Hydrogen generator
Contents
1. production is interrupted with a buzzer and visual alarm Low Out Press When the value is set to 0 0 this check will be disabled Autostart Enabled when power is restored after a black out the system restart and goes into the working mode Disabled when power is restored after a black out the system stays in OFF status Pressure Drop Delay Defines the pressure unit psi bar Psi Bar Bar Temperature Unit Defines the temperature unit F C AAA Chromatography amp Spectrometry MENU Parameter Auto Refill Water Enables the automatic external tank automatic filling function Disabled Enable If Enabled when the level of internal water tank go below 5 d the auto fill start and terminate when the level arrive to 95 Ah see Chromatography amp Spectrometry ZeroAir Module Add a Air Zero generator to connect a combine generator Air Zero Hydrogen AAA Chromatography amp Spectrometry Hydrogen sensor Add a external hydrogen sensor When the customer use hydrogen as carrier gas the only drawback is the danger of explosion in case of a leak in the column oven e dale er el sensor metal pipeline Calibration should be checked every year with a test gas 1 0 Power Supply Voltage From BV lo 30V DC AAA een Chromatography amp Spectrometry MENU Parameter User flow limit Allows to restrict the flow 100 100 En Start Mode Defines the method use2. it AAN enieriaAnalitica Chromatography amp Spectrometry START UP Touch the blue key or slide your finger right to left Or Choose START CLOSED or OPEN 10 jas Chromatography amp Spectrometry Command _ _ START START OPEN CLOSE STARTING Command WORKING ee STANDBY Command STOP OPEN When the machine is in the OFF state production stopped you can give the START command with subsequent opening of the outlet valve START OPEN or not START CLOSE During operation we can give the command to STOP or closure of the outlet valve In the STANDBY state can give the command STOP or opening of the outlet valve AAN e Chromatography amp Spectrometry Change working pressure Setup User parameter F 4 F H History Alarm Alarm and prealarm history Diagnostics Voltage current power values 4 i k 4 Counters Working time and H2 produced ee Y O Service Submenu i Menm OO les gt Leak test unct LON Management of internal p water tank AAA eee Chromatography amp Spectrometry MENU Parameter If the system cannot bring the H2 pipes up to pressure after having waited for the time set in this parameter production is interrupted with a buzzer and visual alarm Out Pressure error Pressure Rise During the filling stage of pipes connected on the H2 outlet if the pressure does not rise with a minimum slope defined by this parameter
3. or 1 year SP H2 WFILT M Run an Automatic dryer regeneration As required or 12 months program for PAR serie Change the dessicant cartridge for ND As required or 12 months series Asse Chromatography amp Spectrometry Unscrew the three screws Pull the top cover and remove Oring and deionizer bag Henu Maintenances Maintenances L Change Water Filter Change Water Filter Change water deioniser bag and water filter Remove black Remove water filter O ring This command must be given when the DEIONIZER BAG is changed and the filter is cleared It resets the counter that registers filter and deionizer bag s life as well as any correlated pre alarms An additional confirmation is requested from the operator to do so the operator touches the Touch Screen for 0 5 seconds IngenieriaAnalitica NINN Chromatography amp Spectrometry Run an Automatic dryer regeneration PAR serie Men The procedure occurs for 3 30 hours Maintenances Maintenances Ds Regeneration Dryer Regeneration Oryer Start Now b Regeneration Dryer 00 19 15 _ To access the dryer regeneration function touch the Touch Screen for 0 5 seconds To immediately enable dryer regeneration select this option by touching the Touch Screen for 0 5 seconds Hydrogen production will be suspended up to the end of the regeneration cycle The advancement bar and the time signal tell the
4. AAA en Chromatography amp Spectrometry Remove the dryer Disconnect the terminal Disconnect CO6 l block central green CO14 CO17 CO32 Rn ed CO33 CO34 q AAA Chromatography amp Spectrometry Check or remove inlet purge valve Unscrew the two screws at the top left and bottom right and r emove the valve Unscrew the central nut Then unscrew the remaining two screws and clean the internal components after verification of the presence of impurities AAA eeen Chromatography amp Spectrometry Check or remove proportional valve Unscrew the two screws at the Then unscrew the remaining two screws and top left and bottom right and r clean the internal components emove the valve after verification of the presence of impurities Aisa Chromato graphy amp Spectrometr y Check the pressure sensor aak ad dn Put a gauge between GLS and dryer START CLOSED tht generator Go to MENU gt DIAGNOSTIC Compare manometer and the value If the pressure gauge increase and the screen value still be 0 change pressure transmitter AAA en Remove the sensor Internal pressure sensor Disconnect the connector Turn left the sensor unplug it and replace it Repeat everything for the second sensor otart the calibration 1 2 3 4 Aisa Sensor calibration 1 Put an external gauge 2 Goto MENU gt MAINTENANCE gt SERVICE gt MANUAL CALIBRATION 3 Inthe display menu select manual pre
5. RVP Chromatography amp Spectrometry Hydrogen generator 18 02 2015 e IngenieriaAnalitica Vive GENERAL INFORMATION OF H2 RUNNING WATER TANK O2 H20 separator H2 H20 separator module module Water come back in the tank GAS LIQUID H20 H2 H20 O2 ELECTROLYSI WATER PUMP FILTER a g E Use onl re water gt 10MO En P Contains deionizer bag Electronic gas liquid separator with 2 levels Tank Capacity 2 3 liters of sensors safety and dust water filter Increase pressure water Separate hydrogen and Oxygen Allows a best speed of water 2H20 gt 4H 4e 02 through the cell to avoid overheating AAS enereAneulice Hydrogen generator ND series THIET lt A we ii ND H2 Purity gt 99 9995 Pressure up to 10 bar Simple dessicant cartridge Nafion tube AMA Hydrogen generator PAR series Purity gt 99 9999 Pressure up to 12 bar on request 16 bar Single column dryer with programmable automatic regeneration via integrated clever calendar AAA en Hydrogen generator M series Purity gt 99 99999 Automatic dryer regeneration Pressure up to 12 bar on request 16 bar AANEEN Touch Screen 0 B 0 ar S07 100 6 4 bar Si HORN 400 nn ee DVIORKING iie WM H2 models PAR H2 models Description Real outlet pressure Pressure set by user set point System status and Pre alarms display see t
6. able 1 and 3 H2 Flow 5 Watertanklevel 6 WM H2 Water or in percentages 100 GOOD 0 BAD rem TZ e Touching this label an HELP windows wil be shown IngenieriaAnalitica NINN Chromatography amp Spectrometry The system is STOPPED and does not produce H2 STARTING The system is generating internal pressure before opening the OUTLET valve CHECKING When the system is pressurized before to open the OUTLET valve the unit make an automatic check of any internal leak FILLING The system is filling the line connected ON the OUTLET with the maximum available flow WORKING The system is working and the line pressure has reached the VALUE set by the user STANDBY The system is internally pressurized and ready but the OUTLET valve is close AA Chromatography amp Spectrometry 1 Open the front door and fill water tank with pure water Deionized ASTM Il lt 0 1uS 2 Remove the plugs from the back fittings of the generator e3 Connect the hose to the hydrogen output fitting ON OFF 4 Connect the voltage wire to the power socket and Turn on the power switch AMA Chromatography amp Spectrometry Set the work set point Real pressure Pressure set Henu Ach ust 1 Touch the screen on the center for at least 2 seconds Pressure 2 Select Adjust Pressure 3 Increase or decrease the pressure with the arrows Out Pressure Set b gt 4 Touch the screen to valid
7. am is valid for all models ND PAR WM Before to proceed you have to confirm with Continue button After confirm DON T TOUCH THE GENERATOR DON T SWITCH OFF DON T STOP THE PROGRAM until you see Upload complete on the white window r InoenieriaAnalitica AARS Chromatography amp Spectrometry PA RA L L E L M O D E The parallel mode is a system that allows you to add up the flow of multiple machines on a single line where each contributes in proportion to their ability Maximum 10 units 4x NM H2 500 Ga 99 9999 H2 lt max 2000 ml min S max 10 BAR 3 incl 1 O board and RS 232 remote control Aya kosriereAraltiea CONNECTION DIAGRAM Connect the RS 485 controller with the BOX of 485 1 of the first generator and the RS 485 to RS 2 of this 485 1 of the second and so on until the last generator SLAVE MASTER ne RS4B5 N 1 2 Parallel N System i Controller Aya peenierfeAnelitice BOX CONTROLLER MASTER BOX controller acts as the master and controls all the generators connected to it This BOX controller has 3 LEDs and a button The meaning of the LEDs is specified in the follow table Green Led Yellow Led Red Led LINK ALARM Functionning OFF JON ____ nodeviceconnected ON ____ orr ___ Iconfiguraztionmode ON Regular FLASHING Good communication OFF OFF OFF All LEDs blink when the controller BOX Master Box can not communicate with the
8. ated with which it can activate stop the generation of hydrogen When this input terminals 3 and 4 is feeding the generator begins to produce when you open the generator stops and goes into the OFF state DANES ETHERNET CONNECTION Ask your costumer to connect his laptop on the USB port on the back of his H2 generator ASK YOUR COSTUMER TO ETHERNET CONNECTION DOWNLOAD TEAMVIEWER PROGRAM EXECUTED THE PROGRAM BEGIN TEAMVIEWER WITHOUT INSTALLING THE APPLICATION THIS WINDOWS APPEAR 243 105 062 6679 HE NEEDS TO GIVE YOU HIS ID AND PASSWORD TO HAVE ACCESS TO HIS COMPUTER WHEN YOU HAVE THE HAND ON YOUR COSTUMER COMPUTER CREAT AN H2 FOLDER TO REGISTER THE PROGRAM AND DOWNLOAD THE PROGRAM EXECUTE THE PROGRAM AND COLLECT DATA jas Upgrade Firmware Upgrade The correct sequence of upgrade the firmware of H2 generators is Upgrade firmware MAIN board Upgrade firmware LCD board Update configurations settings Upgrade Firmware MB GenH2 MP En Upgrade Firmware MB GenH2 MP 5 04 Try COM opened Checking device Device found Reading firmware file done Activating loader done PAY ATTENTION don t switch off the instruments before the pestis is completed Continue Example MAIN board Firmware Upgrade Connect the Generator to a PC by USB cable or serial RS 232 port Install the driver if needed Run the program Firmware MB V504 HW4 exe this progr
9. d for line pressurization Normal Fast Normal Normal The outlet valve is opened only after the internal circuit has been pressurized and after having automatically performed an internal leak test Fast The valve is opened when the internal pressure is greater than the set point set by the user and no internal leak test is carried out ID Address Logical address in case of connection of the unit in a 1 1 31 communication bus Baud Rate Speed of communication of the RS485 port 2400 38400 38400 a RS485 genieriaAnalitica Chromatography amp Spectrometry MENU Diagnostic Diagnost ros Cell M A HHL Cell UH Peak 14 39 Cell I H 1A Cell Power Hll Cell Flow Ec m OLlLagnost pos Int Press lps i Hut Press Eps l Flow Acc py Water C 11 s4u5 Refill Stand By Jp zzz Utaanost pos Dryer Temp aae hel P PaSa Temp oe F S Holta 1 25 981 P S llolt B Abel 4 PEM cell voltage Peak PEM cell voltage PEM current PEM cell power supply H2 Cell flow produced cc min Internal pressure External pressure Actual H2 Flow produced cc min Water conductibility uS Column temperature Power Supply temperature power supply voltage no 1 power supply voltage no 2 only models with flow rates over 400 cc min IngenierleAnelitica AAN MENU gt Maintenance _ _ Change water deioniser bag 4000 working hours or 1 year SP H2 DB01 Check the water filter 1000 working hours
10. emaining life counter using the appropriate function from the MAINTENANCE menu InaenieriaAnalitica AAAn prenten amp Spectrometry A LA R M Low Int Press When the internal pressure cannot Try to restart the system if the problem reach the value pre set by the persists call for service manufacturer Low Out Press When the external pressure does not Check that the line is connected to the reach the outlet pressure set in the H2 outlet port correct time Refill Water When the internal water tank level goes Fill manually the internal tank with new below the minimum level water Bad Water Q When the quality of the water is too poor Completely replace the water in the tank replace the deionizer bag if necessary and check the water filter Hight Cell V When the cell voltage exceeds the alarm Try to restart the system if the problem threshold persists Over Current When the cell current exceeds the alarm Try to restart the system if the problem threshold persists call for service Over Int Press When the internal pressure exceeds the Try to restart the system if the problem alarm threshold persists call for service P S Temp When the electronic power source Check that ambient temperature is less temperature exceeds the maximum than 35 C threshold Check that the intake ventilation fans are not blocked and that the corresponding filters are clean see picture 2 point 7 and 8 Out P
11. generators connected to it Slaves Random FLASHING Bad communication Fast FLASHING Alarm or generator off line Slow FLASHING Generator in pre alarm mode Pressing the start stop button is activated or not the production System in production gystem ready for production PRODUCTION FLASHING Ay jssnsrehneliice SYSTEM IDs CONFIGURATION In order for the system to work properly you must assign a unique number ID for each generator Set ID Parallel 10 i 6 f bar Dy com at O OFF te P p Holding down the button on the BOX controller for more than 10 secondes to start the search procedure of the generators connected to it see par 1 2 Once activated the setup of all generators connected to the currently displayed 1 on the display At this point 1 hold the center button on one of the generators for about half a second 2 the system will beep and all the other generators will see the number 2 3 Repeat the step 1 until the last generator 4 Press the button on the controller BOX If everything works correctly the yellow LED should flash controller of the BOX and evenly on the top LEFT of the display of each generator should see a P The P in reverse indicates that the machine is being used by the system to read the line pressure and control it master flow controller The P is not in reverse indicates that the generator is simply a slave Chromatography amp Spectromet
12. hy amp Spectrometry Open the generator Remove the five screw Disconnect the screen of the main board C037 AANEEN Main Alarm message Low internal pressure Pump failure High cell voltage Gas Liquid Separator failed Power supply failure Other Alarms AANEEN Low internal pressure Raison Not enough pressure Possible causes eLeaks Gas Liquid separator valve still open Problem with dryer eProblem with the sensor Problem with the cell AAN Chromatography amp Spectrometry 8 Use a leak detector Never use soap inside the generator Check all the quick connections AA Gas Liquid separator valve still open Check if there are bubbles in the transparent tube In this case remove it and test the purge valve A ngenieraAnailice Chromatography amp Spectrometry How to remove the GLS _ Unscrew the 2 screws with Allen key eDiconnect the black Wire and then remove the clear tube Disconnect CO35 Disconnect pipes on quick connections How to Clean the GLS valve AN eUnscrew the central nut eUnscrew the two screws at eUnscrew the two screws at the top left and bottom right the top right and bottom left and remove the valve to open the valve Clean the valve AAA en e Chromatography amp Spectrometry Regenrating tube V1 NZ ZN 3 Column 2 Column 1 NZ NZ Silencer Check the dryer OUTLET V1 and V2 Proportion
13. is rapid and intermittent a message identifying the problem is displayed and hydrogen production is immediately interrupted In In case of anomalies which are not serious the LDC display turns yellow the buzzer sounds every 5 seconds and pre alarm messages are displayed IngenieriaAnalitica NINN Chromatography amp Spectrometry P R FA LA R M Power Supply Check that the system working ambient T Too High temperature is less than 40 C Temperature of electronic power supply too high Check that the intake ventilation fans are not blocked and that the corresponding filters are clean see Bad Water Change the water using better quality Quality Poor quality of the water in the tank water Check the water filter and deioniser bag Water Tank l Fill manually the internal tank with new Water level less than 5 of the tank capacity me y Level Low deionised water Dryer Dryer saturated This alarm continues until a dryer i l l Run a dryer regeneration cycle Saturated regeneration cycle is completed Clock Not Set Internal clock not set or working poorly Reset system date and time ee Failed attempt to automatically fill of internal water eG A Refill p y correctly connected and there is water nk ice a inside Check Power Supply Input power voltage not correct Try turning off and turning on the system Change Clean the water filter replace Deionizer deionizer bag and reset the Kilk Water deionization filter saturated r
14. nal Valves V3 and V4 Inlet valves V5 and V6 Purge valves Equilliorating time 1200s Operating time 10800s Regenaration ratio 10 INLET AA AgenccaAraltice Check the dryer Check proportional valve 1 Put an external cap and start the generateur with the command START CLOSED 2 Go to MENU gt MAINTENANCE gt SERVICE Enter the code 345 gt SWITCH DRYER COLUMN 3 Check if the output pressure stay at O bar In the other case remove the proportional valve of the opposite colum and check it 4 Push Two times on the screen to change the column If in this 2 operations the output pressure stay at 0 check the inlet and purge valve A AEN r1oportionnal valve Regenrating tube OUTLET V1 NZ ZN Example Regenration column 1 V1 V2 V4 and V5 are closed Column V3 and V6 is opened 1 Column 2 The output pressure increase the valve V2 is opened and damaged INLET Silencer KA A wi Check the dryer Check inlet and purge valve 1 Remove the grey silencer and exchange it by a cap 2 Start the generator and check if the generator increase and pressure 3 Go to MENU gt MAINTENANCE gt SERVICE Enter the code 345 gt SWITCH DRYER COLUMN Push Two times on the screen to change the regenerating column If in this 2 operations the internal pressure reach correctly check the inlet and purge valve If the pressure still be at 0 check the pressure sensor or the cell
15. operator when the operation will end scrolling from top to bottom interrupts dryer regeneration An additional confirmation is requested To confirm touch this option for 0 5 seconds Instead scrolling from top to bottom returns the screen to the display of the advancement of the process in course NOTE any Dryer Saturated pre alarm is cancelled only upon the conclusion of the regeneration cycle AANEEN MENU gt Maintenance gt Service Service Auto Pressure This procedure can be enabled in case of emergency and when there is no instrument to measure Calibration the pressure in output from the machine Close the output with the special plug and run the procedure Service Man Pressure This procedure is enabled whenever the measurement of the internal pressure sensors needs Calibration calibration CG onnect the sample instrument to the exit of the generator and run the procedure Service Service Upgrade Upgrade MB Firmware LCD Firmware To update the display or main board firmware of the generator Aa AO Remote control Pin Description EN Free contact max 2A 24Vac dc N C En Free contact max 2A 24Vac dc N C Digital INPUT 12 24Vdc Impedance 5Kohm Ea Digital INPUT OV Connection example 12 24Vac dc GENERATOR A free potential contact terminals 1 and 2 which is normally closed and opens when there is a stop of the production for any alarm A digital input opto isol
16. ressure When the outlet pressure remains Check the connections pipes on the H2 error lower than the working set point during outlet port the time set by the user parameter during the line filling phase Memory data When an error is detected in the reading Try to restart the system if the problem of the saved parameters persists call for service Aa oenierieAnalitica ALARM Memory damage When the parameter and alarm Try to restart the system if the chronology storage device fails problem persists call for service G L S failure When a malfunction of the gas liquid Try to restart the system if the separator is detected problem persists call for service Power Supply When the input power voltage of the Try to restart the system if the electronic section is not correct problem persists call for service P S damage When a power source voltage failure Try to restart the system if the is detected problem persists call for service Pump failure When the internal water pump is Try to restart the system if the blocked problem persists call for service Leak Int Pres When an internal pressure leak is Try to restart the system if the detected problem persists call for service Leak Out Pres When an external pressure leak is Check that the gas line is connected detected to the output Heater damage When the dryer heater does not Try to restart the system if the function problem persists call for service Asse Chromatograp
17. ry jas SYSTEM S STATUS From any machine connected to the system you can activate or stop the production open or close the outlet valve change the set of output pressure Check the status of each generator connected to the system To access the status window simply make a scroll from right to left on the touch screen Parallel Status 2 1 Master 6 Sl awe 2 Slave Yr Slave oo lave So Slave 4 Slave Slave Slave 10 Slave The list is displayed for each unit the following records Master Unit to be used to read the line pressure and control it Master flow controller Slave Unit connected to the system as a slave Outline Unit off line interrupted communication with the controller Alarm Units on alarm Pre Alarm Units on prealarm Aya eenereAnalftica MASTER FLOW CONTROLLER Normally the system chooses the car with ID 1 as the master flow controller that is the machine designed to read and control the line pressure If you want to force the system to choose another press for half a second about the touch screen and displays the status Parallel Status 2 Press the touch screen for half a second Force to eten Plant Confirm by pressing the touch screen for half a second Aisa se n hr Bers Troubleshooting Kn A PEEN AAN ALARM PREALARM During operation the system executes other automatic checks In case of serious anomalies the display turns red the buzzer
18. ssure calibration and start the procedure 4 Wait for the terms automatically until the pressure reach 10 bar 5 Read the pressure gauge on the exact set on the generator and press the center of the display to save and exit the menu A ANN Remove the cell Unscrew the two screws on the cables of the cell Remove the two screws below power Disconnect the two transparent tubes inlet Disconnect the two white tubes and outlet water AAA eeen e Chromatography amp Spectrometry Raison The message Pump failure means that the pump don t work Possible causes e The pump is disconnected check the connector C061 e The pump need to be replace AAE Chromatography amp Spectrometry Replace the pump Empty the water tank Unplug the connector CO61 located at the end of the wires yellow red black and Unscrew the two screws Disconnect the two located below the generator transparent tubes jas e Chromatography amp Spectrometry High cell Voltage Raison The voltage of the cell is too high Possible causes e The fan is damaged and the temperature increase e The quality of water is bad e The water filter is full of dust e Problem of the pump e The cell is damaged most probability e The main board is damaged A IngenieriaAnalitica lt Chromatography amp Spectrometry Check and replace the main board Unscrew the four screws Remove the water cap Unplug the connector Cut the
19. three fixing wires central green Disconnect the cable Disconnect the cables connecting Di h le flat h f th connection of the cooling fans the power supply and the earth isconnect the cable flat and the power cords of the ce n InagenieriaAnalitica AAN lt Chromatography amp Spectrometry Check and replace the main board Unscrew the five screws on the rear panel IN Pull the rack Unscrew the sixscrews AAA eeen e Chromatography amp Spectrometry GLS Failure Raison The message GLS failure means that the second IR sensor has detect water Possible causes e The valve doesnt open well e There is a ball of water between 2 IR sensors e There is a defect on the IR sensors The valve doesnt open well Solutions Check the valve Remove Valve Remove GLS Correct position Bad position AANEEN How to Check the IR sensors Go to MAINTENANCE SERVICE PASSWORD 345 COMPLETE TEST When the test is finished take a picture of the screen or write down all the data LEAK TEST C1 PASS C2 PASS GLS PASS IRT XX XXX XXX IR2 XX XXX The first number of IR1 must be under 20 The first number of IR2 must be under 30 but the last numbers of IR2 must be above 100 if not means the second IR sensor has a problem AANEEN Power supply failure Raison The power supply is damaged Possible causes e Check the power supply e Check the electrical connection
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