Hydrogen Generator PGH Series 3 User`s manual
Contents
1. Change the desiccant cartridge when the red colour of the desiccant turns to slight orange The colour of the desiccant can be observed through a view port in the front panel of the generator To remove the desiccant cartridge first loosen the top and bottom connectors These are finger tight no tools are required Then extract the cartridge and replace with a new or regenerated one Reconnect the cartridge to the tubing and tighten the connectors finger tight Return the used cartridge to your reseller for refilling Deionizer replacement Rinse the water tank and replace the deionizer bags approximately every six months or whenever the Change Water message appears Installing the new deionizer bag After having refilled the tank with water the new deionizer bag must be placed in the tank Inspect the bag thoroughly for holes or tears indicated by loose deionizer beads on the outer surface lf the bag is damaged in any way discard and replace it with a new one Only use original parts see Spare Parts Wash the deionizer bag in deionized water before proceeding Insert the free end of the T fastener through the hole in the centre of the water filler cap until it is securely fastened The bag should not block the outlet at the bottom of the tank Once in place the bag should not be allowed to dry out 22 Hydrogen Generator PGH Series 2 User s Manual Maintenance Returning the unit In the event of any faults or d2. MATHESON TRI GAS ask The Gas Professionals Hydrogen Generator PGH Series 3 User s manual MATHESON TRI GAS 166 Keystone Drive Montgomeryville PA 18936 Phone 215 641 2700 Fax 215 641 2714 Email mtgmmville matheson trigas com INDEN lt 22t aida 1 INTRODUCTION lt lt ie 2 SCOPE OF THE MANUAL nein es lcd 2 PETK ATION ee ee E E A E E leeren 2 NOTES ON FOC COMPLIANC oore au 3 CORRECTO Tee AS OTE aiii 3 ANS tate chloe atte etal heats tat nen 4 DESCRIPTION Sn ade 5 INSTAETATION 2 ao once 6 RECEIVING THE GENERATOR 2 usa ii tai 6 PLACING THE GENERA TOR Ense 6 SYMBOLS SED ON THE GENERATOR a2 sea eeedrsiene 6 GAS CONNEC HON S An ae RHEIN ae eee 6 CARTRIDGE INSTALLATION onean ticos 7 8 ELECTRICAL CONNECTIONS sisas idad its 9 REMOTE CONNECTIONS OPTIONAL iia 9 CASCADING OPTION lili placas eses 10 AUTON EL O VON gcc nasa ee ae 11 INITIAESTART UP 2 2 dia 12 PEEING THE WATER TANK a ee ae esse 12 ISIS TABEING THE DION ee ee re ee 13 STARTING THE UND idiota 14 FUNCHONTN Gr radianes 15 CODO dolce 16 18 NR 19 21 MATNTENANCE la da 22 ROUTINE NANI ENAN Bras nee 22 RETURNING TOC ON oo li aia 23 SPARE PARTS TSE rt 24 29 Hydrogen Generator PGH Series 3 User s Manual Introduction Introduction Scope of the manual This manual provides operation and maintenance instructions for model PGH2 100 PGH2 160 PGH2 250 PGH2 300 PGH2 500 and PGH2 600 hydrogen generators Specifications Specifications of the different
3. Change the pressure setting on the master and the slaves will follow the master IMPORTANT The cascading function will only work properly if the gas outlets on all the generators are connected together and the main valves are in the open position 10 Hydrogen Generator PGH Series 2 User s Manual Installation Auto refill option Description The auto refill option gives you the possibility to refill the water tank of the generator automatically from a external water source You can either use a DI water line or a water reservoir The correct refill time is depending on the pressure of the water source A higher pressure needs a shorter refill time Max pressure is 60 PSIG If you are using a water reservoir make sure the minimum water level in the reservoir is 2 3 feet higher than the top of the generator Generator Filter a From DI water line _ _ or water reservoir 100 to 240 VAC Mn 5060 He Input Installation steps 1 Connect the water tubes and the electric wires as in the diagram above 2 Configure the generator as followed Set the generator to standby Set the auto refill function to ON Adjust the auto refill time to 8 s 3 Test the auto refill time as followed Empty the water tank Start the generator Obtain the refilling level Should be approx 30 to 50 of the max level lf the refill level is to little increase the auto refill time Repeat this steps un
4. Manual Spare parts List of spare parts PGH2 160 ml min H210000 004 Cell service on old cell H200 030 New deionizer triangle bag NM200 004 Keyboard 25 Hydrogen Generator PGH Series 2 User s Manual Spare parts List of spare parts PGH2 250 ml min H200 019 Desiccant refill 3 cartridges H210000 004 Cell service on old cell 26 Hydrogen Generator PGH Series 2 User s Manual Spare parts List of spare parts PGH 2 300ml min H200 019 Desiccant refill 3 cartridges H210000 004 Cell service on old cell H200 003 Desiccant cartridge fittings refill 27 Hydrogen Generator PGH Series 2 User s Manual Spare parts List of spare parts PGH 2 500ml min H200 019 Desiccant refill 3 cartridges H210000 004 Cell service on old cell H200 003 Desiccant cartridge fittings refill 28 Hydrogen Generator PGH Series 2 User s Manual Spare parts List of spare parts PGH 2 600ml min H200 003 Desiccant cartridge fittings refill H200 030 New deionizer triangle bag H200 019 Desiccant refill 3 cartridges H210000 004 Cell service on old cell IMPORTANT The manufacturer reserves the right to change or modify its products without prior notice 29
5. models of hydrogen generator Hydrogen flow rate Model PGH2 100 O 100 cc min at STP Model PGH2 160 0 160 cc min at STP Model PGH2 250 0 250 cc min at STP Model PGH2 300 0 300 cc min at STP Model PGH2 500 0 500 cc min at STP Model PGH2 600 0 600 cc min at STP Max outlet pressure 7 bar 100 psi Weight dry PG 100 160 250 300 Power consumption Model PGH2 100 Model PGH2 160 Model PGH2 250 STP Standard temperature and pressure 20 C 1 bar Model PGH2 300 Model PGH2 500 Model PGH2 600 120V 6 3 A T 240V 4A T 5x20 Pressure accuracy 0 1 bar 0 5 Operating conditions temperature 15 C to 40 C relative humidity 80 up to 31 C decreasing linearly to 50 at 40 C Over voltage category Sound pressure level 46 dBA EEE Hydrogen Generator PGH Series 3 User s Manual Introduction Notes on FCC compliance This equipment has been tested and found to comply with the limits for a Class B digital device pursuant to part 15 of the FCC Rules These limits are designed to provide reasonable protection against harmful interference in a residential installation This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instructions may cause harmful interference to radio communications However there is no guarantee that interference will not occur in a particular installation If this equipment does cause harmful interference to radi
6. acking list List of items included in the shipment Hydrogen generator generator A Instruction manual Deionizer triangle bag Water drain with flexible tubing Hydrogen Generator PGH Series 2 User s Manual Description Description The hydrogen generator produces pure hydrogen and oxygen as a by product by the electrolysis of water The key element of the generator is an electrochemical cell assembly which contains a solid polymer electrolyte No free acids or alkalines are used De ionized or pure distilled water is the only liquid which may come into contact with the cell As this is consumed it must be refilled from time to time as required The generated hydrogen gas is accumulated in the hydrogen water separator and the desiccant housing The pressure is controlled by a pressure transducer The output pressure is indicated on the display The hydrogen is dried by passing it through a drying tube and a desiccant cartridge containing desiccant material The hydrogen then passes through the shutoff valve and exits the generator through the outlet port at the rear Gas Liquid Separator Water VANE Tank IN A Desiccant Cartridge pt S t e 7 Shutoff Valve nt Pressure Outlet Sensor Hydrogen Cell Drain Port Hydrogen x Pressure Relief Drying Tube PITT SIN NA AITTTTTTTTT TT ISI Hydrogen Generator PGH Series 2 User s Manual Installation Installation Receiving the generator All units h
7. al is activated in the event of an alarm delay Master Configures the unit as the Master for cascading operation Number of Enter the number of slaves slaves connected to the master Sets the ID number Remote Configures the remote start stop start stop mode function Remote relay Configures the remote relay contacts mode Pre alarms in If set to Yes the pre alarms are also alarm log shown in the alarm log Lock Keyboard If set to Yes the keyboard will be locked automatically after the generator is in the main window for more than 20s To unlock the keyboard press the unlock button and hold for 5s Display contrast Adjusts the contrast of the display Autorefill If set to ON the pre level water alarm is used to trigger an external pump or valve to refill the water tank Autorefill time Sets the duration of water refilling after the pump or valve has been trigged Maintenance Options Range Default bar psi kPa bar scm standard cubic meters scm scf standard cubic feet C and F O 0 1 6 8 bar min 1 4 100 psi min 2 10 min YES NO ON OFF O YES NO Z O Z O 0 32 Start stop Start only Direct control start stop O I O N Z Normally open NO C Normally closed NC YES NO zZ O YES NO O ON OFF O u ul o gt Z O 2 O ep 20 Hydrogen Generator PGH Series 2 User s Manual Maintenance Diagnostic
8. amage first notify the agent or distributor who supplied the unit If this is not possible inform the producer directly Please also provide full details of the problem including the model and serial number Instructions will then be provided for the service or the return of the unit Only if return authorization is provided by the producer as per these instructions will the device be received and repaired by the producer If the one year warranty has expired or the fault is due to misuse of the unit all repair and shipping costs are to be paid by the customer All other costs are borne by the customer except as otherwise expressly agreed upon WARNING If the unit has to be transported make sure that the water tank is completely empty and place the plug supplied with the unit on the oxygen vent at the rear of the unit Close the small hole in the cap on the water tank with a strip of adhesive tape Use suitable packaging The unit should be transported in an upright position this warning should be reported on the outside of the packaging 23 Hydrogen Generator PGH Series 2 User s Manual Spare parts Spare parts list The table below provides a list and description of the spare parts for the hydrogen generator Please also refer to the corresponding figures List of spare parts PGH2 100 ml min H200 019 Desiccant refill 3 cartridges H210000 004 Cell service on old cell 24 Hydrogen Generator PGH Series 2 User s
9. arallel mode One unit has to be defined as the master while the others operate in Slave mode All the slaves need to be configured with individual ID numbers Communication between the generators requires a standard D sub 9 pin serial cable The serial ports are connected as follows H2 H2 Generator H2 H2 Generator Generator Serial Master RS 485 out gt Slave 1 RS 485 out Slave 1 RS 485 in Slave 2 RS 485 in Configuration Configuring the Master up to 10 units 1 Enter menu 2 Scroll until the display shows Master and enter set the value using the buttons to Yes 3 Exit and scroll until the display shows Number of slaves and enter set the number of slaves connected to the master using the buttons 4 Exit and scroll until the display shows ID Nr and enter set 1 5 Exit Configuring the Slaves Enter menu 2 Scroll until the display shows Master and enter set the value using the buttons to No 3 Exit and scroll until the display shows ID Nr and enter set the ID number of the slave Use a different number for each slave starting from ID Nr 2 4 Exit The configuration is now complete Operating in Master Slave Mode Connect the gas outputs of all the generators to the same line Open all the main valves If the configuration and the serial connection is correct the slaves will show Slave Mode after starting up
10. ave been carefully inspected before transport Visual checks for damage and functional tests should be performed upon receipt Any damage must be immediately noted and reported The generator must only be returned according to the shipping instructions provided Placing the generator The hydrogen generator must be placed on a flat level vibration free shock free surface Do not place the generator over a source of heat as this may cause the device to overheat The unit should not be in contact with any other objects on any side and the air inlet must not be blocked Leave at least 30cm of free space at the rear for ventilation Do not operate the generator in a sealed or unventilated room or in close proximity to open flame or other sources of ignition Do not operate the generator at below freezing temperatures Operation is guaranteed at operating temperatures between 5 and 40 C WARNING Normal precautions for any hydrogen supply should be taken when using the generator DO NOT use in sealed or unventilated rooms DO NOT use in close proximity of open flames or other sources of ignition Symbols used on the generator Earth symbol this symbol marks the earth connections to the chassis of the hydrogen generator Gas connections Pure dry hydrogen at regulated pressure is available at the hydrogen outlet port atthe rear of the generator This port must be connected to 1 8 tubing using a stainless steel or copper Swagelock co
11. display em 77777 BE 7 Production Tot Total production of hydrogen 99 999 scf 4000 00 scm Operating time h Total number of hours the unit operation 99 999 hours Wat quality uS Actual water conductivity Cenco Aaronon J Cal voltage Y Acuarcenvot J Cel voltage peak V The maximum cell voltage inthe fe ofthe cof PS temp Actual temperature ofthe power supply PS temp peak The maximum temperature of the power supply reached 21 Hydrogen Generator PGH Series 2 User s Manual Maintenance Maintenance With proper care and maintenance your hydrogen generator should provide you with years of trouble free operation There are no adjustments to be made to the generator The only routine service operations are those described below Nevertheless the generator should be inspected approximately every 2 years Contact your supplier or the producer directly Routine maintenance The following section describes the maintenance operations required for the correct operation of the hydrogen generator Cleaning The internal components of the hydrogen generator do not need to be cleaned and should not be accessed by the user for cleaning To clean the outside of the unit only use a damp cloth no detergents acids or aggressive or abrasive substances Water refilling The tank must be refilled when the water level approaches the lower level and the Refill Water pre alarm message appears Desiccant replacement
12. er before proceeding Insert the free end of the T fastener through the hole in the centre of the water filler cap until it is securely fastened The bag should not block the outlet at the bottom of the tank Once in place the bag should not be allowed to dry out This new triangle deionizer bag has been designed for a higher water purifying capacity It is recommendable to use this bag for new generators in the first 4 to 6 months of operation After this time you can use the standard deionizer bag see spare parts 13 Hydrogen Generator PGH Series 2 User s Manual Initial start up Starting the unit Once all of the previous operations have been performed the generator is ready for operation SO RA O Close the Shutoff Valve located on top of the unit next to the water tank cap Check that the tank is filled with deionized water Check that the hydrogen outlet connector is tightly fitted Check that the plug has been removed from the oxygen vent Turn the Power switch to the ON position Enter the desired set pressure using the Menu buttons and selecting Pressure adjust Press the Start button to start the unit if the unit has been configured for Auto Start see Configuration it will start automatically The unit will immediately begin to build up pressure The LCD display will show the message Reaching normal pressure and the H2 Flow Bar will indicate maximum flow fully illuminated Wait unt
13. he generator will be shut down Start Stop Reset button The Start Stop button places the generator in normal operating mode from Standby and vice versa lt is also used to re start the unit following an alarm When the problem leading to the alarm has been resolved the generator must be reset using the Reset button and then can be started by pressing the Start Stop button Exit Menu button Silences the audible alarm When the problem leading to the alarm has been resolved the Reset button must be pressed before the generator can be restarted also see Special functions The Reset button is also used to access the menu and select The button is also used to exit from a displayed voice of the menu tree 18 Hydrogen Generator PGH Series 2 User s Manual Maintenance Menu Tree Status Normal Flow Menu Press act 6 2 set 6 2 Bar Flow E E EN E Pressure adjust Water AAN EN EE EN EN Cartridge Status Configure Start Open Memu Utilities Scroll Select Exit Pressure Adjust Cartridge Status Configure Utilities 2 SATURATION Set Clock Alarm list 6 Pressure Rise Diagnostics D LIE IE Wet 2 B al en 3 Pressure drop delay System Test y A Exit Reset Exit Scroll Select Exit Scroll Select Exit x fill Set Clock yore Check cartridge Autorefill Pressure Rise Set autorefill time Pressure drop delay Au
14. il the Act pressure reaches the Set value These values are shown on the LCD display It may take a few minutes to reach the Set operating pressure NOTE If the generator does not build up pressure as required the unit will shut down Refer to the Troubleshooting table 10 Once the pressure reaches the Set value the LCD display will show the message 11 Normal pressure and the H2 Flow Bar will indicate no flow no segments illuminated This indicates that there are no gas leaks within the generator itself Open the Shutoff Valve The outlet pressure will fall initially The amount and the duration of this pressure drop is dependent on the volume of the external equipment connected to the generator 12 After the initial pressure drop the outlet pressure should stabilise at the Set pressure A continuing drop in pressure indicates a gas leak in the external equipment or too high hydrogen consumption Check the external equipment for leaks or too high consumption 13 The generator is now in normal operating conditions Normal Flow Press Act 7 bar Set 7 bar Flow Water E E E E EEEE nn Figure 3 LCD Display 14 Hydrogen Generator PGH Series 2 User s Manual Maintenance Operation mi ALE a ere 2 SSS a Desicant Cartridge WaterLevel 15 Hydrogen Generator PGH Series 2 User s Manual Maintenance LCD display All important operating information is shown on the disp
15. lay Layout of the display The LDC display provide the following information Normal Flow Press Act 7 bar Set 7 bar Flow Water E E E E EEE Enn First row status information Sts shows current information on the operating status of the generator The information can be divided into 3 groups Information displays normal operating status Pre alarm indicates that a maintenance intervention will soon be required accompanied by an audible signal Alarms indicates that maintenance intervention is required and that the machine has been shut down accompanied by an audible signal 16 Hydrogen Generator PGH Series 2 User s Manual Maintenance Table 1 List of messages displayed MESSAGE DESCRIPTION TYPE ACTION Standby Device ready for H2 production Reaching Normal Device producing H2 and Information Pressure increasing pressure to the set value Normal Pressure Device producing H2 and has Information reached the set pressure value Normal Flow Device producing H2 and has Information reached the set pressure value with H2 flowing Refill Water Water level approaching alarm Pre alarm Fill the tank with water threshold Change Water The conductivity of the water has Pre alarm Drain and then refill the exceeded 33us tank change the deionizer bag Low Pressure The set pressure can not be Check for internal or reached external leaks Check max H2 consumption Low Water Level There is t
16. nnector Teflon connectors are not suitable The pressure at this port is adjusted and shown on the display The hydrogen relief port at the rear of the unit can be connected to an exhaust hood or other vent system WARNING The line from the relief port should never connected in such a way that back pressure can develop Hydrogen Generator PGH Series 2 User s Manual Installation IMPORTANT gt Remove the plug from the oxygen vent and hydrogen vent before operating the unit Keep this plug for transporting the unit co RELIEF Cartridge installation The desiccant cartridge is shipped separately inside the packaging and needs to be fitted before operating the unit Refer to the photos below for the installation of the cartridge Make sure that the tubing that connects the cartridge is pushed back inside the unit after installation to allow the front door to closely completely Step 1 to Step 4 Preparation for cartridge installation Step 1 Hydrogen Generator PGH Series 2 User s Manual Installation Step 5 to Step 8 Cartridge installation lt lt Ra DL EEE Step 7 Step 8 A A 7 N B when silica gel inside the cartridge has changed completely its colour it s time to substitute it with a new one Loosen the top fitting of the cartridge by screw the fitting counter clock wise then empty the old molecular sieve and refill Make sure the O ring on top of the cartridge the fit
17. o or television reception which can be determined by turning the equipment off and on the user is encouraged to try to correct the interference by one or more of the following measures e Reorient or relocate the receiving antenna e Increase the separation between the equipment and receiver e Connect the equipment into an outlet on a circuit different from that to which the receiver is connected e Consult the dealer or an experienced radio TV technician for help WARNING Any changes or modifications to this equipment not expressly approved by the manufacturer may void the user s authority to operate the equipment Correct use The hydrogen generator is designed to produce hydrogen for laboratory use The unit must only be operated for this purpose according to the specifications and instructions provided in this manual In particular the following warnings must be observed at all times e Indoor use only e Never operate the unit in below zero temperatures This will cause irreversible damage to the electrolysis cell e Only use pure water see Filling the water tank e Only operate the unit in a room with sufficient ventilation see Placing the unit e Always unplug the unit from the mains power supply before accessing the internal components for replacement e Only the parts described in the Spare parts list can be replaced by the user Hydrogen Generator PGH Series 3 User s Manual Introduction P
18. oo little water in the tank Refill the tank Bad Water The conductivity of the water has Drain and then refill the exceeded 38us tank change the deionizer bag High Cell Voltage High cell voltage Notify service agent Second row pressure information Act is the actual pressure of the hydrogen while Set is the set pressure The pressure can be increased using the A button or decreased using the Y button Third row hydrogen flow This row displays the current quantity of hydrogen being produced Each point represents around 10 of maximum capacity This graph also indicates approximately how much hydrogen is being consumed by the connected equipment NOTE The last point on the flow graph will flash only This indicates that the generator is producing at maximum capacity In normal operation this should not be the case as it indicates that the consumption is too near the maximum limit and the unit may shut down if consumption increases further Maximum flow is normal when the unit is building up pressure 17 Hydrogen Generator PGH Series 2 User s Manual Maintenance Fourth row water quality This graph shows the quality of the water With more than 3 points illuminated water quality is good If only 3 or less points are illuminated the conductivity of the water is around 33uS pre alarm level If only 1 point or no points are illuminated the conductivity of the water is equal to or greater than 38uS alarm T
19. til you have a correct refilling volume Note every time you go into the auto refill menu you have to put the generator to standby and start it again Warning If the refill time is to high the water tank of the generator can overflow and damage the unit 11 Hydrogen Generator PGH Series 2 User s Manual Initial start up Initial start up Filling the water tank To fill the generator with water remove the cap on the water tank Carefully fill the tank with distilled or deionized water The conductivity of the water used in the generator must not exceed 2uS Fill the tank to the maximum level indicator Replace the cap and the leave the small hole free for ventilation WARNING Do not fill the water tank higher than the marked level CAUTION To prevent contamination of the cell assembly it is important to use only deionized or distilled water in the generator Water containing metallic impurities will contaminate or damage the cell and will void the warranty 12 Hydrogen Generator PGH Series 2 User s Manual Initial start up Installing the deionizer bag After having filled the tank with water the deionizer bag supplied must be placed in the tank Inspect the bag thoroughly for holes or tears indicated by loose deionizer beads on the outer surface If the bag is damaged in any way discard and replace it with a new one Only use original parts see Spare Parts Wash the deionizer bag in deionized wat
20. ting again with the new one is free of dust before screw Hydrogen Generator PGH Series 2 User s Manual Installation Electrical connections Check the setting of the voltage selector on the rear of the unit The set voltage is indicated by the white arrow To change the voltage proceed as follows e Using a small screwdriver remove the voltage selector insert e Replace the voltage selector insert so that the white arrow points to the correct voltage Remote connections optional The hydrogen generators are fitted with an optional remote control feature which allows the user to check the status of the machine from a remote position and to start stop the production of hydrogen The contacts used in the remote control are potentially free relay contacts The contacts can be configured via software as normally open or normally closed see the Configuration section The maximum voltage and current ratings for the contacts are 1A 48V The pin configuration of the remote connector is shown in the table below Remote connector pin configuration Pin Description Start 12 30 VDC polarity not important Standby System not OK Reaching normal pressure Overproduction Refill water Low water Low water level Too low water 11 12 13 14 Change water Bad water pre alarm Hydrogen Generator PGH Series 2 User s Manual Installation Cascading option The RS 485 interface allows up to 10 generators to be operated in p
21. to start Scroll Select Exit Beeper N Gen H2 in cascading ID number 7 Remote start stop mode Autorefill Set autorefill time Remote tiny mode Autorefill Auto Pre alarms in alarm list Off Pressure units Manual Temp units y A Exit Scroll Select Exit Volume units Lock keyboard Display contrast Set default values Auto Manual 3s 3s Start Stop Exit y A Exit Alarm list Diagnostics System test Alarm Number 1 21 01 03 17 00 Low water y A Exit Prod Tot 10000 scm Oper time 100H W Quality 2 5 uS y A Exit Prod Tot 10000 scm Oper time 100H W Quality 2 5 uS Cell Volt 3 6 V Cell Curr 33 A PS Temp 40 C Cell Vpeak 3 8 V PS Temp peak 45 C Internal Leak Test External Leak Test Flow Test Scroll Select Exit 19 Hydrogen Generator PGH Series 2 User s Manual Configure parameters tem Description Pressure units Sets the desired unit of measure for the pressure Volume units Sets the desired unit of measure for the volume Temp units Sets the desired unit of measure for the temperature Pressure rise Sets how fast the pressure has to increase If the pressure increases at a slower rate a low pressure alarm is activated Pressure drop Sets a delay in seconds to ignore a pressure drop override low pressure alarm Auto start Sets whether the unit automatically starts production when power is switched on Beeper Sets whether the audible sign
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