NITROX. All Models. UHP Laboratory Hydrogen Gas Generators. UHP hydrogen generator

Transcription

1 NITROX UHP hydrogen generator UHP Laboratory Hydrogen Gas Generators All Models

2 HYDROGEN ICOM CONTENTS 1) Installation 3 1.1) Safety Warning 3 1.2) General Information 3 1.3) Technical Specification ) Key Features 5 1.4) Location of the Generator ) Recommended Location for a domnick hunter 6 Hydrogen Generator 1.5) Installation Procedure 7 1.6) Recommended System Layout ) Basic Layout ) Installation with Back-up Supply ) Installation with Multiple Generators 8 1.7) Power Connection and Sequence of Operation 9 1.8) Shutdown Procedure 10 2) Commissioning ) External Instruments and Connections 11/12 2.2) Commissioning Procedure 13 3) Maintenance ) Water Indicators ) Water Conductivity Indicators ) Deioniser Bags ) Desiccant Cartridge Indicator ) Service Kits ) Maintenance Procedures ) Replacing Water ) Filling Water Containers ) Maintaining Non-Interrupted Operation 17 4) Service Instructions ) Shutdown Procedure ) Maintenance Procedure - Replace Water ) Maintenance Procedure - Deioniser Bag Change ) Maintenance Procedure - Desiccant Cartridge Change ) Restart Procedure ) Service Record Log 27

3 5) Fault Finding ) Troubleshooting ) Displayed Errors ) Alarm Modes ) Errors and their Meanings ) External Connections ) Remote Start/Stop ) Inputs 1&2 and 3&4 35/ ) Production Stop (1&2) ) Production Hold (3&4) ) Outputs ) Alarm Out (1&2&3) ) Water Fill (1&2&3) ) Auto Remote Select 37 7) Installation Errors ) General ) Outlet Connection ) Electrical 38 8) Warranty 39 9) Declaration of Conformity 40 10) Notes 41 11) Contact Addresses 42

4 1 - INSTALLATION 1.1) Safety Warning Do not operate the generator until the information contained in this document has been read and understood by all personnel concerned. Hydrogen is not a poisonous gas but, in a concentrated form, there is a risk of asphyxiation. The generator produces a small flow of hydrogen that quickly disperses in the atmosphere, therefore minimising this risk. However, do not inhale the output gas from the outlet pipe. Oxygen is also liberated during operation of the unit. This is vented into the rear water tank. Although, during operation, the volume of hydrogen within the generator is very small, it is essential to keep the generator away from excessive heat and naked flames as there is the possibility of explosion if safety warnings are not adhered to. Position equipment to ensure unobstructed access to rear. All personnel handling, using or maintaining this generator must employ safe working practices and observe all relevant local health and safety regulations. If the equipment is not used in the manner specified by this manual then the protection afforded by the equipment may be impaired 1.2) General Information The generator will produce a constant stream of hydrogen gas at a pre-determined flow rate when connected to a suitable power supply and fed with a suitable quality of deionised water. These units are suitable for use in laboratories and light industrial environments and are non-hazardous for transportation purposes. It should be noted that the Hydrogen generator must be installed and running within three months of despatch from domnick hunter limited, to ensure the optimum efficiency of the SPE cell. If this is not adhered to this will invalidate the warranty. Note: Any interference with the calibration warning labels and internal parts will also invalidate the generator s warranty and may incur costs for rework or recalibration of the generator. If the unit needs to be returned to domnick hunter for any reason, you must drain all the water from the tanks and remove the desiccant cartridge and deioniser bags. The unit must be properly packed and shipped in an upright position.

5 1.3) Technical Specification Models: Dimensions: Weight: Water Specification: Flow Rates: UHP-20H UHP-40H UHP-60H Outlet Pressure: UHP-20H, UHP-40H, UHP-60H 680mm x 345mm x 300mm (HxWxD) 26kg >1 MΩ cm 160cc/min hydrogen 250cc/min hydrogen 500cc/min hydrogen psi g Hydrogen Gas Purity: % Mains Supply: VAC Hz Fuse Rating: Input Mains Fuses Manufacturer, Bussmann, Type S505, Rated 250V, F5AT. Manufacturer, Littelfuse, Type Series 215, Rated 250V, F5AT Alternate Input Mains Fuses Listed, Rated 250V, F5AT Power Consumption: UHP-20H Watts UHP-40H Watts UHP-60H Watts Water Consumption (approximate) UHP-20H: UHP-40H: UHP-60H: 128cc per day/0.9 litres per week 256cc per day/1.8 litres per week 511cc per day/3.6 litres per week Figures based on full flow with 24 hour operation at 22ºC ambient. Gas Drying: Ambient Temperature: Refillable molecular sieve +5 to +40 C

6 1.3.1) Key Features Start-up system check Automatic leak test Automatic calibration Remote start/stop facility Water full indicator Water low indicator Water empty indicator and alarm Flow indicator Conductivity sensor/alarm Maintenance indicator Automatic pressure sensing Safety shutdown on rapid pressure loss Audible alarm warning 1.4) Location of the Generator Locate indoors in a clean environment with good ventilation. Protect from water spillage. Keep well away from static electricity and naked flames. Install on a level site. Allow minimum clearance of 50mm around the generator for ventilation purposes. Ensure mains supply corresponds with the generator rating plate and is fully earthed to ground.

7 1.4.1) Recommended Location for a domnick hunter Hydrogen Generator Environmental conditions: This equipment is designed to be safe at least under the following conditions: indoor use - bench mounted altitude up to 2,000m temperature 5 C to 40 C maximum relative humidity 80% for temperatures up to 31 C decreasing linearly to 50% relative humidity at 40 C mains supply voltage fluctuations not to exceed ±10% of the nominal voltage INSTALLATION CATEGORIES II; POLLUTION DEGREE 2

8 1.5) Installation Procedure 1) Locate the generator in the position it will normally be sited. Site the generator as close to the application as possible, but do not connect gas supply pipework until the recommended system layout has been read and understood. 2) After reading the recommended system layout (page 8), install the unit as follows: Remove the fitting cover from the Hydrogen outlet port Connect to application (using pipework recommended for hydrogen gas). NB. Purge the outlet pipework for at least 15 minutes to remove trapped oxygen before connecting to the application. 3) Obtain a supply of deionised water (see specification on page 4) and fill the water container to the FULL mark on the visual window on the front of the generator. 4) Remove deioniser bags from the packaging; locate the T fastener on the top of each bag through the centre hole on the top cap of the water container. Put one bag into each top cap, then place bags into the water containers and fit caps securely. 5) Open the door on the front of the generator. Remove the plastic caps from the top of the desiccant cartridge and fitting as shown and connect the flexible tubing to the desiccant cartridge. Plastic caps

9 1.6) Recommended System Layout 1.6.1) Basic Layout 1.6.2) Installation with Back-up Supply 1.6.3) Installation with Multiple Generators

10 1.7) Power Connection and Sequence of Operation 1) The generator operating voltage is marked on the rating plate on the rear panel. 2) Make sure that the power switch is in the OFF position. 3) Connect the power cord to the rear panel of the generator. 4) Connect the free end of the power cord to an appropriate power source. 6) Switch generator on. The generator will give audible indication of the start up process, and all LEDs will illuminate for approximately two seconds. 7) During start-up, the unit may automatically revert to the last error mode it experienced. Press the black reset button to clear it and continue with the start up procedure. If it cannot be cleared by this method follow the fault-finding procedure in section 5. 8) The start-up builds internal cell pressure up to 7.2 bar g. (indicated on the main display panel) using maximum current. This takes approximately ten minutes during which the system check LED will flash. 9) The generator will continue the system check and a leak test takes place for two seconds. The system check LED will continue to flash. 10) Outlet solenoid valve opens. The system check is now complete and if successful the LED becomes constantly lit. 11) Set the outlet pressure regulator to give desired pressure. The generator will now run maintaining flow at the set pressure. We advise that the outlet pipework is purged for 15 minutes to remove oxygen before connecting to the application.

11 1.8) Shutdown Procedure If a service or fault-finding procedure requires the generator to be shut down, it is imperative that the following service shutdown instructions are followed carefully. 1) Ensure that the application supplied by the generator no longer requires gas. 2) Switch the generator off at the on/off switch and isolate from mains supply by removing the appliance connector from the appliance inlet. 3) Slowly depressurise the system. Watch the outlet pressure gauge on the front of the generator. Once the gauge shows zero, the valve can be fully opened. The generator is now shut down.

12 2- COMMISSIONING 2.1) External Instruments and Connections Front and rear panels Key: 1) Display screen (see page 12) 2) Water level 3) Desiccant cartridge 4) Hydrogen outlet port (on side panel) 5) Reset switch 6) Hydrogen outlet pressure gauge 7) Hydrogen pressure regulator 8) On/Off switch 9) Water drain port 10) Hydrogen relief vent 11) Excess Hydrogen vent 12) Mains connection 13) Water Tanks 14) External Connection Panel

13 Display Screen Key: a) SPE Cell Pressure LED display b) Alarm (general) c) Maintenance alarm d) Water level indicator e) Remote stop alarm f) System check g) Hydrogen flow h) Water conductivity indicator

14 2.2) Commissioning Procedure 1) Ensure that the generator is connected to a suitable electricity supply using the mains lead supplied, the water bottles have been filled with the correct grade of distilled/deionised water, the desiccant bags are put in the water tanks and the desiccant dryer cartridge is connected. 2) Turn the generator on by pushing the on/off switch on the front of the generator. Observe all the LEDs on the front panel illuminate for approximately two seconds. The generator will go into a system check mode for several minutes. Observe the green flashing LED illuminate while pressure in the system builds up to 7.2 bar g. Observe the red display as the pressure builds up to 7.2 bar g. Once the system check LED illuminates continuously, the system check is complete and an internal leak test will now take place. 3) At this stage the outlet valve on the generator will open. Now set the desired output pressure by opening the door on the front of the generator and turn the pressure regulator clockwise to a maximum of 90 psi g, which will be indicated on the analogue pressure gauge above the regulator. The green LEDs on the scale at the bottom of the display panel will give an indication of flow rate in %. It is recommended that a hydrogen-calibrated flow meter is used to verify the required flow rate in cases where this is likely to be within 10% of the max. capacity of the generator.

15 3 - MAINTENANCE 3.1) Water Indicators To ensure continuous operation, regularly check the water level and top up if necessary. There are four water level indicators on the front of the generator: Top green LED illuminated constantly: Water level full Central green LED illuminated constantly: Water acceptable level Central green LED flashing: Water low, refill as soon as possible Red LED illuminated: Water empty, alarm condition, refill to restart Before filling the water containers, always check the quality of the deionised water and ensure it falls between the tolerances outlined in the technical specification on page ) Water Conductivity Indicators The hydrogen generator has a built-in conductivity meter with alarm to ensure the correct quality of deionised water is used at all times. There are ten LEDs located on the right hand side of the front display panel indicating the following: Seven green LEDs indicating good quality water Two amber LEDs indicating that the quality of water is near the limit for operation One red LED indicating that the quality of water could cause damage to the process. At this point the generator will shut down on alarm The conductivity meter is there for two reasons: 1) To ensure good quality water is used at all times. 2) To give an indication of when the deioniser bags should be changed.

16 3.3) Deioniser Bags There are two deioniser bags for each generator (one for each water container). The deioniser resin scavenges any remaining ions from the water and helps to stop the conductivity from rising during operation. The bags should be replaced: 1) If the conductivity is rising to alarm level when the same quality water is being used consistently. 2) Every six months. 3.4) Desiccant Cartridge Indicator The internally mounted desiccant cartridge is in the system to dry the hydrogen gas before feeding to the application. The life of the cartridge will depend on the gas usage. When the cartridge is new, the desiccant will be a mixture of orange and white material. Regularly check the window on the right hand side of the front door to see any colour change. The flow of gas runs from top to bottom, therefore the colour change (which turns the material to clear) will start from the top. Once the change is visible, order a refill kit (see page 16). The desiccant does not need changing until the colour change reaches the bottom of the window. There are two ways of replacing the desiccant: 1) Order the whole cartridge assembly. 2) Order the refill kit and follow instructions in section 4.4.

17 3.5) Service Kits Deioniser Bags: Replace once every six months or if conductivity increases when using good quality water as outlined in the technical specification on page 4. Deioniser bag kit: Contains two bags. Kit number: Desiccant Cartridge Assembly: Replace when colour change reaches the bottom of the viewing window. Do not regenerate the desiccant material. The cartridge housing is plastic and not suitable for regeneration. Desiccant kit: Contains one full assembly including fittings. Kit number: Desiccant Refill Kit: Replace when colour change reaches the bottom of the viewing window. Refill kit: Contains enough desiccant to refill one cartridge. Kit number:

18 3.6) Maintenance Procedure 3.6.1) Replacing Water If it becomes necessary to replace the water in the hydrogen generator, first switch off the unit by using the shutdown procedure on page 18. Find a watertight container that has a minimum volume of 4 litres and place it at a level that is below the base of the generator. Take the tube and drain connector supplied with generator, open the door on the front of the generator and push the connector into the drain bulkhead. Drain all of the water into the container and dispose of the contents. Never refill the generator with contaminated water that has been drained from the generator. Remove the drain and tube from the bulkhead, take approximately 3-4 litres of fresh deionised water and refill both water containers to the full mark on the level indicator. Follow restart procedure on page ) Filling Water Containers If the illuminated water indicators are showing either the static green or flashing green LEDs illuminated, the water can be filled simply by leaving the generator running and removing the top caps from the containers. Top up the containers with fresh deionised water to the desired level ensuring not to exceed the maximum level shown in the water level window. Replace the container caps securely ) Maintaining Non-Interrupted Operation To ensure that the hydrogen generator runs continuously and to prevent alarm conditions occurring, regularly check the following: Water quality Water level Desiccant cartridge Flow indication LEDs

19 4.1) Shutdown Procedure 4 - SERVICE INSTRUCTIONS If a service or fault finding procedure requires the generator to be shut down, it is imperative that the service shutdown instructions (also on page 10) are followed carefully. Access within the equipment must be limited to suitably skilled and competent technicians. 1) Ensure that the application the generator is supplying no longer requires gas. 2) Switch the generator off at the on/off switch, then isolate from mains supply by removing the appliance connector from the appliance inlet. 3) Slowly depressurise the system. Watch the outlet pressure gauge on the front of the generator. Once the gauge shows zero the valve can be fully opened. 4) The generator is now shut down. 4.2) Maintenance Procedure - Replace Water Draining Water Tanks 1) Place a water container of volume 4 litres or more in front of the generator at a lower level than that of the generator drain port shown. Open the door on the front of the generator and locate the drain fitting and tube supplied into the drain port. Push drain fitting securely into the drain bulkhead to start draining the tanks.

20 3) Once the tanks are completely drained, push the button on the top of the bulkhead down to release the fitting and pull away. 4) Remove tube and fitting, dispose of drained water. DO NOT re-use drained water.

21 Filling Water Tanks 1) Locate the front water tank cap that is at the top of the generator as shown. 2) Take your suitable de-ionised water (check specification on page 4)and fill the container as shown in the diagram. While filling, look at the water level window on the front of the generator door and fill to the FULL mark. Note: The two water containers are joined in parallel internally and, therefore, when you have filled the front bottle to the top, the level will drop. Wait for the water level to settle before filling again to the FULL mark. Repeat this until the level in both tanks is near the top. 3) Replace cap securely.

22 4.3) Maintenance Procedure - Deioniser Bag Change Installing Deioniser Bags 1) Remove both water tank caps. Take the two deioniser bags out of their packaging and push the locating T piece through the hole in the centre of each cap (one deioniser bag in each cap). 2) Pull locating T fully through and hang bag onto the cap as shown. 3) Place one deioniser bag into each water container and replace caps securely.

23 4.4) Maintenance Procedure - Desiccant Cartridge Change Note: It is imperative that the service shutdown instructions are followed carefully PRIOR to commencement of any maintenance procedures. Ensure that the generator has been fully depressurised before proceeding. Replacing Desiccant/Dryer Cartridge 1) Open the door on the front of the generator. Loosen the tubing nut from the top of the desiccant cartridge by turning anti-clockwise and pull the tubing free. 2) Repeat the process with the tube fitting at the bottom of the cartridge.

24 3) Pull cartridge free from the mounting clips. Note: If you are changing the whole cartridge assembly, then go to point 10. 5) While holding the cartridge firmly and upright, remove one end by turning the end cap anti-clockwise. 6) Completely remove end cap and keep in a safe place. Discard all of the used desiccant material. Do not regenerate the desiccant material. The cartridge housing is plastic and not suitable for regeneration.

25 7) Using a clean cloth, carefully wipe the inside of the cartridge to remove any dust. Remove the cap from the desiccant refill kit and slowly pour the material into the cartridge. 8) Fill to the top but be careful not to over fill. 9) Replace cap firmly by turning clockwise. Ensure that the desiccant does not get trapped under the O ring seal on the end cap. If desiccant does get trapped, unscrew cap and remove some desiccant. Re-seal.

26 10) Push the cartridge forward to locate into mounting clips. 11) Re-connect the flexible tubing to the top and bottom fittings on the desiccant cartridge. 12) The desiccant cartridge is now connected.

27 4.5) Restart Procedure 1) Ensure that any spare parts or covers have been replaced and fixed securely into position. 2) Reconnect pipework from the outlet of the recommended isolation shut off valve to the application and turn valve to the closed position. 3) Reconnect mains supply to the back of the generator. 4) Switch ON using the on/off switch. 5) Once the green flashing system check LED illuminates continuously, the generator is ready to use. 6) Purge the system for 10 to 15 minutes to ensure purity and begin to supply application with gas.

28 4.6) Service Record Log Date Deioniser Desiccant Changed Bags Cartridge

29 5 - FAULT FINDING 5.1) Troubleshooting Access within the equipment must be limited to suitably skilled and competent technicians. Fault Found Probable cause Remedy Display will not illuminate Wrong input voltage LED failure on LED system check Generator will not start up on system check Error 2 Remote stop Remote stop fails to operate Error 3 Water empty Fuse blown Power supply failure On/Off switch failure Check mains voltage and serial number plate for voltage spec. Check fuse, replace if necessary. Contact local distributor. Check operation, order a new one if necessary. LED failed Contact local distributor for advice. EPROM failure Contact local distributor for advice. Input signal activated Remove input signal, replace jumper bar and press reset. Volt free signal not Check external electrics. activated Water container empty Refill container to a suitable level with water specified. Check connections on water Conductivity circuit fault containers. Contact local distributor for advice. Error 5 Up to pressure time out Error 6 Pressure decrease above limit Error 7 Pressure leak above limit Internal leak Remove side panels and check all fittings with a suitable leak test fluid, tighten if necessary. Check outlet fitting for gas on start up. Power supply fault Contact local distributor. Massive pressure loss Check external pipework, repair if necessary. Remove side panels and check internal pipework. Contact local distributor if necessary. Internal leak Remove side panels and check all fittings with a suitable leak test fluid, tighten if necessary. Outlet valve leaking Check outlet fitting for gas on start up. If leaking Contact local distributor for replacement.

30 Fault Found Probable cause Remedy Error 8 Voltage too high Error 9 Voltage too low Error A Current too high Error B Current too low Error C Conductivity too high Error E EPROM or calibration fault Error F Watchdog Remote start/stop fails to operate Power supply fault Contact local distributor for advice. Power supply fault Contact local distributor for advice. Power supply fault Contact local distributor for advice. Power supply fault Contact local distributor for advice. Water quality not to spec Switch off, drain water from containers and refill with new supply. Deioniser bags saturated Remove bags from containers and replace. Software fault Contact local distributor for advice. Software fault Contact local distributor for advice. Volt free signal not Check external electrics. activated 5.2) Displayed Errors Error Message Cause Remedy Err 2 Remote Stop Ref: Err 3 Water Empty Ref: Err 5 Up to pressure time out Ref: Err 6 Pressure decrease above limit Ref: Err 7 Pressure leak above limit Ref: Err 8 Voltage too high Ref: Err 9 Voltage too low Ref: Err A Current too high Ref: Err B Current too low Ref: Err C Conductivity too high Ref: Err E Eprom or calibration fault Ref: Err F Watchdog Ref:

31 5.3) Alarm Modes If an alarm condition occurs, the electronic display on the front of the generator will show Err followed by a number or letter. With every alarm condition there will be an audible alarm at different frequencies. The higher the frequency, the more urgent the alarm condition will be. Although under most alarm conditions the generator will stop producing gas, it is important that the fault is looked into promptly and thoroughly to prevent immediate or long-term damage to the generator. Persistent alarm conditions should be reported to the place of purchase immediately for advice. 5.4) Errors and their Meanings In all alarm conditions, the ALARM LED will be illuminated. Where reference is made in italics to an alarm symbol, please refer to the External Instruments and Connections diagram, section 2.1 pages 11 and ) Err 2 - Remote Stop At the rear of the generator is a connection, which allows a volt-free signal to be used to automatically shut down the generator. When this occurs, a low frequency audible alarm sounds, Err 2 is displayed and the production of hydrogen gas stops. Note: the Remote Stop LED illuminates. To activate the remote stop function, open the volt-free contacts. Before the generator can be restarted the contacts must be closed. To re-set this alarm condition, remove the volt-free signal from the back of the generator and either press the re-set button or switch the generator off and then back on again ) Err 3 - Water Empty Although there is a visual display on the front of the generator showing the level of water, there is also a sensor to detect the water level. If this level drops below the permitted level to produce hydrogen without damaging the unit, then Err 3 is displayed and an audible alarm sounds. Note: the Water Empty LED illuminates. To re-set this alarm condition, refill the water containers to the refill or full marks. Once the water is to a suitable level, the generator will automatically restart and will go into the re-start mode.

32 5.4.4) Err 5 - Up to pressure time out When the generator is in start-up phase it has a set time to reach the maximum pressure of 7.2 bar g. If the generator does not reach pressure in the allotted time, then Err 5 will be displayed, the ALARM LED will illuminate and a high frequency audible alarm will sound. This alarm condition will occur if there is a leak internally or if the outlet shut-off valve is passing gas. It is also possible that the current/flow could be low which can be seen on the Flow Display LEDs on the front of the unit. To locate a leak, remove side panels and use a suitable leak testing fluid on the push-in and Swagelok fittings. If a leak is found, tighten carefully with a suitable spanner. If gas is leaking out of the outlet on start-up while the system check LED is illuminated, contact local distributor or domnick hunter for replacement part. If the fault is caused by low current/flow on start-up, it may be caused by a power supply fault. If this occurs, contact local distributor or domnick hunter direct for replacement part ) Err 6 - Pressure decrease above limit This is a safety alarm condition that occurs if there is a break in the pipework, either internally or externally, which results in rapid pressure loss. When this alarm condition occurs, the Alarm and Maintenance LEDs are illuminated, a high frequency audible alarm sounds and the production of hydrogen stops. If this occurs, check external pipework first and repair any leaks immediately, then check internal pipework and fittings by removing side panels and checking for faults. If an internal fault is found, report it immediately to your local distributor or domnick hunter direct for advice and replacement part.

33 5.4.6) Err 7 - Pressure leak above limit At the end of the start-up procedure, before the outlet valve opens, a system leak check takes place for 2.5 seconds. At this time, production of hydrogen stops and the internal pressure is monitored. If the pressure loss over the 2.5 second check is more than the set limit then the alarm is activated. At this time Err 7 is displayed, the Alarm and Maintenance LEDs are illuminated and a high frequency audible alarm sounds. As this condition can only occur on start-up, the two causes of this are an internal leak or the outlet valve is leaking. To remedy this problem, remove the side panels and use a suitable leak test fluid to check all push-in and Swagelok fittings. If a leak is found, tighten the fitting carefully with a suitable spanner or if the push-in fitting is leaking, remove and re-cut the end with a tube cutter before re-fitting ) Err 8 - Voltage too high This alarm condition protects the process within the generator from high voltage. When this occurs, the Alarm and Maintenance LEDs illuminate and production of hydrogen stops. If this fault occurs, do not attempt to re-start the generator in case of damage. Contact your local distributor or domnick hunter direct for advice and replacement part ) Err 9 Voltage too low This alarm condition protects the process within the generator from low voltage. When this occurs, the Alarm and Maintenance LEDs illuminate and the production of hydrogen stops. If this fault occurs, do not attempt to re-start the generator in case of damage. Contact your local distributor or domnick hunter direct for advice and replacement part ) Err A - Current too high This alarm condition protects the process within the generator from high current. When this occurs, the Alarm and Maintenance LEDs illuminate and the production of hydrogen stops. If this fault occurs do not attempt to re-start the generator in case of damage. Contact your local distributor or domnick hunter direct for advice and replacement part.

34 5.4.10) Err B - Current too low This alarm condition protects the process within the generator from low current. When this occurs, the Alarm and Maintenance LEDs illuminate and the production of hydrogen stops. If this fault occurs, do not attempt to re-start the generator in case of damage. Contact your local distributor or domnick hunter direct for advice and replacement part ) Err C - Conductivity too high The generator monitors the quality of deionised water that is fed into the system. If the water is not to the minimum quality domnick hunter recommends, the life of the electrolytic cell could be reduced. The system is also able to record the number of times the generator has been into a conductivity too high alarm. This can be down loaded and viewed by domnick hunter engineers. This information could be used in a warranty claim situation where it is evident that the water fed into the system had been of consistently poor quality. To prevent a conductivity alarm, monitor the indicators on the front of the generator and replace deioniser bags when necessary. If the unit shows an alarm condition, the Alarm LED will illuminate, the production of hydrogen stops, and all the Conductivity indicators will be illuminated. To remedy this, isolate the generator from the mains supply, drain all the water from the unit through the drain port and flush and refill with good quality water. If the indicators still light, check the quality of the water being used ) Err E - EEPROM or calibration fault The EEPROM holds the software that calibrates all the necessary internal parts. If the software and memory are unable to read the system s operation, the generator will go into alarm. When this happens, Alarm and Maintenance LEDs are illuminated, a low frequency audible alarm sounds and the production of hydrogen stops. If this occurs, contact your local distributor or domnick hunter direct for advice and a replacement part.

35 5.4.13) Err F Watchdog The Watchdog monitors the system s electronic operation and will shut down the generator if an internal fault occurs with software. If this occurs, do not attempt to re-start the generator in case of damage to other parts of the generator. In an alarm condition, the Alarm and Maintenance LEDs will be illuminated, a low frequency audible alarm will sound and the production of hydrogen will stop. Switch the generator off and contact your local distributor or domnick hunter direct for advice. If the unit needs to be returned to domnick hunter for any reason, you must drain all the water from the tanks and remove deioniser bags. The unit must be properly packed and shipped in an upright position complete with mains cable and deioniser bags.

36 6 - EXTERNAL CONNECTIONS Auto Remote Selection Links Remote Start/Stop Connections Alarm Out Connections Water Fill Connections ) Remote Start/Stop Rear Panel External SELV Connections The remote start/stop function is an additional feature fitted as standard to the generator. This feature allows the user to shut the generator down remotely at a specific time or following a specific event, and then restart the system automatically. The terminal board features two inputs (Stop, Hold) and two outputs (Alarm, Water Fill). There is also a link arrangement which, if set, will either stop or temporarily halt production upon the alarm output being actuated ) Inputs 1&2 and 3&4 The inputs are provided for users who wish to remotely control the operation of the generator.

37 The inputs are suitable only for connection to volt-free contacts (15 ma,12v DC rated) for example normally open push-button contacts, or normally open relay contacts available in some other related equipment. If either input is activated, then the front panel Remote Start/Stop LED will illuminate. If remote operation is not required then no connection should be made to the inputs ) Production Stop (1&2) Connecting input terminals 1 and 2 together via a remote push button or relay will stop Hydrogen production. This is a latched condition. The remote push button must be released and the front panel reset button must be operated to restart production ) Production Hold (3&4) 6.2) Outputs Connecting input terminals 3 and 4 together via a remote push button or relay will cause Hydrogen production to pause whilst the connection is made. Once the remote connection is broken production will recommence. The outputs are provided for those users who wish to connect external equipment to the generator to monitor operation and/or to provide an automatic water replenishment scheme. The outputs consist of single pole change over relay contact outputs rated at 10A max. for connection to SELV systems only: Maximum 30V r.m.s. or 42.4V peak or 60 V d.c. The legend on the terminal board shows the state of the contacts when the unit is powered off ) Alarm Out (1&2&3) When the unit is powered up, and there is no alarm, the alarm relay is energised so that 1&2 are connected. When the unit is either off or powered up and in alarm then 1&3 are connected.

38 Example: The user requires a remote bell to sound if the generator enters an alarm condition. The remote bell power supply and bell is connected to Alarm Out terminals 1 and 3. On entering an alarm condition or losing mains power the relay will switch, connecting Alarm Out terminals 1 and 3, completing the circuit and sounding the remote bell ) Water Fill (1&2&3) When the unit is powered up and the water level is below Full then the Water Fill relay is energised and 1&2 are connected. If the water level is Full or the unit is switched off then 1&3 are connected. Example: The user has a low voltage water pump for transferring deionised water to the water reservoir. The low voltage supply and pump circuit is wired to Water Fill terminals 1 and 2. When the water level drops below the full sensor the relay will pull in and connect Water Fill terminals 1 and 2 together, completing the circuit and operating the pump. Once the water full sensor is covered with water the relay will drop out and stop the pump. A minimum on time is employed to ensure that the relay does not constantly turn on and off ) Auto - Remote Select The link arrangement allows the alarm output to automatically Stop or hold off production. To enable this function the link for the required operation is fitted horizontally using the centre socket, either Stop or Hold. Once fitted, if the unit goes into alarm then production will cease. Depending upon which link was placed in the auto position, production will either start again once the alarm has been cleared (Hold) or the reset button on the front panel will require actuation (Stop). Placing a link in the auto position disconnects the associated remote terminals. i.e. If the Stop link is put in Auto mode then connecting terminals 1&2 will have no effect.

39 7 - INSTALLATION ERRORS 7.1) General Failure to observe recommended actions in this manual causing the warranty to be invalidated Insufficient ventilation around the generator causing heat build-up Use of non-genuine or non-recommended domnick hunter spare parts The application requires more gas than can be supplied by the generator which means the wrong generator has been requested or the generator is being used for too many applications at the same time Leaks on external hydrogen pipework causing decreased performance Use of poor quality deionised water 7.2) Outlet Connection Use of porous or ferrous pipework allowing ingress of oxygen Outlet pipe diameter incorrect 7.3) Electrical Incorrect supply cable other than that supplied causing over heating and potential fire risk Lack of suitable earth connection causing potential electric shock risk Incorrect mains voltage other than that given on the serial number plate, causing the generator to malfunction

40 8- WARRANTY This warranty applies to HYDROGEN GENERATORS and associated parts (the Equipment) manufactured and supplied by domnick hunter ltd (domnick hunter). Use of the HYDROGEN GENERATORS without the recommended water quality (see page 4) or genuine parts will expressly invalidate the warranty. It should also be noted that the Hydrogen generator must be installed and running within three months of despatch from domnick hunter limited, to ensure the optimum efficiency of the SPE cell. If this is not adhered to this will invalidate the warranty. Should the Equipment be defective as to materials or workmanship, domnick hunter warrants that it will remedy such defect. Where the Equipment is a HYDROGEN GENERATOR, the warranty period will be 12 months from date of commissioning or 18 months from date of manufacture, whichever is the earlier. In the case of Equipment other than a HYDROGEN GENERATOR the warranty period shall commence from the date of despatch. Should any defect occur during the warranty period and be notified in writing to domnick hunter or its authorised distributor within the said period, domnick hunter will, as its sole option, remedy such defect by repair or provision of a replacement part, provided that the Equipment has been used strictly in accordance with the instructions provided with each item of Equipment and has been stored, installed, commissioned, operated and maintained in accordance with such instruction and with good practice. domnick hunter shall not be under any liability whatsoever under the warranty, if, before giving notification in writing to domnick hunter as aforesaid, the Customer or any third party meddles, interferes, tampers with or carries out work whatsoever (apart from normal maintenance as specified in the said instructions) in relation to the Equipment or any part thereof. Any accessories, parts and equipment supplied by domnick hunter but not manufactured by domnick hunter shall carry whatever warranty the manufacturer has given domnick hunter providing it is possible for domnick hunter to pass on such warranty to the customer. To claim under the warranty, the goods must have been installed and continuously maintained in the manner specified in the ICOM. Our product support engineers are qualified and equipped to assist you in this respect. They are also available to make repairs that may become necessary in which event they will require an official order before carrying out the work. If such work is to be the subject of a warranty claim, the order should be endorsed for consideration under warranty. Where Equipment is sold outside the UK mainland direct to the end user the warranty will cover parts only. Any substitution of parts not manufactured or approved by domnick hunter will expressly invalidate the warranty.

41 9 DECLARATION OF CONFORMITY DECLARATION OF CONFORMITY 98/37/EC 89/336/EEC 73/23/EEC Name of manufacturer or supplier: domnick hunter ltd Address: Dukesway, Team Valley Trading Estate, Gateshead, Tyne and Wear, England, NE11 0PZ Description of Product: Laboratory Hydrogen Generator Model Number UHP-20H UHP-40H UHP-60H Place of issue: GATESHEAD, TYNE AND WEAR, ENGLAND Name of authorised representative: DAVID KEAY Position of authorised representative: MANAGING DIRECTOR (GAS GENERATION DIVISION) Declaration: I declare that, as the authorised representative, the above information in relation to the supply/manufacture of this product is in conformity with the standards and other related documents following the provisions of the 98/37/EC, 89/336/EEC, 73/23/EEC directives. Signature of authorised representative pure innovation a member of the domnick hunter group plc

42 10 NOTES

43 11 CONTACT ADDRESSES domnick hunter pty ltd Boronia Victoria Australia Tel: +61 (0) Telefax: +61 (0) domnick hunter Canada inc Ontario Canada Tel: Telefax: domnick hunter (China) Beijing Office Beijing China Tel: Telefax: domnick hunter (China) Shanghai Office Shanghai China Tel: Telefax: domnick hunter Skandinavia Slangerup Denmark Tel: +45 (0) Telefax: +45 (0) domnick hunter France SA Villefranche sur Saône France Tel: +33 (0) Telefax: +33 (0) domnick hunter GmbH Krefeld Germany Tel: +49 (0) Telefax: +49 (0) PT domnick hunter Indonesia Jakarta Indonesia Tel: Telefax: domnick hunter-rl (Malaysia) SDN BHD Petaling Jaya Malaysia Tel: Telefax: domnick hunter Group Pte Ltd Singapore Tel: Telefax: domnick hunter Iberica Barcelona Spain Tel: +34 (0) Telefax: +34 (0) domnick hunter SweTec AB Gothenburg Sweden Tel: +46 (0) Telefax: +46 (0) domnick hunter-rl (Thailand) Co Ltd Bangkok Thailand Tel: Telefax: domnick hunter Ltd Gateshead England Tel: +44 (0) Telefax: +44 (0) gasgen@domnickhunter.com Web site: domnick hunter inc Charlotte NC USA Tel: Telefax: Toll Free: Web site: domnick hunter Nihon Kobe Japan Tel: +81 (0) Telefax: +81 (0) domnick hunter Nihon Yokohama Japan Tel: +81 (0) Telefax: +81 (0)