pd-0100-0034_rev_a hogen h eng

PD-0100-0034 REVISION A

==================== Hydrogen By Wire ======================

PROTON, HOGEN, Hydrogen by Wire, and Transforming EnergyTM are trademarks or registered trademarks of Proton Energy Systems, Inc. 2003 Proton Energy Systems, All Rights Reserved

HOGEN H SERIES

HYDROGEN GENERATOR

Installation & Operation Manual

HOGEN H Series Hydrogen GeneratorInstallation & Operation Manual

PD-0100-0034 REV A CONFIDENTIAL Do not copy Page 2 of 90

HOGEN H Series Hydrogen Generator Installation & Operation Manual

Output:

2, 4, 6 NM3/Hour

Serial Number: ___________________

January 2007

Proton Energy Systems, Inc. 10 Technology Drive

Wallingford, CT 06492 (203) 949-8697

www.protonenergy.com [email protected]

SIC 3569-901 Gas Generating Equipment NAICS 333-999-8556 Gas Generating Equipment

This document is the property of Proton Energy Systems, Inc. and is delivered on the express condition that it is not to be disclosed, reproduced in whole or in part, or used for any purpose other than the operation and servicing of the HOGEN H Series hydrogen generator without Proton Energy Systems, Inc written consent and that no right is granted to disclose or so use any information contained in said document. This restriction does not limit the right to use information obtained from another source.



HOGEN H Series Hydrogen Generator

INSTALLATION & OPERATION MANUAL

Prepared by

PROTON ENERGY SYSTEMS, INC. CONTENTS

1 Introduction .......................................................................................................................................... 8

1.1 Key Definitions, Acronyms, and Abbreviations Used in this Document .................................. 10

1.2 General Description................................................................................................................... 11

1.3 Classification of the HOGEN Hydrogen Generator .................................................................. 12

1.4 Subsystems ................................................................................................................................ 13 1.4.1 Water and Oxygen Management Subsystem ................................................................... 13 1.4.2 Hydrogen Gas Management Subsystem .......................................................................... 14 1.4.3 Control and Power Distribution ....................................................................................... 14

1.5 Enclosure................................................................................................................................... 15 1.5.1 Fluids Enclosure .............................................................................................................. 15 1.5.2 Electrical Enclosure ......................................................................................................... 15 1.5.3 Enclosure Integrity........................................................................................................... 16

1.6 Product Specification ................................................................................................................ 17

2 Safety................................................................................................................................................... 19

2.1 General Information .................................................................................................................. 19

2.2 Using Hydrogen Gas ................................................................................................................. 19

2.3 References ................................................................................................................................. 20

3 Installation .......................................................................................................................................... 21

3.1 Top-Level Steps of Installation ................................................................................................. 22

3.2 Facility Air Ventilation Requirements ...................................................................................... 22

3.3 Operating Environment ............................................................................................................. 25

3.4 Site Preparation ......................................................................................................................... 25

3.5 Instructions on Unpacking the HOGEN Hydrogen Generator .................................................. 27

3.6 Lifting and Moving ................................................................................................................... 28

3.7 Anchoring Instructions .............................................................................................................. 30

3.8 Electrical Interfaces................................................................................................................... 31 3.8.1 Cabling Procedure............................................................................................................ 31 3.8.2 Remote Alarm Contact and Shutdown Connections........................................................ 34

3.9 Mechanical Interfaces................................................................................................................ 35



3.9.1 Physical Layout, Connections and Dimensions ............................................................... 36 3.9.2 Hydrogen Vent Interface.................................................................................................. 38 3.9.3 Vent Line Installation ...................................................................................................... 39 3.9.4 Product Hydrogen Interface............................................................................................. 39 3.9.5 Air Dilution Interface and Integrated Oxygen Disposal .................................................. 40 3.9.6 Coolant Water Interfaces ................................................................................................. 41 3.9.7 Feed Water Interfaces ...................................................................................................... 43

3.10 Connecting the Cell Stack(s) ..................................................................................................... 46

3.11 Calibration Gas Cylinder Installation ........................................................................................ 51

3.12 Inlet and Exit (Optional) Air Filter Housing Installation .......................................................... 51

3.13 External Shroud Installation (Optional) .................................................................................... 55

3.14 Guard Bed Installation Instructions........................................................................................... 57

3.15 First Time Startup Instructions .................................................................................................. 58 3.15.1 High-Powered Connection Torque Requirements ........................................................... 58

3.16 Remote Monitoring Software Installation ................................................................................. 59 3.16.1 Network Specifications.................................................................................................... 62 3.16.2 Cabling............................................................................................................................. 62

3.17 Configuring the System for Network Interface ......................................................................... 63 3.17.1 Resetting Network Settings.............................................................................................. 63

3.18 LAN Installation........................................................................................................................ 66 3.18.1 PC Parameters.................................................................................................................. 66 3.18.2 LAN Configuration Instructions ...................................................................................... 67 3.18.3 Electrical Connections for LAN Installation.................................................................... 69

3.19 Remote Monitoring Setup ......................................................................................................... 69 3.19.1 Remote Software Monitoring Feature.............................................................................. 69 3.19.2 Data Logging Feature ...................................................................................................... 70

3.20 Remote Monitoring Upgrade Instructions ................................................................................. 72

4 Operation ............................................................................................................................................ 74

4.1 Operating Modes ....................................................................................................................... 74 4.1.1 Normal Mode................................................................................................................... 74 4.1.2 Service Mode ................................................................................................................... 74 4.1.3 Keys ................................................................................................................................. 74

4.2 Pre-Start Startup Instructions .................................................................................................... 75

4.3 Applying Power......................................................................................................................... 75

4.4 Control Panel............................................................................................................................. 76

4.5 Generating Hydrogen ................................................................................................................ 77

4.6 Manual Shutdown...................................................................................................................... 78

4.7 Automatic Shutdown................................................................................................................. 79

5 User Interface ..................................................................................................................................... 82 5.1.1 LCD Display Areas.......................................................................................................... 82 5.1.2 Display Screens................................................................................................................ 82

6 APPENDIX A: Options ....................................................................................................................... 83



6.1 Pressure Reducing Regulator Option ........................................................................................ 83

6.2 Coolant Isolation Kit Option (Installed) .................................................................................... 84

6.3 Dewpoint Transmitter Option.................................................................................................... 84

6.4 Backup Manifold Auto Crossover Option................................................................................. 85

6.5 Combustible Gas Sensor Assembly Option............................................................................... 85

6.6 Lab Purity Option...................................................................................................................... 86

6.7 StableFlowTM Performance Optimization Option...................................................................... 86

7 APPENDIX B: Installation Checklist.................................................................................................. 88 LIST OF FIGURES

Figure 1 HOGEN H Series Hydrogen Generator .......................................................................................... 8 Figure 2 HOGEN H Series Interface Connections....................................................................................... 11 Figure 3 HOGEN H Series Hydrogen Generator WOMS Piping and Instrumentation Document (P&ID). 13 Figure 4 HOGEN H Series Hydrogen Generator HGMS P&ID.................................................................. 14 Figure 5 HOGEN H Series Hydrogen Generator Interface Connections .................................................... 21 Figure 6 HOGEN H Series Hydrogen Generator Plan View for Installation .............................................. 26 Figure 7 Removing Bolt from the Shipping Beam ........................................................................................ 27 Figure 8 Additional Beam Location ............................................................................................................. 28 Figure 9 Removing Screws from Bottom Front Panel.................................................................................. 28 Figure 10 Removing Base Fastener Cover Plate ......................................................................................... 29 Figure 11 Lifting the Unit using a Forklift ................................................................................................... 29 Figure 12 Anchoring Diagram..................................................................................................................... 30 Figure 13 Anchoring Holes .......................................................................................................................... 30 Figure 14 Electrical Interface Locations ..................................................................................................... 31 Figure 15 Internal Power and Ground Connections.................................................................................... 32 Figure 16 HOGEN H Series Hydrogen Generator Electrical Interface Locations...................................... 33 Figure 17 Remote Alarm Relay Location ..................................................................................................... 34 Figure 18 Terminals to Wire External Contacts .......................................................................................... 35 Figure 19 TB 3 Location .............................................................................................................................. 35 Figure 20 Left Side View Figure 21 Right Side View............................................................................. 36 Figure 22 Front View Figure 23 3-D View .............................................................................. 36 Figure 24 HOGEN H Series Hydrogen Generator Interface Connections .................................................. 37 Figure 25 Condensate Drain Trap Flow...................................................................................................... 39 Figure 26 Product Hydrogen Interfaces....................................................................................................... 40 Figure 27 Coolant Water Interfaces............................................................................................................. 41 Figure 28 TB 4 Location .............................................................................................................................. 42



Figure 29 TB4 Wiring Locations.................................................................................................................. 42 Figure 30 DI Water Feed Port ..................................................................................................................... 43 Figure 31 Water Feed Valve on Bulkhead ................................................................................................... 45 Figure 32 A200 Tank with Bungee Cord...................................................................................................... 46 Figure 33 Removing the Tie Wrap from the Cell Stack Outlet Fitting ......................................................... 47 Figure 34 Removing the Cap from the Cell Stack Outlet Fitting ................................................................. 47 Figure 35 Tightening the Outlet Fitting on Cell Stack A.............................................................................. 48 Figure 36 Cell Stack and Connection Locations .......................................................................................... 49 Figure 37 Calibration Gas Cylinder Installation ......................................................................................... 51 Figure 38 Filter Element .............................................................................................................................. 52 Figure 39 Removing the Screws ................................................................................................................... 52 Figure 40 Removing the Filter Retaining Clip ............................................................................................. 53 Figure 41 Filter Housing Installed on the HOGEN H Series Hydrogen Generator .................................... 53 Figure 42 Sliding Air Filter into Filter Housing .......................................................................................... 54 Figure 43 Reinstalling Filter Retaining Clip................................................................................................ 54 Figure 44 Installing Screws.......................................................................................................................... 55 Figure 45 Sliding External Shroud over Filter Housing .............................................................................. 55 Figure 46 Tightening Screw on Top of External Shroud.............................................................................. 56 Figure 47 Guard Bed Filter Cartridge and Housing ................................................................................... 57 Figure 48 Guard Bed Cartridge inside Guard Bed Housing ....................................................................... 57 Figure 49 Tightening the Filter Housing...................................................................................................... 58 Figure 50 First Screen in Installation Wizard.............................................................................................. 60 Figure 51 Second Screen in Installation Wizard .......................................................................................... 60 Figure 52 Installation of Software Screen.................................................................................................... 61 Figure 53 Installation Initializing Screen..................................................................................................... 61 Figure 54 Installation Completed Screen..................................................................................................... 62 Figure 55 Ethernet Cable Pinout ................................................................................................................. 63 Figure 56 Server IP Address Location ......................................................................................................... 64 Figure 57 Choosing Settings ........................................................................................................................ 64 Figure 58 Select Set Config Params............................................................................................................. 65 Figure 59 Configuration Parameters Menu ................................................................................................. 65 Figure 60 Remote Monitoring Wiring .......................................................................................................... 66 Figure 61 HCS Monitoring Folder Location................................................................................................ 67 Figure 62 Support Files Folder Location..................................................................................................... 68 Figure 63 MODBUS TCP Configuration.ini Location................................................................................. 68



Figure 64 IP Address Location .................................................................................................................... 69 Figure 65 Default Screen ............................................................................................................................. 70 Figure 66 Enable/Disable Switch for Data Logging Feature ...................................................................... 71 Figure 67 .CSV File Example....................................................................................................................... 71 Figure 68 Data Log Example in Excel ......................................................................................................... 71 Figure 69 Uninstall Wizard.......................................................................................................................... 72 Figure 70 System Uninstalling Software ...................................................................................................... 73 Figure 71 Uninstall Process Completed....................................................................................................... 73 Figure 72 Control Panel Overview .............................................................................................................. 74 Figure 73 LCD Display Areas...................................................................................................................... 82 Figure 74 Example Schematic of the Pressure Reducing Regulator ............................................................ 83 Figure 75 Coolant Isolation Option Installed .............................................................................................. 84 Figure 76 Dewpoint Transmitter .................................................................................................................. 84 Figure 77 Backup Manifold Auto Crossover................................................................................................ 85 Figure 78 Combustible Gas Sensor Assembly.............................................................................................. 85 Figure 79 Lab Purity Kit .............................................................................................................................. 86 Figure 80 StableFlow Process ..................................................................................................................... 87 LIST OF TABLES Table 1 HOGEN H Series Specifications ..................................................................................................... 18 Table 2 HOGEN H Series Hydrogen Generator Interface Connections ...................................................... 21 Table 3 Electrical Interface Connections Reference Dimensions ................................................................ 33 Table 4 Materials to Avoid Contact with DI Water Feed............................................................................. 44 Table 5 Preferred Materials in Contact with DI Water Feed....................................................................... 44 Table 6 High-Powered Connection Torque Requirements........................................................................... 59 Table 7 Network Specifications .................................................................................................................... 62 Table 8 Standard Ethernet Cable Wiring Connections for Normal and Crossover Cables ......................... 62 Table 9 Controller Default Network Settings ............................................................................................... 63 Table 10 Recommended Computer Network Settings................................................................................... 63 Table 11 Error and Warning Codes ............................................................................................................. 81 Table 12 Pressure Drop Data for Pressure Reducing Regulator................................................................. 83



1 INTRODUCTION The HOGEN H Series industrial hydrogen generator (see Figure 1) is a Proton Exchange Membrane, or PEM, water electrolysis system packaged for rapid onsite installation and ease of use. Configured with up to three PEM stacks, the HOGEN H Series hydrogen generator is designed to deliver up to 6 NM3/h (228 SCFH) of 99.9995 percent pure hydrogen at a maximum pressure of 15 barg (225 psig). The HOGEN H Series hydrogen generator may be configured with one, two, or three cell stacks to meet customer hydrogen need through the range of 0 to 6 NM3/h. Hydrogen generation is continuously available and follows customer demand as long as power and deionized, or DI, water are available. The HOGEN H Series hydrogen generator is designed to operate in a well-ventilated, non-classified, indoor environment. Proton Energy Systems, Inc. (PROTON) has provided these instructions to guide the installation and operation of a HOGEN H Series hydrogen generator. These instructions provide technical product information, installation requirements, detailed mechanical and electrical interface specifications, and operating instructions. Important safety information is also included in this manual. Please take time to familiarize yourself with the system and the manual. IT IS THE CUSTOMERS RESPONSIBILITY TO CONSULT WITH THE LOCAL AUTHORITY HAVING JURISDICTION (AHJ) REGARDING LOCAL CODE REQUIREMENTS FOR INSTALLATION AND OPERATION OF THIS EQUIPMENT. DO NOT USE THE HOGEN H SERIES HYDROGEN GENERATOR IN A MANNER NOT SPECIFIED BY PROTON ENERGY SYSTEMS.

Figure 1 HOGEN H Series Hydrogen Generator

Fluids Compartment

Electronics Compartment



This manual attempts to answer most of the frequently asked questions with regards to the 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 technical service support or email [email protected]. Please have the model number and serial number of your unit available. PROTON offers a full range of installation and training services. Contact PROTON Customer Service at 203-949-8697 or your local service provider/supplier for more information. If freezing conditions exist at your site, you must take measures to prevent condensation from freezing and obstructing the H2 vent line and freezing the water supply and drain lines. After performing any service or maintenance work, make sure the doors to the enclosure are completely closed prior to the startup operation of your generator. Do not remove or install the flash card provided with the unit while the unit is powered. It is the customers responsibility to organize a backup hydrogen supply to bridge critical times during maintenance and service.



1.1 Key Definitions, Acronyms, and Abbreviations Used in this Document

PROTON Proton Energy Systems, Inc. ASME American Society of Mechanical Engineers NM3/h - Normal cubic meter per hour (International Normal conditions are 1.01325 bar and 0 Celsius) SCFH - Standard cubic foot per hour (US Standard conditions for air are 14.7 psia and 70F) Bar - 14.5 PSI or 100 KPa (KiloPascals or Newton/cm), a unit of system pressure. Standard atmosphere = 1.01325 bar = 14.696 psi PSI - Pounds force per square inch (lbf /in2=6894.7 Pa), a unit of pressure L/m - Liters per minute flow (for hydrogen, calculated at normal conditions) cc - Cubic centimeter KW - Kilowatt; KVA - Kilovolt-ampere S/cm - MicroSiemen per centimeter, a measure of water conductivity HOGEN - Registered TM of Proton Energy Systems Inc. for packaged water electrolysis based hydrogen generators FNPT Female National Pipe Thread NPT National Pipe Thread NFPA National Fire Protection Association, a Standards Organization CPI Chemical Process Instrumentation VDC Volts Direct Current VAC Volts Alternating Current NEC National Electric Code, NFPA 70 LAN Local Area Network HGMS Hydrogen Gas Management Subsystem WOMS Water/Oxygen Management Subsystem UI User Interface HCS H Series Control System PSU Power Supply Unit - Notes contain helpful suggestions or references. - Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate injury. It may also be used to alert against unsafe practices. This could result in equipment damage or loss of data. - Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.



1.2 General Description The HOGEN H Series hydrogen generator is a fully integrated, packaged electrolysis system that produces high purity hydrogen from water and electricity. The system includes up to three electrolyzer cell stacks, as well as the support systems necessary for regulating electrolyzing operations and pressurizing hydrogen. The support systems are used to aid in the functions of the system: circulating water, drying hydrogen, cabinet dilution, liquid cooling and shutting down the system. The unit contains all of the required sensors and controls to aid in monitoring the safety, performance and automatic operation of the system and to allow for optional remote monitoring and diagnostics. The unit is designed to operate in a well-ventilated, non-hazardous (non-classified), indoor environment. The recommended customer supplied interfaces are outlined in Figure 2.

Figure 2 HOGEN H Series Interface Connections



1.3 Classification of the HOGEN Hydrogen Generator

The HOGEN H Series hydrogen generator is a source of hydrogen, a combustible gas. When the unit is running, it can convert water to hydrogen and oxygen. When it is not running, the production of the combustible gas, hydrogen, stops. Protection against the ignition of a potentially explosive atmosphere inside the generator is accomplished using basic protection techniques described in NFPA 69, Standard on Explosion Prevention Systems and EN 1127-1, Explosive atmospheres Explosion prevention and protection Part 1: Basic concepts and methodology. The primary protection used is containment of the hydrogen. It is contained as much as possible inside the plumbing in the generator and is not allowed to mix with air to form a potentially explosive atmosphere. Dilution is the second protection. A blower moves air through the section of the enclosure where the hydrogen is generated at a rate sufficient to dilute the largest credible hydrogen leak to a level below the lower flammable limit (LFL) of hydrogen. The dilution rate is enough to reduce the area classification inside this section of the enclosure to non-hazardous (Zone 2 NE [negligible extent]). This is confirmed using analysis and testing per IEC 60079-10. Additionally, the power source that drives hydrogen generation is interlocked by sensor(s) that confirm the operation of the dilution blower. The third protection that is provided is the elimination of ignition sources in any potentially explosive atmospheres inside the generator. All of the internal power distribution equipment and as many other electrical components as possible are located in a separate section of the enclosure that is sealed from the section where the hydrogen is generated. The electrical components that remain in the hydrogen generation section are located outside any dilution zones. Again, this is confirmed using analysis and testing per IEC 60079-10. TUV Rheinland, an independent third party testing agency that is both an NRTL for the U.S. and Canada (like UL and CSA) and a Notified Body for the European Union, reviewed this approach to protection against potentially explosive atmospheres. The agency expressed their opinion stating that the H Series hydrogen generator employs primary protection means against potentially explosive atmospheres in the generator and that, since the generator is not designed to be placed inside a (existing) potentially explosive atmosphere, no additional certification or approval is required. As noted above, one of the primary protections against possible explosion is dilution with air. For this to be effective it is essential that the source of the air be non-hazardous (non-classified). Consequently, if fresh (non-hazardous) air is



supplied as required, the exhaust from the generator is non-hazardous as any hydrogen is diluted below the LFL. Therefore, due to the extent of the previously mentioned protection and prevention of explosive atmospheres, the hydrogen generator does not change the area classification of the area it is installed.

1.4 Subsystems

1.4.1 Water and Oxygen Management Subsystem

The Water and Oxygen Management Subsystem (WOMS) (see Figure 3) separates a two-phase mixture of oxygen gas and water from the electrolysis cell stacks. The oxygen may normally contain up to 0.5 percent hydrogen by volume. A combustible gas sensor (P&ID Tag CG220) monitors percent LEL of hydrogen in oxygen. In the event of a failure, the system shuts down if 50 percent LEL is detected. The WOMS subsystem:

Minimizes Evaporation Allows Draining of Water Maintains and Monitors Water Quality Manages Water Inventory Prevents/Accommodates Hazard from Cell Stack Failure Accepts Two-Phase Water and Hydrogen Stream from the Hydrogen

Management System (HGMS) Delivers Cooled and Filtered Water Streams to the Three Cell Stacks Rejects Heat via a Process Water Interface Vents Oxygen

Figure 3 HOGEN H Series Hydrogen Generator WOMS Piping and Instrumentation Document (P&ID)



1.4.2 Hydrogen Gas Management Subsystem

The Hydrogen Gas Management Subsystem (HGMS) (see Figure 4) separates product hydrogen from water and delivers high purity dry hydrogen product at pressure. The HGMS subsystem:

Accepts a Two-Phase Pressurized Hydrogen/Water Stream Delivers a Single-Phase Hydrogen Gas Stream of at Least 99.999 Percent

Purity Delivers a Liquid Water Stream (Which typically includes Dissolved

Hydrogen Gas) to the WOMS

Figure 4 HOGEN H Series Hydrogen Generator HGMS P&ID

1.4.3 Control and Power Distribution

The controls affect the automatic startup, product delivery rate, safety monitoring, and operational control for all modes of operation. The control system:

Provides an Easy-to-Use User Interface for Equipment Operators, Service, and Maintenance Personnel

Provides Optional Remote Monitoring, Diagnostics, Service, and Remote Operation Functions

Provides a Safety Circuit, Including Pressure Monitoring and Cutoff Switches such as E-Stop, Flood, and Main Disconnect, to De-Energize Circuits in Process Enclosure for Type X Pressurization Per NFPA 496



1.5 Enclosure

The enclosure element of the HOGEN H Series hydrogen generator: Protects the Internal Elements of the Generator from Shipment Damage

and the Environment Provides Structural Mounting and Support Consists of both Fluids and Electrical Enclosures and Optional Filter

Housing and Shrouds Prevents Unauthorized Access

1.5.1 Fluids Enclosure

The fluids enclosure largely contains the following elements and provides the listed functions:

Dilution Blower, Cell Stacks, WOMS, and HGMS Bulkhead with Requisite Fluid Interconnect Locations Dilutes and Disposes Vents of Waste Oxygen via Air Flow Provides Dilution to Reduce Internal Environment to Non-Hazardous

(Non-Classified) Per IEC 60079-10 CONTACT WITH HIGH VOLTAGE MAY RESULT IN DEATH OR SERIOUS INJURY.

1.5.2 Electrical Enclosure

The electrical enclosure provides the necessary input and output electrical connections and top-level control. The electrical enclosure contains elements that:

Provide DC Power to the Cell Stacks based upon Hydrogen Requirements Include Test Points for Diagnostic Purposes Provide Control to the Various Subsystems Provide a User Interface Panel for Unit Operation Provide 380-480 VAC Power to Pump, Blower and 24 VDC Power

Supply Provide 24 VDC to Control Circuits and Cell Stack Power Supply Fans

CONTACT WITH HIGH VOLTAGE MAY RESULT IN DEATH OR SERIOUS INJURY.



1.5.3 Enclosure Integrity

Visually inspect the enclosure element for any signs of damage, particularly if it is subject to direct impact or wet conditions. Please keep water, dust and other foreign particles out of the enclosure area. Also, verify that the seals on the doors and panels are not compromised or damaged. Contact PROTON or your local service provider/supplier with questions.



1.6 Product Specification Hydrogen Production H 2m H 4m H 6m

2 Nm3/h 4 Nm3/h 6 Nm3/h Net Production Rate 76 SCF/hr 152 SCF/hr 228 SCF/hr

Delivery Pressure Nominal 15 barg 225 PSIG

8.3 kWh/Nm3 7.0 kWh/Nm3 6.8 kWh/Nm3 Power Consumed/Volume of Hydrogen Gas Produced 21.2 kWh/100 ft3 18.5 kWh/100 ft3 17.8 kWh/100 ft3 Purity Concentration of Impurities: 99.9995 Percent

Water Vapor < 5 PPM Water (-65 C/ -85 F Dewpoint) N2 < 2 PPM, O2 < 1 PPM, All Others Undetectable

Turndown Range 0 to 100 Percent Net Product Delivery Upgradeability Field Upgradeable to

a Max of 6 Nm3/h (228 SCF/hr)

Field Upgradeable to a Max of 6 Nm3/h

(228 SCF/hr)

N/A

DI Water Requirement 1.83 L/hr 3.66 L/hr 5.50 L/hr Rate at Max Consumption Rate .50 gal/hr .96 gal/hr 1.42 gal/hr

Temperature 5 C to 50 C 41 F to 122 F

Pressure 1.5 to 4 barg 21.8 to 58.0 PSIG

Input Water Quality ASTM Type II Deionized Water Required (< 1 micro Siemen/CM) ASTM Type I Deionized Water Preferred (< 0.1 micro Siemen/CM)

Heat Load and Coolant Requirement Cooling Liquid-Cooled Heat Load from System 8.1 kW Max 16.1 kW Max 23.7 kW Max Coolant 0 to 50 Percent Anti-Freeze, Non-Fouling

1.4 to 6.9 barg (20 to 100 PSIG) 5 C to 35 C (41 F to 95 F) 15 to 87 L/min (4 to 23 GPM), Depends on Model and Coolant Temperature

Electrical Specifications Recommended Breaker Rating 22 kVA 40 kVA 58 kVA Electrical Specification 380 - 480 VAC, 3 Phase, 50 - 60 Hz Interface Connections H2 Product Port CPI Compression Tube Fitting, SS H2/H2O Vent Port FNPT, SS DI Water Port FNPT, SS Calibration-Gas Port 1/8 FNPT, Brass Cooling Supply Port 1 FNPT, Brass Cooling Return Port 1 FNPT, Brass Drain Port 3/8 FNPT, Brass Electrical Connect to On-Board Circuit Breaker Communications Ethernet



Control Systems H 2m H 4m H 6m Standard Features Fully Automated, Push Button Start/Stop, E-Stop. On-Board H2

Detection. Automatic Fault Detection and System Depressurization. Remote Alarm Form C Relay (5A, 250V, 150W Max Rated Switching) Remote Shutdown Safety Circuit Trip Enclosure Characteristics Dimensions (L x D x H) 180 cm x 80 cm x 180 cm

71 x 32 x 71 Weight 700 kg

1500 lbs 747 kg

1600 lbs 794 kg

1700 lbs Rating IP43 for Fluids Compartment; Upgradeable to IP55; IP66 for

Electronics Compartment. Environmental Considerations Standard Siting Location Indoor, Level 1, 0 to 90 Percent RH Non-Condensing, Non-

Hazardous/Non-Classified Environment Storage/Transport Temperature 5 C to 60 C

41 F to 140 F Ambient Temperature Range 5 C to 50 C

41 F to 122 F Altitude Range Sea Level to: 2400 m

7874 ft Ventilation Proper Ventilation must be Provided from a Non-Hazardous Area at

a Rate in Accordance with IEC60079-10, Zone 2 NE Safety and Regulatory Conformity

NFPA 69 and EN 1127-1, Clause 6.2 Cabinet Ventilation with Environment Vent Fan Draws Fresh Air up to 28 Nm3/min 1000 ft3/min

Noise dB(A) at 1 Meter < 83 Approvals NYFD Approval Pending Options PROTON offers a wide range of options to tailor your HOGEN

hydrogen generation system to meet your specific operational requirements. Please contact your local Proton Energy representative to discuss the current list of options available to best fit your needs.

Table 1 HOGEN H Series Specifications

Specifications are subject to change. Consult factory for latest spec and tolerances on figures specified without ranges.



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 and dilutes oxygen into the ventilation air stream. 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. It is important to operate the HOGEN in a ventilated, non-hazardous (non-classified) area. (The HOGEN complies with NFPA 70, NFPA 79, and NFPA 496.)

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. If you are not in danger, stop the flow of gas and use water to cool the area. The lower flammability limit of hydrogen is 4 percent hydrogen in air by volume. If fire occurs, do not attempt to extinguish flames, allow the fire to burn out.

Hydrogen gas is lighter than air.

Prevent overexposure to hydrogen. Hydrogen is non-toxic, but it can act as a simple asphyxiant by displacing the oxygen in the air. Effects of oxygen deficiency, resulting from simple asphyxiants, include rapid breathing, diminished mental alertness, impaired muscular coordination, faulty judgment, depression of all sensations, emotional instability, and fatigue. As asphyxiation progresses, nausea, vomiting, prostration, and loss of consciousness may result. The HOGEN H Series hydrogen generator is equipped with a pressure relief valve (P&ID Tags RV308 and RV351). If the system experiences an over-pressure condition, the relief valve opens and allows the system to depressurize by allowing hydrogen to flow out the H2/H2O vent. (Refer to Section 3.9.2 for Pressure Relief Valves and Vent Lines.)

FIRE OR EXPLOSION! KEEP ALL SOURCES OF IGNITION AWAY FROM HYDROGEN. IT IS ESSENTIAL THAT THE SAFETY SYSTEM IS NOT BYPASSED. CONTINUED OPERATION COULD RESULT IN SERIOUS INJURY AND/OR DAMAGE TO THE GENERATOR.



2.3 References

Refer to Section 3.2 for Ventilation Requirements. Refer to Section 3.5 for Lifting and Moving. Refer to Section 3.8.2 for Remote E-Stop and Remote Alarm Refer to the Maintenance Manual for Lock Out/Tag Out Procedure.



3 INSTALLATION The HOGEN H Series hydrogen generator is a fully integrated system. To install the HOGEN generator, mechanical, electrical, fluid, and communication interface requirements must be met. This section describes the interface and installation requirements. Figure 5 illustrates the hardware, mounting points and connections for system integration and packaging.

Figure 5 HOGEN H Series Hydrogen Generator Interface Connections Reference Interface Connection Reference Interface Connection A Calibration Gas Port H Drain DI H20 Port B H2/H2OV Vent Port I AC Power Feed in this Area C H2 Product Port J Communications in this Area D Air Inlet Filter K Remote Alarm & Shutdown in

this Area E DI Water Feed Port L Lifting Eyebolts F Cooling Water Inlet Port G Cooling Water Outlet Port

Table 2 HOGEN H Series Hydrogen Generator Interface Connections

A

B

C

D

EF

GH

I

J K

L



3.1 Top-Level Steps of Installation

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.

3. Siting the unit. 4. Connecting electrical interfaces. 5. Connecting mechanical interfaces. 6. Calibrating the combustible gas detector.

Each of these steps is described in further detail in their sub-sections within this section.

3.2 Facility Air Ventilation Requirements

The HOGEN H Series hydrogen generator design implements ventilation in accordance with NFPA 496, Type Z pressurized ventilation scheme. A blower at the inlet air filter forces 400 to 1000 cubic feet per minute (CFM) of fresh purge air through the fluids compartment. The blower is of sufficient power to maintain an internal positive static air pressure in excess of 0.25 in (5.08 mm) of water column. A pressure switch within the cabinet detects any loss of ventilation pressure and will produce a safety 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 1 percent hydrogen in air (25 percent of the lower flammable limit (LFL)).

Although the unit will not be able to make hydrogen when the safety circuit is triggered, the safety circuit does not shutdown the system entirely. Fans and other areas of the safety circuit will remain engaged.

As an additional benefit, this air ventilation rate excessively dilutes byproduct oxygen to a safe concentration below 23.5 percent, precluding any hazards associated with enriched oxygen atmospheres. PROTON recommends an installation area air change rate of several hundred times the maximum generation rate of the HOGEN H Series hydrogen generator to preclude any possible build up of hydrogen or enriched air concentrations in the facility. In the event the ventilation system fails or the air inlet is restricted, the HOGEN H Series hydrogen generator is equipped with a safety circuit to detect the loss of ventilation and stop any further generation of hydrogen by automatically shutting down. The small amount of hydrogen left on-board is



automatically vented through the vent stack port; however some residual hydrogen remains in the system. The circuit also disconnects power to all electrical equipment in the process (fluids) enclosure, though the fans and other areas of the safety circuit remain energized. Additionally, an internal hydrogen detector produces an automatic alarm if excessive hydrogen is detected. If required, the HOGEN H Series system can interface with facility fire detection systems, combustible gas sensor or other external facility alarms as required.

THE HOGEN H SERIES HYDROGEN GENERATORS ARE DESIGNED TO OPERATE IN NON-EXPLOSIVE, NON-HAZARDOUS, NON-CLASSIFIED ENVIRONMENTS. THE EQUIPMENT CABINET IS VENTILATED WITH FRESH AIR TO MAINTAIN A SAFE, NON-EXPLOSIVE INTERNAL OPERATING ENVIRONMENT (US PATENT 5980726). Coal dust environments require an optional external filter and shroud kit from PROTON (KT-1000-0037). Always refer to local code requirements to determine minimum facility ventilation requirements. A worksheet for estimating minimum ventilation at your facility is given below. How to calculate the ventilation requirements for your site:

1. Record net hydrogen generation rate (P) for your selected generator. (Refer to Table 1):

P = ________ NM3/h (SCFH) If there is a plan to have multiple hydrogen generators in the room, P must be the sum of all generators.

2. Calculate the gross hydrogen generation rate (G). (Add 10 percent):

G =P x 1.1 = ________ NM3/h (SCFH)

3. Calculate recommended ventilation rate (F). (Several hundred times gross generation rate):

F > 100 x G/60 = ________ NM3/min (SCFm)

4. Confirm if actual room ventilation (FA) is adequate, FA =_______________:

a. Is actual room ventilation (FA) greater than or equal to F? YES/NO



If you answered YES for 4a, then you may install the unit in the room. If you answered NO for 4a, then you may not site the unit in the room until improvements are made to the ventilation system.

Example Calculation:

1. Record net hydrogen generation rate (P) for your selected generator. (Refer to Table 1):

P = 228 (SCFH)

2. Calculate the gross hydrogen generation rate (G). (Add 10 percent):

G = 1.1 x P = 250.8 (SCFH)

3. Calculate recommended ventilation rate (F). (Several hundred times gross

generation rate):

F > 100 x G/60 = 25080 (SCFH) / 60 = 418 SCFM

4. Confirm if actual room ventilation (FA) is adequate, FA = 950 cfm a. Is actual room ventilation (FA) greater than or equal to F? YES



3.3 Operating Environment

The HOGEN H Series hydrogen generator is designed for indoor use. It shall be situated on a grade of no more than 1 degrees. The area that the system occupies shall have the ventilation schemes described in Section 3.2. The standard HOGEN H Series hydrogen generator is rated for ambient temperatures and is not designed for freezing conditions (per H Series Specifications discussed in Table 1). If the system is introduced to freezing conditions, damage to the system occurs.

Consult PROTON for information on placing the unit in a freezing environment.

The HOGEN H Series hydrogen generator contains a systems thermocouple that monitors the water temperature in the process water circulation loop of the system. The unit runs 100 percent hydrogen output at 59C. If the system water temperature reaches 60C, the unit begins reducing the maximum hydrogen output and triggers a warning. If the warning is undetected, the unit continues reducing hydrogen output until it shuts down at 65C. If the cooling feed water temperature exceeds 35C, the unit may overheat and shutdown. The HOGEN H Series hydrogen generator can be stored and transported in certain environments (per H Series Specifications discussed in Table 1). 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(s) must be taken out of the system and transported separately. Instructions for the decommissioning of the system are detailed in the Service Manual).

THE GENERATOR IS TYPICALLY SHIPPED WITH THE PEM CELL STACK (S) ALREADY INSTALLED. FOR THIS REASON, DO NOT EXPOSE THE STACK (S) 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. 3.4 Site Preparation

The HOGEN H Series hydrogen generator is designed for indoor installation on a level concrete pad. AC power, deionized water and cooling water that meets the specifications outlined in Table 1 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. PROTON recommends the use of barriers if placing the unit near a vehicle traffic area.



A level floor, 1 degrees, capable of supporting the generator is required. The minimum clearance requirements of the area around the generator are shown in Figure 6. There is a zero minimum clearance requirement on the back of the generator. The minimum clearance requirement on the front, left and right panels of the generator is 1 meter or 3.3 ft. It is the customers responsibility to verify that the local code requirements for this type of equipment are met when installing this equipment. All facility connections are identified in Figure 5. Leave sufficient clearance to permit adequate air movement in and out of the generator from the front and the left side of the unit. Front access is very important for operation, ventilation and maintenance. The generator is controlled from the front control panel, which has start and stop switches, E-Stop, main disconnect, keypad, and service bypass key switch. Opening the door of the fluid compartment permits access for routine maintenance.

Figure 6 HOGEN H Series Hydrogen Generator Plan View for Installation



3.5 Instructions on Unpacking the HOGEN Hydrogen Generator

The HOGEN hydrogen generator arrives with shipping beams used to support the unit during shipment. Please use the following instructions to unpack the hydrogen generator:

1. Using a 9/16 wrench with a socket and a ratchet, unscrew the four (4) nuts

from the beam in the front of the unit. 2. Using a 9/16 wrench with a socket and a ratchet, unscrew the two (2) nuts

from the beam on the right side of the unit. Repeat this step for the two (2) nuts located on the left side of the unit.

3. Once all nuts are unscrewed, push down on each bolt (there are eight {8} bolts total) and take each bolt from the bottom. (Refer to Figure 7.)

Figure 7 Removing Bolt from the Shipping Beam

4. Remove the shipping beams from the unit. 5. Remove the additional shipping beam from the unit, which is located behind

the bolted beam in the front of the unit.



Figure 8 Additional Beam Location 3.6 Lifting and Moving

The HOGEN H Series hydrogen generator is delivered on a pallet and weighs approximately 1750 lbs. (794 kg). The generator can be transported on a pallet using a forklift or by a hoist or overhead crane. To lift and move the generator using a forklift, refer to the following instructions: 1. Using a Number 30 TORX bit, remove the four (4) screws on the bottom front

panels at the base of the unit (see Figure 9).

Figure 9 Removing Screws from Bottom Front Panel

2. Press down and remove the four (4) black, base fastener cover plates.

Base Fastener Cover Plate

Shipping Beam



Figure 10 Removing Base Fastener Cover Plate

3. Using a screwdriver, pry out the bottom front panels. 4. Repeat Steps 1 4 for the rear of the unit. 5. Using a forklift/hand truck, lift the unit from under the floor. Make sure the

forks extend passed the back of the unit.

Figure 11 Lifting the Unit using a Forklift

6. Once the unit is in final position, re-install the base panels and the base fastener cover plates.

If transporting by hoist, align all eyebolts (Item L in Figure 5) down both sides of the unit. Place solid (appropriately sized) bar stock inside the eyebolts to run the entire length of the unit. Lift the enclosure from the bars, as they facilitate an even weight distribution. Attach appropriately sized harness, chain or sling for a more even weight distribution.

Forks Extending Beyond the Rear



3.7 Anchoring Instructions

It is required to properly secure an H Series hydrogen generator to a concrete pad when siting the equipment outdoors. The drawing provided below should be used to locate the anchor points needed to perform the installation. All materials and methods used should be appropriate for anchoring the H Series hydrogen generator in the intended environment.

Figure 12 Anchoring Diagram

Figure 13 Anchoring Holes If the HOGEN H Series hydrogen generator is placed in a freezing environment and there is a loss of power, take necessary provisions to keep the unit from freezing.

Anchoring Holes



3.8 Electrical Interfaces

Once the HOGEN H Series Hydrogen Generator is properly located, electrical connections can be made. All user supplied I/O cables that interface with this system must not exceed 30 meters (98.4 feet) in length.

3.8.1 Cabling Procedure

Ensure that the electrical connections conform to IP66/NEMA4 and are compliant with the local electrical codes. The electrical power connection and data communications connections must be weather-tight to keep out water and dust for reliable and safe operation. The electrical and data connections can be installed on the right side of the generator, in the approximate location indicated by the red arrows in Figure 14. The reference dimensions are listed in Table 3.

Figure 14 Electrical Interface Locations

It is important to verify that the input voltage to the generator maintains stability between 380 to 480 VAC to sustain reliable operation. If the input voltage falls below 360 VAC or rises above 500 VAC, an on board voltage monitoring relay trips the HOGEN hydrogen generator to the OFF position.

Electrical

Data



The cabling procedure is as follows: 1. Size the AC power conductors according to the service rating listed on the

nameplate (Refer to Table 1). 2. Ensure that connections conform to IP66/NEMA 4 standards and are

compliant with the local electrical codes. 3. Remove the right side panel from the unit if required. 4. Verify that the selected connectors are appropriately sized for the pre-drilled

holes. 5. Install the appropriate IP66/NEMA 4 connector into the hole drilled in the

side of the panel. 6. Feed the power and ground conductors through the AC power feed connector. 7. Connect the power conductors to the top of the main circuit

breaker/disconnect in side the unit. 8. Bring the protective earth ground conductor into the unit along with power to

the conductors.

Figure 15 Internal Power and Ground Connections

Protective Earth Ground

3-Phase Input



Figure 16 HOGEN H Series Hydrogen Generator Electrical Interface Locations

Main Power Feed Data Communications

Units Units Reference Dimension Inches mm

Reference Dimension Inches mm

A 5.50 139.70 E 8.50 215.90 B 13.00 330.20 F 21.00 533.40 C 6.14 155.90 G 5.50 139.70 D 8.50 215.90 H 43.03 1903.10

Table 3 Electrical Interface Connections Reference Dimensions



3.8.2 Remote Alarm Contact and Shutdown Connections

An external alarm from the HOGEN H Series hydrogen generator may be connected to announce system availability status. Only Normally Open (NO) contacts are available on the remote alarm relay, located on the right side of the controller assembly, as shown in Figure 17. The form C alarm relay contacts are rated for 1 230V, 5 amps max. DO NOT exceed this rating.

Figure 17 Remote Alarm Relay Location

A normally open contact is available for the remote alarm relay. The contact is rated for 230V, 5 Amp max. DO NOT EXCEED this rating. The remote alarm contact must be wired to 4TB terminals seven (7) and eight (8).

The user may shut down the system remotely by connecting an external contact closure to terminal block 3TB. (Reference XPE2544.) This feature permits the user to interconnect facility alarms to cause the generator to stop operation. Contacts must be rated to 50 W, 1 amp min. Multiple switches can be wired in series to form a user-safety circuit. For installation of all electrical connections to the unit follow the general guidelines as outlined Section 3.8.1.

External contacts must be wired across 3TB terminals 17 and 18. A second external contact can be wired across 3TB terminals 16 and 19.

Remote Alarm



Figure 18 Terminals to Wire External Contacts

The two jumpers (wired across TB 3 on terminals 16/19 and 17/18) installed in the unit represent customer remote E-Stop switches. To install a remote E-Stop, simply remove one of the jumpers, 5-6 or 37-38, and replace it with remote e-stop wiring. Terminal block TB 3 is located in the upper right area of the power panel (see Figure 19).

Figure 19 TB 3 Location 3.9 Mechanical Interfaces

This section provides a detailed description of the mechanical interface requirements. The physical layout and dimensions of the HOGEN H Series hydrogen generator are shown. Detailed interface connections for the hydrogen outlet, DI feed water and cooling water supply are also supplied.



3.9.1 Physical Layout, Connections and Dimensions

The physical layout of the HOGEN H Series hydrogen generator is shown in the following figures (Refer to Section 3.1).

Figure 20 Left Side View Figure 21 Right Side View

Figure 22 Front View Figure 23 3-D View



Figure 24 HOGEN H Series Hydrogen Generator Interface Connections



3.9.2 Hydrogen Vent Interface

The HOGEN H Series hydrogen generator vents hydrogen during startup, system depressurization, dryer purging cycles, and overpressure relief. The HOGEN H Series hydrogen generator vents up to 12.3 liters of hydrogen per minute to purge and condition the Hydrogen Gas Management Subsystem (HGMS).

In the GENERATE-VENT mode, the H Series hydrogen generator shall operate at approximately 6 percent generation while discharging generated hydrogen to vent. This operation purges the phase separation portions of the HGMS with hydrogen to eliminate any air gases that may be present.

At the end of GENERATE-VENT (130 seconds min/10 minutes max), the vent valve (P&ID Tag SV329) closes and the system begins to pressurize. During system shutdown, the on-board inventory hydrogen (< 1.4 SCF/0.036 Nm3) is vented to atmospheric pressure, leaving some residual hydrogen in the system. Depressurization occurs when gas generation stops and the vent valve (P&ID Tag SV329) is opened, allowing hydrogen to flow out of the H2/H2O vent. The internal dryer of the HOGEN H Series hydrogen generator is a pressure-swing dryer. Each bed operates alternately in two half-cycles of equal duration: pressurization followed by adsorption and depressurization, followed by a purge with product hydrogen from the alternate bed. It is during this purge that desorbed water vapor with hydrogen is blown out of the non-operating bed and directed out the H2/H2O vent. During these purge cycles, approximately 13.8 liters per minute (max) of hydrogen exits the H2/H2O vent port with desorbed moisture. The H2/H2O vent port uses FNPT connection. Figure 5 shows the connection location. The vent line to be attached to the port should be installed per best practice for hydrogen vent lines and must not be reduced or restricted. Refer to local standards, NFPA 50A, CGA G5.5, and ASME B31.3.

DO NOT ALLOW HYDROGEN TO VENT INDOORS, NEAR VENTILATION INTAKES, WORK AREAS, OR ANY SOURCE OF IGNITION. THE HYDROGEN VENT LINE AND VENT STACK TO ATMOSPHERE MUST REMAIN FREE FROM OBSTRUCTIONS AND KEPT FROM FREEZING. A condensate drain trap (As shown in Figure 25) is recommended to remove condensate from the vent stack and can be purchased from PROTON (Part Number 02-2000-0002).



Figure 25 Condensate Drain Trap Flow

3.9.3 Vent Line Installation

The connection for the hydrogen vent is FNPT. The vent port is located at the top of the bulkhead panel and is clearly labeled. For proper hydrogen dryer operation and compliance with pressure safety codes, 3/8 tubing (10mm) or larger is required.

The vent line shall not be restricted by excessive length of tubing or by the use of check valves. Vent backpressure adversely affects the moisture content of the hydrogen produced. In applications operating below freezing, precautions must be taken to prevent freezing of the vent lines. The vent line must be installed to minimize the possibility of restriction or blockage due to animals, insects, dirt, rust, etc

3.9.4 Product Hydrogen Interface

The HOGEN H Series hydrogen generator is designed to produce hydrogen that contains no more than < 5 PPM of water and



The product hydrogen port uses a Parker CPITM compression tube fitting for OD stainless steel tubing with .035 wall. Figure 5 shows the connection location.

Figure 26 Product Hydrogen Interfaces Parker CPITM is a trademark of the Parker Hannifin Company

3.9.5 Air Dilution Interface and Integrated Oxygen Disposal

The HOGEN H Series generator is shipped with an air inlet grill on the left side of the unit and air dilution discharge grills on the front face of the unit. This configuration is designed to IP 43. An optional outlet filter housing and shroud kit is available and is designed to IP 56. The installation area (the source of the HOGEN ventilation air) must be non-hazardous (non-classified) and well ventilated. It is very important that the inlet and exhaust dilution grills are not blocked or restricted in any way. Section 3.2 describes the air dilution protection scheme inside the HOGEN H Series hydrogen generator, which recommends the minimum facility air dilution requirements. Byproduct oxygen is diluted and disposed into the HOGEN H series air dilution stream, so there is no need for an oxygen port on the HOGEN H series. During maximum operation, the oxygen concentration increase is only 0.5 percent.

The air inlet grill needs to be replaced with an air filter housing at installation. Refer to Section 3.11 for instructions.

ADEQUATE DILUTION AND INDOOR AIR EXCHANGES MUST BE PROVIDED TO ASSURE THAT OXYGEN AND HYDROGEN CONCENTRATIONS DO NOT BUILD TO UNSAFE LEVELS (REFER TO SECTION 3.2).



3.9.6 Coolant Water Interfaces

The coolant water supply and return are 1 FNPT connections. Figure 5 shows the connection locations of these ports. It is recommended that the user provide isolation valves to permit maintenance and servicing of the coolant loop. Proton has an Automatic Coolant Isolation Kit (KT-1000-0017) available. The following instructions guide the wiring of the automatic valve. Complete instructions are in PD-0101-0019, which are included in the kit. A strainer must be installed on the fluid inlet to prevent clogging of the system with particulate. Typically, strainers have low holding capacities and are only designed for a low numbers of particles. Facilities with high particle counts in the cooling water may require additional filtration to prevent frequent clogging of this strainer. PROTON recommends a 50 mesh filter element.

Figure 27 Coolant Water Interfaces

PROTON also recommends using pressure gauges to monitor filter/strainer pressure drops and available facility cooling water.

Never operate the unit without the inlet strainer installed!



To wire the automatic isolation valve, use the following instructions: 1. Use a minimum14 AWG cable suited for the environment (600V, 90 C,

UL/CE Approved). 2. Lockout/Tagout the unit. 3. Route the cable the unit through the right hand panel of the electrical

enclosure (see Figure 5). All connections through the electrical panels must be made with an IP66-rated strain relief to maintain the integrity of the electrical enclosures environmental rating.

4. With the solenoid valve in position, make an electrical connection to terminal 7 and 8 on terminal strip block TB4, which is located on the right hand side of the electrical enclosure door (see Figure 28).

Figure 28 TB 4 Location The positive wire should be connected to unused terminal 2 and the negative wire to unused terminal 5. Refer to Figure 29.

Figure 29 TB4 Wiring Locations



3.9.7 Feed Water Interfaces

The DI water Feed port is a FNPT connection. Figure 5 shows the connection locations of this port. Polypropylene plastic tubing is highly recommended for the water feed line. FEP and PFA plastics are also acceptable. 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.

Figure 30 DI Water Feed Port The HOGEN H Series hydrogen generator uses de-ionized water to produce hydrogen and to actively cool the cell stack. It requires a minimum of ASTM Type II de-ionized water. ASTM Type II de-ionized water calls for a resistivity of at least 1.0 M-cm (or conductivity below 1 Siemen /cm) and a maximum 50-g 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 required, ASTM Type I de-ionized water is recommended. By using the highest quality water recommended, the life of the guard bed cartridge and the cell stack will be extended. The water quality sensor will trigger a fault if water quality drops below 1 M-cm (or the water conductivity exceeds 1 Siemen /cm). Therefore, it is highly recommended that ASTM Type I de-ionized water be used to prevent this fault.

DO NOT USE: copper, aluminum, iron or other metal for de-ionized water inlet tubing as this will result in significant contamination and performance loss over time. PVC plastics are not acceptable, as they will damage the electrolyzer cell stacks. In order to assure integrity of structure and fluid containment and minimize ionic and particle contamination please follow the guidelines outlined below. Preferred materials



for DI water feed plumbing and connections are given in Table 5. Materials to avoid are given in Table 4. DI water treatment options are available. Please consult PROTON or your service provider/supplier with any questions.

Copper Brass

Bronze Aluminum or Aluminum Alloy (Bare, Conversion-Coated, or Anodized)

Pure Nickel Nickel Plating Carbon Steel

High Strength Low Alloy Steel (e.g. 4130, 4340, etc) Cast Iron Cadmium

PVC

Table 4 Materials to Avoid Contact with DI Water Feed

Material Surface Treatment Common Uses Polypropylene - -

Polyethylene Plastic - - Titanium, Commercially Pure - Tube CRES 316L (Or Equivalent) Passivate per AMS-QQ-P-35

Type VI or Equivalent Vessels, Plumbing, Fittings, Valve

and Sensor Bodies Where Welding or Brazing is Used

CRES 316 (Or Equivalent) Passivate per AMS-QQ-P-35 Type VI or Equivalent

Vessels, Plumbing, Fittings, Valves, and Sensor Bodies

CRES A286 (Or Equivalent) Passivate per AMS-QQ-P-35 Type VIII or Equivalent

Moderate Strength Fasteners, Manifold

INCONEL 718 (Or Equivalent) - High Strength Valve Bodies, Pins INCONEL 625 (Or Equivalent) - Heat Exchanger, Valve Body

Table 5 Preferred Materials in Contact with DI Water Feed

The HOGEN H Series hydrogen generator controller controls water levels. When the water level drops below a set point in the Oxygen/Water Phase Separator, the Water Feed Valve (P&ID Tag SV510) opens to allow water into the system through the water inlet. (Refer to Figure 31.) Water may drain from the system during startup and when water quality is not maintained.



Figure 31 Water Feed Valve on Bulkhead

The drain line should not be raised overhead. The unit must drain downward to a drain, or a pumping station is required. The unit drain is pump assisted during operation, however when the water level gets low, it is a gravity only drain, and must go to a lower level than the system. During normal unit operation the maximum volume of DI water drained from the unit is approximately 2.5 gallons at a maximum flow rate of 1.5 gallons per minute. The maximum volume of DI water in the A200 is approximately 10 gallons and may need to be drained entirely during a service or maintenance operation (at the same rate). An obstructed drain line could prevent the HOGEN H Series hydrogen generator from draining properly and may result in permanent damage.



3.10 Connecting the Cell Stack(s) Use the following instructions for connecting the cell stack(s) on the HOGEN H Series hydrogen generator: Customers with 4Nm- or 6Nm units have up to two additional cell stacks (Cell Stack B and Cell Stack C, respectively).

1. Shut down the unit. 2. Remove power to the unit. 3. Ensure the system is fully drained before connecting the cell stack(s).

Connect one stack at a time to avoid a connection mix-up.

4. Remove and discard the bungee cord used to secure the A200 during shipment. (Refer to Figure 32.)

Figure 32 A200 Tank with Bungee Cord

5. Starting with Stack A, using shears, cut the tie wrap from around the cell stack outlet fitting. (Refer to Figure 33.) (Refer to Figure 36 for stack locations.)

Bungee Cord



Figure 33 Removing the Tie Wrap from the Cell Stack Outlet Fitting

6. Using a 7/8 wrench, remove the cap from the cell stack outlet fitting. (Refer to Figure 34.)

Figure 34 Removing the Cap from the Cell Stack Outlet Fitting

7. Connect the outlet hose to the cell stack. Tighten the fitting with a 7/8 wrench. (Refer to Figure 35.)



Figure 35 Tightening the Outlet Fitting on Cell Stack A

8. Still working on Stack A, using shears, cut the tie wrap from the around the cell stack inlet fitting.



Figure 36 Cell Stack and Connection Locations

9. Using a 7/8 wrench, remove the cap from the cell stack inlet fitting. 10. Connect the inlet hose from FSW250 A to the cell stack. Tighten the fitting with a

7/8 wrench. Verify the inlet and outlet hoses are connected properly. Do not over-tighten the fittings.

11. If one or more additional cell stacks need to be installed (Stacks B and C), repeat steps 4 through 9.

Cell Stack A

Cell Stack B

Cell Stack C

FSW250A

FSW250B

FSW250C

Outlet Hose Fitting on Cell

Stack A

Inlet Hose from FSW250C to Cell Stack C

Negative Buss Plates

Positive Buss Plates



Refer to Section 3.15 in the H Series Installation and Operations Manual, PD-0100-0030, for instructions on starting up the system for the first time.



3.11 Calibration Gas Cylinder Installation

The combustible gas sensor, which is calibrated at 50 percent of LFL (and provides an alarm at the same value), needs to be calibrated every three months for proper operation of gas detecting equipment within the hydrogen generator. Auto calibration permits the hydrogen generator to calibrate automatically with minimal user prompting and eliminates the need for manual calibration, a process where the unit triggers the user to apply 50 psig of Cal gas to the Cal gas port. Upon installation of the hydrogen generator, install the calibration gas cylinder using the following instructions, 1. Remove the plastic dust cover cap from the new bottle. 2. Thread the new bottle to the Cal subassembly by turning clockwise. 3. Secure the bottle with the strap clamp. (Refer to Figure 37.)

Figure 37 Calibration Gas Cylinder Installation 3.12 Inlet and Exit (Optional) Air Filter Housing Installation

The HOGEN H Series hydrogen generator uses an air filter to protect the inside of the system from contamination from the outside environment (ingress protection). The HOGEN generator uses one disposable air filter to remove contaminants from the dilution air entering the system, and uses one disposable air filter to prevent water from entering the unit when it is not running.

Units placed in excessive dust or water locations should use an optional filter and shroud to protect the inlet and exit filters.

Strap Clamp



The filter housing for the inlet air filter is required and supplied with the unit.

To install the air filter housings, use the following instructions:

1. Pull off the pop-off standard filter louver. Lift up on the bottom of the louver. 2. Once the pop-off standard filter louver is off, you can see the filter element.

Remove the filter element from the inlet air filter. Discard filter element.

Figure 38 Filter Element Save filter element for use on the outlet vent if the HOGEN H Series generator does not utilize the extended filter/external shroud option and is not installed in a coal dust environment.

3. Using a 25 TORX screwdriver, unscrew the four screws surrounding the filter. Be sure to save the four screws you remove from the filter. You will need them to screw the filter housing in to the unit.

Figure 39 Removing the Screws

4. Remove the filter retaining clip and wing nut.



Figure 40 Removing the Filter Retaining Clip

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