High Duty Cycle

I know this issue HAS to have been covered here already but the search engine doesn't bring anything up at all !
Basic Facts:
'05 Nissan Pathfinder
V6 4.0 L 4x4
Factory MPG = 13/19
HHO MPG = 18/22

Using the 6-cyclinder generator from Dry-Cells.com. (7 plates I think?)
PWM, bubbler...
PWM setting is for 12.0v

System ran great after first install and for over the entire winter. Summer came and I wanted to flush the water and add new.
1) I drained cell from the drain plug under neath.
2) Closed plug, filled reservoir, then drained again.
3) Closed plug, filled reservoir, Added KoH (about 1/2 cup).
4) Started it up and let it run.

My problem is now the Duty Cycle is up to 85% most of the time but can be spotted at 99.6% other times!

1) I've added more KoH.....Duty cycle came down immediately, but went right back up
2) Added more Koh.... same as above.
3) I added Spa DeFoamer (about a cap full) NO improvement.
4) Now I just keep driving.

Again, I am sorry if this is not appropriately placed in the correct forum discussion. A search of "duty cycle" brings up nothing.
Any help would be greatly appreciated!
Thanks everyone