How to avoid Poor terminal connections fault. Last week (June 2017) I checked the operation of My Hydrogen generator system and noticed that one of the terminals in the engine bay , that was delivering current through a relay unit to the Hydrogen system , had been affected by heat such that the plastic insulation was deformed as shown in the photo 1 below
I checked the temperature of every terminal in the systems as it was operating and noticed that the suspect terminal was operating at 60 celcius , while all other terminals were operating at 32 celcius.
Apart from the deformed plastic the suspect terminal looked fine and was conducting current through the relay.
I replaced the terminal and sPrayed it with lanolin lubricant to stop any future oxidation of the copper leads.
I have operated the system for the past 7 days and have consistently shown an increase in fuel economy of 1.7 km/litre, so that I am now achieving 19.5 km/litre.
I tested the terminal with a multimeter and noticed only a small increase in terminal resistance in low current flow conditions , but also noted that the internal resistance increases by over a 200 mili ohm when operating at 12 volt and 20 amp
This equates to a waste of electrical Power of P=I x I x R = 20 x 20 x 0.2 = 80 watts (80 joules per second)
The input Power = V x I = 12 x 20 = 240 watt (240 joules per second)
Wasting 80 watt for a total of 240 watt input is a massive 33%
I recommend testing the terminals with Infra red laser thermometers , to check the condtion of the electrical terminals and identify faulty terminals which could adversely affect the operation of your Hydrogen generator system.
Moral to the story is it is crucial to check and ensure that all terminals are in good condition – and preferable treated with a liquid such as with lanolin corrosion inhibitor.. Alternately with oxidation any electrolysis unit will generate heat rather that hydrogen