purchaser must examine such products immediately upon receipt thereof and determine whether the same conform to the description thereof as set forth in the product description. If any such product does not conform to any of the literature descriptive criteria, or any such product appears to be defective in any respect, such product shall be immediately returned to SELLER for replacement and/or repairs as appropriate to the product. Such inspection and return of any allegedly defective product shall be made within five (5) days from date of delivery thereof to the original purchaser and, if not so returned, this warranty shall be void and of no effect whatsoever. Any allegedly defective product returned for repair or replacement within said five day period will be repaired or replaced and reshipped to the original purchaser with fifteen (15) days after return of the defective product to SELLER. (Applies to USA only).

The restrictive and limited nature of SELLERS warranty obligations as herein set forth is required by reason of the character of the products and the circumstances and conditions under which the same are likely to be used.

The warranty obligations of the SELLER shall be limited to repair or replacement of any allegedly defective product as set forth above and UEI shall not be liable or responsible under any circumstances or in any amount for incidental or consequential damages or for injury or damages to person or property using or used in connection with any of such products, whether or not defective, or for loss of profits or other costs, expenses or charges of any kind whatsoever.

SELLERS warranty obligations as set forth above shall be absolutely void if the allegedly defective product is not returned within the five day inspection period set forth above, or if the product is misused, neglected, or damaged, or if the instructions for its use as set forth in the accompanying data sheet have not been strictly followed or if anyone other than the SELLER has made any attempt whatsoever to repair or to alter the product in ant respect. There are no warranties or representations by the SELLER other than set forth herein, either express or implied, as to any of the products the origin thereof or any other matter relating thereto, and no person, name or on the behalf of UEI, contrary to any of the provisions or conditions of this statement.

Return Policy
Unless said products purchased are found to be defective and approved for return by SELLER, purchased products will be accepted for return ONLY if approved by SELLER within the five day inspection period prior to returning said products to UEI.

If said products have been agreed upon by SELLER for return for reasons other than being defective, and have not been put in to use, there will be a 50% restocking fee of the original purchase price. All returns of purchased products will be at the expense of the purchaser,

Umpqua Energy Inc., their management, representatives, relations, owners, relatives, now or in the future, does not accept any liability, expressed or implied, either personal, private, partial or total, direct or indirect in the use or misuse, intentional or unintentional, installation of the product, unit or its direct or indirect cause, products/units production or malicious mischief of any kind. Umpqua Energy, Inc. cannot be responsible for either installation or use of the products, therefore, cannot be responsible for any damages either by its products or the production of fuels, gases, air, water, chemicals or other substances, known or unknown, airborne or otherwise. The units must be used for their intended purpose only, and any and all exposure to liability of any type mentioned above, will not be accepted by Umpqua Energy, Inc. We at Umpqua Energy, Inc. do understand that the units can be used for a variety applications and that many liquids may be applicable as a medium, however, we have no history or data to support such or the introduction of other substances in its products (other than those specified by Umpqua Energy, Inc.) and therefore no responsibility of liability of damages or injury.

EXCEPT TO THE EXTENT EXPRESSLY PROHIBITED BY APPLICABLE LAW, THE FOREGOING LIMITED WARRANTY IS IN LIEEU OF ANY KIND AND ALL OTHER WARRANTIES, EXPRESSED OR IMPLIED, INCLUDING BUT NOT LIMITED TO ANY WARRANTIES OF FITNESS OR MERCHANTABILITY.