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The HHO welder project started with a concept of: (single, twin, or quad) cells for (Jeweler, Home, or Commercial) welding respectively. The Jewelers single cell to be powered by a 12 volt battery and charger. The Home HHO Welder twin cell to be powered by line voltage. The Commercial quad welder to be powered by 220 service. When brainstorming for a cart or some type of enclosure, I came across the idea of mounting into the bottom of a roll around tool chest. Mobility plus drawer storage in a cost effective and very available form factor. This photo was taken near the beginning of the project.
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Twin EBN 8" HHO Generators form the foundation for our HHO welder prototype. These are the most efficient HHO Generators on the market today. With 20 amp line voltage, this configuration will easily produce 1-10 LPM and may top out as high as 13-15 LPM. I will post accurate LPM when the project is finished and data points are established.
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HHO flows out of the top of the cells and into the elyte reservoir separator. These are taller than the normal 8" (PL42K) reservoirs. The custom height is matched to the tool chest compartment height.
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HHO flows out of the top of the separator and into the bottom of the bubbler res. Both reservoirs feature FlashPort safety venting. The bubbler tank is hard mounted throught the side of the tool cabinet with PVC fittings.
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These fittings, on the outside of the cabinet, form the clear tube - elyte level indicator. HHO travels upward towards the torche tip from this point.
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This is also our electrolyte low point and serves as a great location for a drain. System drains are very handy. I recommend them on every HHO system design.
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Line voltage or 110 service powers the system. We start with a cord and plug that can handle 20 Amps. AC power is switched with a mounted 20 Amp on/off switch. Switched AC travels down the conduit and into the bottom area.
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Our switched AC enters from the right and connects to the bridge rectifier. Whenever the power switch is on, the bridge rectifies AC to puplsing DC. The SSR (Solid State Relay) forms our means of control. A 5LB pressure switch, which mounts into the bubbler, controls when the SSR is on. The bridge & SSR are mounted to a heat sink. The heat sink acts as the lid to the junction box. I am bending and holding the wires down to reveal the components and get this photo. The capacitor mounts inside the adjacent box.
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The role of the capacitor is to smooth the pulsating 110 volt DC. This process also has the added advantage of raising the voltage to 155 volts DC. Service varies around the country. At my home it measures 170 volts. Most survive contact with 110 AC. However, Rectifying to DC and adding that cap make it deadly. Please use EXTREME CAUTION whenever those wire connections are exposed. Closing the lower tool box with a padlock is recommended during opperation. Builders beware! This voltage is deadly. You will not likely get a second chance to learn proper safety. Please ensure safety first.
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This is the most recent photo. More progress was made on this prototype. And then I gutted it for use on the HHO Flyer. So much to do, so little time... Something has to be on the back burner....
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