Horizon Fuel Cell FCJJ-40 User manual
Horizon Energy Box
User Manual
www.horizonfuelcell.com
300001246
Warning
Model No.: FCJJ-40
Table of Contents
Safe Information．．．．．．．．．．．．．．．．．．．．．．． Inside front cover
Parts List．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
Hydrogen Energy ．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．．
Wind Energy . . . . . . . . . . . . . . . . ．．．．．．．．．．．．．．．．．．．．．. . .
Solar Energy . . . . . . . . . . . . . . . . . . . ．．．．．．．．．．．．．．．．．．．．．
Bio-Energy . . . . . . . . . . . . . . . . . . ．．．．．．．．．．．．．．．．．．．．．．．
Mechanical Energy . . . . . . . . . . . . . . . . . ．．．．．．．．．．．．．．．．．
Thermanl Energy . . . . . . . . . . . . . . . . . . . . . . . .．．．．．．．．．．．．
Salt Water Energy . . . . . . . . . . . . . .. . ．．．．．．．．．．．．．．．．．．．
Multi Energy Powered Car. . . . . . . . . . . . . . . . .．．．．．．．．．．．．
REM User Guide . . . . . . . . . . . . . . . . . ．．．．．．．．．．．．．．．．．．．
Safe Experimentation
Here are some important instructions for parents, teachers, and students. All activities described in this manual
can be conducted without risk if you follow instructions and rules conscientiously.
To avoid the risk of property damage, serious injury or death:
1. Read carefully and fully understand the instructions before assembling this kit.
2. This product is intended only for use by persons 14 years old and up, and only under the supervision of
adults who have read and understood the instructions in this user manual.
3. Pay special attention to the indications of quantity and to the sequence of the individual steps.
4. Some parts are small and fragile: please be careful when handling and connecting parts to avoid breakage.
Handle all parts and components with care.
5. Do not attempt to use any part, item, or component provided in this kit for any other purpose than what is
instructed in this manual. Do not attempt to disassemble any part, item or component in this kit.
6. Keep small children away, because this kit contains small parts that could be swallowed.
7. Wires are not to be inserted into socket-outlets.
8. Save these instructions and review frequently during use.
9. Do not use any other parts or devices than those delivered with the kit.
10. Do not eat, drink, or smoke near the fuel cell device and hydrogen storage.
11. Use fuel cell and hydrogen storage only at a site with good ventilation and keep all sources of ignition away.
12. Clean your hands after use.
Safety Information
Before you start working with the Horizon Energy Box take notice of the following.
Under certain circumstances, hydrogen can create an explosive gas mixture.
Though these devices in this box are designed such that they can be used as described without danger, the
advice below must be followed at all times:
• The fuel cell and hydrogen storage may not be operated without supervision.
• Hydrogen (H2) is much lighter than air and thus rises rapidly. In conjunction with oxygen, a gas mixture capable
of explosion can form. A potentially explosive mixture arises for hydrogen concentrations from 4.0 to 77.0% in air.
Therefore, it holds that:
• The fuel cell must only be operated either outside or in sufficiently ventilated rooms.
• Oxygen (O2) is a strongly oxidizing gas. When this gas gets in contact with organic substances (e.g. oil,
grease) spontaneous combustion may occur at room temperature.
• Do not insert the cables into an electrical outlet.
• Do not connect the fuel cell or motor to other power sources.
• The removing and inserting of batteries is to be conducted by the adults only. Ensure to respect the polarity.
• Non-rechargeable batteries are not to be recharged.
• Different types of batteries such as rechargable, alkline and standard batteries or new and used batteries are
not to be mixed and should be used separately.
• The battery pack cables are not to be inserted into an AC socket.
• The supply terminals of the battery pack are not to be short-circuited.
• The two spare red & black cables are not to be inserted into an AC socket.
• Exhausted batteries are to be removed from the battery pack.
• Dispose of dead batteries properly and without delay.
• Do not attach the battery wires directly to each other.
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Horizon Energy Box
User Manual
2
Parts List:
1. Hand crank generator
2. Ethanol fuel cell module
3. Reversible fuel cell
4. Salt water fuel cell
5. Multi car chassis
6. Battery pack
7. LED module
8. Mini fuel cell base
9. Potentiometer
10. Super capacitor
11. Water tank base
12. Solar panel
13. HYDROSTIK PRO
14. Pressure regulator
15. Mini fuel cell
16. Thermoelectrical system
17. Rotor Base
18. Blade holder
19. Assembly lock
20. Main body assembly
21. Variable resister module
22. Base assembly
23. Blade A (3pcs)
24. Blade B (3pcs)
25. Blade C (3pcs)
26. Windpitch post assembly
27. Spanner
28. Screwdriver
29. Water & oxygen tank
30. Water & hydrogen tank
31. Fuel solution container
32. U locker for HYDROSTIK PRO
33. HYDROSTIK PRO suport
34. Syringe
35. Fuel cell base
36. Multi connection base
37. Solar panel support
38. Heavy fan module
39. Fan module
40. Fan blade
41. Ethanol fuel tank with lid
42. Wires
43. Wheel
44. Purging valve
45. Clamp
46. PH paper
47. Silicon tubes
48. Red & black pins
49. Fan blade & wheel adapter
50. Windpitch post screws
51. Reversible fuel cell
52. Thermometers
53. REM USB cable
54. REM
1 2 3 5
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96 7 8 10
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1411 12 13 15
28
16 26 27
32
2017 18 19 21 22
23 24 25
29 3330 31 34
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37 38
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43 44
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4845 46 47 49 50
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51
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1
54
Step 1. Preparing the micro-fuel cell module
a. Insert the PEM fuel cell (a) into its slot on the base (g).
Make sure the fuel cell fits well in its base.
What you need:
a. Micro-fuel cell
b. HYDROSTIK PRO (hydrogen storage)*
c. Pressure regulator
d. Heavy fan module
e. Fan blade
f. HYDROSTIK PRO base
g. Micro-fuel cell base
h. Wires
i. Fan blade adapter
j. HYDROSTIK PRO support
k. Clamp
l. Silicon tubes
b. Use the short black & red wires to connect the fuel cell to its base as shown below. Make sure
you respect the color code when you plug each wire into the corresponding socket.
Step 2. Preparing the fan module
a. Connect the adapter (i) to the motor axis. Insert the fan blade (e) onto the adapter.
Make sure the connection is tight.
a b c
d
ef
ghi
jkl
HYDROSTIK PRO SAFETY INFORMATION
● DO NOT try to disassemble, open or repair the cartridges when broken or worn out!
● DO NOT store cartridges under direct sunlight.
● Keep it away from fire. Fire Hazard!
● Keep in a safe, dry and cool place.
● Keep away from temperatures above 50˚C while filling, storage and using.
● Provide adequate ventilation and refrain from placing items on or around the appliance
during operation. Refrain from placing the appliance in enclosures or causing the appliance to not vent freely.
● Keep away from alkaline and acidic environment.
● This is not toy – keep away from children.
● The HYDROSTIK PRO must be placed horizontally when it is being charged otherwise the cartridge can crack!
● HYDROSTIK PRO contents are flammable. Do not disassemble. Avoid contact with HYDROSTIK PRO contents.
● Remove the HYDROSTIK PRO from the pressure regulator immediately after use.
● Hydrogen shall be stored, handled and used with caution so life and health are not jeopardized and the risk
of property damage is minimized.
● This appliance is not tested for use with medical devices.
● Save these instructions and review frequently during use.
You will also need the following items
(not included in this box):
- HYDROFILL PRO for charging the HYDROSTIK PRO
- Scissors
Hydrogen Energy
*Note: The HYDROSTIK PRO contains no hydrogen when you get it for the first time, you have to fully charge the
HYDROSTIK PRO with the refilling station HYDROFILL PRO (not provided) or hydrogen charging tube (not provided).
Or please contact your local dealer for detailed information.
3 4
Step 4. Preparing the hydrogen source
Step 5. Power the fan with the hydrogen energy
a. Screw the HYDROSTIK PRO to the pressure regulator tightly.
b. Open the clamp to purge some amount of hydrogen out and then quickly close. The fan will immediately
start to run.
Note:
1. If the fan does not run at this time, it may need to be flicked with your finger to start.
2. After every 10 minutes, it is suggested open the clamp to release some amount of hydrogen out to
ensure the good performance of the fuel cell.
3. Remove the HYDROSTIK PRO from the pressure regulator immediately after use.
Now you may use a multi-meter (not provided) or Horizon’s REM to measure the output voltage & current
produced by the fuel cell or do various experiments.
b. Use the black & red wires to connect the fan module to the fuel cell module.
Make sure you respect the color code when you plug each wire into the corresponding socket.
a. Cut a 15cm long silicon tube. Unscrew the pressure regulator and put the bolt around the tube. Connect the
tube to the pressure regulator.
b. Connect the other end of the tube from the pressure regulator to the remaining nozzle of the fuel cell.
Make sure the connection is tight.
Step 3. Connect the fan to the fuel cell
a. Cut a 6cm long silicon tube. Let the tube go through the clamp. Connect one end of the tube to the inlet of the
fuel cell (lower nozzle). Keep the clamp closed.
c. Place the HYDROSTIK PRO support (j) onto its base (f).
d. Place the HYDROSTIK PRO onto its support.
Fuel cells can be thought of as alternative energy devices. They convert chemical energy into electrical
energy. Hydrogen fuel cells do this very cleanly, with no toxic emissions, and with a high efficiency.
Fuel cells do not generate energy out of thin air. They use hydrogen. Hydrogen is an outstanding carrier of
energy. Hydrogen is non-toxic, renewable, easily obtained, and packed with energy. When it combusts with
oxygen, it turns into water. This water can again be split into hydrogen and oxygen via electrolysis. The
generated hydrogen can be combusted once again, thus undergoing a limitless cycle without toxic emissions.
With a fuel cell, you can convert hydrogen into electric current without combustion.
Fossil fuels are converted into usable energy through combustion. The energy released during combustion is
inherently difficult to capture and inefficient. It also produces carbon dioxide, which cannot easily be converted
back into a usable fuel. A fossil fuel combustion engine at a power plant is only about 30 to 40% efficient. This
means it coverts only 30 to 40% of the energy in the fossil fuels to usable energy (electricity). Engines in a car
are even less efficient, and reach the level of 15 to 20% of efficiency. Where does the rest of the energy go? It
escapes as heat, vibration, and noise.
On the other hand, fuel cells can operate at 40 to 65% efficiency. This means that they can convert 40 to 65%
of the energy contained in hydrogen into electricity.
Why Fuel Cells and Hydrogen?
5 6
Step 4. Preparing the hydrogen source
Step 5. Power the fan with the hydrogen energy
a. Screw the HYDROSTIK PRO to the pressure regulator tightly.
b. Open the clamp to purge some amount of hydrogen out and then quickly close. The fan will immediately
start to run.
Note:
1. If the fan does not run at this time, it may need to be flicked with your finger to start.
2. After every 10 minutes, it is suggested open the clamp to release some amount of hydrogen out to
ensure the good performance of the fuel cell.
3. Remove the HYDROSTIK PRO from the pressure regulator immediately after use.
Now you may use a multi-meter (not provided) or Horizon’s REM to measure the output voltage & current
produced by the fuel cell or do various experiments.
b. Use the black & red wires to connect the fan module to the fuel cell module.
Make sure you respect the color code when you plug each wire into the corresponding socket.
a. Cut a 15cm long silicon tube. Unscrew the pressure regulator and put the bolt around the tube. Connect the
tube to the pressure regulator.
b. Connect the other end of the tube from the pressure regulator to the remaining nozzle of the fuel cell.
Make sure the connection is tight.
Step 3. Connect the fan to the fuel cell
a. Cut a 6cm long silicon tube. Let the tube go through the clamp. Connect one end of the tube to the inlet of the
fuel cell (lower nozzle). Keep the clamp closed.
c. Place the HYDROSTIK PRO support (j) onto its base (f).
d. Place the HYDROSTIK PRO onto its support.
Fuel cells can be thought of as alternative energy devices that unlock the power of hydrogen. They convert
chemical energy into electrical energy. Hydrogen fuel cells do this very cleanly, with no toxic emissions, and
with a high efficiency. Hydrogen and fuel cell technologies have many potential clean energy applications –
from running our vehicles, to powering our cellular phones and laptops, to heating our hospitals and homes.
Fuel cells do not generate energy out of thin air. They use hydrogen. Hydrogen is an outstanding carrier of
energy. Hydrogen is non-toxic, renewable, easily obtained, and packed with energy. When it combusts with
oxygen, it turns into water. This water can again be split into hydrogen and oxygen via electrolysis. The
generated hydrogen can be combusted once again, thus undergoing a limitless cycle without toxic emissions.
With a fuel cell, you can convert hydrogen into electric current without combustion.
Fossil fuels are converted into usable energy through combustion. The energy released during combustion is
inherently difficult to capture and inefficient. It also produces carbon dioxide, which cannot easily be converted
back into a usable fuel. A fossil fuel combustion engine at a power plant is only about 30 to 40% efficient. This
means it coverts only 30 to 40% of the energy in the fossil fuels to usable energy (electricity). Engines in a car
are even less efficient, and reach the level of 15 to 20% of efficiency. Where does the rest of the energy go? It
escapes as heat, vibration, and noise.
On the other hand, fuel cells can operate at 40 to 65% efficiency. This means that they can convert 40 to 65%
of the energy contained in hydrogen into electricity.
The development of hydrogen and fuel cell technologies and products around the world will improve the air we
breathe, ensure secure and reliable energy, reduce the emissions that cause climate change and create
highly skilled jobs.
Why Fuel Cells and Hydrogen?
5 6
FAQ
1. What are the refill options for HYDROSTIK PRO cartridges?
a. HYDROSTIK PRO can be recharged using Horizon’s HYDROFILL cartridge refilling solution.
b. You may contact your local Horizon service provider for HYDROSTIK PRO refill support at
c. If needed HYDROSTIK PRO can be disposed after use, they are fully recyclable and do not contain any harmful
materials.
2. I want to purchase more HYDROSTIK PRO Metal Hydride Cartridges, should I have received a (gas pressure)
regulator of any kind with it?
No, pressure regulators are not included as standard you will need to order those as well. You can purchase one
online visiting the Horizon Online Store or contact info@horizonfuelcell.
3. I would like to exchange my cartridge for a different size, can we do this at any Horizon related outlet?
No, for now we only distribute a single size HYDROSTIK PRO Metal Hydride Cartridge.
4. Can I take Metal Hydride cartridge HYDROSTIK PRO abroad?
No more than two spare metal hydride cartridges may be carried by a passenger in carry on baggage, in checked
baggage, or on the person.
8. How can I monitor how much gas is left in a cylinder?
This can be measured by weight, measuring the empty weight gives you the benchmark level and then you can
work out the total amount of hydrogen by that 11Liters of Hydrogen =1gram so make sure your scales can
work in 1/10th of 1/100th of a gram to get accurate readings. Pressure cannot be used as a measurement of the
amount of Hydrogen in the canister as the pressure is almost the same between 10%-90% full.
9. Can I store HYDROSTIK PRO in cars parked in full sun?
HYDROSTIK PRO is advised to be stored in maximum 50C temperatures, but cars parked in full sun can reach
inside temperatures which exceed 60C. HYDROSTIK PRO is still safe at these temperatures; however we do
not recommend storing HYDROSTIK PRO in such conditions.
10. Where do I recycle a spent or damaged HYDROSTIK PRO?
Contact your local consumer waste recycling center or return the HYDROSTIK PRO to a Horizon Fuel Cell
Technologies vendor. Typically, HYDROSTIK PRO can be recycled where rechargeable batteries are recycled.
Recycle Procedures The materials in the HYDROSTIK PRO are 100% recyclable, and so in order to get the
HYDROSTIK PRO metal hydride cartridges recycled properly, return the cartridges to your local outlet or
distributer.
Normal Disposal Procedures
The HYDROSTIK PRO metal hydride cartridges do not contain any dangerous substances for the environment,
we would recommend that they still be disposed of in a similar way you would dispose of a standard battery.
Troubleshooting
1. The fan does not run after the HYDROSTIK PRO supplies hydrogen to the fuel cell.
a. The fan may need to be flicked with your finger to start.
b. Recharge the HYDROSTIK PRO fully.
c. Open the clamp to purge a little bit amount of hydrogen out of the system.
d. Make sure the HYDROSTIK PRO is connected to the pressure regulator tightly.
2. The fan runs slower than before.
a. Recharge the HYDROSTIK PRO fully.
b. Open the clamp to purge a little bit amount of hydrogen out of the system.
If none of these tips helped solve the problem, go through the instructions from the beginning and
make sure you followw each step completely.
Efficiency (%)
70
60
50
40
30
20
10
0
100,000100,001,000
100
100
Power (KW)
PEM Fuel Cell
Gas Turbine
Auto Engine
5. Does the HYDROSTIK PRO lose its energy content over time, if I don’ t use it?
Hydrogen remains stored as a hydride in the HYDROSTIK PRO. The cartridge will not lose its energy or latent
hydrogen content if the cartridge is not being used.
6. Can we refill HYDROSTIK PRO with our own electrolyzer?
No, the HYDROSTIK PRO can only be recharged using the HYDROFILL or Horizon approved refilling stations.
7. How many hours of electricity are provided by a HYDROSTIK PRO Metal Hydride Cartridge?
The HYDROSTIK PRO Metal Hydride Cartridges contain up to 11Wh of electricity. So if drawing 1W from the
fuel cell, it will run for 11hours.
7 8
Diesel Engine
Wind Energy Step 1. Blade Unit Assembly
Main Body Assembly
Part List
1. Left Housing
2. Right Housing
3. Generator
4. Printed Circuit Board Assembly
5. Polypropylene Vane
6. Screw, M2.5 x 8 mm
7. Hex Nut, M2.5
8. Rotor Base
9. Molded Profile Blade
10. Profile Blade Holder
11. Blade Assembly Lock
12. Polypropylene Sheet Blade
13. Aluminium Post
14. Screw, M3 x 2 mm
15. Output Wire
16. Support Base Assembly
17. Output Socket
18. Post Secure Screw
Profiled Blade:
Place the Rotor Base (8) onto the flat surface
of a table. Install 3 pcs of the same type of
profiled blades (marked B or C) evenly on
the Rotor Base. Pay attention that the snap
joint must be pushed into the Rotor Base.
Place the Blade Holder (10) on top of the
installed blades. Pay attention to the
direction of the Blade Holder. Screw the
Blade Assembly Lock (11) onto the top of the
Blade Assembly.
Sheet Blade:
Place the Rotor Base (8) onto the flat surface of
a table. Install 3 pcs of the same type of Sheet
blades (12) (marked A) evenly on the Rotor
Base. Pay attention that the snap joint must be
pushed into the Rotor Base. Place the Blade
Holder (10) on top of the installed blades. Pay
attention to the direction of the Blade Holder.
Screw the Blade Assembly Lock (11) onto the
top of the Blade Assembly.
*Do not over tighten the Blade Assembly
Lock otherwise you may have a difficult time
in unlocking the Blade Unit Assembly.
*Do not over tighten the Blade Assembly
Lock otherwise you may have a difficult time
in unlocking the Blade Unit Assembly.
2
2
What you need:
1. Blade holder
2. Rotor Base
3. Assembly lock
4. Main body assembly
5. Heavy fan or wheel module
6. Blade A (3pcs)
7. Blade B (3pcs)
8. Blade C (3pcs)
9. Windpitch post assembly
10. Spanner
11. Screwdriver
12. Windpitch base assembly
13. LED module
14. Electrolyzer fuel cell base
15. Mini fiuel cell base
16. Electrolyzer fuel cell
17. Water & O2 tank
18. Water & H2 tank
19. Battery pack
20. Silicon tubes
21. Post secure screws
22. Red & black pins
23. Mini fuel cell
24.Clamp
25. Purging valve
26. Fan blade
27. Fan & wheel adapter
28. Water tank base
29. Variable resister module
30. Wires
31. Wheel
32. Circuit board
33. REM
34. REMUSB cable
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4
5
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9
7
10 11
12 13 14 15 16
17 18
You will also need the following items
(not included in this box):
- Purified or distilled water
- AA batteries
- Scissors, screwdriver & spanner
9 10
19 20 21 22 23
25 27
26 28
24
29 30
4
31
32 33 34
Step 2. Blade Unit Installation
Step 3. Post and Support Base Assembly
Push the rotor shaft to the rotor base to ensure the main body
and rotor head are properly connected. Make sure you press
the Blade Unit all the way onto the shaft. Check that the Blade
Unit is securely connected onto the shaft of the turbine. If not
properly installed, the rotor may not effectively turn the rotor
shaft and will not generate electricity.
Enable Yawing:
Disable Yawing (Not shown in the Assembly Drawing):
Yaw- To turn about on vertical axis.To move unsteadily or weave.
The wire connector hole should be located on the same side of the tube (13) with two vertically aligned holes. Insert
the Aluminium Tube into the Support Base. Install the Body Assembly onto the top of the Aluminium Tube and secure it with
the screw (14). The screw should be secured from the back side of the wind turbine body into the groove of the plastic
stud to enable yawing and movement of the turbine body.
The wire connector hole should be located on the opposite side of the tube (13) with two vertically aligned holes.
Insert the Aluminium Tube into the Support Base. Install the Body Assembly onto the top of the Aluminium Tube and
secure it with the screw (14). The screw should be secured from the front side of the wind turbine body through the
hole on aluminum tube into the solid plastic stud to disable yawing and movement of the turbine body.
5
V
*
3
3
To adjust and set the pitch of the blades,
carefully pull out the blade and rotate it to adjust
the pitch. Totally you have 3 pitches, which can
be adjusted.
The blades themselves have different set angles at different sections to enhance the performance. This setting is
to compensate the rotating speed of the blade at different radius (sections) so that the blades will not stall at a
particular section. You may have to learn more about a parameter called Tip Speed Ratio to understand more
thoroughly. This Ratio defines how fast the turbine is rotating under a wind speed environment. By changing the
blade pitch, this ratio will be changed. Thus the output power of the turbine is changed. Each adjustment
represents a change of 22 degrees. Therefore, the pitch is allowed to be adjusted from 6 to 50 degrees.
At smaller pitch value settings, the start up wind speed has to be very high. Maximum output power occurs at a
pitch of around 28 degrees. The start up wind speed is higher at a lower pitch setting. If the wind speed is low you
should increase the pitch so that you can achieve a higher power output.
Step 4. Blade Pitch Setting
The Pitch Angle
4
50
o
28
o
6
o
11 12
18
There are three types of profiled blades included in the Wind Energy kit. After you obtain the maximum output
power with a particular blade type, you may replace with another type of profiled blade and evaluate it's
performance in comparison.
The difference between these 3 profiles is the amount of material on the side facing the wind. All of them have a
much more curved profile on the Rear side (down wind side) to increase the distance for the wind to travel. The
Blade Type no. is engraved on the root part of the Blade for your reference.
A B C
There are 6 positions for the installation of blades and it is possible to install up to 6 blades. However, with 6 blades
installed the pitch adjustment is limited. It is recommended to experiment with numbers of 2, 3, 4, and 6 blades installed
under various wind speeds and blade pitch settings.
If you have enough wind try reducing to 2 blades as you may get a little more power than using 3 blades. More
blades installed will allow the turbine to start rotating more quickly under low wind conditions.
Different Blade Types
Changing the Number of Blades
Blade Type
Blade A 3 10 50 1.15 28 0.03 400
490
705
0.04
0.125
30
50
1.35
2.50
50
50
10
10
3
3
No. of Blade Wind Speed
(mph)
Load
(Ohm)
Output Voltage
(V)
Output Current
(mA)
Output Power
(W)
Rotor Speed
(RPM)
Wind Kit Technical Specifications:
Blade B
Blade C
Your Wind Energy Kit is now ready for
experimentation and be placed in line
with an appropriate wind source.
Experiment 1. Using a Wind Turbine to
Power the LED Module
Power the LED module by attaching the wind
turbines cables to their respective slots on the
LED module base. Position turbine to directly face
the direction of wind source.
Connect the red and black cables to the corresponding terminals located on
the wind turbine and reversible fuel cell. For best results using the WindPitch
to generate hydrogen using the included reversible fuel cell, setup the wind
turbine hub with 3 profiled blades marked C supplied with the kit.
Set the blade pitch to 6 degrees. Make sure that the wind turbine is
generating AT LEAST 2.5 volts. If not, move the wind turbine closer
to the fan until it does. The wind turbine is sensitive to this setting at
high wind speeds.
Allow the table fan and wind turbine to run for about 60 minutes
on high wind speed setting to generate sufficient amounts of
hydrogen and oxygen gases that are stored in the water/gas
tanks.
Experiment 2. Preparation of the Electrolyzer Module and Wind Powered Hydrogen
Production (See next chapter Solar Energy for detailed assembly for H2 preparation)
Battery
Pack
13 14
Below table indicates expected RPM speed, current, voltage, and power when placing the WindPitch in
constant windspeed of 10mph when connected to load of 50 Ohms. This level of resistance may be
applied using Horizon’s variable resister module included in this box.
(alternative): Using the Battery Pack to Perform Electrolysis (in the case of
no wind)
Make sure the switch on the battery box is in the "off" position before you
place the batteries into the box.
WARNING: If the cable is short circuited the batteries inside could
become hot and potentially cause burns, melting of parts, or create
risk of fire.
Please remove the screw from cover of battery box using a screw driver.
Push and slide the cover and open the battery box.
Try NOT to touch the cables when you open the cover.
Place two AA batteries as indicated.
Push and slide the battery box cover to closed position and screw fightly
into place using screw driver.
Push and slide
open the cover
AA Battery
AA Battery
Remove the screw
from the cover
Procedure for repeated gas production: Disconnect the small plugs from the tubes connected to the
nozzles on the reversible fuel cell. This will allow water into the inner cylinders to replace the gasses and
reset water levels to “0” line. Re-insert the plugs into the tubes and repeat electrolysis again.
Note: You may also use the battery pack to perform electrolysis (In the case of no wind source)
If the wind is sufficient the system will now start to produce hydrogen and oxygen in the
respective cylinders. When bubbles begin to surface in the hydrogen cylinder the cycle is complete.
Disconnect the reversible fuel cell from the Wind Turbine.
15 16
USING FUEL CELLS TO CONVERT HYDROGEN TO ELECTRICITY
Preparation of the Fuel Cell System
Insert the fuel cell into the base with the red terminal on the same side as the red terminals on the base.
Connect a green purging valve to one end of a 2cm tube and the other end to the upper nozzle on the hydrogen
side of the fuel cell.
Clench the tube connected to the electrolyzer and
hydrogen cylinder so that none of the hydrogen in the
cylinder from the last experiment can escape. Next
disconnect the tube from the electrolyzer and connect it
to the lower nozzle on the fuel cell.
Experiment 3: Using a PEM Fuel Cell to Power the LED Module
Connect the fuel cell to the fuel cell base using the red and black wires. Make sure to connect the black
wire with the black terminals and red with red terminals. Now connect the LED module to the base in the
same manner.
You should see the LED lights begin flashing. If not, purge a very small amount out of the valve to allow
some of the gas to move into the fuel cell. As the LED light consumes electricity the fuel cell will
consume hydrogen from the cylinder and you will see the water level reflect the changes in amount of
gases consumed.
Experiment 4: Using a PEM Fuel Cell to Power the Small Electric Fan Module
Repeat the hydrogen production and fuel cell
preparation steps.
Next, connect the small fan/wheel motor base to
the fuel cell base to generate power to the motor.
EXPERIMENT 3
EXPERIMENT 4
1. Assembly of the small electric fan:
Connect small round white adapter to the motor axis. Connect the fan blade to the adapter.
2. Assembly of the car wheel:
Firmly connect the other (tapered) white adapter to the motor axis. Attach the small wheel to the adapter.
Take your Wind Kit experimentation to the next level !
Listed below are additional wind experiments that can be performed with the Wind Kit wind turbine
using a multimeter or with Horizon’s Renewable Energy Monitor Lab and your computer.
● Using Different Blade Shapes Create Power
This experiment demonstrates how blades with different curvatures produce different
degrees of power output. Wind turbine blades are shaped like airplane wings, and
one size does not fit all requirements. You will measure and understand how using
the right blade shape can produce optimum power for different wind conditions.
● How Many Blades Are Best? 1, 2, 3, 4…
Using the right number of blades for a given wind condition is important in extracting
the maximum electrical power from a wind turbine. You will measure and understand
the choices between the numbers of blades that are necessary to produce best results.
● Adjusting Blade Pitch for Best Performance
Angling the blades into and away from the wind are important elements in creating
maximum power – or slowing the speed of rotation. This experiment will show you
the techniques for stalling and furling as well as adjusting the blade pitch to extract
the maximum degree of power from the wind.
● How Much Power Can Be Extracted from the Wind
While power from the wind is free as long as it blows, it is still limited to certain physical
laws. This experiment will show you how to measure wind speed versus extracted wind power.
● Using Wind Power to Generate Hydrogen
One important use of wind power is to generate hydrogen in a clean, non-polluting
manner. This experiment shows you exactly how to do it.
● Measure Wind Turbine Performance Using RPM
Using our electronic measurement tool you can measure the voltage, current, power
and RPM (revolutions per minute) rotational speed of the wind turbine and see it
displayed on the measurement tool as well as your computer. Watch the RPM as it
changes with wind speed and resistor loading and witness how to slow down and even
stop the wind turbine spinning without even touching it – just by adding the right resistor
combinations. Make measurements for wind power and turbine efficiency to really
understand how this remarkable device works.
● Build a Wind Farm
Arrange multiple Wind Kit turbines in series and parallel configurations in order to
study the voltage, current, and power generated. Design a simulation of a commercial
wind farm in model scale and learn the potential of wind power as a mass energy source.
Purchase additional Wind Energy Kits and Circuit Board Module Base and red/black hookup
leads needed to connect multiple turbines in series and parallel here-
http://www.horizonfuelcell.com/store.htm
Most commonly a floor or basic desk fan is the source of wind used for experimentation with the Wind Kit. A larger fan
allows you to test the performance of the turbine at higher wind speeds. You can switch the fan to a lower setting or
increase the distance between the fan and the turbine to achieve low wind speeds. It is difficult to achieve high wind
speeds with a small fan. A fan of 16” diameter is suitable for doing most wind power experiments.
For optimum performance, align the centre of the fan with that of the nacelle of the turbine. Therefore, it will be better
if the height of the fan is adjustable.
Wind from a natural source is never steady. Therefore, the output power of the turbine is always varying. This may
lead to uncertainty in taking readings and measurements in the experiments. In order to reduce the variation of wind
speed due to turbulence, operate the setup at the middle of a hall or use a wind tunnel. The wind speed will be more
stable under these conditions.
With the included LED Module, wheel and fan blade module you can demonstrate the output power created by the
Wind Kit and use this power to illuminate the LED Lights on the Module. You can use the Renewable Energy Monitor
provided to measure the LED.
This LED Module, wheel and fan blade module is intended as a basic demonstration device. To perform much more
detailed experiments and explore the full educational value of your Wind Kit refer to the educational CD. With the
device and in combination with Horizon’s PEM electrolyzers you can perform a multitude of experiments including:
EXPERIMENT 5
EXPERIMENT 6
Experiment 6: Using a PEM Fuel Cell to Power the Small Fan/Wheel Motor Module and the
LED Module in Parallel
Repeat the hydrogen production and fuel cell preparation steps. Next, connect the small fan/wheel motor base
and the LED module base to the circuit board. Then connect the circuit board to the fuel cell module base to
generate power to both modules in parallel.
17 18
Experiment 5: Using a PEM Fuel Cell to Power the Small Car Wheel Module
Repeat the hydrogen production and fuel cell
preparation steps. Next, connect the small
fan/wheel motor base to the fuel cell base to
generate power to the motor.
Safety
Before you proceed to perform experiments with the turbine, please note that the rotor can rotate at a few
thousand RPM’s (Rotations per Minute), especially when no load is connected. When the wind speed is
high and the turbine is set to output high power, the rotating speed of the rotor can also be very fast.
Bodily injury may result if struck by the rotating blades. Wearing goggles is suggested in the case that
your head will be close to the rotating blades. You should also install the turbine properly so that it will not
“walk” or topple over. The weight of the base has been increased from previous versions to prevent the
turbine from “walking”. Placing a rubber mat, polyfoam, or a thin book under the base helps stabilize the
turbine if the surface of the table is too hard. In the case that the turbine topples at high rotational speed,
to avoid being hurt, do not try to catch it. Arranging the wires from the turbine to run inside the aluminium
tube through the opening on the post and base prevents the wires from tangling by the rotating blades.
All of the above measures help to reduce accidents during operation of the turbine. However, you have
to make sure that the environment is safe for doing experiments. Adult supervision is required. This wind
turbine is not suitable for children under 14 years old.
1. The water levels do not drop when the gas outlet tubes on both sides of the fuel cell are unplugged.
Solution:
Check whether the holes on the wall of the inner container are blocked. If so, turn the inner container until
water enters the holes and fills up the inner container.
2. The electrolyzer does not produce hydrogen and/or oxygen.
Solution 1:
Check whether the wires are appropriately connected, and whether there are any loose connections. The
fuel cell could be completely destroyed if the red wire of the battery pack is connected to the black jack of
the fuel cell.
Solution 2:
Replace the old batteries with new one in the battery pack.
3. The load cannot work while there is hydrogen left in the inner container.
Solution:
Push the green purging valve to release tiny amount of hydrogen. You can then observe the load working
well again.
4. The water electrolysis process slows down.
Solution:
Inject water to the oxygen side of the fuel cell by using the syringe and wait for about 3 minutes before
using the electrolyzer again.
5. No hydrogen is produced using the windturbine outdoors.
Solution:
If the wind speed is not sufficient electricity will not be created. Use a common desk fan with faster wind
speed to perform the electrolysis using the electrolyzer, or conduct the experiment under stronger wind
conditions.
6. The fuel cell can not generate electricity while there is hydrogen still left in the hydrogen container.
Solution 1:
Push the purging valve to release remaining amounts of hydrogen.
Solution 2:
Use the syringe to clear the water out of the fuel cell.
Troubleshooting
19
Experiment 1: Use a Solar Panel to Power
the LED Module
Connect the cables to the solar cell/panel and
circuit board to power LED module as shown. Make
sure black and red cables are used with the red
and black terminals respectively.
EXPERIMENT 1
EXPERIMENT 2
Experiment 2: Use a Solar Panel to Power the Small Fan/Wheel
Motor Module
1. Assembly of the small electric fan:
Connect small round white adapter to the motor axis. Connect the fan blade
to the adapter.
2. Assembly of the car wheel:
Firmly connect the other (tapered) white adapter to the motor axis. Attach the
small wheel to the adapter.
Solar Energy
What you need:
a. Electrolyzer fuel cell
b. Mini fuel cell
c. Battery pack
d. Solar panel
e. LED module
f. Water & Hydrogen tank
g. Water & Oxygen tank
h. Clamp
i. Wheel
j. Purging valve
k. Heavy fan module
l. Fan blade
m. Water tank base
n. Reversible fuel cell base
o. wires
p. Syringe
q. Silicon tubes
r. Mini fuel cell base
s. Red & black pins
t. Fan & wheel adapter
u. Circuit board
d
efghij
kl
mn
opq
rs
You will also need the following items (not included in this kit):
- Purified or distilled water
- AA batteries
- Scissors
ab
c
20
t
u
3. Connect the solar panel to the circuit board then to the motor base as shown.
The fan may need to be flicked with your finger to start.
Experiment 3: Preparation of the Electrolyzer Module and Solar
Powered Hydrogen Production
1. Insert the electrolyzer, terminals on top, into the slot on the base. Cut 2 x
4cm length pieces of rubber tube and insert a black pin into the end of one
tube. Place the tube with the black pin into the top pin on the hydrogen side
(with black terminal). Place the other tube firmly onto the top input nozzle on
the oxygen side.
2. Fill the syringe with DISTILED water. On the red oxygen side of the
electrolyzer, connect the syringe to the uncapped tube. Fill the electrolyzer
until water begins to flow out of the tube. Attach a red plug to the Oxygen
side tube. Let settle for 3 min.
3. Attach the round cylinders to the cylinder base by pressing downward into
round slots and twisting into place. Then add water up to the "0" line.
4. Cut out a 20cm length tube. Place it through the holes on the white
clincher, with the clincher 4 cm from the end of the tube.
5. Place inner containers into outer cylinders minding that the gaps are not
blocked by inner plastic rims. Make sure the water is still level to the “0” line.
If not, remove some water with the syringe so that water level is at “0” line.
Connect the tubings to the top nozzles on the inner containers. If the tubing
is connected to the inner cylinders last there will be no air trapped inside the
inner containers.
EXPERIMENT 3
Distilled water
21
As sson as the electrolysis is completed, you can use the energy contained in the hydrogen
tank to power other systems. Please refer to the experiment 3-6 in Wind Energy chapter.
Battery
Pack
Using the Battery Pack to Perform Electrolysis (in the case of no sun)
Make sure the switch on the battery box is in the "off" position
before you place the batteries into the box.
WARNING: If the cable is short circuited the batteries inside could
become hot and potentially cause burns, melting of parts, or
create risk of fire.
Note: Battery’s energy may be consumed after 4-5 times of use.
Make sure to connect the black cable to the black plug, the red
cable to the red plug on the fuel cell.
Please remove the screw from cover of battery box using a
screw driver. Push and slide the cover and open the battery box.
Try NOT to touch the cables when you open the cover.
Place two AA batteries as indicated.
Push and slide the battery box cover to closed position and
screw fightly into place using screw driver.
Push and slide
open the cover
AA Battery
AA Battery
Remove the screw
from the cover
22
6. Connect the other end of the tube to the bottom end of the black hydrogen side of the electrolyzer.
Connect the other end of the tube to the bottom end of the red oxygen side of the electrolyzer.
7. Connect the electrolyzer to the solar panel using the corresponding cables and expose to direct sunlight.
Or connect the battery pack (with battery in) to the electrolyzer and turn it on (Important: make sure
connections are correct or permanent damage can occur. Make sure the clincher is OPEN.)
The system will now start to produce oxygen and hydrogen in the respective cylinders. When bubbles begin
to surface in the hydrogen cylinder the cycle is complete. Disconnect the electrolyzer.
Procedure for repeated gas production: Disconnect the small plugs from the tubes connected to the nozzles
on the electrolyzer. This will allow water into the inner cylinders to replace the gasses and reset water levels
to “0” line. Re-insert the plugs into the tubes and repeat electrolysis again.
1. The water levels do not drop when the gas outlet tubes on both sides of the reversible fuel cell are
unplugged.
Solution:
Check whether the holes on the wall of the inner cylinder are blocked. If so, turn the inner cylinder until
water enters the holes and fills up the inner cylinder.
2. The reversible fuel cell does not produce hydrogen and/or oxygen.
Solution 1:
Check whether the wires are appropriately connected, and whether there are any loose connections. The
reversible fuel cell could be completely destroyed if the red wire of the battery pack is connected to the
black jack of the reversible fuel cell.
Solution 2:
Make sure the batteries are inserted with the correct polarity.
Solution 3:
Replace the old batteries with new one in the battery pack.
3. The water electrolysis process slows down.
Solution 1:
Inject water to the oxygen side of the reversible fuel cell by using the syringe and wait for about 3 minutes.
Solution 2:
Replace the old batteries with new one in the battery pack.
4. The motor does not run while there is hydrogen left in the inner container.
Solution:
Unplug the black pin of the short tube on the reversible fuel cell and quickly attach the pin back to the tube
to purge out impure gases. You should then see the motor begin to turn again.
5. No hydrogen is produced under the sunlight.
Solution:
If the sunlight is not strong enough electricity will not be created. Use the battery pack provided to perform
the electrolysis using the reversible fuel cell.
Troubleshooting
23
What you need:
Preparing a 10% ethanol solution:
WARNING:
DO NOT mix the fuel solution in the fuel tank (c), otherwise the fuel tank could be easily damaged.
Do not pour pure ethanol in the fuel container (b). The DEFC creates power using 5-15% alcohol only. A
concentration higher than 15% could damage the fuel cell and make it stop working. In order to obtain the best
performance please use a mixture of 10% ethanol and 90% purified or distilled water. Keep ethanol away from
the fire or flame source while you are mixing the solution. Igniting the ethanol and the ethanol solution is
strongly forbidden.
Step 1: Fill the solution container (b) with 10ml of pure ethanol (fill container to the 10ml level).
Step 2: Fill the remainder of the container with water to the 60ml level.
Step 3: Stir the liquid in the container thoroughly.
Experiment 1: Create electricity from ethanol and water
Step1: Cut one 15cm long tube and put it
through the plastic clamp,
Step 2: Connect the tube to the fuel tank (c) and close the
clamp.
Step 4: Pour the fuel solution into the fuel tank (c).
Put the lid back to the tank.
Step 3: Connect the other end of the tube to the fuel
cell lower fuel inlet. Make sure the connection is tight.
Cut a 10cm long tube and connect it to the other
outlet of the fuel cell (the remaining nozzle).
a. Fuel cell module
b. Fuel solution container
c. Fuel tank with lid
d. Fan module
e. Fan blade
f. Silicon tubes
g. Clamp
h. Wires
i. PH paper
j. Syringe
abc
d
efg
hi
You will also need the following items (not included in this kit):
- Purified or distilled water
- Ethanol
- Scissors
j
Bio-Energy
24 25
Step 7: Open the clamp. You can notice the liquid flows out of the tube through the fuel cell. Once you see the
liquid flows out of the tube, close the clamp.
Wait for 5-10 minutes, you will notice the fan starts to rotate.
Experiment 2: Exploring polarity
Step 1: Connect the red cable to the red socket of fuel cell and the
fan module.
You will notice the fan will turn clockwise.
Step 2: Now repeat the process, this time however connect the red
socket of the fan module into the fuel cell black one. You will notice
the fan will turn counter-clockwise.
Conclusion: The current flows from positive to negative, creating a
clockwise spin of the fan. By inverting the polarity connections, the
current flow reverses and makes the fan spin in the opposite
direction.
Experiment 3: Ethanol fuel consumption
When the fan begins to run slower or stops running
completely, this means the ethanol present in the fuel
cell chamber is mostly consumed. In normal
temperature conditions, the majority of the ethanol
inside the fuel cell chamber turns into acetic acid,
which is the main component of vinegar.
Let’s investigate the consumed fuel (acetic acid) when
the fan begins to run slowly.
Step 1: Place a piece of PH paper under the outlet of
the outlet tube.
Step 2: Open the clamp slowly , and release drops of
the solution onto the pH paper, and then close the
clamp. You can see the paper color changing to a
reddish color quickly.
Step 3: Dip a new pH paper into the solution container. You will notice that the color of the PH paper
changes very little.
The difference in pH paper coloring indicates the change of the acidity level. Ethanol turns into acetic
acid during the reaction taking place at anode side of the fuel cell, and the pH of the solution noticeably
changes from pH level 6 to pH level 2 showing a red color. The chemical reactions taking place at the
anode showing that acetic acid is formed as hydrogen protons depart from the ethanol molecule and
the water molecule. These hydrogen protons cross the fuel cell membrane, and the liberated electrons
form the electricity that is able to propel the fan.
Conclusion: The Direct Ethanol Fuel Cell creates electricity by chemically converting the ethanol
solution into an acid solution, which is close to common vinegar. In order to obtain a continuous
functioning of the fan, “spent” fuel must be replaced with new fuel regularly.
Experiment 4: Exploring the effect of varying fuel concentrations
You can make the different concentrations of ethanol fuel in the initial mix. For a 15% solution, add 9 ml
of pure ethanol and fill water to the level of 60 ml. You can use a multi-meter or Horizon’s REM product
ref. FCJJ-24 to measure the voltage difference produced by the fuel cell. Through experimentation, you
will find that increasing or decreasing the concentration of the Ethanol does not noticeably make the fan
run faster.
The reason for this is that the capability of the catalyst used on proton exchange membrane in the fuel
cell is limited. Similarly to many people going through a narrow door, the speed of people going through
the door is determined by the width of the door, but not by the amount of people.
Warning: The safe experimentation range for the this Kit is within ethanol concentrations ranging from
5-15%. Please note that the concentration cannot be higher than 15-20% otherwise it will permanently
damage the fuel cell.
Tip: If the device will not be used for more than one day, first open the clamp to purge out all solution in
the fuel cell and pour purified or distilled water in the fuel tank. Make sure all of the purified or distilled
water flows out of the fuel tank. Do not let the solution stay in the fuel cell otherwise it will damage the
fuel cell.
Step 5: Remove the fan blade from the box.
Push the blade onto the axis of the motor slowly
and carefully.
Step 6: Use the wires to connect the fuel cell module
to the fan module. Make sure you respect the color
code when you plug wires into the sockets.
Notes: Once the fan stops rotating, open the clamp to purge
some solution out of the fuel cell and close the clamp. Wait for
5-10 minutes, the fan should start rotating by itself once
connected. If the fan does not run at this time, it may need to be
flicked with your finger to start.
Make sure you repeat the waiting period of 5-10 minutes after
each purging. Since the reaction is slow, the fan can run for up
to several hours without purging.
IMPORTANT NOTES:
After the first use of the fuel cell, you have to cut a 2 cm long
tube on the remaining tube and to connect this one to the
syringe. You will use it to clean the system after every use of the
product.
After each usage, you have to fill the syringe with purified water.
Then, remove the fuel inlet tube and replace it by the syringe
tube. Inject the water into the fuel chamber to flush out the
methanol solution out of the system. Disconnect the syringe and
fill it with some air. Make the connection again and inject the air
into the system in order to completely purge the remaining water
out. The fuel cell then could be stored until the next use.
26 27
Experiment 5: Create electricity from wine or beer
Try using different types of alcohol such as wines made from grapes or rice instead of the ethanol/water
solution.
Follow up the steps in the experiment 1: create electricity from ethanol and water to create electricity.
WARNING:
1. Alcohols used should stay within the range of 5-15% alcohol. If you are using an alcohol that has a
higher concentration than 20% please mix the adequate amount of water into the alcohol to keep the
required concentration range of 5-15%.
2. Using impure ethanol can damage the performance of the fuel cell. You may want to conduct
experiments using impure ethanol once all other experiments using pure ethanol are completed.
When you have finished all the steps as in experiment 1, you may notice the fan may run very slowly, or
may not run. When using different alcohol types, this can affect performance. This has to do with the
purity of the solution, since some alcohols such as wine contain elements that can clog the membrane
on the fuel cell, limiting its permeability. Use a multi-meter or Horizon’s REM ref. FCJJ-24 to measure
the voltage or current produced by the fuel cell under various conditions and slowing the speed of the
chemical reaction.
See experiment 6: You will be able to prove that at different temperature conditions, different voltages
are produced, and you can plot these results into a chart to determine the optimal temperature
conditions for the fuel cell to generate the best results for each kind of alcohol you use.
Experiment 6: Exploring the effects of temperature.
Note: Before you blow warm air towards the fuel cell, feel the air temperature with your hand first to
make sure the air is not too hot (temperature under 60℃are preferred).
Step 1: Use a hair drier to blow warm air towards each side of the fuel cell or place a warmer
ethanol/water solution into the fuel tank. You will observe that the motor and fan will be operating at a
faster speed.
Step 2: Use a multi-meter or Horizon’s fuel cell software adaptor product ref. FCJJ-24 to measure the
voltage produced by the fuel cell. You will be able to test that at different temperature conditions,
different voltages are produced, and you can plot these results into a chart to determine the optimal
temperature conditions for the fuel cell.
At higher temperatures, atoms tend to move faster and are more likely to interact with the catalysts
located on the surface of the membrane. With more interactions, the reaction accelerates and more
electricity can be produced, which means the fan starts to turn faster.
Conclusions:
(1) Higher temperature will make it more likely for ethanol molecules to interact with the catalysts
located on the surface of the membrane, which accelerates the speed of the chemical reaction.
(2) High temperature can also make the membrane more active, so it will demonstrate an increased
ability of proton exchange within the membrane and an increase the speed of the fan motor. Increasing
the power capability of ethanol fuel cells can be done by increasing their operating temperature, or the
temperature of their fuel.
Troubleshooting
A. The fan begins to run slower or stops running completely
Solution:
a. Disconnect the fuel celll module from any load. Place the outlet tube above a container or suitable
receptacle. Open the clamp to let a few drops of acetic acid flow out, allowing the mixture of the fresh
ethanol solution to re-enter the fuel cell.
b. If the solution level is too low in the fuel tank and it can not flow into the fuel cell chamber, mix new
solution and pour it into the tank to reach proper level. Or you can lift the fuel tank up to make the
solution level in the tank higher than the inlet nozzle on the fuel cell.
d. Wait for 5-10 minutes before reconnecting the loads to the fuel cell. Once reconnected, watch the fan
start rotating again at constant speed. The fuel cell is able to start the reaction once more (and more
hydrogen protons can permeate through the membrane).
B. After all the wires and tubes have been connected, the fan still cannot run.
Solution:
a. Make sure that the red and black wires are connected correctly.
b. Make sure that the tube from the fuel tank is well connected to the fuel cell inlet.
c. Make sure there is enough ethanol solution to circulate into the fuel cell and that the tubing is not
blocked.
C. I opened the clamp, but no soluiton flows out of the tube.
Solution:
a. Add fresh fuel solution to the fuel tank.
b. Lift the fuel tank up to make the solution level in the tank higher than the inlet nozzle on the fuel cell.
28 29
Step 1. Preparing the super capacitor module
a. Insert the super capacitor support (g) into the base (f).
Make sure they fit well.
What do you need:
a. Hand crank generator
b. Potentiometer
c. Super capacitor
d. Heavy fan module
e. Fan blade
f. Capacitor base
g. Capacitor support
h. Wires
i. Fan blade adapter
abc
def
gh
b. Place the super capacitor (c) onto its support (g).
Make sure the capacitor fits well in its support.
c. Plug the red cable (h) and black cable (h) in the capacitor red and black socket.
Ensure to respect the color code.
Otherwise energy from the hand crank can not be stored into the capacitor.
Step 2. Preparing the energy storing kit
a. Connect the other end of the cable to the potentiometer (b).
Ensure to respect the color code.
b. Connect the red and black cable to the hand crank (a).
Ensure to respect the color code.
i
Mechanical Energy
30 31
Step 3. Energy generating and storing
Step 4. Power the electrical fan with the energy stored in the capacitor
Step 5. Power the electrical fan directly with the hand crank generator
After connecting the wires, rotate the arm in a circular motion to generate power. You should crank the
arm to reach a speed of two revolutions per second, fast is better. Initially you will feel some
resistance, which will become smaller after a few seconds. If you feel the resistance increase again, it
means you’ve slowed down and need to speed back up.
WARNING: DO NOT crank the arm too fast otherwise the hand crank generator could be easily broken
by the strong force.
c. Connect the other end of the cable from the hand crank generator to the potentiometer.
Ensure to respect the color code.
a. Firmly grasp the rotary handle of the hand crank generator with one hand and grip the main handle with
the other hand.
b. Rotate the arm clockwise to generate power for charging the capacitor. You should crank the arm to
reach a speed of two revolutions per second. Initially you will feel some resistance, which will become
smaller after a few seconds. If you feel the resistance increase again, it means you’ve slowed down and
need to speed back up.
Note: At the same time you can notice the potentiometer is moving towards green part, which means you
are generating energy and the energy is being stored in the super capacitor.
WARNING: You are not allowed to rotate the arm anti-clockwise to charge the super capacitor.
Otherwise the super capacitor will be damaged by the countercurrent. Note:
Finding the appropriate speed and technique will take a little practice. After you have spent a little time
acclimating yourself to the hand crank generator, you should develop an easy rhythm that is not strenuous
to sustain.
Although the generator is easy to crank, you may eventually tire. When you find yourself slowing down,
stop and take a rest, cranking slower is harder and may not generate enough power to charge the
capacitor or power the load.
The generator can be cranked in either direction, with either hand.
Try to rotate your hands around each other instead of trying to hold the generator still and moving one
hand in a circle. This prevents one arm from tiring faster than the other.
Experiment with what works best for you. As long as the handle is cranked at approximately 2 revolutions
per second the generator it will produce enough power to power the device provided.
a. Connect the adapter (i) to the motor axis. Put the fan blade (e) onto the adapter.
Make sure the fan blade is connected tightly to the motor shaft.
b. Use a cable to connect the fan module to the capacitor module.
Ensure to respect the color code.
Once they are connected, the fan moves fast immediately.
ADVANTAGES of a Hand Crank Generator:
- Does not require solar, wind, or fuel to charge. Charge it anytime, anywhere!
- Does not require additional purchases of fuel during an emergency, when gasoline is scarce.
- Can be operated indoors without deadly fumes or threat of theft while outdoors.
- Easy to operate. Even children can safely operate the hand crank generator.
- Silent operation. No loud generator noise!
- Easy to set up. No confusing mounting or home alterations needed.
32 33
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