Power Control Module Installation Instructions
The power control module is explained in much more detail in the article, Important: Minimum Safety Circuitry for HHO Installs. For a diagram of the components of the module, and a description of how it all works, please see that article. This article will just cover the basics of how the unit is used.
When you receive the Power Control Module from the factory, you will find that there is a loop of 10 gauge wire coming out of it. This wire is used to make your main current connection between the battery and the HHO cell. That cable needs to be cut, and one end connected to your battery + terminal, and the other will connect to your HHO cell. You’ll notice that there is piece of heat shrink marking one of the cables as it comes out of the box. The marked cable needs to be connected to you battery, and the other piece (after making the cut) will connect to your cell. But you shouldn’t cut it until you know exactly where you want to mount the module.
Mount the module, and then route the marked part of the cable to your battery. Then cut the cable, making sure you will have enough slack to crimp on a ring terminal and make the connection to your battery. Then, after making the cut, you can route the other end of the cable to your cell. Power to the cell will then be controlled by the Power Control Module.
There are several ways that the power is controlled. First is that 12 volts must be supplied to the small 18 gauge red wire. Without 12 volts on that wire, the Power Control Module will never switch on. It is intended that small red wire be connected to the fuel pump relay. In most vehicles, this relay will only provide 12 volts when the engine is actually running. If the key is turned on, but the engine is not running, this relay will not be powered up. You should test your own fuel pump relay to be sure it has the same functionality. But if it does, this is the desired place to connect the small red wire from the Power Control Module. By connecting to the fuel pump relay, you ensure that your HHO cell can only operate when the engine is running.
The next way to control the system is with the switch on the Power Control Module. Assuming you have 12 volts to the small red wire, the switch will now control the power to your cell. When you see the red LED glowing on the switch, that means that the switch has control power and it is turned on. When the LED is out, either the switch is off, or the 18 gauge control wire is not powered. The normal way to use the switch is to leave it on all the time. Let the system be turned on and off by the fuel pump relay every time you start your car. However, if you have to take your system out to work on it, or you run out of electrolyte, and need to shut down your HHO system, you can flip the switch on the Module. When in the off position, your HHO system cannot receive power.
The final way to control the system is by adding a remote switch. You can add your own remote switch so that you can turn your HHO system on and off from the driver’s seat. The description of how to add the remote switch is in the above referenced article.
The functions of the circuit board terminals are as follows:
Ground: A small ground wire of any gauge is needed on this terminal in order to make the relay work.
Relay Coil: When 12 volts is applied to this terminal, the relay will fire, which turns the system on.
“Switch” & “Remote Switch”: These 2 terminals were provided as a convenience but do not connect to anything else on the circuit board. They are just a place to join 2 wires together. These terminals can be used to connect your remote switch into the circuitry.
Amps Measure (+ & -): These terminals are used to read the amperage that is running through the Power Control Module. Any meter that will display milliamps can be used. Amperage will be equal to one amp per millivolt at these 2 terminals. For instance if you read 12 millivolts, then 12 amps are running through the module. This is a convenience only and doesn’t need to be used.
When you receive your Power Control Module, all of the wires needed to use it are already connected to the circuit board. You just need to connect them to your battery, HHO cell and fuel pump relay. If you decide to add a remote switch then be sure to read Important: Minimum Safety Circuitry for HHO Installs for details on how that is done.