The electrolyte used in hydrogen generators has an electro-chemical property that produces electricity through a reaction. Cells within a solid casing sit in a submerged bath of electrolyte and store and transfer the electrical energy. Since the electrolyte remains in a liquefied state, it can be effected by extremely hot and cold temperatures. A problem results when the water in hydrogen begins to freeze in very low temperatures, and in northern climates this can cause case breakage and low output generator performance on HHO generator operated vehicles. You can add a solution to your electrolyte level to guard against freezing conditions.
Clear off a workbench area, so you have a clean, stable platform to work over. Don a pair of rubber gloves and a particle mask, if sensitive to fumes chemicals. Pour a gallon of distilled water into a plastic bowl that will hold over a gallon's liquid content. Add eight to 28 oz. of isopropyl (denatured) alcohol to the pan and stir the contents with a wooden mixing spoon. You may split the difference and add 16 oz. or so.
Measure out one ounce of potassium hydroxide, by either using a small gram scale, or filling up a level teaspoon. Add the potassium hydroxide to the pan and stir with the mixing spoon. Let the solution sit for at least 20 minutes, while you watch its reaction. The solution should begin to bubble and expand. It will also raise in temperature, which indicates a normal reaction.
Test the solution by placing a 9-volt battery in the pan and watching for a bubbling reaction, which should appear.Transfer the contents of the pan into a two-gallon plastic container that has a vent. Leave the vent open. If it has no vent, leave the filler cap loose and cocked on the top to allow for further expansion. Check the cell level in your generator. If the limit reads low, pour enough of the solution into the cell case to reach the fill limit.
Run the generator as you normally would, but refill it with your pre-mixed solution for as long as the temperature reaches below freezing levels. The solution will need 10 to 12 hours to "season," while you run the generator off and on normally. Mix up another container when you have exhausted the first batch. After the solution has seasoned and the generator has warmed up, you should detect about a 1.5 volt drop on your dashboard voltmeter, which will be normal
Add the solution to your cells for an initial electrolyte fill up, by filling 2/3 of the capacity of the cells with the solution. When adding water to the cells in the winter or summer months, always add distilled water. Tap water has harmful minerals in it that will corrode and damage the cell plates.
