Hydrogen on Demand System Manual and Installation Page
Wiring instructions must be followed EXACTLY! Do not take shortcuts!! Run separate wire for every step!
Not following instructions can cause serious problems.
Training for fleet installation will be provided by
Global Hydrogen Solutions, LLC and or GHS Distributor.
Global Hydrogen Solutions, LLC
Installation and Manual
Warning!
Note: not following these instructions can cause serious damage.
Note : No step box or tool box is needed for bus installation. System can be installed inside luggage compartment near engine.
Step 1: Decide where you are going to mount the tool box or step box. If you decide to mount the tool box or step box from the truck frame you will need to drill four 5/8” holes in the rear of the box at where the reinforced vertical aluminum angle is located in the corners of the tool box or step box. Use four grade 8 bolts to mount the box. Be very careful where you drill these holes. There is 2” vertical aluminum angle welded in the corners for extra strength. This is where the holes are to be drilled. Next you will need to use four 5/8” grade 8 bolts to install your system toolbox. If longer or shorter bolts are needed they can be purchased from most hardware stores. They must be 5/8” grade 8 bolts. The box may be spaced a little away from the truck frame if needed by placing spacers between the box and frame at the outer edges of the box behind the aluminum angle in the corners. Heavy duty steel "J hooks" can also be used to mount the box to the frame without drilling any holes in the truck frame. (See picture below).
Step 2: Now run the ½” id (inside diameter) hydrogen supply hose to the air intake. Note: the hydrogen supply line must be kept far enough away from the turbo and other hot objects so not to get hot enough to melt supply line. You will need to drill a hole in the air intake boot, after the air filter housing, (keep in mind that the turbo gets very hot) and before the turbo. Then install a threaded ½” barbed fitting (supplied with system) into the threaded hole in the intake boot. Then connect the hydrogen supply hose from the box (system) to the air intake barbed fitting. Be sure to secure supply line real good.
Step 3: Be sure the hydrogen supply line runs up hill all the way to the air intake with no dips or low spots in the line. This is very important, so that no liquid from the tank or supply line will collect in the line causing a blockage. If there is no way to avoid from having a lower spot in this line, a tee fitting can be placed in the line at the low point. A 12” piece of hose can be connected to this tee and pointed straight down with a rubber plug installed at the bottom of this hose. Note that the rubber plug must have a small cut in it to allow for accumulated water to drain.
See drawing below for basic air intake connection.
Do not connect wires to the positive side of the battery until all other wires are connected!
*Connect Battery Positive* Last!
Step 4: Connect the power wire to a keyed power source or switch that turns on and off with the ignition key.
Step 5: Next is installing an AUX Power Switch. (Optional) but recommended.
This gives you the protection of shutting down your Hydrogen System without shutting off your vehicle for emergency and maintenance operations.
Do not connect wires to the positive side of the battery until all other wires are connected! *Connect Battery Positive* Last!
Step 6: Now it is time to install the main power wire (8 gauge) from the battery to the power supply terminals on the rear of the box.
The Black terminal is to be connected to the negative post on the battery and to the Black terminal on the rear of the box.
The Red terminal is to be connected to the positive post on the battery and to the Red terminal on the rear of the box.
Read all of this section and the next section below before proceeding.
Please call us if you have any questions on setting up your system.
The following is for Summer new system setup only.
Installing your new system in the winter can be found in the next section.
Step 7: This is the most important part. Be very careful. Your system requires approximately 5 to 5 ½ gallons of distilled water to be at the proper water level - do not over- fill. The following is for summer new system setup only. We will cover installing your new system in the winter time in the next section. We will also cover winterizing and summarizing your system in the following sections.
First for summer new system setup, Fill the tank to the level line found on the end of the water tank with distilled water (distilled water only). Now turn the system on with the keyed power. Next let the system run for a few minutes then add distilled water to bring water to full line located on end of tank. Next locate the mode button, there are three buttons, up, down and mode located on the power supply. Now push and hold the mode button for about five to ten seconds till the status light stops blinking, then use the up or down buttons to adjust the current that you want to supply to the hydrogen cell. Normal current to set this to is 60 amps. After you set the amps push the node button again. If you find that 60 amps drain you batteries you can lower the current setting to a lower number. Now its time to start adding the sodium hydroxide. Next you will need to locate the sodium hydroxide we supplied with your system. Be very careful adding the sodium hydroxide, as it only takes very little to reach the proper current on the display. This number on the display will go up very fast as you add very little sodium hydroxide. Now while adding the sodium hydroxide to the tank, with the system on notice the amp reading on the digital display located on the face of the power supply. Let it run for a few minutes, Keeping an eye on the amp reading on the digital display. Bring the amp level numbers up to as close to 45 amp as possible.WATCH THE DIGITAL DISPLAY and add only about 1/16 of a teaspoon of sodium hydroxide into the distilled water that is in the tank. ADD IT VERY SLOWLY OVER SEVERAL MINUTES. DO NOT ADD TOO MUCH OR YOU WILL HAVE TO DRAIN THE COMPLETE SYSTEM AND START ALL OVER. Be very careful not to get any of the sodium hydroxide on your skin, if you do, wash off immediately with vinegar, then water. When water level starts to get low as you drive, top off with distilled water only. Using any other water that is not distilled will harm the system.
The following is for Winter new system setup only.
Step 8: Note setting up for winter time is the same as above but you will mix 50% of denatured alcohol mixed with distilled water to prevent Generator freeze-up during cold weather. Note this is for setting up a new system only in the wintertime. Be very careful. During the winter time if the temperature is going to get below freezing keeping the system from freezing is critical. The only exception to this provision is the use of approximately 50% of denatured alcohol mixed with distilled water to prevent Generator freeze-up during cold weather. Customer is responsible for keeping the system from freezing. It is recommended testing different amounts of denatured alcohol mixed with distilled water at deferent freezing temperatures before adding denatured alcohol to your system. Your system requires approximately 5 to 5 ½ gallons to be at the proper level - do not over- fill. Fill the tank to the level line found on the end of the water tank with a mixture of distilled water and denatured alcohol. When water level starts to get low as you drive, top off with a 50% mixture of distilled water and denatured alcohol. Using any other water that is not distilled will harm the system.
Winterize your system
Step 9: In this section we will be going over how to winterize your system. This section is for systems that are already up and running and need to be winterized for winter time. When winter time arrives and the temperature starts dropping it is time to setup your system for winter time use. Start by draining the water tank and the cell at the pump. First thing is you will need to remember that your system holds approximately 5 to 5½ gallons. You will need to drain off approximately 2 ¾ gallons of water from your system and replace it with denatured alcohol. This would give you a 50% mix. (Fill to line on end of water tank). Do not overfill. This will bring the water level to the proper level. Next is to locate the sodium hydroxide that came with your system. Add very little bout 1/32 of a teaspoon of sodium hydroxide into the distilled water that is in the tank. Be very careful not to get any of the sodium hydroxide on your skin, if you do, wash off immediately with vinegar, then water. Now after adding the sodium hydroxide to the tank, with the system on notice the amp reading on the digital display located on the face of the power supply. Let it run for a few minutes, Keeping an eye on the amp reading on the digital display. Bring the amp level numbers up to as close to 45 amp as possible. When water level starts to get low as you drive, top off with distilled water and denatured alcohol. If done correctly your system should now be ready for winter time operation.
Summer time use
Changing your system from winter use to summer time use.
Step 10: In this section we will be going over how to get your system changed over to summer time use. Just as soon as the temperature starts to warm up, your hydrogen on demand system will need to be drained. This will empty almost all the denatured alcohol from the system from winter time use. After you drain the system, fill the water tank with distilled water (distilled water only) into the water tank until you reach the fill line located on the end of the water tank. (Do not over fill). Next you will need to locate the sodium hydroxide we supplied with your system. Now turn the system on with the keyed power. Now its time to start adding the sodium hydroxide. Be very careful adding the sodium hydroxide, as it only takes very little to reach current amps level. Add only about 1/32 of a teaspoon of sodium hydroxide into the distilled water that is in the tank. Be very careful not to get any of the sodium hydroxide on your skin, if you do, wash off immediately with vinegar, then water. Now after adding the sodium hydroxide to the tank, with the system on notice the amp reading on the digital display located on the face of the power supply. Let it run for a few minutes, Keeping an eye on the amp reading on the digital display. Bring the amp level numbers up to as close to 45 amp as possible. When water level starts to get low as you drive, top off with distilled water only. Using any other water that is not distilled will harm system.
Note: Be sure to check for any water leaks. Check all hoses. Make sure they are all secure and be sure to keep all lines away from anything sharp or hot also make sure all lines are kept away from the drive lines and turbo as this could damage the lines. This should finish your install.
If you have any questions, contact our tech support group
Wiring Design For Our New Power Supply At Bottom Of Page
Use 12 Volt power supply only with 12 Volt system.
Use 24 Volt power supply only with 24 Volt system.
We recommend using a 160 AMP or larger alternator with our Hydrogen Systems
Wire Layout for power Supply
This is for a 12 volt system
The 24 volt system wires the same way
Wire Hookup On The Main Terminals:
Vin: 12VDC Positive Wire from Battery (fuse with a 1A fuse)
GND: Ground from Battery
SEN1 IN: (Not Used on these Demo Units) temperature sensor for generator cell
GND: (Not Used on these Demo Units) temperature sensor for generator cell
SEN2 IN: Liquid level sensor blue wire
SEN2 PWR: Liquid level sensor red wire
GND: Liquid level sensor black wire
K1: attach one K1 terminal to battery power source for fan (fuse appropriately)
K1: attach the other K1 terminal to the power wire on the radiator fan. Attach the other fan wire to vehicle ground.
K2: attach one K2 terminal to battery power source for pump (fuse appropriately)
K2: attach the other K2 terminal to power wire on pump. Attach the other pump wire to vehicle ground.
