STAFOR HHO MAF/MAP fully digital and automatic enhancer (corrector). Installation manual. Version 05.14. HHO hydrogen on demand dual fuel systems
Introduction The present MAF/MAP Sensor Enhancer is fully digital and after first regulation work in automatic mode. It is designed to work together with STAFOR HHO PWM (Pulse Width Modulator), but can be connected to any other HHO system. This device was designed to work with an HHO generator system (Hydrogen Fuel Cell) and should not be installed isolated. In this installation manual it is included detailed information regarding installation, regulation and maintenance based on the tests made by our Team in a large number of vehicles. Even if you have good mechanical skills, you should consult first a qualified mechanic before installing this device. You should have with you the repair manual of your vehicle in order to help you find the MAF/MAP sensor and locate the wire that goes from this sensor to the computer. Improper installation of this STAFOR HHO MAF/MAP Sensor Enhancer may cause problems with your vehicle's electrical system. Safety Precautions Read and follow these safety precautions to avoid hazards. If you do not understand these instructions or do not like to work on vehicles, please have a qualified mechanic do the installation for you. Incorrectly installing or using the Hydrogen on Demand Dual Fuel Generator Systems may result in serious damage to you and/or your vehicle. It should take approximately half an hour to install this unit, so ensure that you have enough time to complete the installation. Be sure to work outside, no smoking at any time during the installation, make sure the engine is off and very importantly, NOT HOT. Be sure to wear goggles and rubber gloves and only use professional tools, use common sense and general safety procedures used for any work carried out on automotive installations and maintenance. Components An Electronic Control Unit (ECU) controls the internal combustion operation of the engine. The simplest ECUs only control the quantity of fuel injected into each cylinder per engine cycle. The more advanced ECUs also control the ignition timing, variable valve timing (VVT), the level of boost maintained by the turbocharger, and other engine peripherals. ECUs determine the quantity of fuel, ignition timing, and other parameters by monitoring the engine through sensors. In most cars and trucks the more important sensors are the MAP/MAF (airflow) and oxygen sensors. For an engine with fuel injection, the ECU will set the quantity of fuel to inject based on a number of parameters. For example: If the accelerator pedal is pressed further down, this will open the throttle body and allow more air to be pulled into the engine. The ECU will inject more fuel according to how much air is passing into the engine. A mass air flow sensor (MAP or MAF) is used to find out the mass of air entering a fuel-injected internal combustion engine. The mass air flow information is the most important one and necessary for the engine control unit (ECU) to balance and deliver the correct fuel mass to the engine. How does the MAF/MAP Sensor Work? 1
As mentioned before the Manifold Absolute Pressure (MAP) or the Mass Air Flow (MAF) are the two sensors normally found in cars responsible for giving information to the computer (ECU - Environmental Control Unit) regarding the quantity of air being aspirated by the engine and, in this way, be able to calculate the quantity of fuel needed to be injected in order to maintain the predetermined air/fuel ratio. If more air is going into the engine then more fuel will be injected in the engine and vice-versa. The MAF/MAP sensor pick a 5 volt signal from the ECU, and returns a lower voltage signal in accordance with the aspiration in the engine and the quantity of air going inside. A higher output voltage means more air passing, which is then calculated as "more fuel is needed". Lower output signal indicates higher engine vacuum, which requires less fuel. It's not just fuel control. The MAF/MAP sensor signal gives the computer a dynamic indication of engine load. The computer then uses this data to control not only fuel injection, but also gear shift and cylinder ignition timing. STAFOR HHO MAF/MAP Enhancer Digital STAFOR MAF/MAP Enhancer is a hi-end electronics development. After installed digital MAF/MAP enhancer must be regulated only one time. After that enhancer automatically adjusts to car each time you start the engine. Digital sensor adjusts correction of MAF/MAP sensor to your driving style in real time. In difference of all other MAF/MAP enhancers for HHO generators with digital STAFOR HHO MAF/MAP enhancer you will not feel loss of car power and it will not damage to your car s engine. The MAF/MAP is a small device normally installed in your intake manifold after the air filter box. It has normally 5 Volts coming in, and it simply senses the airflow in the manifold and attenuates (reduces, weakens) this incoming voltage by a certain factor. In other words it reduces the supply voltage to a direct-current voltage in the range of 15% to 60% of the supply voltage (depending on the car's design these numbers will vary), and this varying (but non-pulsing) signal is then sent back to the computer. Our STAFOR HHO MAF/MAP sensor enhancer box simply takes this already attenuated (reduced, weakened) signal and attenuates it further. In this way the ECU will think that less air is going inside the engine (although it is the same in reality) and give order to inject less fuel. The loose of power is compensated by the injection of the HHO gas by STAFOR HHO hydrogen generator kit or any other HHO system. Principle of STAFOR HHO MAF/MAP enhancer work Digital MAF/MAP enhancer will write in memory information about cars MAF/MAP sensor information at engines idle state (working, but not driving). That information will be updated each time you start the engine, but only with timeout in approximately 5-10 seconds. It is important as weather conditions, fuel quality can change. Green LED will show that digital enhancer have written information at memory bank. In further work there will be no corrections made to MAF/MAP signal when engine is at idle state, to avoid damage of engine. When car will start to drive, the MAF/MAP signal voltage will be reduced (attenuated). Maximal reduce (attenuation) coefficient is 0.5 from original signal (according to post installation regulation). 2
Post installation regulation must be done only one time. It can be done by the rotating clockwise and counterclockwise of the potentiometer (ADJ) on device. The idea is that turning potentiometer will "enhance" or "reduce" the voltage. Too much attenuation kills the engine, it will simply shut off. Yet if you control it correctly, you can lean down the mixture from the balance of ingredients which is factory set at 14.7:1 (14.7 parts of air to 1 part gasoline) - down to 20:1, maybe even 50:1. Without attenuation, that is when the ADJ potentiometer is set to end counter-clockwise, the air to fuel ratio will be maintained at 14.7 parts air to 1 part fuel. When you begin to turn it, this ratio increases. If you turn the regulator (ADJ) too far, the engine will shut down due to lack of fuel. If you will need fast acceleration and accelerator will be pressed down STAFOR HHO digital MAF/MAP enhancer will cancel all corrections and allow you to have acceleration you need. This happens because STAFOR HHO MAF / MAP detects abrupt voltage rise in signal of air sensor when car is under hard acutely acceleration. Sensibility of this fast voltage rise can be adjusted via potentiometer ADJ2. Actually using ADJ2 You can configure (install) the maximum abrupt voltage rise at which STAFOR HHO MAF / MAP should cancel all corrections. When you finish a sharp acceleration digital MAF / MAP amplifier will return to normal operation as power surge passes. 3
Installing and Tuning Description of internal connections and regulators (potentiometers) inside STAFOR HHO MAF/MAP enhancer: 1. -IN contact terminal input from STAFOR HHO PWM (or input from battery (negative) if another HHO system used) 2. -OUT contact terminal input from STAFOR HHO PWM (or input from battery (negative) if another HHO system used) 3. +IN contact terminal input from STAFOR HHO PWM (or input from battery (positive) if another HHO system used) 4. SEN contact terminal input from MAF/MAP sensor signal wire (app. 5V) 5. ECU contact terminal output to cars ECU (corrected signal from MAF/MAP sensor) 6. MAF/MAP sensor signal reducing (attenuation) trimmer (potentiometer, regulator) must be tuned only one time. 7. Green LED indicates that digital STAFOR HHO MAF/MAP enhancer have written information in memory and working properly 8. Potentiometer (trimmer) for setting sensibility of fast (abrupt) acceleration of car (setting surge voltage value at which the signal from MAF / MAP must not be corrected should be set once during the installation. 4
Please refer to the illustrations below for typical connection of the STAFOR HHO MAF/MAP Sensor Enhancer to STAFOR HHO PWM (Pulse Width Modulator) or any other HHO system: 5
Locate the wires connected to the MAF/MAP sensor. The wire to cut will be the one where the voltage change with the acceleration of the engine. If you cannot locate the sensor or the wires, or you're not sure, you'd better get an auto-electrician to install it for you. To find the MAP/MAF Sensor Signal Wire, use a Circuit Tester to find the correct wire. You can hook this tester in series with your multi-meter to find the actual voltage of the wires coming out of the MAF/MAP Sensor. The 6
correct wire is the one with the lowest voltage or the one with a voltage that varies when the engine RPM is increased. Now cut the wire, and join the cables from the MAF/MAP enhancer like shown in the diagram above. The wire from ECU contact goes to ECU, and the wire from SEN contact goes to MAP/MAF sensor. Put a short lengths of heat shrink on cables, bare ends and twist connections together. Solder, then slip heat shrink back over joint and gently apply heat to make water tight seal. Secure cables with cable ties. Post Installation Tuning on the Road (only one time after installing) Turn ADJ potentiometer all the way to the left. Turn ADJ2 potentiometer all the way to the right. Make sure your HHO Generator is operational. Warm up the engine and drive a while before regulating ADJ potentiometer. DO THE NEXT STEP WITH CARE - JUST IN CASE YOUR ENGINE STOPS UNEXPECTEDLY. 1. Now, start turning the potentiometer clockwise, the mixture will turn leaner and leaner until the car stalls or bucks as you drive. Back the ADJ regulator off slightly after the bucking and chugging. 2. Keep the danger of overheating in mind. If your HHO Generator device is non-operational and STAFOR HHO PWM is not working, digital MAF/MAP will not make any corrections to sensor signal. 3. Sharply press acceleration pedal till maximum (sharp peak acceleration). If you feel that the car accelerates not enough quickly, gently turn the potentiometer ADJ2 counterclockwise. This way you decrease maximum surge during hard acceleration of car. 4. Remember that reducing the maximum limit of a voltage surge during acceleration with ADJ2 to much, can cause that STAFOR HHO MAF / MAP will not correct standard signal from airflow sensor. In this case, please, again turn ADJ2 all the way to the right (clockwise) and start tuning from point 3. NOTE: When this device turns on for the first time, sometimes the "check engine Light comes on and this needs resetting with a ScanGauge-II or an OBD-2 Connector (1996 cars or newer). When this has been done if your connections are correct, it will stop off. MAXIMIZE BENEFITS You will get improved economy straight away but it is dependent on your HHO generator performance. The better performance you get from this, the more lean your car, but don t overwork the engine by leaning it too much - play around until you find the PERFECT BALANCE point. The way you drive also has quite an influence, if you need fast acceleration, you will not be able to lean it out as much, as driving normal. Our STAFOR HHO MAF/MAP Enhancer is ideal for different driving styles, or types of driving. Fast and town or normal and towing. Digital enhancer will automatically detect how you drive and make corrections in sensors signal. All you will need to do is - tune it only one time after installing on car. 7
WARRANTY Name Data Additional information Model Serial number Car model Engine, type/volume Reg.number of car Name, surname/client Client phone number Date of installation Installation made by I have no claims and objections: (signature) (name, surname) Installation made by: (signature) (name, surname) Z.v. 8
STAFORHHO.com E-mail: info@staforhho.com Phone: +371 27124103 Phone: +371 28444384 Address: 45/47 Mukusalas street, Riga, Latvia, LV1046 Fax: +371 67603399 9