Step-by-step install logic.

Nine steps, in order.

1. 01

   Confirm the unit matches the engine

   Match the PEM unit to engine displacement and duty cycle before fitting. Compact A-series units cover 1.0–7.0 L; H-900 and D-900 are the heavy-duty cabinets for commercial trucks, prime movers and generator sets up to 16.0 L. Voltage is 12 V or 24 V DC across the range.

   • ▸A-450 — 1.0–1.8 L passenger / light commercial
   • ▸A-675 — 2.0–2.5 L sedans, SUVs, light fleet
   • ▸A-900 — 2.7–7.0 L 4WDs and light commercial
   • ▸H-900 — heavy commercial / 20–30 kW gensets, up to 7.0 L
   • ▸D-900 — prime movers, road trains, large gensets, up to 16.0 L
   → Compare all five systems→ Full system catalogue
2. 02

   Choose the mounting location

   The unit needs a stable, vibration-isolated mounting point with clear access to the air intake and the starting / charging circuit. Installation is non-destructive and fully reversible — no engine, fuel-system or after-treatment modification is required.

   • ▸Passenger vehicles — boot / trunk on a vibration-isolated bracket
   • ▸Light commercial / utility — behind the cab, vibration-isolated
   • ▸Heavy commercial — behind cab, under chassis, or enclosure-mounted
   • ▸Generator sets — pad-mount cabinet beside the genset skid
   • ▸Keep away from direct exhaust heat; respect the +5 °C to +45 °C envelope
   → FAQ · Installation & operation
3. 03

   Wire to the switched 12/24 V DC supply

   Power comes from the starting / charging circuit through the supplied inline fuse and relay. Continuous draw is ~80–170 W depending on model and output setting — negligible against a typical alternator (1–3 kW) or genset charging circuit. Built-in under-voltage and over-voltage protection shuts the electrolyser down before the starter battery is affected.

   • ▸Use the supplied inline fuse and relay — do not bypass
   • ▸Switched feed so the unit cannot draw with the engine off
   • ▸Verify polarity and torque battery / chassis connections
   → FAQ · Electrical load
4. 04

   Route the 8 mm gas line to the intake

   Hydrogen-oxygen mixed gas is injected upstream of combustion, downstream of the MAF sensor, as a small fraction of total airflow. The fuel system and ECU are untouched. On heavy-duty units the line ties into the intake on the clean-air side of the turbo / MAF in the same way.

   • ▸8 mm OD outlet line, kept clear of exhaust and moving parts
   • ▸Inject downstream of the MAF sensor
   • ▸Secure the line so engine vibration cannot work it loose
   • ▸On gensets, tie into the intake plenum on the clean-air side
   → FAQ · How is it installed?→ PEM electrolysis overview
5. 05

   Fill with purified / deionised water only

   Feed water must be purified or deionised, TDS ≤ 5 µS/cm. The onboard ion-exchange polisher keeps the water within spec during service. Never add antifreeze, glycol, methanol or any freeze-point depressant — these destroy the PEM membrane and void warranty.

   • ▸Deionised / purified water, TDS ≤ 5 µS/cm
   • ▸Use the sight glass and water-shortage alarm to time refills
   • ▸Resin filter is replaced annually as routine service
   → FAQ · Water, resin filter, service→ Replacement resin & accessories
6. 06

   Set vibration-sensor sensitivity

   The control board uses a vibration sensor to detect engine operation and start / stop gas production automatically. Sensitivity is adjustable so the unit responds correctly whether it is mounted on a small passenger car, a heavy truck behind the cab, or a stationary genset skid.

   • ▸Adjust sensitivity to the host platform's idle / running vibration
   • ▸Confirm the unit starts only when the engine runs, and stops when it stops
   • ▸Re-check after the first road / load test
   → FAQ · Manual switching not required
7. 07

   Commission: alarms, leaks, auto operation

   Before handover, run the unit through a full start–run–stop cycle. Verify the integrated alarms trigger correctly: water-shortage, high-TDS, over-temperature and overload each force an automatic shutdown. Walk the gas line for leaks and confirm the auto-stop on engine-off.

   • ▸Cold start → confirm auto-on within seconds of engine start
   • ▸Engine off → confirm auto-stop and standby
   • ▸Trigger each alarm path and confirm shutdown
   • ▸Soap-test the gas line at fittings
   → FAQ · Startup / shutdown procedure
8. 08

   Cold-climate protection (if applicable)

   The system is water-based. For sub-zero or remote cold-climate sites, mount the unit inside a heated / insulated enclosure that holds internal temperature above freezing, or drain the reservoir and feed lines when the unit will be idle in freezing conditions. Do not add freeze-point depressants.

   → FAQ · Operating in freezing conditions
9. 09

   Baseline before any efficiency claim

   Log fuel consumption (L/100 km or L/hr) for a representative period before the install, then for an equivalent period after. The combustion effect tends to build progressively over roughly the first ~1,000 km of mixed driving as in-situ carbon cleaning takes effect, so a same-day before/after read is not a fair comparison.

   • ▸Match route, load and driver where possible
   • ▸Allow a build-up period before measuring
   • ▸Use the calculator to model what a given % reduction is worth on your fuel spend
   → Field results & trial data→ Fuel savings calculator→ Structured fleet trial programme