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TESTING DATA

I found the flame characteristics to be identical to my electrolyzer gas. See my "Brown's Gas, Book 2".

Preliminary testing of total wattage efficiency showed close to 5 watt hours to a liter of gas. This is total machine power draw to make a liter of gas; includes the fan and computer power as well as the transformer and diode losses. These kind of losses are fully explained in "Brown's Gas, Book 2" as are the reasons I choose to have an electrolyzer design that doesn't have a transformer.

We put a 100 amp watt-meter (Kh=7.2) in line, to measure the watts drawn from the wall.

We first measured the "stand-by" wattage, used by the fan and electronics with no gas production. It took 145 seconds to make one revolution of the watt-meter wheel. So (7.2 x 1 x 3600)/145 = 178 watts "stand-by" power. (Very efficient fan!)

The wall power available is 240 VAC and the electrolyzer was pulsing about once a second, drawing up to 36 AAC then settling down to a steady 30 AAC till the computer shut off the SCR. This made the watt-meter move fast, then nearly stop and it was difficult (but not impossible) to get an accurate reading.

To measure total machine efficiency, we used our regular technique of filling a 4.082 liter plastic container with the gas; displacing the water out of it. With the BN 1000E set at 1,000 Liters per hour, we filled the container with gas in 16.2 seconds. We used 280 marks of the watt-meter wheel to do this (2.8 revolutions of the watt-meter wheel). We did this several times and were very close each time. (7.2 x 2.8 x 3600)/16.2 = 4480 watts. 4.082/16.2 = 0.2519 L/sec. 0.2519 x 3600 = 906.84 liters per hour. So 4480/906.84 = 4.9 watt-hours per liter of gas.

We are now experiencing a shut-down problem in the machine (started during testing yesterday), and it's getting worse. The electrolyzer will only run a few minutes (Initial shut-off happened after about an hour of continuous use) and then it shuts itself off by turning off the main relay; which, as I understand it, it isn't supposed to do until the red shut-off button is pushed. All computer controlled shut-downs are only supposed to turn off the SCR (electrolyzer itself) leaving the computer and fan running.

The shut-down gets progressively worse as you continue to try to operate the machine, first shutting down after fifteen minutes of operation, then (after immediate start-up) shut-down after five minutes and then (again after immediate start-up) shut-down after one minute. Combine this problem with the "water" light coming on when you first start up the electrolyzer and I suspect that the main computer PID chip is malfunctioning; perhaps heating up and causing the shut-down condition.

To test the BN 1000E at a lesser amperage, we installed 40 of 4 uF @ 440 VAC capacitors and spent some time wiring them into a capacitive amperage limiting configuration. We wire them in series with the main transformer (through the main relay, which we've disconnected from the computer's control and turn on with our own switch). This allows us to test the BN 1000E in a "steady state" condition; allowing more precise measurements (we left the fan in the circuit, to cool the transformer and the diodes). This test allowed 8 amps AC @ 235 VAC into the transformer, which allowed about 52 amps DC through the electrolyzer @ 24.2 VDC. We filled our 4.083 Liter container in 35.3 seconds. It took 14.4 seconds to make one turn of the watt-meter wheel. This works out to about 112% gas.

The next test was to remove the capacitive amperage limiting and run the electrolyzer in a "steady state" at full power. We drew 35 AAC @ 230 VAC from the wall and had 203 ADC @ 26.4 VDC across the electrolyzer. We filled a 4.083 liter container in 8 seconds and it took 29.4 seconds to turn the watt-meter wheel ten revolutions. The electrolyzer efficiency was about 128%.

The electrolyzer pressure kept building as the gas production increased as the electrolyzer slowly "ran away"; using more amps as the cells heated up, and heating up the cells faster as the amperage increased. The BN 1000E uses a calibrated resistance to form a "current sensing" device, which causes the computer to shut down the amperage to the electrolyzer (by shutting off the SCR) if the amperage exceeds about 180 ADC.

Note: The pressure on the BN 1000E read at 0.5 MP and an actual pressure gauge (we tried two) read at 8 psi. Since a Mp is about 145 psi, there is a serious problem with the pressure coming out of the BN 1000E. The pressure is too low; I don't know why it didn't backfire as we were using the torch.
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