HHO Controller V1.1c

Supporting Documentation and Assembly Tips

Schematic Diagram

Click To View

Wiring Diagram

Click To View

HHO Controller V1.1c Recommended Parts List
Note:  You may substitute equivalent components in most cases without affecting circuit operation.  Be sure to check component dimensions when substituting to be sure they will fit on the PC board.  If you're not sure how this is done, we recommend using the part numbers listed.  Updated: July 3, 2010
PC Board Components
Designation	Part	Qty	Description	Supplier	Part No.
	PC Board	1	HHO Controller V1.1c Bare PCB	Alt Fuel Systems	AFS-PCBHHOV1.1C $19.95 ea
U1	7810	1	Positive 10V regulator	Mouser	512-LM7810ACT $0.38 ea
U2	LM324N	1	Quad Op-Amp	Alt Fuel Systems	STM-LM324N $0.44 ea
				Mouser	512-LM324N $0.54 ea
U3	LM555CN	1	555 Timer	Mouser	512-LM555CN $0.31 ea
BR1, BR2	DF01M	2	Bridge Rectifier	Mouser	512-DF01M $0.37 ea
D1, D2	1N4005	2	Diode	Mouser	652-1N4005-E3/54 $0.04 ea
R1	1.8K	1	1/4 Watt 5% Resistor	Mouser	291-1.8K-RC $0.10 ea
R2	22K	1	1/4 Watt 5% Resistor	Mouser	291-22K-RC $0.10 ea
R3, R4, R5	10K	3	1/4 Watt 5% Resistor	Mouser	291-10K-RC $0.10 ea
R6	6.2K	1	1/4 Watt 5% Resistor	Mouser	291-6.2K-RC $0.10 ea
R8	100K	1	1/4 Watt 5% Resistor	Mouser	291-100K-RC $0.10 ea
R9, R10	100	2	1/4 Watt 5% Resistor	Mouser	291-100-RC $0.10 ea
R11	1M	1	1/4 Watt 5% Resistor	Mouser	291-1M-RC $0.10 ea
R12, R13	1K	2	1/4 Watt 5% Resistor	Mouser	291-1K-RC $0.10 ea
R14	15K	1	1/4 Watt 5% Resistor	Mouser	291-15K-RC $0.10 ea
R15	200	1	1/4 Watt 5% Resistor	Mouser	291-200-RC $0.10 ea
R16, R17	10	2	1/4 Watt 5% Resistor	Mouser	291-10-RC $0.10 ea
R18	10	1	1/2 Watt 5% Resistor	Mouser	660-RC1/2TT52R100J $0.32 ea
VR1, VR2, VR4, VR5	20K	4	Multi-turn trimmer potentiometer	Mouser	652-3299Y-1-203LF $2.63 ea
VR3	1K	1	Multi-turn trimmer potentiometer	Mouser	652-3299Y-1-102LF $2.63 ea
C2, C9	0.1uF	2	Ceramic cap	Mouser	594-K104K15X7RF5TH5 $0.06 ea
C3	0.022uF	1	Polyester cap	Mouser	80-MMK5223K63J01L4 $0.26 ea
C4, C7, C8, C10	47uF	4	Electrolytic cap	Mouser	140-L35V47-RC $0.32 ea
C5	4.7nF	1	Polyester cap	Mouser	80-MMK5472K63J01L4 $0.29 ea
C6	0.01uF	1	Poly cap	Mouser	80-MMK5103K63J01L4 $0.12 ea
C1a, C1b	2200uF	2	Electrolytic cap	Mouser	594-2222-021-17222 $2.59 ea
J6, J7		2	Screw Terminal	Mouser	571-2828414 $1.50 ea
T1	TY-300P	1	Transformer	Mouser	553-TY300P $5.56 ea
Off Board Components See wiring diagram for additional information.
Designation	Part	Qty	Description	Supplier	Part No.
	IRFP064N	1	Power MOSFET	DigiKey	IRFP064NPBF-ND $2.18 ea
	MUR420G or equiv	1	Fast recovery diode	Mouser	863-MUR420G $0.43 ea
	TO-247 thermal pad	1	Aluminum oxide	Mouser	532-4180, $0.70 ea
			Mica	MCM Electronics	21-1170 $4.29/25
	Heat sink compound	1g	Heat sink compound	Mouser	526-NTE303 $2.77 ea
	Heatsink	1	CPU cooler w/ fan	NewEgg	N82E16835150018 $5.99 ea
			CPU cooler w/ fan	Directron	FAN-ALU-7 $3.99 ea
			Small CPU cooler no fan	Mouser	567-628-65AB $3.20 ea
	#6-32 x 3/4" screws	1	To mount the MOSFET.
	#6 lock washer	1
	#6 flat washer	1
	Hookup wire		18AWG stranded copper
	Power wire		12AWG or 10AWG or 8AWG stranded copper
	Project enclosure	1	Waterproof enclosure recommended for under hood auto installations
	Fuses	2	See wiring diagram for amp rating.
Additional items you may need: Tools, solder, fuse holders, #6-32 threading tap, drill bits, grommets, shrink wrap, wire terminals, wire ties

Assembly Tips

The Bare Printed Circuit Board

Buy a bare board

The Assembled Controller Board

Polarity

Several components must have proper orientation durring assembly.  Look at the orientation/polarity markings shown in the picture.  Some components can only be inserted one way.  The electrolytic capacitors (barrel shaped with silver top) can generate excessive heat, smoke, explode, etc. if not installed properly. Check, double check and recheck polarity before powering up the PWM.  The bridge rectifiers BR1 and BR2 have markings that are nearly impossible to see.  If you find that your EFIE output voltage is very low or not adjustable, the most likely cause is that these were not properly oriented.  The resistors and small capacitors can be installed in any orientation.

Large Capacitors

The large filter capacitors C1a and C1b are mounted on the rear of the printed circuit board.  These capacitors should be the last components installed as they cover the solder pads on the back of the board.  Clip all component leads below the capacitors as close to the board as you can to prevent them from piercing the insulative jacket on the capacitor body.  Mount them using double sided foam tape.  Observe polarity - these caps can explode if installed backwards!  If you find that mounting the capacitors on the circuit board will make it difficult to mount the board in your enclosure, the capacitors can be mounted elsewhere inside your enclosure and connected to the board with insulated wire leads.  Keep the capacitors as close to the board as possible, and keep the wire leads short.

Check Engine Light

Many new vehicles perform sensor tests when the vehicle is parked. One of the tests checks the operation of the oxygen sensors. The design of the EFIE circuit in this controller can interfere with this test on some vehicles and set an error code in the ECU. The system will seem to function properly durring driving, then after being parked for a period of time, when restarting the vehicle the check engine light will illuminate. This error can be avoided by connecting a relay in the O2 sensor circuit that reconnects the sensors to the ECU in their original factory configuration when the unit is powered off.

If you find the check engine light illuminates while driving, the most likely cause (assuming the vehicle systems are functioning properly) is the EFIE offset voltage is to high, causing a "sensor voltage out of range" error. This can be fixed by reducing the offset voltage setting of the EFIE to keep the sensor voltage within the measurable range of the ECU. Most vehicles that have narrowband O2 sensors, will need to have the EFIE offset voltage set below 0.5 volts.