Home

HOGEN S SERIES 2 HYDROGEN GENERATOR

1. PROTON HOGEN S Series 2 Hydrogen Generator GS P ON SITE Installation Operation Instructions Interface Connections Reguirement 10 20 40 Electrical Connect to On Board Circuit Breaker Communications RS 232 Ethernet Control Systems Requirement 10 20 40 Fully Automated Push Button Start Stop E Stop On board H2 detection Automatic fault detection and system depressurization Form C Relay 2A 30VDC rated switching Standard Features Remote Alarm Remote Shutdown Circuit Breaker Shunt Trip Enclosure Characteristics Requirement 10 20 40 Dimensions L x D x H 31 x 38 x 42 97 cm x 79 cm x 106 cm Weight 475 Ibs 215 kg Rating IP22 Environmental Considerations Requirement S10 S20 50 Standard Siting Location Indoor Level 1 0 to 90 RH Non condensing Non hazardous Non classified Environment Storage Transport Temperature 41 F to 140 F 5 C to 60 C Ambient Temperature Range 41 F to 104 F 5 C to 40 C Altitude Range Sea Level to 5000 ft Sea Level to 1520 m Proper ventilation must be provided from non hazardous area at a rate in accordance with IEC60079 10 Zone 2 NE Ventilation Safety and Regulatory Conformity Reguirement Cabinet Ventilation with Environment 10 20 40 NFPA 69 and EN 1127 1 Clause 6 2 Vent Fan Draws Fresh Air
2. 6 66 66 6660006 0 6 6066 FIGURE 32 ETHERNET SYSTEM INFORMATION WINDOW 70 aa 66 6 66 171718113017 FIGURE 33 COMMUNICATIONS MODULE APPLICATION 71 0 60 66 6000006 1178851113 FIGURE 34 COMMUNICATIONS MODULE HOSTED REV M CONFIDENTIAL Do not copy Page 4 of 72 2120 0100 0001 R 0 T O N HOGEN S Series 2 Hydrogen Generator o ON SITE Installation Operation Instructions N m LISTS OF TABLES TABLE 1 HOGEN S SERIES 2 HYDROGEN GENERATOR SPECIFICATIONS 0666000060666 0 6 66 0 9 TABLE 2 HOGEN S SERIES 2 HYDROGEN GENERATOR INTERFACE CONNECTIONS 00000606 600 66 6 6 11 TABLE 01001001 TA Isa ea a a kaia assist 17 TABLE 4 ALARM CONTACT CONNECTIONS iieiaeie ea amen saa A AATUN UUT NA VA TAA 20 TABLE 5 DIMENSIONS FOR FRONT RIGHT SIDE AND REAR 18179 0 0 0 066 aak aa 21 TABLE 6 PERCENT LFL TO HYDROGEN IN AIR 00111718185101159 00 6000006 6 60
3. 6 28 TABLE CONTROL PANEL DETAILS 1 1 1 1 1 1 00000 ces sedueaeuebendves EE ANE aa 34 TABLE 8 OPERATING PARAMETERS 37 TABLE 9 WARNING AND ERROR CODES FOR HOGEN S SERIES 2 HYDROGEN GENERATOR 66 41 TABLE 10 POST 1 1 1 1 1 1 1 1 00 42 TABLE 11 FUNCTION NEEDS FOR USERNAMES AND PASSWORDS 006666606000006 600 000 64 2102 0100 0001 REV M CONFIDENTIAL Do not copy Page 5 of 72 a a o er 3 Ci T Cj N HOGEN S Series 2 Hydrogen Generator Nee ON SITE Installation Operation Instructions 1 INTRODUCTION The HOGEN S Series 2 hydrogen generator is a fully automated Proton Exchange Membrane PEM based water electrolysis system Depending on the mode the HOGEN generator is designed to output up to 40 standard cubic feet per hour SCFH of 99 999 percent pure hydrogen Hydrogen is delivered at a maximum of 200 psig 13 8 barg The HOGEN generator s operation is continuous when supplied with power and deionized water It is designed for indoor operation only Proton Energy Systems Inc PROTON has provided these instructions to guide the installation and operation of a HOGEN S Series 2 hydrogen generator It provides technical product information Installation requirements are also provided along with detailed mechanical and electrical interf
4. a e P 3 Ci T O N HOGEN S Series 2 Hydrogen Generator Nee A ON SITE Installation Operation Instructions esi HTDROGEN PRODUCT HYDROGEN VENT tL k R1 M tH i 1 7 WATER INLE 0 PI WATER GUTLET Figure 12 Rear View 3 6 2 Product Hydrogen Interface The HOGEN S Series 2 hydrogen generator is designed to produce hydrogen that contains no more than 5 PPM of water and 1 PPM of other containments Hydrogen can be delivered at pressures ranging from 0 to 200 psig and up to the unit s rated flow rate For conditions that do not require hydrogen product in the customer process such as initial equipment commissioning maintenance and repair conditions PROTON suggests plumbing in the product bypass line at the time of hydrogen generator installation Refer to Figure 13 for suggested plumbing orientation The product hydrogen port uses a Parker CPI compression tube fitting for 14 OD tubing Figure 3 shows the connection location PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 22 of 72 P R 0 T O N HOGEN S Series 2 Hydrogen Generator ON SITE Installation Operation Instructions To Outdoor Vent H2 Product Make sure water cannot drain back into product line Hydrogen Generator Condensate Drain trap Drip pan or open gravity drain Figure 13 Suggested Plumbing Orientation Hydrogen Vent Interface The HOGEN S Series 2 Hydrog
5. FIGURE 21 OPTIONS DIAGRAM FIGURE 22 CROSSOVER MANIFOLD gnister ein 49 49 600 6600006 141 0 14 FIGURE 23 WALL MOUNTABLE CROSSOVER MANIFOLD 50 6100 52 FIGURE 25 PRESSURE REDUCING REGULATOR SCHEMATIC 006606000 006 66 60 moon 54 666666000 0211011 FIGURE 26 AQUA SOLUTIONS DI WATER 57 6 60 6 FIGURE 27 SYSTEM MONITORING SCREEN FIGURE 28 DIAGNOSTICS WINDOW 1 000000000000000 58 FIGURE 29 CONFIGURATION AND CALIBRATION WINDOWS cccessesssceeececsesssececececesceeseaeseeceessaeaeseeseeesesseaeeeeeeeeeenees 60 61 00 666600606666660 FIGURE 30 FPGA AND APPLICATION WINDOWS 62 6 66 66 666600006 6 6066 1 121120177 FIGURE 31 REAL TIME DATA CONFIGURATION 70
6. The system displays an error code su 1 O The system waits for the red STOP RESET button to be pressed again which resets the controller The operator is not allowed to reset the unit until the 60 second circulation of water is complete By switching the main power disconnect switch OFF all power for the system is disconnected simultaneously and the HOGEN generator is depressurized The E stop is a NORMALLY CLOSED circuit Engaging the E Stop trips the contactor but leaves the breaker and line filter energized The generator safely depressurizes when the E Stop is engaged Repeated manual stops while the system is operating in its generate vent state may cause an A300 flooded condition To avoid potential A300 flooded conditions and possible water in the plumbing lines downstream of the A300 PROTON highly recommends that if possible the operator wait until a generate vent state is completed after the initial 60 seconds of hydrogen generation prior to manually shutting the system down PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 39 of 72 NOTE NOTE CAUTION HOGEN S Series 2 Hydrogen Generator Installation Operation Instructions PROTON ON SITE 4 10 Automatic Shutdowns The HOGEN S Series 2 hydrogen generator provides automatic shutdowns through continuous monitoring of critical operating parameters If a parameter is not within its specified limits the controller takes the appropriate acti
7. 0 Purge Air Exhaust l Main Power Disconnect Switch D Water Inlet Port J AC Power Feed E Water Drain Port K Purge Air Inlet F Oxygen Vent Port Table 2 HOGEN S Series 2 Hydrogen Generator Interface Connections PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 11 of 72 a e er 2 Ci T Cj N HOGEN S Series 2 Hydrogen Generator Nee ON SITE Installation Operation Instructions The top level steps of installation are as follows 1 Installing proper ventilating schemes within the area the HOGEN generator is to occupy 2 Verifying the proper environmental conditions the HOGEN generator is to be exposed to Siting the unit Connecting electrical interfaces Connecting mechanical interfaces Calibrating the combustible gas detector Installing the cell stack eS X N JA Hydrating the cell stack Each of these steps is described in further detail in their sub sections within this section 3 1 Shipping Crate Removal Instructions 1 Using a Phillips screwdriver remove 14 Phillips screws from the top cover of the crate 2 Remove the top cover from the crate Refer to Figure 4 Figure 4 Removing Top Cover 3 Using a Phillips screwdriver remove a total of 11 Phillips screws five 5 on the right panel five 5 on the left panel and one 1 on the bottom of the front panel to loosen the front panel of the crate Refer to Figure 5 PD 0100 0001 REV M CONFIDENTIAL Do not copy Pag
8. ON AVAILABLE Code Type UNAVAILABLE ode Type UNAVAILABLE Change Path Company Name UKAVAILAELE if company ai any Name UNAVAILAELE Project UNAVAILAELI roject UNAVAILABLE Release Date ONAVARABLE elease Date UNAVAILABLE jelease Time UN A ma CRC AN specified fil BelairA S Series Sottware Sottware Hii 40 App Bmary Release Time UNAVAILABLE Image CRC UN AVAILABLE no file specitied el PR Ta an ADP RIN Identify Image Into Identitylmage Image TT Figure 30 FPGA and Application Windows Cycle power to the system after the device is sent 9 FOR APPLICATION FILES ONLY To retrieve the version of Application Code presently loaded into the system select the Get From Device button No security required for version retrieval Real Time Data Collection To perform real time data collection use the following procedure 1 Select VIEW gt REAL TIME DATA and select the Configuration button PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 61 of 72 wee P J O T 0 N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions N o Real Time Configuration 0 xj 01 A D Water Quality Mohm Done 02 Bo Combustible Gas LFL v Send Settings To Unit 03 a 05 OE Get Settings From File 06 an va Save Settings To File 07 A D een Temperature Degree NOTE In order to have our changes take effect 09 1 v ou must send the settin
9. 0001 REV M CONFIDENTIAL Do not copy Page 2 of 72 HOGEN S Series 2 Hydrogen Generator Installation Operation Instructions PROTON ON SITE HOGEN S Series 2 Hydrogen Generator INSTALLATION OPERATION INSTRUCTIONS Page 3 of 72 NTENTS Introduction sirrien E ich send 11 2 2 1 1 2 Product Specification 1 1 11 SAKOT os junasta akan Name asu E MADSEN 2 1 General Information ooooooossa asa ae a aan ana 2 2 Using Hydrogen Gas na na na ae Installato saries 11 3 1 Shipping Crate Removal Instructions 3 2 Facility Air Ventilation Requirements 3 3 Operating Environment ssnornnornvnvnrnvnvnnnvnnnvnnvvnnvvrnrnevavevaveravvrnvnen 3 4 Site Preparation rsonnonvnvnvonnvonnvennvennvvnnvvnnvevnnennnnnvennvevnvvnvsvesvnne 35 Electrical Interfaces oerna ites este 3 6 Mechanical Interfaces 3 7 Combustible Gas Sensor Calibration P amp ID Tag CG220 3 8 Installing the Cell Stack orvonnvennvonvovonnvennvnnnnrennvennvennvevnevvevvnee 3 9 Hydrating the Cell Stack oronnvonnvonvovne
10. 0001 REV M CONFIDENTIAL Do not copy Page 26 of 72 a e P 3 Cj T Cj N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions Use the following procedure to calibrate the combustible gas sensor 1 Shutdown the system and remove power using the main power disconnect switch on the rear panel of the unit 2 Gain access to the fluids bay and remove the combustible gas sensor head by removing the two 2 screws that hold the sensor head mounting plate to the sensor shield See Figure 15 Remove screws 2 on side of shield Figure 15 Combustible Gas Sensor Removal 3 Pull the sensor head and plate from the assembly See Figure 16 Do not disconnect the wiring harness as the sensor needs to be powered to complete the calibration Figure 16 Combustible Gas Sensor Removed PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 27 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions N sea 5 4 Power up the system while depressing the SELECT and SYSTEM PRESSURE buttons This enters the system into the combustible gas sensor calibration state 5 After powering up the system in the calibration state the symbol BC FAIL displays for 10 seconds to signify gas calibration 6 After the BC AL symbol is removed the symbol OAP is displayed to signify 0 percent LFL 7 Depress the START button to begin a
11. 30 second timer to allow the gas sensor to stabilize to 0 percent LFL Once the START button is depressed the display counts down from 30 to 0 8 Upon completion of the countdown done is displayed Then select the START button to continue No further action is accepted until donb appears 9 Once the START button is selected the symbol SOFC is displayed 10 Select the UP display scroll button to increase or the DOWN display scroll button to decrease the display reading to match the percentage level of calibration gas being used The acceptable range of calibration gas is 30 percent to 50 percent LFL The first two digits of the display changes to reflect the selection Values increase by 1 percent LFL LFL Hydrogenin LFL Hydrogen in Air Air 50 2 39 1 56 49 1 96 38 1 52 48 1 92 37 1 48 47 1 88 36 1 44 46 1 84 35 1 4 45 1 8 34 1 36 44 1 76 33 1 32 43 1 72 32 1 28 42 1 68 31 1 24 41 1 64 30 1 2 40 1 6 Table 6 Percent LFL to Hydrogen in Air Conversions 11 Install the calibration hood onto the combustible gas sensor head When installing the calibration hood onto the combustible gas sensor attach one of the tube ends on the hood to a 14 flex hose which is connected to the calibration gas supply The other tube end remains open to the atmosphere PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 28 of 72 a N P 3
12. Diagnostics software enter the IP address assigned to the Communication Module into the Address section of Windows Explorer ex http 192 168 10 99 and select ENTER If the website can be accessed then a connection to the Communication Module exists and the user must verify the System Information and Options sections of the Windows Diagnostic software If while performing a Read or Write operation and communication is lost a Socket Error message may appear at the bottom of the Windows Diagnostics page If communication does not re establish automatically try on the following e Close and then Re Open the Windows Diagnostics Software Reboot the Control Board To prevent a potential communication loss perform only one action a time For example stop sampling or logging data prior to performing a write operation such as logging into the system as a Technician Also once communication is re established after a loss such as reconnecting a cable it may take up to 60 seconds before full communication to the control board can be restored PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 67 of 72 NOTE NOTE ee 3 O T O N HOGEN S Series 2 Hydrogen Generator o ON SITE Installation Operation Instructions se 5 APPENDIX G COMMUNICATIONS MODULE SOFTWARE OPERATION PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 68 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON S
13. O T 0 N HOGEN S Series 2 Hydrogen Generator Neo ON SITE Installation Operation Instructions Figure 17 Calibration Hood installed on Combustible Gas Sensor 12 Open the calibration gas supply and allow 0 5 to 1 liter minute of calibration gas to flow to the combustible gas sensor Fully open the calibration gas supply when using the Cal Kit An orifice located within the valve assembly sets the correct flow rate 13 Once there is flow to the combustible gas sensor head then select the START button to begin a 60 second timer to allow the gas sensor to stabilize to the user selected percentage of LFL Once the START button is depressed the display counts down from 60 to 0 14 Upon completion of the countdown done is displayed The START button must be depressed to continue Do not turn off Cal gas until you depress the START button No further action is accepted until done appears Lunn When not using the calibration gas the supply should be shut off 15 Once the START button is selected the message TIFF is displayed 16 Ensure the Cal gas bottle is turned Off 17 Cycle the power to the unit by shutting off the power to the unit through the main power disconnect switch on the rear panel 18 At any point during the calibration procedure except during timer countdown if an error has occurred or if the user must repeat the previous step the STOP RESET button may be depressed Depr
14. Once the PRE START operation is complete the green START key light flashes indicating the completion of the PRE START state The operator can either allow the HOGEN generator to maintain an idle state or enter the GENERATE VENT state by pushing the green START key 4 4 GENERATE VENT Operation The GENERATE VENT state is initiated after all of the PRE START conditions are met and the operator presses the green START button Pressing the button at this time activates the following sequence 1 The circulation pump P amp ID Tag CP205 is turned on 2 The water flow rate is verified 3 The quality of the water is verified 4 During the circulation tests a dashed line moves in a racetrack pattern around the perimeter of the display 5 Full current is applied to the system after approximately 120 seconds Once current is applied to the cell stack a yellow H gt indicator light illuminates signaling that hydrogen is being generated 6 The system verifies hydrogen water phase separator P amp ID Tag A300 level controls 7 The system verifies the voltage conditions within the cell stack 8 The system verifies the rectifier operation During the sequence the system vents oxygen and hydrogen at full production Once the system goes through the sequence above and the unit passes all the checkpoints PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 35 of 72 WARNING fie a a H R O T O N HOGEN S Series 2 Hy
15. degrees capable of supporting the generator is required The minimum clearance requirements of the area around the generator are shown in Figure 7 Itis the customers responsibility to verify the local code requirements for this type of equipment are met when installing this equipment Not using a fork truck or pallet lift to move the HOGEN hydrogen generator may cause Caution harm to the stabilizing structure of the unit PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 16 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions Wo 5 THE GENERATOR IS TYPICALLY SHIPPED WITH THE CELL STACK ALREADY INSTALLED FOR THIS REASON DO NOT EXPOSE THE STACK TO FREEZING CONDITIONS WHEN THE UNIT IS NOT RUNNING PLEASE CONSULT THE FACTORY FOR SPECIAL STORAGE AND HANDLING INSTRUCTIONS IF THE UNIT WILL BE EXPOSED TO FREEZING CONDITIONS PRIOR TO INITIAL START UP All gas water electrical and communications connections are made from the rear of the system Access to the rear panel is also required for routine air filter maintenance Leave sufficient clearance to permit adequate air movement in and out of the generator at the rear of the unit The generator is controlled from the front control panel which has start and stop switches process status LED indicators and a RS232 Service access port Opening the two front doors will permit access for water filter replacement and routine mainte
16. log modify configuration settings and download software to the system control board Instructions on how to operate these functions are detailed below System Information To obtain miscellaneous system information use one of the two following procedure screens cannot be used at the same time 1 System Monitoring Monitoring I O To monitor any analog or digital signal available from the system use the following procedure 1 Select VIEW gt SYSTEM MONITORING from the toolbar 2 Select Start Monitoring button to start monitoring data 3 Select Stop Monitoring button to stop monitoring data PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 56 of 72 AO P R 0 T O N HOGEN S Series 2 Hydrogen Generator o ON SITE Installation Operation Instructions HOGEN 40 v1 289 File Edit View Tools Window Help Disul a x me 2 v z H2 VENT H2 PRODUCT lt onn Flow lpm SV511 SCFH 51 510 NC i RV223 Lsw201 i voikin DEE TU i Flood TE218 gt Jo High 7 Ja Low System Temperature Sva42 SVa4t H20 DRAIN BG syst SV211 NC ISV345 Start Monitoring EE Sel EE s i i 51 329 NO LSW301 PSW121 Flood High Syste Errors and Wamin 2 None m State 9 lone lone 5 Log Data Switch Low Controlle
17. of 72 1 Select VIEW gt DIAGNOSTICS from the toolbar 2 Once in the Diagnostics screen ensure the Inhibits Writes box is checked CONFIDENTIAL Do not copy PD 0100 0001 REV M fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions N sea 5 3 Check the appropriate boxes for all signals desired for monitoring i e Analog Inputs Digital Inputs Digital Outputs and Stack Current 4 Select the Start Sampling button to begin data monitoring 5 Select the Stop Sampling button to end data monitoring 6 To perform updates for particular sets of I O select the Update Data button NOTE For Digital Inputs and Outputs Green implies ON or that a state has been met Red implies OFF or that a state has not been met Logging 1 0 To data log any analog or digital signal available from the system use the following procedure 1 Select VIEW gt DIAGNOSTICS from the toolbar 2 Once in the Diagnostics screen ensure the Inhibits Writes box is checked 3 Ensure the Enable Logging box is checked 4 Check all Log boxes for signals desired for logging Use Al and None buttons as required sa Select a desired sample rate from the pull down menu 6 Use the Change Path button to select the file where the data is to be logged to Configuration and Calibration Parameters T
18. performance loss over time PVC plastics CAUTION are not acceptable as they will damage the cell stack PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 25 of 72 fie a H R O T O N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions N sea 5 3 7 Combustible Gas Sensor Calibration P amp ID Tag CG220 The HOGEN S Series 2 hydrogen generator contains an e2v Technologies VQ603 2 combustible gas sensor that monitors both the purge air and the oxygen stream from the oxygen water phase separator A200 for hydrogen gas The detection of 50 percent of the lower flammability limit LFL of hydrogen within air triggers a safe shutdown of the system The combustible gas sensor needs to be calibrated prior to the initial startup of the HOGEN generator THE COMBUSTIBLE GAS DETECTOR NEEDS TO BE CALIBRATED EVERY 3 MONTHS FOR PROPER OPERATION OF GAS DETECTING EQUIPMENT WITHIN WARNING THE HOGEN GENERATOR The following items are needed to perform the calibration e Combustible Gas Sensor Calibration Kit OR 2 Percent Hydrogen in Air Calibration Gas Calibrated Air Flow Meter capable of reading 0 5 to 1 liter minute Included in the Cal Kit with the regulator and the valve e Gas Sensor Calibration Hood Portable Gas Detector and Charger for 115V or 220V applications 8 mm hex Wrench 5 16 Wrench Figure 14 Combustible Gas Sensor Calibration Kit with Calibration Hood PD 0100
19. separator be checked for loose connections or signs of blockage Once the sample line is verified to be functioning properly restart the system and verify the warning has cleared and does not reappear Continued warnings could signify problems with the combustible gas sensor The HOGEN S Series 2 hydrogen generator is also equipped with software that monitors the system temperature In the event the system temperature falls below a specified limit C 30 flashes as a warning providing 48 hours of operation prior to an E 30 shutdown See Table 9 for other warnings 4 9 Manual Shutdown Manual shutdowns of the HOGEN S Series 2 hydrogen generator occur in three ways by pressing the red STOP RESET button engaging the E Stop or switching the main power disconnect switch to the OFF position Do not use the E Stop or main power disconnect switch to stop gas generation except in the event of emergency To properly stop the process or reset the control processor press the red STOP RESET button PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 38 of 72 CAUTION fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions N sea 5 By pressing the red STOP RESET button the following sequence occurs The system de energizes all outputs except the circulation pump Water is circulated for 60 seconds after the button is pressed The power supplies are disabled
20. the parameter on display The following is a list of parameters and the associated symbol identifier Units Parameter English SI Symbol System Pressure default PSI kPa SP Product Pressure PSI kPa PP Hydrogen Flow Rate SCFH LPM HF System Temperature F SE Cell Stack Voltage VDC VDC SU Cell Stack Current Amps Amps SC If kPa is selected for pressure display then LPM and C will be displayed Table 8 Operating Parameters The display area has an indication of the measurement units in use English or SI Underneath the 4 digit 7 segment display is a button to toggle between the two unit measurements e Elapsed Timer The amount of time that has elapsed in 10 hour counts of system generation time current lt 1 amp can be accessed through the display panel Pressing both the product and system pressure keys simultaneously for 5 seconds accesses this option e Error Code The output from the shutdown circuit is displayed as a numerical code 0 43 e System Idle Condition When the water levels are being adjusted the display segments flash in a sequential pattern PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 37 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions Wo 5 4 8 Automatic Warnings The HOGEN S Series 2 hydrogen generator provides an automatic warning when the combustible gas sensor P amp ID Tag CG22
21. the room until improvements are made to the ventilation system CAUTION Example Calculation 1 Record net hydrogen generation rate P for your selected generator P 40 SCFH 2 Calculate the gross hydrogen generation rate G Add 10 percent G 1 1 x P 44 SCFH 3 Calculate recommended ventilation rate F Several hundred times gross generation rate F gt 100 x G 60 4400 SCF H 60 73 3 SCFM 4 Confirm if actual room ventilation F4 is adequate F4 950 SCFM a Is actual room ventilation Fi greater than or equal to F YES 3 3 Operating Environment The HOGEN S Series 2 hydrogen generator has been designed for indoor use only The HOGEN generator shall be situated on a grade of no more than 3 degrees The area in which the system occupies shall have ventilation schemes described in Section 3 2 PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 15 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions Wo 5 The HOGEN generator is rated for ambient temperatures ranging from 41 F to 104 F 5 C to 40 C The HOGEN generator is not designed for freezing conditions If the system is introduced to freezing conditions damage to the system may occur IF FREEZING CONDITIONS EXIST AT YOUR SITE PRECAUTIONS MUST BE WARNING TAKEN TO PREVENT THE UNIT FROM FREEZING The HOGEN generator contains a thermistor probe that measures the system water temp
22. whether written or oral relating to sale and or use of Proton products or services including liability or warranties relating to fitness for a particular purpose merchantability or infringement of any patent copyright or other intellectual property right Proton products are not intended for use in medical life saving or life sustaining applications Proton may make changes to specifications and product descriptions at any time without notice This document as well as any software processes or procedures described in it is furnished under license and may only be used or copied in accordance with the terms of the license The information in this document is furnished for informational use only is subject to change without notice and should not be construed as a commitment by Proton Proton assumes no responsibility or liability for any errors or inaccuracies that may appear in this document or any software that may be provided in association with this document Except as permitted by such license no part of this document may be reproduced stored in a retrieval system or transmitted in any form or by any means without the express written consent of Proton Proton Proton OnSite Proton Energy Systems the Proton design StableFlow StableFlow Hydrogen Control System and design HOGEN and FuelGen are trademarks of Proton Energy Systems Inc Any other brands and or names used herein are the property of their respective owners PD 0100
23. 0 has not been calibrated within 14 days of its three 3 month calibration interval If the sensor has not been calibrated the LED display flashes C 00 for one 1 second and then returns to normal display for five 5 seconds before flashing the warning again The combustible gas sensor must be calibrated and the power to the unit must be cycled for the warning to be cleared Once the calibration interval is beyond the three 3 month interval the warning results in an automatic shutdown with error code E 25 shown on the LED display The HOGEN S Series 2 hydrogen generator is equipped with software that monitors the health of the combustible gas sensor It detects a blocked or a removed gas sampling line from the oxygen water phase separator to the combustible gas sensor and provides combustible gas sensor health check monitoring based on hydrogen water phase separator cycles The software provides an automatic warning if it detects the combustible gas sensor is not sensing an adequate flow of hydrogen The automatic warning flashes C 01 if a too low level of combustible gas is detected The automatic warning flashes C 02 if an expected cyclical pattern of combustible gas is not detected To clear the warning the system must be stopped and the combustible gas sensor must be calibrated While calibrating the combustible gas sensor it is recommended that the sample stream to the combustible gas sensor from the oxygen water phase
24. 0 0001 REV M CONFIDENTIAL Do not copy Page 62 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions Wo 5 1 Select TOOLS gt OPTIONS from the toolbar 2 To select the Communications Port and other settings select the Communications tab and select the appropriate Com port for the local computer 3 If communicating via a Communications Module over Ethernet select the TCP IP connection box and enter the IP address assigned to the Communications Module 4 To select default file paths for configuration calibration Application and FPGA files select the Directories Tab Usernames and Passwords To log into the system use the following procedure 1 Select TOOLS gt LOG IN from the toolbar and enter a valid username and password service level or higher security required 2 To log out of the system select TOOLS gt LOG OUT from the toolbar To update usernames or passwords select TOOLS gt USERNAMES PASS WORDS from the tool bar and enter a valid username and password a To obtain existing usernames and passwords from the system select the GET button b To modify a username or password make changes to the appropriate boxes Selecting from the pull down menus can modify user levels c To send a set of usernames and passwords to the system select the SEND button A service administrator must always be sent to the system or the u
25. IDENTIAL Do not copy Page 30 of 72 a o er 2 O T O N HOGEN S Series 2 Hydrogen Generator Nee ON SITE Installation Operation Instructions 3 8 Installing the Cell Stack The cell stack is typically installed in the system prior to shipment However if freezing conditions were anticipated the cell stack may have been shipped separately In that event separate installation instructions will be provided with the cell stack Store the cell stack in a non freezing area The installed stack is full of water and has all input and output ports capped Connections to the stack should be the last step in the installation process and should not be done until all previous steps are completed NEVER ATTEMPT TO DISASSEMBLE THE CELL STACK AS THERE ARE NO SERVICEABLE PARTS INSIDE AVOID CONTACT WITH THE POSITIVE BUSS ESA PIATE AS A CAPACITIVE CHARGE IS RETAINED AND A SEVERE ELECTRICAL SHOCK MAY RESULT IF YOU SUSPECT A PROBLEM WITH THE CELL STACK PLEASE CALL PROTON S SERVICE DEPARTMENT IMMEDIATELY Never leave the input and output ports uncapped Irreversible damage to the stack results if it is allowed to dehydrate 3 9 Hydrating the Cell Stack In the event the HOGEN S Series 2 hydrogen generator is not placed in service upon receipt the cell stack must be properly hydrated Check for DI water content in the hoses every 30 days If DI water is not present in the hoses rehydrate the hoses as needed A hydration kit is available
26. ITE Installation Operation Instructions N sea 5 Communication over Ethernet Requirements e Host Computer with Windows 2000 or Windows XP Professional e Ethernet Card and associated cable Maximum cable length of 100 meters between transmitter and receiver Adjusting Ethernet Communication Options for IP and Email Addresses To set or adjust Ethernet communication options for IP and Email addresses use the following procedure 1 Select VIEW gt SYSTEM INFORMATION from the toolbar Entries are required for the following sections and must be obtained from a Network Administrator IP Address Subnet Mask Gateway DNS Server To Email address SMTP Server SMTP Domain 3 The remaining sections can entered in based on the user s specific descriptions For example the Model Number Serial Number and Build Date are specific to the HOGEN Generator The Subject is the message appearing in the header each time an email is sent To activate email notification in the event of a warning shutdown or other system status change ensure the Enable Remote Email Notify button is checked 4 System information must initially be sent to the control board via RS232 The Communication Module leaves the factory with default settings 5 A system power cycle or a control board reset is required for the parameter change to be accepted Select the From Device button to upload parameters from the system 7 Select the From File button to o
27. N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions N sea 5 APPENDIX B OPTIONS DIAGRAM PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 46 of 72 o lt O T O N HOGEN S Series 2 Hydrogen Generator GS jari o ON SITE Installation Operation Instructions a i Vent to Outside NOTE This schematic is intended only to Atmosphere represent a functional diagram Itis not intended to be a specific process diagram For actual equipment installation refer to the installation manual and applicable codes and standards Required Condensate Trap Part 02 2000 0002 To Process Dip Pan lt lt O F O or Drain H2 ETE EE Vent ac 205 240 VAC 5 1 Phase 4 50 60 Hz a L Ethemet Or i 1 9 i RS 232 i Optional Low Pressure F ig Tank with Accessories 1 System HOGEN 20 40 EE 1 i i Le EE Pii i 1 Optional Diagnostics Software 1 J Figure 21 Options Diagram PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 47 of 72 fie yl R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions Wo 5 APPENDIX C CROSSOVER MANIFOLD OPTION PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 48 of 72 a e P R O T 0 N HOGEN S Series 2 Hydrogen Generator Neo A ON SITE Installation Operation Instructions The crossover manifol
28. On Generate On Generate On Generate On Circ Test 10s All States Active at Power Up Active at Power Up Active at Power Up Active at Power Up Active at Power Up Active at Power Up Active at Power Up Active at Power Up Active at Power Up Sensor P amp ID Tag LS301 PWR102 3 PS121 PWR102 1 PWR102 2 N A PWR102 1 N A N A M101 N A N A N A TS218 WS207 LS201 LS301 PT307 PT307 PT312 PT312 TS218 TS218 PROTON ON SITE Description Default Limit A300 Pre Start Timeout gt 2 Hours Fault Signal High lt 0 2 Water Column Fault Signal High Fault Signal High Internal Watchdog Failure Control Board gt 150 Amps 1 Restart Max Calibration Past Due E Stop Open lt 2 LFL lt 1 LFL Range on A300 Cycle lt 1 LFL Range on A300 Cycle gt 5 C Control Board Closed on Power Up Input is Below 0 25V Input is Above 4 75V Input is Below 0 25V Input is Above 4 75V Input is Shortened Input is Open Rectifier 3 Fault Cabinet Purge Pressure Low Rectifier 1 Fault Rectifier 2 Fault Processor Fault FPGA Fault High Current A300 Flooded Restarts CG Sensor Out of Calibration E Stop Circuit Fail CG Drift Error CG Peak Error CG Full Production Peak Error System Temperature Low State Machine Fault Flow Switch A200 Invalid State A300 Invalid State System Pressure Transducer System Pressure Transducer Product Pressure Transducer Product Pressure T
29. Operation Instructions 4 OPERATION The HOGEN S Series 2 hydrogen generator is a fully automated system Upon depressing the green START key the system starts a control sequence that leads to the generation of hydrogen gas Error codes are embedded in the control scheme of the HOGEN generator The error codes spawn from the monitoring of system parameters Push Stop Reset Button Pre Start Push Push Stop Start Reset Button Button TF Generate Vent Pressurize System Display Error Code Stop and Depressurize Steady State Figure 19 Basic Control Sequence PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 33 of 72 a N ce P 0 T O N HOGEN S Series 2 Hydrogen Generator Neo ON SITE Installation Operation Instructions 4 1 Control Panel The HOGEN S Series 2 hydrogen generator s control panel contains all the buttons to operate the unit Figure 20 shows the layout of each interface point 4 8 F G Figure 20 Control Panel Details Reference Detail Reference Detail A Product Pressure E Hydrogen Generation Indicator B System Pressure F Units Toggle Select C Display Scroll Keys G Stop Reset Button D Start Button Table 7 Control Panel Details 4 2 Turning ON the Main Power Turning on the main power to the cabinet initiates the on board air purge blower The blower pressurizes and cools the cabinet The cabinet doors must remain closed and secured
30. PROTON PD 0100 0001 wo e THE LEADER IN ON SITE GAS GENERATION REVISION M HOGEN S SERIES 2 HYDROGEN GENERATOR Installation amp Operation Instructions wee P R O T O N HOGEN S Series 2 Hydrogen Generator A e ON SITE Installation Operation Instructions N m Model Numbers 54 0101 0000 HOGEN Hydrogen Generator 54 0101 0001 HOGEN 40 Load Following Hydrogen Generator 54 0101 0002 HOGEN 40 Tank Filling Hydrogen Generator 54 0101 0005 HOGEN 20 Load Following Hydrogen Generator 54 0101 0006 HOGEN 20 Tank Filling Hydrogen Generator 54 0101 0013 HOGEN 20 Tank Filling Hydrogen Generator Serial Number Proton OnSite 10 Technology Drive Wallingford CT 06492 Main 203 678 2000 Customer Service 203 949 8697 www protononsite com customerservice protononsite com SIC 3569 901 Gas Generating Eguipment NAICS 333 999 8556 Gas Generating Eguipment 2010 2011 Proton Energy Systems Inc d b a Proton OnSite All rights not expressly granted herein are reserved Information in this document is provided in connection with Proton Energy Systems Inc d b a Proton OnSite Proton products and services No license express or implied by estoppel or otherwise to any intellectual property rights is granted by this document Except as provided in Proton Terms and Conditions of Sale for such products and services Proton assumes no liability whatsoever and Proton disclaims any express or implied warranty
31. T Product Pressure I psi 25 225 v Step 2 Adsorb A Regen B 195 15 02 Number of Cells Cells 20 20 v Step 3 Adsorb A Pressurize B 240 15 03 Stack Voltage High Volts 600 30 Step 4 Adsorb B Transition to Regen A 243 P 04 Stack Voltage Low Volts I 20 0 fio v Step 5 Adsorb B Regen A 435 5 09 Water Quality High I mo 2 2 I step AdsoibB Pressuize A 180 75 06 Water Quality Low mo Tf v Pa System Pressure High psi 250 25 v lt si 0 eerie 1 ulate Setti evice 12 09 Combustible Gas High I xu so minutes iv aio z P10 System Temperature High I c 5 60 z fowtctmT zel z PT Refil Pressure I psi 5 50 v EG PEAK TIME I seconds 120 120 p Current PWM Limit 86 3 v percent Ignore Faults j Current Control Scheme EG RANGE I 1 p IV Rectfiert1 Load Following Old IV Rectifier 82 LoadFollowi je IEN FFULCPROD_CG_RANGE MIN 0 Rectifier 3 Sys Press Timeout 60 sec Tank Filling Gas Cal Max Time 3 v months feteste stanses pm z EG STRIKES I Control G iso kp ki kd pane SSS SYSTEM PRESSURE I 180 I 0 18 0 SPARE I EG TESTS ENABLED I Get From Device Sendto Device N 0 Send to File Communications port COMA closed 373072003 e17AM Figure 29 Configuration and Calibration Windows 4 Select the Send to Device button to send a particular set of parameters to the system 5 Select th
32. Up to 28 m3 min 1000 ft3 min lt 70 dBa cTUVus UL and CSA equivalent CE PED ATEX LVD Mach Dir EMC NYFD Approval Received Noise dB A at 1 Meter Approvals Table 1 HOGEN S Series 2 Hydrogen Generator Specifications PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 9 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions Wo 5 2 SAFETY The safety guidelines below may not cover all situations If there are concerns or questions please call PROTON or check with local authorities 2 1 General Information This system produces hydrogen It is important for users to be aware understand and comply with all local safety requirements related to the handling of hydrogen and compressed gases 2 2 Using Hydrogen Gas Hydrogen is odorless tasteless colorless and highly flammable It is highly combustible in the presence of oxygen and burns with a colorless flame Leaking gas may be hot and pose a burn danger If you are not in danger stop the flow of gas and use water to cool the area The lower explosive limit of hydrogen is 4 percent by volume If fire occurs do not attempt to extinguish flames allow the fire to burn out Prevent overexposure to hydrogen Hydrogen is non toxic but can act as a simple asphyxiant by displacing the oxygen in air Effects of oxygen deficiency resulting from simple asphyxiants inclu
33. ace specifications Important safety information is also included in this guide Please take time to familiarize yourself with the system and the manual DO NOT USE THE HOGEN S SERIES 2 HYDROGEN GENERATOR IN A MANNER NOT SPECIFIED BY THE MANUFACTURER IT IS THE CUSTOMER RESPONSIBILITY TO CONSULT WITH THE LOCAL BUILDING INSPECTOR AND OR FIRE MARSHALL REGARDING LOCAL CODE REQUIREMENTS FOR INSTALLATION AND OPERATION OF THIS EQUIPMENT Figure 1 HOGEN S Series 2 Hydrogen Generator This manual attempts to answer most of the frequently asked questions with regards to installation and operation of the unit However should you have any questions the PROTON technical staff stands ready to answer them and support the successful deployment of this equipment Please call 203 949 8697 and ask for field service technical support or email customerservice protonenergy com Please have the part number and serial number of your unit available PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 6 of 72 WARNING WARNING ae lt 0 T 0 N HOGEN S Series 2 Hydrogen Generator ON SITE Installation Operation Instructions a e se 1 1 General Description The HOGEN S Series 2 hydrogen generator is a fully integrated system that produces hydrogen from water and electricity The system includes an electrolyzer cell stack as well as all the auxiliary equipment necessary for regulating electrolyzing operations and pressurizing hydrogen The auxil
34. as required by the facility manager or local code compliance officials THE HOGEN S SERIES 2 HYDROGEN GENERATORS ARE DESIGNED TO OPERATE IN NON EXPLOSIVE ENVIRONMENTS IT UTILIZES A FRESH AIR WARNING PURGE OF THE SEALED EQUIPMENT CABINET TO ESTABLISH A SAFE NON EXPLOSIVE INTERNAL OPERATING ENVIRONMENT US PATENT 5980726 Always refer to local code requirements to determine minimum facility ventilation requirements A worksheet for estimating minimum ventilation at your facility is given CAUTION below How to calculate the ventilation requirements for your site 1 Record net hydrogen generation rate P for your selected generator P Nm h SCFH PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 14 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator GS ON SITE Installation Operation Instructions If there is a plan to have multiple hydrogen generators in the room P must be the sum of all NOTE generators 2 Calculate the gross hydrogen generation rate G Add 10 percent G P x 1 1 Nm h SCFH 3 Calculate recommended ventilation rate F Several hundred times gross generation rate F gt 100 x G 60 Nm min SCFM 4 Confirm if actual room ventilation F 4 is adequate F4 a Is actual room ventilation Fi greater than or equal to F YES NO If you answered YES for 4a then you may install the unit s in the room If you answered NO for 4a then you may not site the unit in
35. at EOL 24 6 kWh 100 ft 23 7 KWh 100 ft 21 9 kWh 100 ft3 Purity Concentration of Impurities 99 9995 Water Vapor lt 5 PPM Water 65 C 85 F Dewpoint N2 gt 2 PPM 0 gt 1 PPM All Others Undetectable Turndown Range 0 to 100 Net Product Delivery Upgradeability N A DI Water Requirement Requirement 10 20 40 Rate at Max Consumption Rate 0 08gal hr 0 13 gal hr 0 25 gal hr 0 26 L hr 0 47 L hr 0 94 L hr Temperature 41 F to 95 5 C to 35 C Pressure 21 8 to 58 PSIG 1 5 to 4 barg Input Water Quality ASTM Type II Deionized Water Required lt 1 micro Siemen cm gt 1 megOhm cm ASTM Type Deionized Water Preferred lt 0 1 micro Siemen cm gt 10 megOhm cm Heat Load and Coolant Requirement Requirement 10 20 40 Cooling Air Cooled Heat Load from System 1 3 kW Max 2 2 kW Max 4 3 kW Max Coolant Ambient Air 41 F to 104 F 5 C to 40 C Electrical Specifications Requirement 10 20 40 Recommended Breaker Rating Base 6 kVA 8 KVA 12 KVA Configuration Electrical Specification 205 240 VAC Single Phase 50 or 60 Hz Interface Connections Requirement 10 20 40 H2 Product Port Ys CPI Compression Tube Fitting SS H2 H2O Vent Port CPI Compression Tube Fitting SS DI Water Port 7 Tube Push to Lock Polypropylene Drain Port 7 Tube Push to Lock Polypropylene PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 8 of 72
36. ator The Subject is the message appearing in the header each time an email is sent To activate email notification in the event of a warning shutdown or other system status change ensure the Enable Remote Email Notify button is checked 4 System information must initially be sent to the control board via RS232 The Communication Module leaves the factory with default settings 5 A system power cycle or a control board reset is reguired for the parameter change to be accepted Select the From Device button to upload parameters from the system 7 Select the From File button to obtain a specific file installed on host computer or via a network connection Select the To Device button to send a particular set of parameters to the system 9 Select the To File button to save a particular set of parameters to a file D po PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 66 of 72 NOTE fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions N sea 5 10 The Send Test Email button is for a feature to be activated in future releases V287 and higher Communication Module Website As a troubleshooting aid the Communication Module hosts a simple website This website consists of the PROTON logo along with a computer that is updated every five 5 seconds In the event the user is unable to communicate to the Communication Module with Windows
37. btain a specific file Installed on host computer or via a network connection Select the To Device button to send a particular set of parameters to the system Select the To File button to save a particular set of parameters to a file 0 The Send Test Email button is for a feature to be activated in future releases V286 and higher D oo PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 69 of 72 a e P f 0 T O N HOGEN S Series 2 Hydrogen Generator Der ON SITE Installation Operation Instructions HOGEN 40 1 8 x File Edit view Tools Window Help olsa a uv e System aN arena lei Mask Model Number TACE raste ae fe Perean fo foto Pm To E mail Address 7 Build Date Jidoe abccompary com 02212005 Te Calibration Date 02212005 Today From Email Address Send Test Email H40R8D SMTP Server ie 192 168 10 100 m SMTP Domain _FROM Device fis2 168 10 100 T0 File m Subject alarm Condition FROM File Figure 32 Ethernet System Information Window Communications Module Application To download the Communication Module application Service Level or higher security reguired use the following procedure 1 Select VIEW gt COMM MODULE OPTIONS as reguired from the toolbar 2 To select a file to download select the Change Path button The file installed on host computer
38. d Outputs INPUTS I Enable Logging AI II II III III II ITE include i in Constant og Set Time and Date Read Time and Date Click the button below to refresh this data HOGEN 40 Diagnostics GALE RAW FINAL IGAS DETECT ICG2201 I PRODUCT PRESSURE IPT3121 I SYSTEM PRESSURE IPT3071 I psi WATER QUALITY R52091 I I Ma TACK VOLTAGE I I Volts STACK CURRENT I Amps SYSTEM TEMPERATURE TEZIS i B3VDC SENSE I r Volts 24 0 VDC SENSE T U Volts SPARE THERMISTOR I I DVOC SENSE I I Volts 25 V REFERENCE I I Volts BOARD TEMPERATURE I U T 5 01 0 SENSE Sampling CURRENT PWR102 Eick Read Time and Date to update Reset Elapsed Timer Elapsed Timer Include Click Read Elapsed Ta to update Start Sampling Read Unit Information Figure 28 Diagnostics Window 2 Select the Read Unit Information button to obtain the FPGA version and the Board Hardware version 3 To set or read the system time and date select the appropriately labeled button To set the system time and date requires technician level or higher security access 4 To reset or read the system Elapsed Run Timer in hours select the appropriately labeled button To reset the system Elapsed Run Timer requires technician level or higher security access Communications port COMA closed Monitoring I O To monitor any analog or digital signal available from the system use the following procedure Page 58
39. d option is available for use when high pressure backup storage is desired Figure 22 Crossover Manifold The crossover manifold is available from PROTON using the following part numbers e Part 02 3500 0001 for SS e Part 02 3500 0000 for Brass NOTE There is a 50 psi pressure drop with this component To install the crossover manifold use the following instructions 1 The cross over manifold assembly is wall mountable a Hole Pattern 3 13 16 X 5 14 on center Hole Size 5 16 Figure 23 Wall Mountable Crossover Manifold Diagram 2 The left side of the manifold is for high pressure feed and is labeled H P IN with a 4 000 psi pressure gauge This side is connected to a storage tank or a high pressure back up a Plumbing connection is CGA or 4 FNPT 3 The right side of the manifold is for low pressure feed hydrogen generator connection and is labeled L P IN with a 250 psi pressure gauge a Plumbing connection is 4 CPI or 4 FNPT 4 The hydrogen supply exit is located at the top right a Plumbing connection is 4 CPI or 4 FNPT This option may not be compatible with the StableFlow Hydrogen Control System as part of the total integrated solution Consult with the Proton Energy Systems Applications or Service NOTE Departments for further information PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 49 of 72 4 8 o P 3 Ci T Cj N HOGEN S Series 2 Hydrogen Generator e ON SITE In
40. de rapid breathing diminished mental alertness impaired muscular coordination faulty judgment depression off all sensations emotional instability and fatigue As asphyxiation progresses nausea vomiting prostration and loss of consciousness may result FIRE OR EXPLOSION KEEP ALL SOURCES OF IGNITION AWAY FROM HYDROGEN BYPASSING ANY OF THE HYDROGEN GENERATOR SHUTDOWN CIRCUITS IS NOT ADVISEABLE OPERATION OF THE GENERATOR WITH BYPASSES INSTALLED COULD RESULT IN SERIOUS INJURY AND OR DAMAGE TO THE GENERATOR PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 10 of 72 WARNING WARNING a e er 2 O T O N HOGEN S Series 2 Hydrogen Generator Nee ON SITE Installation Operation Instructions 3 INSTALLATION The HOGEN S Series 2 hydrogen generator is a fully integrated system To install the HOGEN generator mechanical electrical communication and packaging interface requirements must be met This section describes the interface and installation requirements Figure 2 introduces the mechanical system boundaries and principle interfaces for integration Figure 3 illustrates the hardware mounting points and connections for system integration and packaging G A B H I J D E F K Figure 3 HOGEN S Series 2 Hydrogen Generator Interface Connections Reference Interface Connection Reference Interface Connection A H2 HO Vent Port G Remote Shutdown Serial Port B Product Hydrogen Port H Modem Ethernet Connections
41. drogen Generator eo ON SITE Installation Operation Instructions N sea 5 approximately 60 seconds the unit closes the vent valve P amp ID Tag SV329 and the system begins pressurization 4 5 PRESSURIZE STORAGE Operation This operation starts when the HOGEN generator s vent valve P amp ID Tag SV329 closes after the GENERATE VENT state During this state the system pressurizes its hydrogen lines up to the back pressure regulator set point The system pressure is set through the backpressure regulator P amp ID Tag BPR310 4 6 STEADY STATE Operation During STEADY STATE operation the system outputs hydrogen through its product hydrogen port There are two modes the system can run in during SIEADY STATE operation load following mode or tank filling mode 4 6 1 Load Following Mode This mode maintains pressure at the set point 225 psig for current production units and 200 psig for early production units as long as the demand for hydrogen does not exceed the rated capacity of the product 4 6 2 Tank Filling Mode In tank filling mode the product pressure transducer P amp ID Tag PT312 controls the gas generation cycle of the HOGEN generator At pressures below the product pressure set point full rated flow of hydrogen is delivered When product pressure reaches the product pressure set point the power used to generate hydrogen is automatically switched off and the unit goes into an idle state The HOGEN generator maintai
42. e Send to File button to save a particular set of parameters to a file 6 FOR CALIBRATION FILES ONLY To copy the calibration constant values to a clipboard select the Copy Data to Clipboard button Application and FPGA Downloads To download application and FPGA codes to the system Service Level or higher security required use the following procedure 1 Power off the unit 2 Press and hold the stop and select button on the keypad display 3 While holding the stop and select button power on the unit PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 60 of 72 8 e 3 O T O N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions 4 Continue to hold the stop and select button until the word IDLE is displayed on the screen The unit is now in IDLE mode and it is safe to load the software Select VIEW gt APPLICATION or FPGA OPTIONS as reguired from the toolbar 6 To select a file to download select the Change Path button file installed on host computer or via a network connection 7 To download a listed file to the system select the Send to Device button HOGEN 40 1 289 File Edit View Tools Window Help oela S mel e z v FPGA BIN Path J Application BIN Path D NAAPP BIN Send to Device n r Presence ID UNAVAILAELE Sandi Deres ode Presence ID UNAVAILABLE ersion UNAVAILABLE IN version
43. e 12 of 72 a e L R O T 0 N HOGEN S Series 2 Hydrogen Generator Nee ON SITE Installation Operation Instructions The front panel of the crate is marked with the words Removable Panel The screws that need to be removed from the crate are marked with red for recognition purposes Figure 5 Removing the Front Panel Marked Removable Panel 4 Remove the front panel Ensure that trained personnel use the forklift to avoid serious injury and potential damage CAUTION to the unit 5 Usinga forklift slide the left fork underneath the left side of the unit and the right fork underneath the right side of the unit 6 Usinga forklift lift the unit up 6 inches before backing the unit out of the crate Refer to Figure 6 Figure 6 Removing Unit from Crate with Forklift PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 13 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions N sea 5 Do not slide or push unit on its leveling feet The leveling feet will break off Leveling feet CAUTION must be fully retracted and the unit must be lifted to be moved 3 2 Facility Air Ventilation Requirements The HOGEN generator design implements ventilation in accordance with EN60079 10 Zone 2 NE In reference to NFPA 496 a Type Z pressurized ventilation scheme is implemented A blower at the fresh air inlet forces an excess of 750 cubic feet per minute CFM of fresh p
44. ececsessnsececeeeceeseesnsaececceesseaeceesesesenseaeseeeeeeeenees 19 20 60 66060666 0 0666 FIGURE 10 ALARM CONTACT CONNECTIONS 21 200 50 FIGURE 11 FRONT AND 22 0 101 1 1 1 1 1 1 1 1 1 1 1 FIGURE 12 REAR VIEW 23 6 6 06 60 00600000000066 FIGURE 13 SUGGESTED PLUMBING ORIENTATION 26 06 66666660 FIGURE 14 COMBUSTIBLE GAS SENSOR CALIBRATION KIT WITH CALIBRATION HOOD FIGURE 15 COMBUSTIBLE GAS SENSOR REMOVAL ccscsesssceeececsesssuececececcecseueaeseeececeesuasececececeessaeeeeececeeseaaeaeeeeeceene 27 FIGURE 16 COMBUSTIBLE GAS SENSOR REMOVED csssesssseeececsesessececececcecseseaececccecseaaececececsesesaeeeeececeeneausaeeeeeeeene 27 FIGURE 17 CALIBRATION HOOD INSTALLED ON COMBUSTIBLE GAS SENSOR ccccceesesssseeececeesessececeeeceenenseaeeeeeeeeceenes 29 FIGURE 18 CELL STACK AND HYDRATION HOSES porcie aeei pee e RENE a ESE REA E E IRES EE ati 31 33 FIGURE 19 BASIC CONTROL SEQUENCE virsien e EE E E a ATT E A s ES EESE 34 FIGURE 20 CONTROL PANEL DETAILS siniese oeeie sis RE AEE E i 47 E E E EERE E
45. efer to Figure 10 24 VDC is present on pin 6 NOTE PJ43 Pin Connections l Number Relay Com Relay NC Relay NO Remote E Stop Remote E Stop o 02 PO Figure 10 Alarm Contact Connections Table 4 Alarm Contact Connections 3 6 Mechanical Interfaces This section provides a detailed description of the mechanical interface requirements The physical layout and dimensions of the HOGEN S Series 2 hydrogen generator are shown Detailed interface connections for the hydrogen outlet and water supply are supplied also 3 6 1 Physical Layout Connections and Dimensions The physical layout of the HOGEN S Series 2 hydrogen generator is shown in the following figures PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 20 of 72 HOGEN S Series 2 Hydrogen Generator Installation Operation Instructions 0 Page 21 of 72 Units Inches Reference Dimension O DIO VO Z ZTA PROTON ON SITE Units Inches cm 30 9 78 5 40 9 103 9 21 9 55 6 25 9 65 8 38 2 97 0 35 6 90 4 4 5 11 4 2 1 5 3 11 5 29 2 4 6 11 7 Figure 11 Front and Right Side Views Tal th Reference Dimension A C T O TIIMI OD O W Table 5 Dimensions for Front Right Side and Rear Views CONFIDENTIAL Do not copy P PD 0100 0001 REV M
46. en Generator vents hydrogen during startup system depressurization dryer purging cycles and overpressure relief During startup of the HOGEN generator the full production rate of hydrogen is vented while the unit is in the GENERATE VENT state Once the system switches states the vent valve P amp ID Tag SV329 closes and the system begins to pressurize During system shutdown the entire on board inventory of hydrogen approximately 0 5 SCF 0 01 Nm is vented Depressurization occurs when the vent valve P amp ID Tag SV329 is opened allowing hydrogen to flow out of the H H O vent The internal dryer of the HOGEN generator is a pressure swing dryer In order to function properly each bed operates alternately in two half cycles of equal duration pressurization followed by adsorption and depressurization followed by a purge It is during this purge that hydrogen is blown out of the non operating bed and directed out the H2 H20 vent During these purge cycles approximately 10 percent of the production rate of hydrogen will exit the H2 H2O vent port with residual moisture If a vent bypass valve is implemented reference Figure 13 for a suggested plumbing orientation This suggested orientation prevents any water build up in the vent line from entering the hydrogen product line when the vent bypass valve is opened a e Ne 3 6 3 PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 23 of 72 fie a a H R O T O N HOGEN S Series 2 Hydr
47. erature The maximum rated operating temperature for the HOGEN generator is 140 F 60 C The system will shutdown automatically when the system temperature is over this rating Temperatures above the maximum rating will damage the cell stack The HOGEN generator can be stored and transported in environments that range from 41 F to 140 F 5 C to 60 C and 0 percent to 95 percent relative humidity non condensing In the event that the unit is to be transported in a freezing environment water must be drained from the system and the cell stack is to be taken out of the system and transported separately Instructions for the decommissioning of the system are detailed in the Service Manual PD 0300 0001 If freezing conditions exist at your site you must take measures to prevent condensation from freezing and obstructing the H vent line and freezing the water supply and drain caution lines 3 4 Site Preparation The HOGEN S Series 2 hydrogen generator is designed for indoor installation on a level concrete pad AC power and deionized water are the key utilities required Ensure the generator is located so that it is safe from vehicle traffic and is in compliance with local safety regulations The HOGEN generator sits on four leveling feet and weighs about 500 Ibs 227 kg To move the generator use a fork truck to lift it from under its frame Alternatively straps can be used around the bottom and sides as a lift method A level floor 3
48. eries 2 hydrogen generator for a period of longer than 1 month then make provisions to keep the cell stack hydrated Page 42 of 72 Contact PROTON field service for advice on your application CONFIDENTIAL Do not copy PD 0100 0001 REV M fie yl A R O T 0 N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions Wo 5 APPENDIX A INSTALLATION CHECKLIST PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 43 of 72 we oe f O T 0 N HOGEN S Series 2 Hydrogen Generator Neo ON SITE Installation Operation Instructions Installation Checklist This checklist is intended to guide installation personnel during the initial installation of a HOGEN hydrogen generator at a customer site This form should be completely filled out and faxed back to Proton personnel arriving on site for the installation verification and initial start up phase 1 Power 1 1 Provide the plated electrical service including Protective Earth ground to the hydrogen generator following local wiring codes for industrial equipment installation Refer to Section 3 5 Initial Date 1 2 Verify proper electrical service is provided for the installation Unit Volts Phase Amps Hz kVa S10 205 240 1 30 50 60 5 8 520 205 240 1 30 50 60 7 2 540 205 240 1 50 50 60 12 0 Actual Initial Date 2 Fluids Hookup 2 1 General guidel
49. essing the STOP RESET button cancels all actions of the current step and brings the user back to the previous step A calibration error is signified by displaying EE FARA 19 To verify calibration power up the system while depressing the SELECT and PRODUCT PRESSURE buttons This allows the system to enter the combustible gas sensor verification state PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 29 of 72 P R 0 T O N HOGEN S Series 2 Hydrogen Generator ON SITE Installation Operation Instructions After powering up the system in the verification state the symbol BE FL displays for 10 seconds to signify gas verification After the BC FC symbol is removed the symbol OAE is displayed to signify 0 percent LFL assuming the sensor is reading 0 percent LFL Apply the calibration gas to the sensor head by turning on the calibration gas supply The first two digits of the symbol lt OOFPO change based on the sensed value of combustible gas If the 0 and cal gas percent readings are not within 2 percent LFL as determined by the user the calibration procedure is to be repeated If the verification readings are acceptable shut down the system using the main power disconnect switch Reinstall the combustible gas sensor removed in Step 2 using the two 2 retention Screws Restart the unit in normal operating mode 20 21 22 23 24 a e Ne PD 0100 0001 REV M CONF
50. gen concentration does not build to unsafe levels THE OXYGEN VENT LINE MUST REMAIN FREE FROM OBSTRUCTIONS AND KEPT FROM FREEZING 3 6 5 Water Interfaces The water ports are 14 diameter polypropylene plastic tube fittings Figure 3 shows the connection locations of these two ports Polypropylene plastic tubing is highly recommended for the water feed line FEP and PFA plastics are also highly recommended for protecting the cell stack The only recommended metal line is clean passivated 316SS The drain line should be appropriately plumbed based on your specific facility requirements Post deionization water tanks should be constructed from polypropylene only as stainless steel tanks will leach out impurities that will damage the system The HOGEN generator uses deionized water to produce hydrogen and to actively cool the cell stack The HOGEN generator requires a minimum of ASTM Type II deionized PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 24 of 72 CAUTION WARNING WARNING CAUTION WARNING R 0 T O N HOGEN S Series 2 Hydrogen Generator ON SITE Installation Operation Instructions water ASTM Type II deionized water calls for a resistivity of at least 1 0 MQ cm and a maximum 50 ug total organic carbon per L of water Other qualities of the water can be found in ASTM designation D1193 99 Standard Specification for Reagent Water Although ASTM Type II water is reguired ASTM Type I deionized water is recomme
51. gs to the unit 15 v Sample Rate 16 v Figure 31 Real Time Data Configuration Window a To obtain a file of parameters signals to collect select the Get Settings From File button b To save a particular set of data collection parameters to a file select the Save Settings To File button c Tosenda selected set of signals for data collection to the system along with a sample rate use pull down menus as necessary to make selections Upon completion of the selections select the Send Settings To Unit Button d Upon completing the configuration setup for the Real Time Data Collection select the Done button 2 To monitor a pre selected set of parameters see Step 1 select the Start Monitoring button To end the monitoring session select the Stop Monitoring button 3 To begin streaming data collection of a pre selected set of parameters select the Start Streaming button and verify the Direct to File box is checked a Select the file name and path to stream to then select Save b To end the Real Time Streaming session select the Stop Streaming button 4 If communication to the system is lost while in the middle of real time streaming select the Reset Unit button to stop the streaming process and allow for proper disconnection from the system Options To set or adjust file paths and communication options use the following procedure PD 010
52. iary equipment is used to aid in the functions of the system circulating water drying hydrogen pressurizing hydrogen and shutting down the system The unit contains sensors and a control board to aid in monitoring system performance and to automate operation Figure 2 shows the HOGEN S Series 2 hydrogen generator schematic The design also shows the system s boundaries and important interface connections Water is introduced into the system Hydrogen water and oxygen are emitted Figure 2 HOGEN S Series 2 Hydrogen Generator Schematic 0001 REV M CONFIDENTIAL Do not copy Page 7 of 72 H2 PRODUC v MARELESE TUBE H20 v r PUS FOLDER H20 DRAIN FOLOGK PD 0100 fie a N H R 0 T 0 N HOGEN S Series 2 Hydrogen Generator et ON SITE Installation Operation Instructions Wo 5 1 2 Product Specification Description On site hydrogen generator in integrated automated site ready enclosure Load following operation automatically adjusts output to match demand Electrolyte Proton Exchange Membrane PEM Caustic Free Hydrogen Production Requirement 10 20 40 Net Production Rate 10 SCFH 0 26 Nm3 h 20 SCFH 0 53 Nm3 h 40 SCFH 1 05 Nm3 h 4 7 SLPM 9 4 SLPM 18 8 SLPM 0 56 kg 24hr 1 14 kg 24hr 2 27 kg 24hr Delivery Pressure Nominal 200 PSIG 13 8 barg Power Consumed Volume of 9 4 kWh Nm3 9 0 kWh Nm3 8 3 kWh Nm3 Hydrogen Gas Produced Est
53. iguration File Calibrate CG sensor Set Time and Date Call Factory Reset default passwords Reset Elapsed Timer Load System Info File Call Factory Call Factory Call Factory Call Factory Call Factory Load System Info File Load System Info File Table 10 Post Error Codes Corrupt PID Load Corrupt Parameter Load Corrupt GasCal Load Corrupt RTC Set Corrupt RTC OSC Corrupt Name amp Password Corrupt Generation Hours Corrupt System Information Corrupt CG Test Load Corrupt CG Drift Recal Corrupt CG Peak Recal Corrupt CG Full Prod Recal Watchdog Test Failure Post Remote Info Load Post Remote Email Load Code SININ MN A NM rR oO ALANA NA ninihnihninininmihnihnihnininininin i O NM A WD PR gt 4 11 Routine Maintenance and Extended Shut down Routine maintenance schedules are defined in the Maintenance Manual PD 0200 0001 Operators should regularly inspect the incoming air filter to establish the change frequency required under local or seasonal conditions Extended shut down of the HOGEN S Series 2 hydrogen generator is considered to be one month or longer without operation The HOGEN generator must be kept hydrated or damage to the PEM cell stack may occur PROTON recommends a schedule of monthly operation of the generator to maintain good water hydration of the cell stack If you need to shut down the HOGEN S S
54. in place as the cabinet must maintain a minimum of 0 2 water column 25 Pa pressure in order for the system to operate 1 Verify the cabinet doors are closed and secured 2 Verify the air inlet and exhaust openings refer to Figure 3 are not blocked Switch the Main Power Disconnect Switch refer to Figure 3 from the OFF O position to the ON position I position POWER IS STILL PRESENT AT THE CIRCUIT BREAKER Electrical Schematic Tag CB101 IN THE GENERATOR UNTIL THE MAIN POWER DISCONNECT SWITCH IS WARNING DEPRESSED TO THE OFF POSITION PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 34 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions Wo 5 ONLY USE THE E STOP IN EMERGENCY SITUATIONS TO REMOVE POWER TO THE SYSTEM USE THE STOP BUTTON ON THE KEYPAD DISPLAY AND WAIT FOR THE SYSTEM TO COMPLETE A NORMAL STOP RED LED ON STOP BUTTON WILL BE FLASHING 4 3 PRE START Operation PRE START operation begins automatically when the main power disconnect switch is turned ON During this operation the following occurs 1 The system flushes itself out if water guality is below the reguired resistivity 2 Water levels in the oxygen water phase separator P amp ID Tag A200 and hydrogen water phase separator P amp ID Tag A300 are adjusted if they are low 3 During the PRE START process a dashed line moves across the center of the display
55. ines All water drain and vent lines should be heat traced and insulated if freezing temperatures may be experienced All plumbing materials should conform to the guidelines outlined in Section 3 6 Listed below are the fluid connections that need to be connected prior to system operation e Feed water in accordance with ASTM TYPE II minimum required ASTM TYPE I recommended gt 1 M2 cm Initial Date PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 44 of 72 fie a A R O T 0 N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions N sea 5 e DI water drain connected and free from obstruction and freezing Initial Date e Verify the oxygen vent is free from obstruction and freezing Initial Date e Hydrogen vent installed in accordance with local codes and free from obstruction and freezing Initial Date e Hydrogen product connected to process in accordance with local codes Initial Date Pressure must be reduced prior to the process connection if less than 200 psig is required NOTE 3 Site Information Generator Model Serial Number Customer Name Customer Site Site Contact Site Phone Signature Please fax Installation Checklist to ATTN Customer Service at 203 949 8016 PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 45 of 72 fie yl A R O T 0
56. n Operation Instructions N sea 5 APPENDIX E DI WATER OPTION PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 53 of 72 4 De o P 3 Ci T Cj N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions Agua Solutions amp Deionized DI water treatment system is designed to support the S Series 2 HOGEN hydrogen generator The system is designed to provide Type 2 or better DI water to one or more HOGEN S Series hydrogen generators The system reguires tap water a drain and a grounded 100 240 VAC 50 60 Hz electrical outlet in order to operate properly The system can be bench wall or shelf mounted up to 10 feet from the hydrogen generator Figure 26 Agua Solutions DI Water Option Refer to the Agua Solutions Model H 40 C Operating Manual Revision 3 02 10 04 or later for information regarding your DI water system PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 54 of 72 iee 3 O T O N HOGEN S Series 2 Hydrogen Generator Se ON SITE Installation Operation Instructions se a APPENDIX F WINDOWS DIAGNOSTIC SOFTWARE OPERATION PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 55 of 72 a e P R O T 0 N HOGEN S Series 2 Hydrogen Generator Neo A ON SITE Installation Operation Instructions Windows based Diagnostic Software is available as an option for the HOGEN S Series 2 hydrogen generator and can be purchased through Proton The software enables users to monitor data data
57. n the control board PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 65 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions Wo 5 Pop Up Errors To view the Pop Up Errors use the following procedure 1 Select VIEW gt ERRORS from the toolbar 2 The Pop Up Error box displays all current Warning and Shutdown Error Codes associated with the system 3 In order for the Pop Up Error box to automatically display on a Warning or Shutdown condition the Diagnostics screen must be Sampling Data Errors and Warnings can also be seen in the System Monitoring screen while monitoring the unit Communications over Ethernet TCP IP 10 100 Base T Requirements e Host Computer with Windows 2000 or Windows XP Professional e Ethernet Card and Associated Cable Maximum Cable Length of 100 Meters between Transmitter and Receiver System Information To set or adjust Ethernet communication options for IP and Email addresses use the following procedure 1 Select VIEW gt SYSTEMS INFORMATION from the toolbar 2 Entries are reguired for the following sections and must be obtained from a Network Administrator IP Address Subnet Mask Gateway DNS Server To Email Address SMTP Server and SMTP Domain 3 The remaining sections can be entered in based on the user s specific descriptions For example the Model Number Serial Number and Build Date are specific to the HOGEN gener
58. nance Figure 7 HOGEN S Series 2 Hydrogen Generator Plan View for Installation Reference Units Reference ents Dimension Inches cm Dimension inches om A 54 9 139 5 E 12 0 30 5 B 12 0 30 5 F 38 25 97 2 C 12 0 30 5 G 20 0 50 8 D 13 0 33 0 H 76 25 193 7 Table 3 Plan View Dimensions PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 17 of 72 WARNING fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions Wo 5 3 5 Electrical Interfaces Electrical interface connections are made prior to mechanical connections Once the HOGEN S Series 2 Hydrogen Generator has been properly located electrical connections can be made All user supplied I O cables which interface with this system must not exceed 30 meters 98 4 feet in length 3 5 1 Surge Protection The HOGEN hydrogen generator is designed tested and certified to meet the electrical surge immunity standards as stated in IEC 61000 4 5 Supply voltages higher than specified may result in system damage Voltage surges higher than 2 Kv may result in system damage It is recommended that the customer provide CAUTION adequate surge protection in the plant power distribution so as to minimize any potential damage to the HOGEN system PROTON offers a Surge and Under Over Voltage Relay Module KT 1000 0032 to minimize the effects of out of specification line voltage conditions such a
59. nded By using the highest guality water recommended the life of the guard bed cartridge and the cell stack will be extended The water guality sensor will trigger a failure if water quality drops below 1 MQ cm Therefore it is highly recommended that ASTM Type I deionized water be used to prevent this failure Water levels are controlled within the HOGEN generator control logic system When the water level drops below a set point in the Oxygen Water Phase Separator the Water Feed Valve P amp ID Tag SV510 is opened to allow water into the system through the water inlet Water is drained from the system during startup and when water guality is not maintained During initial startup approximately 2 gallons 8 liters of deionized water may automatically be drained out of the system When water quality is below 1 MQ cm the system flushes out by opening the Drain Valve P amp ID Tag SV211 and water feed valve P amp ID Tag SV510 This allows water to be drained while adding fresh deionized water to the system An internal water guality sensor controls this process This feature ensures that the water guality meets the minimum reguirements before electrolysis begins ME 109 0 Ne An obstructed drain line could prevent the HOGEN generator from draining properly and may result in permanent damage CAUTION DO NOT USE copper aluminum iron or other metal for deionized water inlet tubing as this will result in significant contamination and
60. ns Module Software Operation ss CONFIDENTIAL Do not copy a e CO 1 App App App App App App App PD 0100 0001 REV M PROTON HOGEN S Series 2 Hydrogen Generator et ON SITE Installation Operation Instructions LISTS OF FIGURES aa ennen 6 enaa naa aa 6 06 FIGURE I HOGEN S SERIES 2 HYDROGEN GENERATOR oooooossunn 7 6 6 6 6 06 00 501113114112 FIGURE 2 HOGEN S SERIES 2 HYDROGEN GENERATOR 11 66 0 6 6 06 00 0 0000 FIGURE 3 HOGEN S SERIES 2 HYDROGEN GENERATOR INTERFACE CONNECTIONS 12 13 FIGURE 5 REMOVING THE FRONT PANEL MARKED REMOVABLE PANEL 13 1011611171 FIGURE 6 REMOVING UNIT FROM CRATE WITH 17 6 6 6 1011 666 1 1 1515 FIGURE 7 HOGEN S SERIES 2 HYDROGEN GENERATOR PLAN VIEW FOR FIGURE 8 ELECTRICAL INTERFACES ON THE REAR PANEL ccccecessesscecececsesseaeeecececceceeeseeeccesesseaeaesecseeeseusaeseeeeeeeenees 19 FIGURE 9 TERMINAL CONNECTIONS OF MAIN POWER FEED ssessscce
61. ns the idle state until the product pressure drops below the product refill pressure set point When this does occur the HOGEN generator again delivers full gas production until the product pressure reaches the product pressure set point PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 36 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions N sea 5 4 7 Monitoring Operation The HOGEN S Series 2 hydrogen generator is equipped with on board sensors to monitor system conditions within the unit The digital display is a 4 digit 7 segment display with the ability to display five different parameters during normal operation Pressure Set Point The output of the pressure set point circuit is scaled for 0 to 225 psig 0 to 1 551 kPa 200 psig for units before serial number 342 and is accessed by pressing either display scroll key for 5 seconds There are two pressure set points that can be set Product Pressure and System Pressure The Product Pressure Key and the System Pressure Key gives the operator the ability to toggle between the two values Operating Parameters Basic system operating parameters can be accessed once the system has reached pressure and is delivering gas The parameters can be displayed by adjusting the up down arrow keys while the generator is in this mode of operation The display of a particular parameter is preceded by a 2 letter symbol identifying
62. o retrieve or send configuration or calibration parameters Technician level or higher security required for sending use the following procedure 1 Select VIEW gt CONFIGURATION or CALIBRATION OPTIONS as required from the toolbar 2 Select the Get From Device button to upload parameters from the system Note Configuration parameters P 00 through P 11 will appear in the shaded boxes 3 Select the Get From File button to obtain a specific file installed on host computer or via a network connection PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 59 of 72 wee P f O T 0 N HOGEN S Series 2 Hydrogen Generator o ON SITE Installation Operation Instructions HOGEN 40 v1 289 8 x File Edit View Tools Window Help plela S lele e z v xi GAS DETECT WATER QUALITY Offset 333 34836426 Reference Voltage 119 fan 061727305 fan 003133303 PRODUCT PRESSURE Curent Ref us 21 8321532 mm ms fan Josissessa SYSTEM PRESSURE Send to Device onset 52 80787653 foss __SetFomDevice STACK VOLTAGE ps Offset 0 32420959 Get From File ran 1 02389526 Copy Data to Clipboard m STACK CURRENT Offset 0331 03943 aain 0 157501 22 Unit Configuration 70 HESTER SE ra rss Device Settings Relative Time Absolute Time P 00 System Pressure I psi I 225 225 v Step 1 Adsorb A Transition to Regen 8 3 P
63. ogen Generator eo ON SITE Installation Operation Instructions N sea 5 The HOGEN generator is equipped with a pressure relief valve If the system experiences an over pressure condition the relief valve cracks open and allows the system to depressurize by allowing hydrogen to flow out the H2 H2O vent The pressure relief valve RV308 is factory set at 265 psi and should not be adjusted The H gt H gt 0 vent port uses a Parker CPI compression tube fitting for 1 2 OD tubing Figure 3 shows the connection location The vent line to be attached to the port should be installed per NFPA 50A The hydrogen should be vented separately into an approved hydrogen vent stack Due to the residual moisture that exits through the H2 H2O vent port it is recommended that a trap is employed to properly handle the accumulation of condensate DO NOT ALLOW HYDROGEN TO VENT INDOORS NEAR VENTILATION INTAKES WORK AREAS OR ANY SOURCE OF IGNITION THE HYDROGEN VENT LINE MUST REMAIN FREE FROM OBSTRUCTIONS AND KEPT FROM FREEZING 3 6 4 Oxygen Interface The HOGEN generator produces oxygen in its electrolysis process This oxygen gas and small amounts of water condensate are vented out of the system via the oxygen vent port The oxygen gas production rate is approximately 50 of the hydrogen production rate and exits at ambient pressure from the Oxygen Water Phase Separator P amp ID Tag A200 Adequate ventilation must be provided to assure that oxy
64. on to the HOGEN generator gas generation process Upon shutdown of the unit the controller shows the error code for Time Activated On Power Up On Start Switch On Start Switch On Pressurize 60 120 Sec S40 S20 amp S10 Dependent On Power Up On Power Up On Power Up On Power Up On Power Up On Power Up On Power Up On Power Up On Power Up On Power Up On Circ Test 10 Sec On Power Up On Generate 5s On Generate 5s On Start Switch On Drain 30s On Generate On Generate 15 30s S40 S20 amp S10 Dependent On Circ Test 20s On Circ Test 20s On Circ Test 10s On Power Up C 03 180 sec On Power Up On Power Up On Circ Test 10s On Power Up 2 hrs Page 40 of 72 Sensor P amp ID Tag N A CG220 CG220 PT307 N A N A N A N A N A N A N A N A N A PT312 TS218 Stop Switch N A N A LS201 1 LS201 4 LS301 1 LS301 4 RS209 RS209 WS207 PT307 PT307 PT312 CG220 TS218 LS201 Default Limit gt 3 Months lt 2 LFL lt 1 LFL lt 180 psig VCC lt 4 75 VCC gt 5 25 VEE lt 5 25 VEE gt 4 75 lt 3 135 gt 3 465 lt 22 8 lt 22 8 gt 25 2 gt 250 220 psig gt 50 Switch Closure gt Cells x 2 6 lt Cells x 0 5 lt Empty Level gt Flooded Level lt Empty Level gt Flooded Level lt 1 MO cm gt 18 MQ cm lt 3 79 LPM 1GPM gt Pressure Set Point 25 50 psig lt 180 psig g
65. or via a network connection 3 To download a listed file to the system select the Send to Device button 4 A system power cycle or a control board reset is reguired for the parameter change to be accepted erogena IITTI sep File Edit View Tools Window Help osa a selel sllu 133 Application BIN Path E H40COMMS bin Send to Device re 6 CB SF PM mre CRC 23 56 23 4E Figure 33 Communications Module Application Window PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 70 of 72 we P 3 Ci T O N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions N 5352 Communications Module Website As a troubleshooting aid the communications module hosts a simple website This website consists of the Proton logo along with a counter that is updated every five 5 seconds In the event the user is unable to communicate to the communications module with Windows Diagnostic software use the following instructions 1 Enter the IP address assigned to the communications module into the Address section of Windows Explorer example http 192 168 10 99 and select ENTER 2 If the website can be accessed then a connection to the communications module exists Verify the System Information and Options sections of the Windows Diagnostics software 18 xJ Quo BS 8 1 x 26 N Hogen 40 Webpage Me y Ef Addres
66. r IP Address 2777 i Path D Mlogging tsv SV340 No I Data Log Log On L 30 00 Power and ENERGY SYSTEMS Control Equipment Software Version Communications port COM4 closed 9711 2009 17 20 AM Figure 27 System Monitoring Screen Logging Data 1 Select Path and choose a file name and location to log the data to 2 Select a sampling Interval minimum 3 seconds maximum 60 seconds 3 Click on the Log Data Switch Errors and Warnings Errors and Warnings are displayed live while the software is monitoring To clear Errors and Warnings from the screen press the Clear button The System Monitoring screen must be stopped press the Stop Monitoring button to perform other functions use Diagnostics screen get set configuration or calibration files etc 2 Diagnostics 1 Select VIEW gt DIAGNOSTICS from the toolbar PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 57 of 72 Monitoring Button Clear and Buttons Start Path NOTE HOGEN S Series 2 Hydrogen Generator Installation Operation Instructions 8 13AM 3 30 2009 SET j Stack Current Enable 2 Oef mn 13 Joer 0 log F Errors S Warnings POST Errors I Log Errors and Wamings Fv peke Update Inhibit Writes Monitor Mode ae PROTON we ON SITE Inputs an
67. ransducer System Temperature Sensor System Temperature Sensor Code E 16 E 17 E 18 E 19 E 20 E 21 E 22 E 23 E 24 E 25 E 26 E 27 E 28 E 29 E 30 E 31 E 32 E 34 E 35 E 36 E 37 E 38 E 39 E 40 E 41 value for units before serial number 342 or Tank Filling Units Table 9 Warning and Error Codes for HOGEN S Series 2 Hydrogen Generator Table 9 lists the possible warning and error code displays their cause and the system response as warning or controlled shut down and depressurization Consult the maintenance manual or PROTON field service for corrective action Page 41 of 72 CONFIDENTIAL Do not copy PD 0100 0001 REV M Activated On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U On Power U 5 3 o o o o o eprops Io 82 HOGEN S Series 2 Hydrogen Generator Installation Operation Instructions Sensor N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A N A PROTON ON SITE Description Comment Corrupt FPGA Load Call Factory Corrupt FPGA Scratch Call Factory Corrupt Dataflash Init Call Factory Corrupt Calibration Load Load Calibration File Load Configuration File Load Conf
68. rvnnnvnnvvrnvernvnnnenrennrennvennee Operation sama EA 4 1 Control 2 lt 9100 4 2 Turning ON the Main Power 4 3 PRE START Operation ronnrononvnonnnnnnrnnnnnnnnvrnnvennnerervrarvrervrnsvenve 4 4 GENERATE VENT Operation ccccccsccsesceesceesceeecesecnsecnseenseens 4 5 PRESSURIZE STORAGE Operation 660666660666666 66 60 4 6 STEADY STATE 0263 0110114 102226620613 8601 64 11661 ai 4 7 Monitoring 002310180116 4 8 Automatic Warnings 421 1 1 49 Manual 1 1 1 1 1 1 1 1 1 avas es aan asen seen 4 10 Automatic Shutdowns 4 11 Routine Maintenance and Extended Shut down endix A Installation Checklist uuoouussn in n an aan aa endix B Options Diagram eouuuusssss nene n an eaa naa naa naene eaa endix C Crossover Manifold Option osusssss n ae endix D Pressure Reducing Regulator Option osusosss nenne endix E DI Water Option ee eee e e na ea a aa irine endix F Windows Diagnostic Software Operation 0 0 0 0 eee eeeeees endix G Communicatio
69. s Section ENERGY SYSTEMS 18 This page refreshes every five seconds S counter 1134916113 a Ea 8 HO a a0 Ad EI 8 Done E nternet Figure 34 Communications Module Hosted Website If while performing a Read or Write operation and communication is lost a Socket Error message may appear at the bottom of the Windows Diagnostics page If communication does not re establish automatically try one of the following 1 Close and then re open the Windows Diagnostic software 2 Reboot the control board PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 71 of 72 NOTE a e P R O T 0 N HOGEN S Series 2 Hydrogen Generator Nee ON SITE Installation Operation Instructions To prevent a potential communication loss perform only one action at a time For example stop sampling or logging data prior to performing a Write operation such as logging into CAUTION the system as Technician or Service Once communication is re established after a loss such as reconnecting a cable it may take up to 60 seconds before full communication to the control board can be restored NOTE PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 72 of 72
70. s low voltage or large voltage transients NOTE To ensure proper operation the user of this system is responsible for providing adequate surge protection for power being supplied to the system Otherwise in the event of an AC main high voltage surge the system may shut down in the following manner e Product hydrogen flow and pressure will be lost e System pressure will begin to bleed down until the C 03 Low System Pressure warning is reached The system may then shutdown on E 02 Low Cell Stack Voltage e Upon shutdown the system power will need to be shutdown for a minimum of 5 seconds The circulation pump must be allowed to perform its normal 60 second water circulation This shutdown allows the power supplies to clear a latched fault e After the minimum 5 second shutdown the system may be restarted and brought to normal operation 3 5 2 Cabling Procedure The power connections made must be weather tight airtight and compliant with electrical codes A minimum 6 AWG wire is recommended The power connection must be sealed to prevent air pressure leakage The internal cabinet Gronow Must be pressurized during operation Air pressure must be maintained PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 18 of 72 o s E O T O N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions No Figure 8 Electrical Interfaces on the Rear Panel Proton requires the use of ferr
71. sername and password feature will no longer be fully operational to the customer once the service administrator logs out of the NOTE _ System Also sending a list of new usernames and passwords without the default usernames and passwords will result in deleting the defaults from the control board 4 Reference the attached Table for a list of username and password permissions Function Performed Minimum Security Level Set Time and Date Technician Reset Elapsed Timer Technician Calibration File Load Technician Configuration File Load Technician Application Load Service PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 63 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator e ON SITE Installation Operation Instructions FPGA Load Service User Name and Password Change Service Real Time Data N A Diagnostics Logging N A Read Time and Date N A Read Elapsed Timer N A Read Calibration File N A Read Configuration File N A Read Application Version N A Table 11 Function Needs for Usernames and Passwords 5 The Default password for the control board is case sensitive Username Technician Password PRTNTECH Technician 6 In the event they have been corrupted or eliminated performing a specific power up sequence will retrieve default usernames and passwords Power down the system Power the system back up while depressing keypad buttons Start Stop Selec
72. stallation Operation Instructions To Procesa H Storage EEE Cross Over Manifold _ 4 Hydrogen Generator Figure 24 Crossover Manifold Diagram PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 50 of 72 fie yl 3 O T O N HOGEN S Series 2 Hydrogen Generator et ON SITE Installation Operation Instructions N sea 5 APPENDIX D PRESSURE REDUCING REGULATOR OPTION PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 51 of 72 a e P R O T 0 N HOGEN S Series 2 Hydrogen Generator Neo ON SITE Installation Operation Instructions The HOGEN S Series 2 is capable of supplying product hydrogen up to 200 psig The hydrogen product line pressure can be reduced from 200 psig down to ambient using a pressure reducing regulator The pressure reducing regulator may be installed anywhere between the product outlet on the HOGEN S Series 2 system and the point of use Selection of a regulator must be rated for hydrogen service The reducing regulator should be sized for the desired pressure drop and maximum flow rate The unit can only produce its rated output of flow If flow requirements exceed the unit s rated output flow it cannot maintain the desired delivery pressure Reducing HOGEN 40 Figure 25 Pressure Reducing Regulator Schematic PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 52 of 72 CAUTION fie yl H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installatio
73. t Product Pressure Set Point 25 20 psig gt 50 LFL gt 60 C gt 2 Hours CONFIDENTIAL Do not copy the type of shutdown on the 4 digit 7 segment display Description Calibration Gas Warning Calibration Gas Drift Warning Calibration Gas Peak Warning System Pressure Low Warning VCC Low Warning VCC High Warning VEE Low Warning VEE High Warning 3VDC Low Warning 3VDC High Warning 24VDC Low Warning VREF Low Warning VREF High Warning High Product Pressure System Temperature Low Warning Manual Shutdown Cell Voltage High Cell Voltage Low A200 Empty A200 Flooded A300 Empty A300 Flooded Poor Water Ouality Failed Water Ouality Sensor Low Recirculation Flow System Pressure High System Pressure Low Product Pressure High Hydrogen Leak Detected System Temperature High A200 Pre Start Timeout Code C 00 C 01 0 02 C 03 C 04 C 05 C 06 C 07 C 08 C 09 C 10 C 11 C 12 C 13 C 30 E 00 E 01 E 02 E 03 E 04 E 05 E 06 E 07 E 08 E 09 E 10 E 11 E 12 E 13 E 14 E 15 PD 0100 0001 REV M HOGEN S Series 2 Hydrogen Generator Installation Operation Instructions Time Activated On Power Up 2 hrs On Generate 5s On Power Up 10s On Generate 5s On Generate 5s On Power Up All States On Generate After 1 E 06 On Circ Test 45s On Power Up
74. t and the Up arrow simultaneously Upon power up the control board will chirp Once the chirping has stopped the default passwords will have been reset Errors Warnings To view a list of runtime error codes use the following procedure 1 Select HELP gt ERROR CODES from the toolbar 2 To view a list of start up power up error codes select HELP gt POST ERROR CODES from the toolbar 3 To view a list of warning codes select HELP gt WARNING CODES from the toolbar 4 To view a list of shutdown error codes select HELP gt ERROR CODES from the toolbar 5 To view a list of Post Power Up error codes select HELP gt POST ERROR CODES from the toolbar Emulated Console PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 64 of 72 a e P R O T 0 N HOGEN S Series 2 Hydrogen Generator Neo ON SITE Installation Operation Instructions To view the Emulated Console use the following procedure 1 Select VIEW gt CONSOLE from the toolbar 2 The Emulated Console is a virtual representation of the front keypad display on the system In order for the Emulated Console to be active the Diagnostics screen must be Sampling Data 3 To stop the generator remotely select the STOP button o Service level security required RESET i 4 To reset or reboot the control board select the button Service level security required A RESET is required after any write command performed o
75. through PROTON KT CAUTION 1000 0022 PAJAN Amami Figure 18 Cell Stack and Hydration Hoses PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 31 of 72 a e P R O T 0 N HOGEN S Series 2 Hydrogen Generator Neo A ON SITE Installation Operation Instructions Perform the following procedure to hydrate the cell stack 1 Apply power to the generator by turning the breaker to the ON position 2 Wait for the green START button LED to begin flashing It may take approximately 20 minutes for the light to begin flashing after power is applied to the unit If the feed water pressure is low it may take over an hour for the internal water vessels to NOTE fill If this occurs Error Code 15 is triggered and the system needs to be reset 3 Once the light is flashing depress the START button 4 After 20 seconds depress the red STOP button DO NOT use the EMERGENCY STOP button to shut the system down The yellow GENERATE light illuminates after 120 seconds indicating hydrogen generation If you do not wish to generate hydrogen it is important to press the red STOP button before NOTE the 120 second time period to stop the system 5 The system circulates water through the cell stack for 60 seconds after the STOP button is depressed PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 32 of 72 a e nE 3 Cj T Cj N HOGEN S Series 2 Hydrogen Generator Nee ON SITE Installation
76. ules to connect power cables to the circuit breaker terminal CAUTION lug Figure 9 Terminal Connections of Main Power Feed 1 Remove the rear panel from the unit 2 Feed the power and ground cables through the AC Power Feed Refer to Figure 8 M 3 Connect the power cables to the terminal lugs inside the unit Refer to Figure 9 Terminals 1 and 3 are used for single phase hookup NOTE 4 Connect the ground cable to the power supply frame ground point 5 Bring the protective earth ground conductor 6 AWG into the unit along with power to the conductors 6 Terminate the conductors on the chassis ground point on the circuit breaker bracket Refer to Figure 9 3 5 3 Remote Alarm Contact and Shutdown Connections An external alarm to the HOGEN generator may be connected to confirm system status Both Normally Closed NC and Normally Open NO contacts are available on the 9 pin serial connector located on the rear panel of the generator as shown in Figure 9 The PD 0100 0001 REV M CONFIDENTIAL Do not copy Page 19 of 72 fie a a H R O T O N HOGEN S Series 2 Hydrogen Generator eo ON SITE Installation Operation Instructions N sea 5 form C alarm relay contacts are rated for 2 Amps DO NOT exceed this rating An external switch can shut down the system Multiple switches can be wired in parallel An external dry contact closure across pins 6 and 7 will trip the input power breaker and safely shut down the HOGEN generator R
77. urge air through the electrical compartment through the HOGEN generator compartment and then through the exhaust The blower is of sufficient power to maintain an internal positive static air pressure in excess of 0 2 in 50 mm of water column A pressure switch within the HOGEN generator cabinet detects any loss of ventilation pressure and will produce an automatic shutdown of the generator upon loss of pressure Further the air purge rate is such that it dilutes any internal hydrogen leakage to a concentration below the lower flammable limit LFL of hydrogen in air 4 percent A combustible gas sensor is located at the exit of the air purge stream to detect the presence of hydrogen This sensor will cause an alarm and an automatic shut down of the HOGEN generator when it detects the concentration of hydrogen within the purge air stream is in excess of 1 2 percent PROTON recommends an area air change rate of several hundred times the maximum generation rate of the HOGEN generator to preclude any possible build up of hydrogen concentration in the facility In the event of internal equipment failure such that a brief hydrogen leak occurs the HOGEN generator is equipped with an internal hydrogen detector safety circuit that will stop any further generation of hydrogen by automatically shutting down the HOGEN generator Additionally the system can be tied into facility fire detection systems combustible gas sensors or other external facility alarms

HOGEN S SERIES 2 HYDROGEN GENERATOR

Contents

Download Pdf Manuals

Related Search

Related Contents