Manual Hidrigeneradora

We're Ready.
PEM Electrolyzer
Hylyzer Hydrogen Generator
Hylyzer Hydrogen Generator Installation, Operation and Maintenance Manual
Revision 3
This product is protected under one or more of the following US Patents: 7,117,106 and/or other pending patents.
DOC. P/N: 1039133-03
We're Ready.
PEM Electrolyzer
Hylyzer Hydrogen Generator
Hylyzer Hydrogen Generator Installation, Operation and Maintenance Manual Revision 3

All rights reserved. No part of this manual may be reproduced or transmitted in any form or by any means, electronic or mechanical, including photocopying, or recording, without written permission from Hydrogenics Corporation. Printed in July 2011.
PEM ELECTROLYZER
Revision History
REV. LEVEL 2 3 Initial Release Installation, Operation, Maintenance and Troubleshooting sections expanded CHANGE DESCRIPTION DATE 14 December 2010 12 July 2011
Warranties and Liabilities

Guarantees, warranties, and liability limitations are described in the contractual agreements between Hydrogenics Corporation and the buyer. The information included in this manual has been reviewed for accuracy and completeness but Hydrogenics Corporation reserves the right to revise the included information at any time, without notice.
Patents, Trademarks and Proprietary Rights

This product is covered under the following US patents: 7,117,106 and/or other pending patents. Other brand or product names are patented trademarks or registered trademarks of their respective owners. Hydrogenics, HyPM, HyPX, HySTAT, HyLYZER, HyWARE are trademarks of Hydrogenics Corporation. Hydrogenics is a registered trademark of Hydrogenics Corporation in Canada, USA, Europe and Japan. HyPM and HyWARE are registered trademarks of Hydrogenics Corporation in Canada, USA and Europe. Other brand or product names marked are the registered trademarks of their respective owners. The information, data, and illustrations contained in this manual are the property of Hydrogenics Corporation and may not be reproduced or transmitted in any form or by any means, electronic or mechanical, without the prior written permission of Hydrogenics Corporation.
About Hydrogenics Corporation

Hydrogenics Corporation is a leading global developer of clean energy solutions, advancing the Hydrogen Economy by commercializing hydrogen and fuel cell products. The company has a portfolio of products and capabilities to serve the hydrogen and energy markets of today and tomorrow. Contact Information: 220 Admiral Boulevard Mississauga, Ontario Canada, L5T 2N6 General Inquiries: +01.905.361.3660 Sales: +01.905.361.4584 Customer Ser vice: +01.905.361.3339 Fax: +01.905.361.3626
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INSTALLATION, OPERATION AND MAINTENANCE MANUAL
Contents
1| Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1
1.1 Intended Audience . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.1.1 Technical Terms and Abbreviations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1.2 Intended Use of the Product . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.3 Customer Assistance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.4 Reference Documents . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1.4.1 Compressed Gas Association (CGA) Publications . . . . . . . . . . . . . . . . . . . . . . . 2 1.4.2 National Fire Protection (NFPA) Association Publications . . . . . . . . . . . . . . . . . 3 1.4.3 The Society of Automotive Engineers (SAE) . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 1.4.4 International Organization for Standardization (ISO) . . . . . . . . . . . . . . . . . . . . 3 1.4.5 International Organization for Standardization (ISO) . . . . . . . . . . . . . . . . . . . . 4
2|
Safety . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
2.1 Warning Labels and Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.1.1 Typical Hazard Symbols . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 2.1.2 Safety Notices in the Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2.2 Potential Hazards and Safety Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.2.1 General Precautions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2.2.2 Mechanical and Handling Hazards. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2.3 Electrical Hazards . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2.4 High Temperatures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2.2.5 Flammable Gas Atmosphere and Fire/Explosion Risks . . . . . . . . . . . . . . . . . . . 10 2.2.5.1 Action in the Event of Fire . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10 2.2.6 Enriched Oxygen Atmospheres . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11
3|
Product Overview. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 13
3.1 Technical Specifications. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 14
4|
Installation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17
4.1 Environmental Requirements . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 4.2 Uncrating and Inspection Instructions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18
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4.3 PEM Electrolyzer Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.3.1 Process Connections. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18 4.3.1.1 Hydrogen (H2) Output . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.3.1.2 Combustible Vent . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.3.1.3 DI Water Supply . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19 4.3.1.4 DI Water Drain . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.3.1.5 Leak Check and Nitrogen Purge . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.3.2 Power Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20 4.3.3 Diagnostic Connection (for service use only) . . . . . . . . . . . . . . . . . . . . . . . . . 21 4.4 Storing the PEM Electrolyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 21
5|
Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
5.1 Pre-Operation Checks . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23 5.2 Control Interface . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26 5.3 Operating Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 5.3.1 Initialization . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28 5.3.2 Dryer Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 30 5.3.3 Continuous Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32 5.4 Shutdown Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
6|
General Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33
6.1 Maintenance Intervals and Spare Parts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
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6.2 Maintenance Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.2.1 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.2.2 E-stop Operation Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.2.2.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.2.2.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.2.2.3 Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 35 6.2.3 Gas/Water Leak Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.2.3.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.2.3.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.2.3.3 Leak Check Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36 6.2.4 Check/Clean Radiator and Ventilation Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 6.2.4.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 6.2.4.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37 6.2.4.3 Checking Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.2.4.4 Cleaning Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.2.5 Hydrogen Gas Detector Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 6.2.5.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 6.2.5.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6.2.5.3 Hydrogen Gas Detector Check Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 6.2.6 Oxygen and Hydrogen Filter Elements Replacement . . . . . . . . . . . . . . . . . . . 42 6.2.6.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 6.2.6.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 6.2.6.3 Filter Replacement Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 6.2.7 Air Flow Speed Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6.2.7.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6.2.7.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6.2.7.3 Air Flow Speed Sensor Check Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45 6.2.8 Pressure Regulators Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6.2.8.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6.2.8.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47 6.2.8.3 PRV3004 Setpoint Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 48 6.2.8.4 PRV2023 Setpoint Adjustment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 49 6.2.9 Cell Stack DC Cable Connection and Equipment Grounding/Bonding Check 51 6.2.9.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.2.9.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51
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6.2.9.3 Electrical Connection Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 51 6.2.10 Drain Traps DT 2004 and DT3006 Check . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6.2.10.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6.2.10.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6.2.10.3 Drain Trap Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 52 6.2.11 Current Sensor CM1500 and Voltage Sensor VM1500 Check and Replacement 54 6.2.11.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 6.2.11.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 54 6.2.11.3 Current Sensor and Voltage Sensor Check . . . . . . . . . . . . . . . . . . . . . 54 6.2.12 Pressure Transmitter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 6.2.12.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 6.2.12.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 57 6.2.12.3 Pressure Transmitter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58 6.2.13 Solenoid Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 6.2.13.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 6.2.13.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62 6.2.13.3 Solenoid Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Preventative Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Causes of Improper Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Valve Disassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 63 Valve Re-assembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 67 Common Reassembly . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 70 6.2.14 DI bed, Catalyst and Molecular Sieve Check and Replacement . . . . . . . . . . 71 6.2.14.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 72 6.2.14.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 6.2.14.3 DI Resin Bed Replacement . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 73 6.2.14.4 Catalyst and Molecular Sieve Replacement . . . . . . . . . . . . . . . . . . . . . 75
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6.3 Process Adjustment Procedures . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 6.3.1 Dryer Regeneration Flow Rate Check and Adjustment . . . . . . . . . . . . . . . . . . 77 6.3.1.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 6.3.1.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 77 6.3.1.3 Regeneration Flow Rate Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78 6.3.2 Shutdown Depressurization Rate Check and Adjustment . . . . . . . . . . . . . . . . 81 6.3.2.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 6.3.2.2 Personal Protective Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81 6.3.2.3 Shutdown Depressurization Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81
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Troubleshooting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 83
7.1 Faults . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 84 7.2 Technical Support. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 91
Appendix A: Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1
Appendix B: CAN Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

B.1 Overall CAN Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-2 B.2 Byte Message Details . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 B.2.1 CAN ID 100 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-4 B.2.2 CAN ID 103 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-5 B.2.3 CAN ID 200 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . B-7
Appendix C: Material Safety Data Sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . C-1
Appendix D: P&ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1
Appendix E: Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1
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1 | Introduction
This is the Installation, Operation and Maintenance manual for the Hydrogenics Hylyzer Hydrogen Generator, part number 1039008.
1.1
Intended Audience
This manual is intended as the primary technical reference for users of Hydrogenics Charge Station product. Hydrogenics assumes that appropriate end-user documentation will be prepared by the systems integrator for use by its customers. The integration information required for installing, setting up, controlling and maintaining the Charge Station is presented in this manual.
1.1.1 Technical Terms and Abbreviations

For definition of the potentially unfamiliar terms and abbreviations used in this manual, refer to Appendix A:Glossary on p. 1. Some terms that do not appear in the manual have been included to help gain a general understanding of Hydrogenics electrolyzer technology.
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INTENDED USE OF THE PRODUCT
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The terms user or operator in this manual refer to the party who will oversee the Charge Stations (automatic) operation. In most cases, the direct operator will be a system control device, which must be programmed to respond to the Charge Stations fault messages and other feedback safely and appropriately for the intended application.
1.2
Intended Use of the Product

The Hylyzer Hydrogen Generator uses clean de-ionized water and electricity to produce
hydrogen and oxygen.
1.3
Customer Assistance
For technical assistance with the installation, operation or maintenance of this product contact: Hydrogenics Corporation Service Department 220 Admiral Boulevard Mississauga, Ontario Canada, L5T 2N6 Main: (905) 361-3660 Customer Service: (905) 298-3328 Fax: (905) 361-3626
1.4
Reference Documents
A list of recognized guidelines applicable to hydrogen installations, fuel cells and related systems and technologies is presented here for reference. Anyone responsible for such an installation or fuel cell application should become familiar with the applicable regulations of their local authorities.
1.4.1 Compressed Gas Association (CGA) Publications

Compressed Gas Association Inc. 4221 Walney Road, 5th Floor Chantilly, VA 20151 Phone: 703-788-2700 Fax: 703-961-1831 www.cganet.com
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REFERENCE DOCUMENTS
G-5 Hydrogen Physical Properties G-5.3 Commodity Specifications for Hydrogen G-5.4 Standard for Hydrogen Piping at Consumer Locations G-5.5 Hydrogen Vent Systems S-1.2 Pressure Relief Device Standards-Part 2 - Cargo and Portable Tanks for Compressed Gases S-1.3 Pressure Relief Device Standards-Part 3 - Stationary Storage Containers for Compressed Gases
1.4.2 National Fire Protection (NFPA) Association Publications

National Fire Protection Association 1 Batterymarch Park, PO Box 9101, Quincy, MA 02269-9101, USA Phone: 617-770-3000 Fax: 617-770-0700 www.nfpa.org NFPA 1 Uniform Fire Code NFPA 55 Standard for the Storage, Use, and Handling of Compressed Gases and Cryogenic Fluids in Portable and Stationary Containers, Cylinders, and Tanks. NFPA 70 National Electric Code
1.4.3 The Society of Automotive Engineers (SAE)

SAE International 400 Commonwealth Drive Warrendale, PA 15096-0001 Phone: 1-877-606-7323 Fax: 724-774-0790 www.sae.org SAE J2578 Recommended Practice for General Fuel Cell Vehicle Safety
1.4.4 International Organization for Standardization (ISO)

International Organization for Standardization (ISO) 1, ch. de la Voie-Creuse Case postale 56 CH-1211 Geneva 20 Switzerland
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REFERENCE DOCUMENTS
PEM ELECTROLYZER
Phone: +41 22 749 01 11 Fax: +41 22 733 34 30 www.iso.org ISO 22734-1:2008 - Hydrogen generators using water electrolysis process -- Part 1: Industrial and commercial applications
1.4.5 International Organization for Standardization (ISO)

Bureau de Normalisation du Quebec 333, rue Franquet Qubec, QC G1P 4C7 Phone: 1-418-652-2238 Fax: 1-418-652-2292 www.bnq.qc.ca 1784-000 CAN/BNQ - Canadian Hydrogen Installation Code
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2 | Safety
Installations and equipment supplied by Hydrogenics are designed to comply with relevant safety standards and to prevent the formation of flammable atmospheres. The equipment and protective systems are designed and manufactured to ensure safe operation. The systems and equipment shall be operated and maintained by qualified and authorized personnel only. Read this manual thoroughly before proceeding. Retain this manual for future reference. Personnel responsible for operating or maintaining the equipment described in this manual must: Read, understand and comply with the instructions presented throughout this manual; Read the Safety Information section of this manual in order to understand the potential hazards associated with the systems or equipment. Retain this manual for future reference. Fully understand and comply with all applicable local safety by-laws, codes, and regulations.
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WARNING LABELS AND SYMBOLS
PEM ELECTROLYZER
2.1
Warning Labels and Symbols

Be aware of the warning and cautionary signs, labels, and faults associated with the equipment and the area where you are working. These symbols, as well as the notices in this publication marked as Warning, Caution and Note, should be observed to ensure your own personal safety, as well as the safety of others, and to protect the product and its components from damage. When working with the Charge Station, adhere to any warning and cautionary symbols that may be attached to the components. For more information on these symbols, refer to the Workplace Hazardous Material Information System (WHMIS) handbook.
2.1.1 Typical Hazard Symbols

Make sure you are familiar with all safety or hazard symbols in use in your workplace. The following list is not exhaustive, but does represent typical potential hazards which may be associated with the product in some operating environments:
CAUTION: Refer to Accompanying Documents This symbol indicates important instructions accompanying the product or, used within a document, indicates potential hazards of a general nature.
WARNING: Electrical Hazard This symbol indicates the potential for high voltages within the product that may present a risk of electric shock.
WARNING: Hot Surface This symbol indicates that the product may be hot enough in some areas to cause burns to the skin if touched.
WARNING: Flammable This symbol indicates that the product may cause a fire or an explosion when exposed to heat, sparks, or flames or as a result of friction.
WARNING: Explosive or Flammable Gas Atmosphere This symbol indicates that the product may cause a flammable gas atmosphere that may explode when exposed to heat, sparks, flames, or as a result of friction.
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WARNING LABELS AND SYMBOLS
WARNING: Oxygen Enrichment (Toxic Atmosphere/Inhalation) This symbol indicates that the product may pose a risk of oxygen enrichment if not properly ventilated.
WARNING: High Gas Pressure This symbol indicates that the product develops gas pressures that may cause injury if released suddenly.
CAUTION: Protective Conductor Terminal (Ground) This symbol identifies a location for grounding equipment to Protective Earth (P.E.). As a warning, it also indicates that grounding is required for safe operation of the equipment.
2.1.2 Safety Notices in the Manual

Several conventions and symbols are used throughout this manual to ensure the safe and proper operation of the equipment. The integrator(s) should carefully read and fully understand the information these conventions and symbols provide:
NOTE: Notes provide supplementary detail such as exception conditions, alternative methods for a task, time-saving tips, and references to related information.
The words Warning and Caution are used to draw attention to potential hazards of differing levels of severity. Each such hazard notice identifies a specific risk, lists the potential consequences, and indicates the action required to avoid or remedy the risk:
WARNING: These notices describe precautions to prevent hazardous conditions that may cause injury or death to people working with the equipment.
CAUTION: These notices describe precautions to prevent hazardous conditions that may damage the equipment.
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POTENTIAL HAZARDS AND SAFETY PRECAUTIONS
PEM ELECTROLYZER
2.2
Potential Hazards and Safety Precautions

WARNING: Failure to follow the safety precautions listed below may result in property damage, personal injury, or even death.
2.2.1 General Precautions

Only qualified and authorized personnel should operate the equipment and must read this
manual before proceeding
Prior to operating the equipment, fully understand and comply with all the applicable local safety by-laws, codes, and regulations Be aware of the physical nature of the gases and fluids operating within the Charge Station. Consult your gas supplier and/or an applicable Material Safety Data Sheet (MSDS) for proper safety and handling procedures. Become familiar with all fault features associated with the equipment Wear protective eyewear and safety shoes when working around the equipment Gases are to be plumbed in accordance with all applicable local safety by-laws, codes, and regulations Do not use the Charge Station if damage to any of the components is suspected Modifications should not be made to the equipment or any of its components for applications other than those specified by the manufacturer. Unauthorized modifications can result in a dangerous shock hazard and can void the warranty Inspect the equipment periodically: ensure that cables and wiring have not loosened up during operation and that all electrical connections are in place; use a hand-held sensor to check for hydrogen leaks from equipment piping Do not operate the Charge Station in temperatures below 5 C or above 40 C Do not store the Charge Station in temperatures below 5 C
WARNING: Unauthorized modifications may result in unsafe operation, potentially dangerous electrical shock, explosion or burn hazards which could lead to damage to equipment, injury to persons or even death. Unauthorized modifications will void the warranty.
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2.2.2 Mechanical and Handling Hazards

WARNING: Improper handling, operation, or maintenance of the equipment may cause personal injury and also lead to equipment damage.The Charge Station system weighs approximately 250 kg. Attempting to lift it may present a serious risk of muscle strain or other personal injury.
Use appropriate safety equipment and lifting practices when installing or moving the Charge Station to another location.
2.2.3 Electrical Hazards

WARNING: High levels of voltage exist within the product that present a risk of electric shock. The 17-cell electrolyzer stack operates at up to 38 VDC and draws up to 202 Amperes. Due to the presence of residual reactants, the stack may continue to have a potentially dangerous electrical charge at its terminals, even after shutdown.
The cell stack must be disconnected from the power source, and purged with nitrogen before any service is performed. Do not touch the potentially high-voltage areas, such as the wiring harness, the stack terminals and the power cables.. Do not open the cabinet or touch any internal Charge Station components immediately after shut-down as voltage may still be present. Do not short-circuit charged components of the stack with metal object. Do not wear metal or electrically conductive jewelry while performing any service work on the equipment.
NOTE: Protective Conductor Terminal (Ground) -to protective earth (PE).
Ensure that the product is adequately earthed to protect against stray currents and static electricity hazards, in accordance with national codes and regulations.
2.2.4 High Temperatures

WARNING: Product surfaces and internal components can become hot and may cause severe burns. Ensure the Charge Station has completely cooled down before servicing.
Ensure the unit has cooled down before draining DI water from the system.
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PEM ELECTROLYZER
2.2.5 Flammable Gas Atmosphere and Fire/Explosion Risks

WARNING: The hydrogen gas produced by the product may cause a fire or an explosion when exposed to heat, sparks or flames, or as a result of friction, especially in enclosed areas or under conditions of inadequate ventilation.
The process output of the Charge Station is hydrogen, which is a flammable, colourless, odourless and tasteless gas. Hydrogen is non-toxic and cannot be detected by human senses. Hydrogen and air mixtures are highly combustible/explosive. A hydrogen leak from any part of the equipment or its auxiliaries could create a combustion/ explosion hazard. Ensure that equipment containing hydrogen is adequately ventilated. Electrically ground hydrogen-conveying equipment, water lines and vent stack, etc. Keep all sources of ignition away. Prohibit open flames (smoking and welding) in a hydrogen area. Maintain a positive pressure in hydrogen vessels to prevent the entry of air. Periodically check for hydrogen leaks from the equipment piping using a hand-held sensor and/or SnoopTM. Hydrogen pressure should be monitored periodically. See the Reference Documents section at the beginning of this manual for sourcing important reference materials concerning use and safe handling of hydrogen.
2.2.5.1 Action in the Event of Fire

The most effective method to fight a hydrogen fire is to extinguish the source of hydrogen supply, provided this can be done safely.
WARNING: Risk of explosion. Extinguishing a hydrogen fire while the source of hydrogen continues to leak/flow can quickly create an explosive atmosphere more hazardous than the fire itself.
Where hydrogen cannot be isolated, do not extinguish the hydrogen fire while the flow of leaking hydrogen continues, as the danger of creating an explosion or an explosive re-ignition is a greater potential hazard than the existing fire. Use water jets or sprays to cool surrounding equipment, especially pressurized hydrogen
containers, during the fire, but DO NOT use water to extinguish the hydrogen fire directly.
Ensure that personnel responsible for operating the Charge Station and/or its related components are properly trained to respond to an emergency situation.
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2.2.6 Enriched Oxygen Atmospheres

WARNING: The product produces oxygen as it operates. An oxygen enriched atmosphere represents a hazardous condition and it is a serious physiological risk. The equipment produces oxygen as it operates. The discharge from the anode system is pure oxygen.
Ensure that the Charge Station operates in an adequately ventilated environment. Ensure that the hydrogen vent line is properly vented to the outdoors. Periodically check for leaks from the equipment piping. Oxygen and hydrocarbons (oil and grease) can react violently, potentially resulting in explosions , fire, injury and/or property damage. Never allow oil and grease to come in contact with oxygen under pressure. Even small amounts of hydrocarbons (or any organic matter) in the presence of high concentration, low pressure oxygen can be hazardous. Ensure that all tools, clothes, hands and personal protective equipment are free of organic oils and grease when servicing oxygen lines.
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PEM ELECTROLYZER
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3 | Product Overview
The Hylyzer Hydrogen Generator is a small-scale, modular electrolyzer which uses clean de-ionized water and electricity to produce up to 1.1 normal cubic metre per hour (Nm3/h) hydrogen. The electrolysis reaction takes place within a stack of 17 proton exchange membrane (PEM) cells. The Hylyzer Hydrogen Generator is built into a sturdy equipment cabinet, and is designed to operate fully automatically once it has been started. Product features:
PEM electrolyzer stack Cabinet mounted on wheels or adjustable feet Indoor operation Air cooled Automatic operation - unit stops and restarts hydrogen production based on pressure of external hydrogen storage vessel/tubing.
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TECHNICAL SPECIFICATIONS
PEM ELECTROLYZER
3.1
Technical Specifications
Table 3-1: Charge Station Technical Specifications PROPERTY PRODUCT INFORMATION Model Number Part Number Stack Technology Stack Size - number of cells Maximum Current PHYSICAL Overall Dimensions (L x W x H) Mass PERFORMANCE Hydrogen Production System Operating Pressure Ambient Operating Temperature Hydrogen Purity Water Content Oxygen Nitrogen DI WATER REQUIREMENTS Inlet Water Consumption Resistivity Water Supply Temperature Water Supply Pressure L/h Mcm C kPa (psig) ~ 1.2 2 545 170791 (10100) Nm3/h kPa (psig) C % ppm ppm ppm 1.1 101.4894 (0115) 540 > 99.995 < 15 <2 <2 mm kg 660 x 740 x 1170 250 A Hylyzer Hydrogen Generator 1039008 Proton Exchange Membrane Electrolyzer 17 202 UNIT VALUE
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Table 3-1: Charge Station Technical Specifications PROPERTY ELECTRICAL POWER REQUIREMENTS Maximum Power Consumption Maximum Current Draw Stack Operating Voltage MAIN SAFETIES Internal Hydrogen Level High HWSS Over-Pressure HWSS Over-Temperature H2 De-Pressurizing Timeout O2 De-Pressurizing Timeout FCVM Cell Voltage Out of Limits (optional) FCVM Cell Voltage Offset Over-Limit (optional) H2 in O2 detection O2/H2Differential Pressure Water Flow Low Overvoltage / Undervoltage Overcurrent / Undercurrent Water Level Low De-oxo Overtemperature Air Flow Automatic Purge kW A Vdc 6.8 40 38 UNIT VALUE
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PEM ELECTROLYZER
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4 | Installation
This section details the steps for receiving and installating the PEM Electrolyzer.
4.1
Environmental Requirements
The PEM Electrolyzer is designed for indoor use. Please observe the following installation requirements: It should be installed in a dry, clean, temperature-controlled environment ( 540C). Use only in a well-ventilated area, where the air is exchanged frequently. Position the PEM Electrolyzer cabinet with space around it, so that its ventilation grilles will not become obstructed. Position the unit such that there is minimum 1 metre clearance front and back and 0.3 metres clearance on either side.
WARNING: The PEM Electrolyzers product oxygen is released within the cabinet. To prevent any potentially hazardous oxygen concentrations, all cabinet ventilation grilles must remain unobstructed and the PEM Electrolyzer must be run in a well ventilated environment.
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UNCRATING AND INSPECTION INSTRUCTIONS
PEM ELECTROLYZER
The combustible vent line must be run to the outdoors, as explained in Section 4.3.1.2 Combustible Vent on page 19.
4.2
Uncrating and Inspection Instructions

Inspect the shipping container for damage. If the PEM Electrolyzer container has been damaged during shipment, immediately report it to Hydrogenics Corporation and the shipping personnel. If there is no visible external damage, open the crate and remove all the packaging around the unit. Inspect the unit for any damage which may have occurred during transportation.
CAUTION: If any damage is suspected, do not use the PEM Electrolyzer without the written approval of Hydrogenics Corporation.
Use a lifting device when moving the unit to another location (until it is unpacked and placed on its wheels, if provided in the order). Once the PEM Electrolyzer is placed in its final position, lock the wheels. Check the freeze indicator. If it indicates that the unit has been exposed to freezing temperatures immediately report the situation to Hydrogenics Corporation.
NOTE: If practical, please retain the original packing materials against the event that the unit may need to be returned to Hydrogenics for service or repairs.
4.3
PEM Electrolyzer Connections

The unit connections can be divided into 3 main categories: process, power and diagnostic.
4.3.1 Process Connections

In general terms, process connections are the points where fluids (DI water, hydrogen, oxygen) enter and/or leave the PEM Electrolyzer. Process interconnect tubing should be SS316 rigid or flexible braided tube with an appropriate pressure rating (meeting local regulations) and compatible with the process fluid. With the exception of DI water feed/drain lines, PVC, teflon or other types of plastic tubes are not recommended. Process Interconnect tubing must be equal to or larger than the process interface fittings (no downsizing allowed) Figure 4-1: Process Connections (typical)
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PEM ELECTROLYZER CONNECTIONS
WARNING: All metal tubes must be connected to a common grounding system.
NOTE: The drain is only required when draining the unit for service. It is not used during operation of the PEM Electrolyzer.
4.3.1.1 Hydrogen (H2) Output

A bulkhead compression fitting, 316SS, has been provided to connect to the hydrogen line. Interconnect hydrogen tubing should be minimum 1/4-.039 316SS.
4.3.1.2 Combustible Vent

A bulkhead compression fitting, 316SS, has been provided to connect to the combustible vent line. During operation a small amount of gas flows out of the vent to regenerate the dryer.
The vent line must run outside the building. Once outside, terminate the vent line with a goose-neck, to prevent rain from entering the line. Place the output of the vent line away from any possible sources of ignition or other ventilation outputs (especially oxygen vents). Place the output of the vent line such that it cannot exhaust on people or building surfaces.
When the PEM Electrolyzer is powered up, the hydrogen purge valve is automatically activated to purge the system and allow product gases to reach reasonable levels of purity. This purge valve is also activated during the shut-down procedure of the PEM Electrolyzer, or if there is an internal over-pressure.
4.3.1.3 DI Water Supply

The DI water is used both to cool internal PEM Electrolyzer components and as the source for conversion to hydrogen and oxygen. The customer must supply a source of DI water outside the PEM Electrolyzer cabinet. A bulkhead compression fitting, 316SS, has been provided to connect to the DI water input line. DI water input requirements are:
Consumption: 1.2 L/h Flow rate: 1 L/min Pressure: 10100 psig Temperature: 5 to 45 C
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PEM ELECTROLYZER CONNECTIONS
PEM ELECTROLYZER
There must be no oil or particulates present in the DI water stream. A minimum 10-micron filter should be used ahead of the DI water supply connection. The DI water quality must be at least 2 Mohmcm.
4.3.1.4 DI Water Drain

DI water is generally consumed by the electrolysis process. There is no need to drain water during operation; a permanent drain connection is optional. When required for maintenance, the customer may drain the water into a pan or vessel. A bulkhead compression fitting, 316SS, has been provided to connect to the gravity fed DI water drain.
4.3.1.5 Leak Check and Nitrogen Purge

After installation of site interconnection tubing and hydrogen storage has been completed, a pressure test and leak test must be performed. The pressure and leak tests should follow local requirements. The PEM Electrolyzer is pressure tested at the factory and only requires a leak test. A nitrogen purge of the hydrogen storage tank and adjacent tubing is mandatory every time the system components have been (or are suspected to have been) exposed to air. Typically a successful purge requires a dilution of oxygen content below the level at which a potentially flammable gas mixture exists. This level is known as the limiting or minimum oxygen concentration (MOC) and for hydrogen is typically taken as 4% oxygen by volume. A dilution below half of this level is generally accepted as safe. For a typical storage system previously exposed to air (21% oxygen), this level can be achieved by pressurizing the system to ~30psig and then venting to ~7psig for a minimum 4 times. During or after the pressurizing/ venting cycle, the pressure should never be allowed to drop to ambient.
4.3.2 Power Connections

The PEM Electrolyzer must be supplied with a 200-250 VAC, 60 A, 1 phase 50/60Hz electrical connection. Figure 4-2: Power Interface (right view) Before connecting the PEM Electrolyzer to a power source, ensure the following:
All process/site interconnecting tubing is complete and pressure/leak tested (Section 4.3.1.5 Leak Check and Nitrogen Purge on page 20). All site interconnecting H2 gas tubes and all H2 storage vessels have been purged with nitrogen or other inert gas (Section 4.3.1.5 Leak Check and Nitrogen Purge on page 20) PEM Electrolyzer is properly connected to a common grounding system as per application All hand valves in normal operating position
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STORING THE PEM ELECTROLYZER
DC power is provided to the PEM Electrolyzer via an Anderson SB3350 connector. The pinout is:
+ : positive input (200-250 VAC, 60 A, 1 phase 50/60Hz) - : negative (200-250 VAC, 60 A, 1 phase 50/60Hz)
WARNING: DO NOT connect to a positive grounded system.
4.3.3 Diagnostic Connection (for service use only)

A diagnostic port is located on the same panel as the power input. The mating Tyco connector part number is 796188-1 (connector qty 1) and 66399-3 (socket qty 2). Pin 14 is CAN H, pin 13 is CAN L. The port is only to be used by authorized service personnel.
4.4
Storing the PEM Electrolyzer

Always store the PEM Electrolyzer in a heated (> 5C) environment. If the unit is to be stored for an extended (non-operational) period: Shut unit down and switch off the unit, then disconnect power. Shut off and/or disconnect the DI water supply. Isolate the hydrogen out line from the hydrogen storage vessel and vent the line. Disconnect the hydrogen out line. Drain the DI water from the system. Replace any fluid and gas port caps.
CAUTION: The PEM Electrolyzer stack must be protected from freezing at all times: do not expose the PEM Electrolyzer to temperatures below 5 C. The maximum storage temperature for the PEM Electrolyzer is 40 C in a dry location.
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STORING THE PEM ELECTROLYZER
PEM ELECTROLYZER
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5 | Operation
This section describes system functions and controls.
Once the PEM Electrolyzer has been installed and initialized, it can operate automatically indefinitely, as long as there is an uninterrupted supply of power, DI water and available hydogen storage capacity. The PEM Electrolyzer will produce gas until the line pressure reaches 100 psig (~790 kPa), at which point it will shut down. Once line pressure is reduced to a pre-defined setpoint, the PEM Electrolyzer will re-activate and continue to produce gas.
5.1
Pre-Operation Checks
Prior to starting the unit:
1. Remove the PEM Electrolyzer rear cover. 2. Ensure that all valves are set for normal operating position as follows: DI tank drain hand valve (HV5001) closed, see Figure 5-1 Cell stack drain hand valve (HV5002) closed, see Figure 5-2 Deoxo heating coil hand valve (HV5003) open, see Figure 5-3 3. Ensure that the ventilation fan blades can spin freely and no debris is present in the radiator fan housing.
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PRE-OPERATION CHECKS
PEM ELECTROLYZER
4. Replace the PEM Electrolyzer rear cover. 5. Ensure that the valves between the PEM Electrolyzer and the storage tank are open. 6. Ensure that the DI water supply valve is open and that the DI water system is operating.
CAUTION: Do not touch regulating valves PRV2023, PRV3004 or metering valves 2017 and 2018. These valves and regulators are factory set; changing their setpoints may lead to poor PEM Electrolyzer performance. If the setpoint of any of the valves has been accidentally altered, please see Section 6.2.8 Pressure Regulators Check on page 47and Section 6.3 Process Adjustment Procedures on page 77 for information on correct setting.
7. Check the H2 vent for blocakge.
Figure 5-1: DI Tank Drain Valve (HV5001)
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PRE-OPERATION CHECKS
Figure 5-2: Cell Stack Drain Valve (HV5002)
Figure 5-3: De-oxo Heating Coil Valve (HV5001)
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CONTROL INTERFACE
PEM ELECTROLYZER
5.2
Control Interface
The controls and displays, from left to right in Figure 5-4, are used as described in Table 5-1 below. Refer also to the state transition diagram,Figure 5-5: State Transition Diagram, on page 27.
Figure 5-4: PEM Electrolyzer Control Panel Table 5-1 LED Legend Control Start Button (green) Function The start button puts the system in the Start Ready state, which means that it will produce hydrogen whenever the pressure-activated demand switch allows (i.e., storage pressure is below activation setpoint). The stop button shuts down the PEM Electrolyzer and returns the system to Standby State. It will not produce hydrogen again until Start is pressed. Clears past faults and prepares system for initial operation. The Start button will not function until Reset has occured. Press Reset to put system in Standby state. The e-stop button shuts down the system as if there were a fault (to preStandby state) This button latches, and must be turned to be released before system will operate again This counter indicates hours the system has been in operation. The status display (HMI) will indicate the systems current state or display a fault message if any are in effect Main power switch. When this switch is off, all functions of the system are disabled. Turn On to initialize system.
Stop Button (red) Reset Button (blue) E-Stop (Emergency Stop, red) Hour Meter Status Display On/Off Switch
WARNING: The On/Off switch is not sufficient for personal protection when servicing the PEM Electrolyzer. The PEM Electrolyzer must be properly disconnected/locked out/ tagged out at a disconnect upstream of the On/Off switch.
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CONTROL INTERFACE
1036215 State Machine

Power On
Init
30s & Anode/Cathode Pressure < 20psig
Estop
13
Reset Button & HWSS OK=True
Estop Button or Fault
Standby
Yes
Start Button Stop Button
Start Ready
No
Stop Button Pressed?
Anode/Cathode Pressure < 20psig & 30 more seconds
Shutdown
12
Stop Button
Demand Switch = True
Demand Switch = False
Cabinet Purge
15s
11
Temperature Recovery
Stack Temperature > 65C
Run
10
Fill Water
DI Water Tank Full (DI Water Tank High Level Switch = True & Inlet Water Tank High Level Switch = True)
60s
Prime Pump
Stack Temperature < 50C
H2 Purge
DI Water Flow OK (DI Water Flow Switch = True for 10s)
Cathode (H2) Pressure > 85psig
Polish Water
Water Resistivity > 2M
Pressurize System
Figure 5-5: State Transition Diagram
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OPERATING PROCEDURE
PEM ELECTROLYZER
5.3
Operating Procedure
Please refer to the operational schematic in Figure 5-6 for the discussions in Sections 5.3.1 - 5.3.3.
SYSTEM RUN PURGE HYDROGEN WATERINITIALIZING CABINETRESET PRESSURIZING PRIME START PRESS PUMP FILL WATER POLISHING PURGE
START HYDROGENICS STOP RESET E-STOP
PURGE FAN
H2 BACKPRESS REG
H2 VENT
DC POWER SUPPLY
CELL STACK
DEOXO
L I V E
O2
O2 SEPARATOR
O2 BACKPRESS REGULATOR
REG
DRYER A
DRYER B
SEPARATOR CYCLE COOLING FAN FAN CYCLE REGEN FLOW 20%
RECIRCULATION PUMP DI WATER IN
DI WATER PUMP
DI Water tank
SW DRY
NEXT SLIDE
DI TANK CYCLE
O2 VENT
STSSTORAGE TANK
Figure 5-6: Operational Schematic
5.3.1 Initialization
To set the system to automatic hydrogen production from Off: 1. Ensure unit is plugged in to power source, that DI water is connected and available, that
Hydrogen output is connected to storage and that the combustible vent line is properly connected and running to the outdoors.
2. Turn On/Off Switch ON. The PLC and status display (HMI) will initialize. 3. Wait for the Press Reset Button message to appear on the HMI. 4. Press Reset Button. Doing so clears the PEM Electrolyzer safeties for operation. 5. Wait for the System Standby - Press Start button to purge system message to appear on
the HMI.
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OPERATING PROCEDURE
6. Press Start Button.

Once the start command is received, the status display (HMI) will display the following status sequence:
Cabinet Purge: This is intended to remove any hydrogen that may have accumulated inside the process compartment due to a hydrogen leak while the PEM Electrolyzer was in
standby. The cabinet purge fan will run while HMI displays "PURGE CABINET". If the airspeed sensor does not read between factory set minimum and maximum values, the HMI will display AIR FLOW SPEED SENSOR OUT OF RANGE. If the air flow speed is within range but the air flow speed is too low for a specific period of time (both speed and time limits are factory default settings), the HMI will display "AIR FLOW SPEED UNDER LIMIT. DI Water Fill: If the DI water tank is empty, the DI water feed solenoid valve SV4003 will open; otherwise this step will be skipped. Once DI water tank has filled, the DI water feed pump PMP1000 will turn on and solenoid valve SV1127 will open to fill the oxygen separator TK1002. The HMI displays "FILL WATER". Prime Pump: When oxygen separator is full, the water circulation pump PMP1003 starts and the HMI will show the "PRIME PUMP" message while the electrolyzer waits for a steady flow confirmation. During this step the pump can cycle (start and stop) several times if the steady circulation flow is not confirmed within a certain time. If the maximum number of cycles is reached without steady flow being established, the system will fault and the HMI will display the "FAIL TO PRIME PUMP" fault message. Polishing Water: Once the steady flow has been established, the DI water resistivity is checked. If found less than 2 Mcm, the system will continue to circulate water via the cell stack circulationloop in an attempt to improve it. During this time, the HMI will display the "POLISH WATER " message. If DI water quality fails to improve within a certain time, the system faults and the HMI displays "FAIL TO POLISH WATER". If water resistivity is greater than 2 Mcm then this step is skipped. Pressurization: Once DI water resistivity is > 2 Mcm, the cell stack is energized, generating hydrogen and oxygen. System pressure starts rising; the HMI displays "PRESSURIZE SYSTEM. The PEM Electrolyzer must pressurize to a preset pressure in a certain time otherwise it will fault and the HMI will display "FAIL TO PRESSURIZE SYSTEM. During this step the differential pressure control is active. It is very important to maintain differential pressure within specific limits in order to preserve the PEM membrane integrity. Differential pressure is maintained by: -active control at process level by the means of oxygen backpressure regulating valve PRV3004, dome loaded hydrogen backpressure regulating valve PRV2007 (reference pressure set by oxygen pressure) and non return valve CHK2037. The PRV3004 sets the cell stack pressure. This same pressure is being applied to the dome of hydrogen backpressure regulating valve PRV2007, ensuring the set point of the two PRVs is actively balanced. -reactive control by triggering the Emergency Shut Down mechanism based on oxygen and hydrogen pressure transmitters (PT1010 and PT1100 respectively) when the low or high pressure differential limits are reached. The HMI displays (respectively) "DIFFERENTIAL PRESSURE LOW" or "DIFFERENTIAL PRESSURE HIGH". In normal operation some hydrogen is evacuated from the PEM Electrolyzer during the short pressurization phase through the hydrogen vent stack.
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OPERATING PROCEDURE
PEM ELECTROLYZER
H2 Purge: Once pressurized, the PEM Electrolyzer begins the hydrogen purge phase. The HMI displays "PURGE HYDROGEN". The pressure continues to rise to the point set by PRV2007 (implicitly by PRV3004). Once set point pressure has been reached the oxygen starts flowing out and pressure is maintained at a constant value (normal set in the range of 100-115 psig). Simultaneously, the hydrogen pressure rises to the same value and the hydrogen is conveyed via oxygen removal reactor (Deoxo) R2009, and dryers VSSL2014 and VSSL2015 (first through dryer VSSL2014, then dryer VSSL2015) to the hydrogen vent stack (dryer depressurization valves are open during this phase). The non return valve CHK2036 ensures a positive relative pressure in the purification system so air cannot re-enter even if solenoid valves SV2014 and SV2018 are open. Run: After the PEM Electrolyzer has been purged, the system advances to hydrogen production. The HMI displays SYSTEM RUNNING. Hydrogen and oxygen pressure is balanced as described above with hydrogen pressure 0.5-5psig higher than oxygen pressure. This prevents oxygen from migrating into the hydrogen stream. Conversely, hydrogen-inoxygen crossover leaks are detected by hydrogen detector GD1000. A reading greater than 40%LFL (1.6 % by volume) or a defective sensor will trigger an Emergency Shut Down. The hydrogen flows into Oxygen Removal Reactor R2009. Here a very small amount of hydrogen is recombined with any residual oxygen forming water. The reaction requires a palladium based catalyst found in the Oxygen Removal Reactor (Deoxo). After passing through the Deoxo vessel, hydrogen enters the dryers where moisture content is dropped down to 15 ppm.
5.3.2 Dryer Operation

Drying of the hydrogen stream occurs by pressure swing adsorption. Drying vessels VSSL2014 and VSSL2015 are filled with an alumina based desiccant (molecular sieve) that captures moisture from hydrogen stream. In principle one dryer is active at a time while the other is regenerating. Regeneration of desiccant is necessary to release moisture trapped during the active phase. The 3-way valve SV2012 initially directs hydrogen towards dryer VSSL2014. The hydrogen flows from Deoxo into dryer VSSL2014 for 15 minutes, exiting with less than 15 ppm moisture content. Regeneration valve SV2014 is kept closed (energized) as long as dryer VSSL2014 is active. Approximately 80% of the hydrogen flow will be directed to the user line via 3-way valve SV2013 and dryer backpressure regulating valve PRV2023. PRV2023 ensures that pressure in the active drying vessel is maintained at 85-95 psig (necessary for adsorption to occur). However, the PRV2023 setpoint must be lower than that of PRV3004 in order to keep the oxygen and hydrogen pressures balanced. The remaining 20% of the hydrogen flow is directed to dryer VSSL2015 (now in regeneration) via metering valve OR2017 and then out to the vent stack via open (de-energized) regeneration valve SV2018. Regeneration of dryer VSSL2015 happens at low pressure (1-3psig) over a 10 minute period. After 10 minutes, regeneration valve SV2018 will close (energize) and the vessel will pressurize (while regeneration flow through OR2017 slowly drops) until it reaches the same pressure as active drying vessel
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OPERATING PROCEDURE
VSSL2014. When pressure in the two dryers is balanced, the regeneration flow stops and dryer VSSL2015 remains pressurized until the end of active phase of dryer VSSL2014. Total pressurization and standby time of dryer VSSL2015 is 5 minutes. After 15 minutes the two drying columns reverse roles: dryer VSSL2014 goes into regeneration while dryer VSSL2015 becomes active. Figure 5-7 illustrates the dryers operation and pressurization/depressurization cycle.
Figure 5-7: Dryer Cycling
Zone A: Drying column A is active and fully pressurized. 100% of hydrogen produced by the cell stack flows through. Drying column B is in regeneration at low pressure. 20% of the already dry hydrogen flow (from downstream drying column A) passes through and then out to the vent stack. This flow is wasted to atmosphere. Zone B: Drying column A is active and fully pressurized. 100% of hydrogen produced by the cellsatck flows through. Drying column B is in regeneration but the regeneration valve (SV2018) is now closed and pressure is rising while regeneration flow is dropping from 20% to zero. It will reach full pressure in less than 5 minutes. Zone C: Drying column A is active and fully pressurized. 100% of hydrogen produced by the cellsatck flows through. Drying column B is pressurized at full pressure and in standby. At this point, 100% of cell stack hydrogen produced is directed to the user line. The next three phases (zones D, E and F) mirror the first three (zones A, B and C respectively) Zone D: Drying column B is active and fully pressurized. 100% of hydrogen produced by the cell stack flows through. Drying column A is in regeneration at low pressure. 20% of the already dry hydrogen flow (from downstream drying column B) passes through and then out to the vent stack. This flow is wasted to atmosphere.
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SHUTDOWN PROCEDURE
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Zone E: Drying column B is active and fully pressurized. 100% of hydrogen produced by the cellsatck flows through. Drying column A is in regeneration but the regeneration valve (SV2014) is now closed and pressure is rising while regeneration flow is dropping from 20% to zero. It will reach full pressure in less than 5 minutes. Zone F: Drying column B is active and fully pressurized. 100% of hydrogen produced by the cellsatck flows through. Drying column A is pressurized at full pressure and in standby.
5.3.3 Continuous Operation

After passing through the purification system (Deoxo and drying vessels) the hydrogen stream is directed to the user via backpressure regulating valve PRV2023 and solenoid valve SV2019. Unit will remain in "RUN" state for as long as user line pressure is below the pressure switch PS2026 high setpoint. (also referred to as automatic shutdown pressure). This is factory set to 100psig but may be altered within certain limits at customer request. Once the pressure high setpoint is reached the PEM Electrolyzer shuts down and the shutdown depress is activated. The HMI displays "SHUTDOWN - WAIT FOR SYSTEM DEPRESSURIZATION. Once the shutdown phase is complete, the PEM Electrolyzer goes to standby. It remains in standby for as long as user line pressure is above the lower setpoint of pressure switch PS2026 (also referred to as automatic restart pressure). This is factory set to 60psig but may be altered within certain limits at customer request. The HMI displays "SYSTEM READY WAIT FOR DEMAND". Once user line pressure pressure drops below automatic restart pressure, the unit restarts and runs the cycle described above.
5.4
Shutdown Procedure
1. Press Stop Button. 2. Wait for display to read System in standby. 3. Shut off power switch. 4. Shut off water. 5. Shut off hydrogen line.
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6 | General Maintenance
Regular inspection and maintenance must be performed to maintain the PEM Electrolyzer in optimal working condition and prolong the life of its components. Additionally, the operating times must be logged for the purposes of meeting maintenance intervals as outlined in this section. The systems and equipment shall be operated and maintained by qualified and authorized personnel only. Personnel responsible for operating or maintaining the equipment described in this manual must: Read, understand and comply with the instructions presented throughout this manual; Read the Safety Information section of this manual in order to understand the potential hazards associated with the systems or equipment. Fully understand and comply with all applicable local safety by-laws, codes, and regulations. Be trained in working with live electrical circuits.
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MAINTENANCE INTERVALS AND SPARE PARTS
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6.1
Maintenance Intervals and Spare Parts

Inspection and service intervals are specified below.
Table 6-1Maintenance Intervals

MAR MAY APR NOV AUG JAN FEB OCT JUL MAINTENANCE ITEM Check H2 vent stack Check E-stop operation Check Fault Log for past month Check for Gas leaks Clean / check rad fan operation Check tubing and pipe supports Check H2 area detector Check equipment (connected to a common ground) Replace FLT2004filter element Check air flow switch Replace H2 area detector Check all regulator settings Check AC and DC power cables / connections Check drain trap DT2004 Check DC voltage / current sensors 6.2.5 6.2.9 1031226 6.2.3 6.2.4 6.2.2 SECTION HYG P/N DEC SEP JUN
X X X X X X X X
1005300
X X X
X X X
X X X
X X X
X X X
X X X X X X X X X X
X X X
X X X
X X X
X X X
X X X
6.2.6 6.2.7 6.2.5 6.2.8 6.2.9
1031226
X X X
6.2.10 6.2.11
1018604 2000902/ 1027409 2000075 See Note a
X X X X 3000 hoursb 4 years X X X X X X X X X X X X
Check pressure transducers Check / replace solenoid valves Check / replace DI bed Check / replace dryer desiccant Run test a
6.2.12
6.2.14 6.2.14
1020583 2003448
a. Normally open (SV2014, SV3018, SV3005) P/N: 1036463; Normally closed (SV1127,
SV4003) P/N: 1039043; 3-way (SV2012, SV2013) P/N: 1036358 b. Varies with feed water quality
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MAINTENANCE PROCEDURES
6.2
Maintenance Procedures
The following maintenance procedures explain how to access parts to perform the inspections and replacements mentioned in Section 6.1 Maintenance Intervals and Spare Parts on page 34.
6.2.1 Cleaning
Use mild cleansers (soap and water) and a damp cloth to clean the exterior covers of the PEM Electrolyzer if cleaning is required.
6.2.2 E-stop Operation Check

In order to ensure that the PEM Electrolyzer can be manually stopped in event of an emergency, the operation of the E-stop button should be checked regularly as per the maintenance schedule in section 6.1.
6.2.2.1 Tools Required

None
6.2.2.2 Personal Protective Equipment

Safety glasses
6.2.2.3 Steps
1. Turn power on and bring unit to run state (displayed on HMI) 2. Allow PEM Electrolyzer to run for 10 minutes 3. Press E-stop. The PEM Electrolyzer should shut down instantaneously and display the E-stop condition on the HMI 4. Allow 4-10 min for depressurization 5. Reset E-stop push button (by rotating/pulling out) and then press the Reset push button. Observe that the E-stop condition has been cleared (on HMI). Apply the same steps to every other E-stop push button installed. After all E-stop buttons have been checked and functionality has been confirmed, run the PEM Electrolyzer for at least 10-15 additional minutes and then set up for automatic operation. Please note that if user line has been previously pressurized above the production automatic restart set point the PEM Electrolyzer will not run. The HMI display will show the "Wait for demand switch" message.
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6.2.3 Gas/Water Leak Check

WARNING: Before removing covers or servicing, turn off the unit and then check bus bar voltage every 10 minutes until it has fallen to less than 1 Vdc. Verify voltage across the load bus bars using a voltmeter or multimeter. Use personal protective equipment.
WARNING: Ensure the PEM Electrolyzers is depressurized before servicing.
WARNING: Risk of severe burns. Do not attempt to service the PEM Electrolyzer while it is still operating. Ensure the unit has completely cooled to ambient temperature before servicing.

Swagelok SNOOP or equivalent leak testing fluid Open wrench (9/16, 11/16, 7/8)

Safety glasses Safety shoes
6.2.3.3 Leak Check Steps

1. Switch power off and remove unit back cover 2. Apply SNOOP liquid to the fitting(s) suspected of leaking 3. Turn power to the unit on and start unit up. Allow unit to reach run status and to pressurize 4. Check fitting(s) under test for leaks (bubbles and/or foam formation). If a leak has been detected, stop the unit and allow the PEM Electrolyzer to completely depressurize and for the electrolyzer stack to electrically discharge. Proceed with tightening fittings only once you are certain that the PEM Electrolyzer has been completely depressurized and stack discharged 5. Repeat the above steps in order to verify that the leak has stopped 6. Reinstall back cover and set the PEM Electrolyzer for automatic operation.
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NOTE: In some cases removal of respective subassembly will be necessary in order to fix the leak.
NOTE: Water leaks are visible without use of Snoop leak detector liquid.
6.2.4 Check/Clean Radiator and Ventilation Fans

Radiator fans and ventilation fans are located inside the process compartment and the electrical compartment.
WARNING: Before removing covers or servicing, turn off the unit and then check bus bar voltage every 10 minutes until it has fallen to less than 1 Vdc. Verify voltage across the load bus bars using a voltmeter or multimeter.

Brush Compressed Air

Safety glasses Dust mask Safety shoes
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6.2.4.3 Checking Steps

1. Make sure that the PEM Electrolyzer has been switched off and power locked out 2. Remove PEM Electrolyzer back cover and open electrical cabinet doors 3. Visually inspect radiators and fans for dust, debris and blade condition. Turn blades by hand to verify free movement 4. Turn power on and run unit. Verify if ventilation fans are running. During run mode verify that water cooling radiator fan cycles 5. Switch unit off, reinstall back cover and close electrical cabinet doors. 6. Run unit again and set for automatic operation.
6.2.4.4 Cleaning Steps

1. Make sure that the PEM Electrolyzer has been switched off and power locked out 2. Remove PEM Electrolyzer back cover and open electrical cabinet doors 3. Remove radiator fan guard 4. Remove any debris from inside radiator fan housing 5. Blow radiator fins clean using a brush and compressed air 6. Reinstall fan guards 7. Turn power on and run unit. Verify if ventilation fans are running. During run mode verify that water cooling radiator fan cycles 8. Switch unit off, reinstall back cover and close electrical cabinet doors. 9. Run unit again and set for automatic operation.
6.2.5 Hydrogen Gas Detector Check
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WARNING: Risk of severe burns. Do not attempt to service the PEM Electrolyzer while it is still operating. Ensure the unit has completely cooled to ambient temperature before servicing. WARNING: Use of other than oxygen compatible lubricants on oxygen service lines is a serious hazard. Spontaneous combustion can occur. Ensure that your hands are clean and free of organic grease or lubricants when servicing oxygen lines. Do not use tools or equipment contaminated by orgainc grease or lubricants.

Open wrench 9/16 Span gas kit (50% and 20% LEL H2 in air span gas, pressure reducing head 2 L/min minimum flow rate, hose), both shown below
Figure 6-1: Span Gas Kit
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Figure 6-2: Span Gas Cylinder Hose

6.2.5.3 Hydrogen Gas Detector Check Steps

1. Switch power off and remove unit back cover 2. Remove tube connection between PRV3004 and OR2018 (PID dwg 1038516 rev 3)
Figure 6-3: Hydrogen Tube Disconnection
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3. Connect the pressure reducing head to 20% LEL span gas cylinder and attach one end of the hose to the cylinder. Connect the other end of the hose in place of the tube that was just removed from PRV3004
Figure 6-4: Span Gas Hose Attachment to Cylinder
4. Make sure that the end tube located in front of the hydrogen gas detector (GD1000, PID dwg 1038516 rev3) lines up with H2 sensor circular orifice
Figure 6-5: Hydrogen Tube Alignment with Sensor
5. Turn power on and after HMI initializes press Reset push button. DO NOT PRESS START PUSH BUTTON as unit must NOT RUN 6. Apply 20 %LEL span gas by turning span gas cylinder valve on and allow a couple of minutes for sensor response 7. Observe that the hydrogen gas detector status LED indicates a warning condition. This warning condition must not induce an E-STOP status on HMI
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8. Repeat these steps using 50%LEL span gas 9. Observe that the hydrogen gas detector status LED indicates a fault condition and also HMI indicates the E-STOP status. 10. Remove test kit and reinstall the inch stainless steel tube between PRV3004 and OR2018 11. Reinstall back cover, reset and restart unit. After 10-15 min unit can be set for automatic operation.
6.2.6 Oxygen and Hydrogen Filter Elements Replacement
WARNING: Risk of severe burns. Do not attempt to service the PEM Electrolyzer while it is still operating. Ensure the unit has completely cooled to ambient temperature before servicing. WARNING: Use of other than oxygen compatible lubricants on oxygen service lines is a serious hazard. Spontaneous combustion can occur. Ensure that your hands are clean and free of organic grease or lubricants when servicing oxygen lines. Do not use tools or equipment contaminated by orgainc grease or lubricants.

Open wrench (9/16, 11/16, 7/8) Strap wrench Shop cloth or paper towel

Safety glasses
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6.2.6.3 Filter Replacement Steps

The following replacement steps apply to both the O2 and H2 filters. The figures below show the O2 filter. 1. Locate the red oxygen filter (FLT3007) as shown in Figure 6-6. An identical filter has been installed on hydrogen line (FLT2004). Record the housing inlet and outlet orientations.
Figure 6-6: Oxygen Filter Location
2. Carefully remove the drain line shown in Figure 6-7 below (make sure not to break the transparent water trap). DI water may drain from the filter. Wipe it dry using a clean cloth or paper towel. Undo inlet and outlet compression fittings and remove filter body from the unit
Figure 6-7: DI Filter Housing
3. Once filter is out, unscrew the filter from its head. This can be done by hand or using a strap wrench. Inspect the seal ring and replace if damaged in any way.
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4. Unscrew the filter element holder as shown in Figures 6-8 and 6-9 and remove the filtration element. Replace the element and reinstall filter holder following the same steps in reverse order. Hand tighten the filter holder ahd filter body. Do not use tools. Do not overtighten the filter element holder; doing so may damage the filter element and/or threads. Do not overtighten filter body or compression fittings. Ensure the housing is re-installed in the same orientation as found in step 1. 5. Perform a leak check as per Section 6.2.3 Gas/Water Leak Check on page 36.
CAUTION: Do not use any grease or lubricants on fittings, filter, filter element or any other part that may come in contact with oxygen gas. New or contaminated fittings, filter body and/or tubing must be oxygen cleaned before installation.
Figure 6-8: Oxygen (Hydrogen) Filter Housing Disassembly
Figure 6-9: Oxygen (Hydrogen) Filter and Housing Components
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6.2.7 Air Flow Speed Sensor Check

None

6.2.7.3 Air Flow Speed Sensor Check Steps

1. Switch power off and remove unit back cover 2. Locate the electrical connector of the enclosure purge fan and disconnect so that the enclosure purge fan cannot run. The electrical connector can be found on or close to the fan mounting bracket by tracing the fan power feed wire (see Figure 610) 3. Air speed sensor is located behind the cabinet purge fan (see Figure 6-11)
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Figure 6-10: Air Speed Sensor Disconnect
Figure 6-11: Air Speed Sensor Location
4. Turn power on and start up the unit. On the HMI observe that unit goes in "cabinet purge" status 5. After 60 seconds the air flow speed out of range is shown on the HMI and the unit will stop 6. Reconnect the air speed sensor electrical connector 7. Reinstall back cover, reset and restart unit. After 10-15 min unit can be set for automatic operation
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6.2.8 Pressure Regulators Check
WARNING: Use of other than oxygen compatible lubricants on oxygen service lines is a serious hazard. Spontaneous combustion can occur. Ensure that your hands are clean and free of organic grease or lubricants when servicing oxygen lines. Do not use tools or equipment contaminated by orgainc grease or lubricants.

Monitoring software 0-150psig pressure gauge Open wrench 9/16 compression union cross (Swagelock P/N SS-400-4) SS316 compression nuts and ferrules (2 sets) SS316 x 0.035 tube (0.3meters)

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6.2.8.3 PRV3004 Setpoint Adjustment

1. Connect monitoring software and confirm internet connection 2. Ensure the PEM Electrolyzeris completely depressurized For units without dryer pressure indicator: 3. Switch power off and lock/tag out main disconnect 4. Remove back cover of the unit 5. On the most accessible dryer, remove outlet compression "T" union (Figure 612) and replace with union cross compression (Figure 6-13). Reconnect adjacent tubing and connect the pressure gauge to the open port of the union cross (Figure 6-13). Make sure all compression nuts are properly swaged
Figure 6-12: Dryer Outlet Compression "T" Union
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Figure 6-13: Pressure Gauge Connection to Compression Cross Union
6. Turn power to the unit back on and bring the monitoring software on line For all units: 7. Start up unit and allow at least 15 min of operation 8. Using monitoring software read oxygen pressure (under "System" screen). This pressure must be in the range of 100-115psig. If the pressure is lower than 100 psig, adjust the set screw of PRV3004 (PID dwg 1038516 rev3) by slowly turning it clockwise till the desired pressure has been reached. Run PEM Electrolyzer for a couple minutes to make sure that pressure reading stabilizes to the proper value. Readjust setpoint if necessary.
CAUTION: Regulator PRV3004 must be set for higher pressure than regulator PRV2023 at all times otherwise damage or underperformance of the system will occur.
9. There are 2 drying columns, each running 15 minute drying cycles. While one dryer is running an active drying cycle, the second runs a 10 minute regeneration plus 5 minute pressurization cycle. Every 15 minutes, the dryers switch cycles such that the dryer that was active goes into regeneration and vice versa.
6.2.8.4 PRV2023 Setpoint Adjustment

PRV 2023 (PID dwg 1038516 rev3) can be adjusted similarly to PRV3004 (described in Section 6.2.8.3 above). However, the setpoint must be 85-95 psig and the reading should be taken from the dryer pressure gauge. For units without a manufacturer installed pressure indicator, use the test gauge that was used for the PRV3004 setpoint adjustment (Figure 6-13) and wait for the respective dryer to become active.
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NOTE: During dryer operation, pressure will "swing" from one dryer to the other so that at times only one dryer is pressurized. There is also a pressurization phase when pressure raises from 0 to maximum set by PRV2023 for each dryer and cycle. Set point adjustment has to be made and pressure reading must be taken when dryer fully pressurized! For units with no factory installed pressure indicator this must be done during drying phase of the dryer on which the test pressure indicator was installed.
For units without dryer pressure indicator: 1. When PRV2023 has been properly set, stop PEM Electrolyzer operation by pressing Stop push button and allow time for the unit to fully depressurize (pressure can be checked on line using monitoring software). Remove test gauge and union cross and reconnect all tubing as per manufacturer original build. For all units: 2. Reinstall unit back cover 3. Restart electrolyzer and allow minimum 15 minutes operation before setting it for automatic run
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6.2.9 Cell Stack DC Cable Connection and Equipment Grounding/ Bonding Check

None

6.2.9.3 Electrical Connection Check

1. Switch power off and lock/tag out main disconnect. Cell stack must be completely free from any residual electrical charge and at rom temperature. 2. A visual inspection must check but shall not be limited for imperfect electrical contact, oxidized contacts/wire, loose cable strands, broken wire, insulation conditions, signs of overheating, etc. 3. Check all electrical connections for tightness.
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6.2.10 Drain Traps DT 2004 and DT3006 Check
6.2.10.1Tools Required
None
6.2.10.2Personal Protective Equipment

6.2.10.3Drain Trap Check

1. Confirm that the PEM Electrolyzer has run for at least 100 hours total (not necessarily continuous) since the last drain trap check/cleaning. Run time is recorded on the hour meter mounted control panel (Figure 5-4). 2. Switch power off and lock/tag out main disconnect. Cell stack must be completely depressurized and free from any residual electrical charge. 3. Remove unit back cover. 4. Locate drain traps (Figures 6-14 and 6-15) and visually inspect the water level inside them. There must be some water inside each drain trap but the level must not be to
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the point where the float actuates the drain valve. If a drain trap is dry then the seat of the float valve may not be sealing properly. Further possible symptoms are low production rate; low oxygen and/or hydrogen pressure, failure to pressurize unit and/or high/low pressure differential. If drain trap is completely full with water than a failed closed float valve or drain tube blockage can be suspected. Further possible symptoms are: wet/saturated oxygen and/or hydrogen gas, water carry over in gas lines, poor Deoxo and Dryer Columns performance, high/low pressure differential.
Figure 6-14: Drain Trap
Figure 6-15: Drain Trap
5. Re-install the back cover. 6. Run unit and set up for automatic operation.
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6.2.11 Current Sensor CM1500 and Voltage Sensor VM1500 Check and Replacement

DC current clamp meter (0-250 A, calibrated) DC voltmeter (0-50Vdc, calibrated) Monitoring software

Safety glasses Safety shoes Electrician gloves
6.2.11.3Current Sensor and Voltage Sensor Check

1. Switch power off and lock/tag out main disconnect. Cell stack must be completely depressurized and free from any residual electrical charge. 2. Remove back cover of the unit. 3. Install clamp meter on the stack positive or negative power cable (Figure 6-16). Consider electrical power flow through the stack when deciding the orientation (polarity) of clamp meter.
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Figure 6-16: Cell Stack Current Measurement using Clamp Meter
4. Turn power back on and make sure that monitoring software runs on line. 5. Turn unit on and allow it to reach run state. 6. Record the clamp meter current measurement and monitoring software current measurement (Figure 6-17 - current measurement). The load can be adjusted using the on board potentiometer (see Figure 6-39 on page 79). 7. Compare the two readings. The software current measurement must be within +/3% of the clamp meter measurement.
Current Measurement Voltage Measurement
Figure 6-17: System Monitoring Software Current/Voltage Measurement
8. Repeat this procedure for a lower load (e.g. 80A). 9. Turn power back on and make sure that monitoring software runs on line. 10. Turn unit on and allow it to reach run state.
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11. Run unit at full load. 12. Measure and record voltage across cell stack power terminals (Figure 6-18). Record the monitoring software DC voltage reading (Figure 6-17 - voltage measurement).
Figure 6-18: Cell Stack Voltage Measurement
13. Compare the two readings. The software voltage measurement must be within +/1% of the voltmeter measurement. 14. Repeat this procedure for a lower load (e.g. 80A). 15. Shut power off and disconnect from power source. Lock out disconnect and tag. Allow time for unit depressurization and stack discharge. 16. Re-install the back cover. 17. Run unit and set up for automatic operation.
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6.2.12 Pressure Transmitter Check
Monitoring software 0-100psi pressure gauge Open wrench 9/16, 11/16, 7/8 100 psi nitrogen supply Shop cloth or paper towel Flexible tubing and fittings rated for 200 psi

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6.2.12.3Pressure Transmitter Check

1. Switch power off and lock/tag out main disconnect. Cell stack must be completely depressurized and free from any residual electrical charge. 2. Remove load side wires of contactor CT318 and isolate. This is to prevent cell stack for being accidentally energized during test. 3. Remove unit back cover. 4. Disconnect recirculation pump (PMP1003) electrical connector (Figure 6-19).
Figure 6-19: Recirculation Pump
5. Identify oxygen (PT1010) and hydrogen (PT1100) pressure transmitters (Figure 620). Label transmitters and their corresponding electrical connectors (socket) accordingly.
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Figure 6-20: Pressure Transmitters
6. Disconnect electrical connectors and remove transmitters from installation. Some DI water may drain at the point of process fitting disconnect. 7. Connect the transmitters and pressure calibrator to a common pressurized nitrogen source. All three instruments must "see" same pressure during test (Figure 6-21).
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PEM ELECTROLYZER
Figure 6-21: Pressure Transmitters and Calibrator connected to common pressure
8. Reconnect the two pressure transmitters to their respective electrical connectors. 9. Turn power back on and make sure that monitoring software runs on line. Bring the PEM Electrolyzer to standby status by pressing the "Reset" button on the control panel (Figure 5-4).
Important: Do NOT press START button at any time during test. PEM Electrolyzer MUST be in "STANDBY" state for the entire duration of the test.
10. Apply zero pressure to both pressure transmitters and pressure calibrator. Record the monitoring software oxygen and hydrogen pressure readings (Figure 6-22).
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Figure 6-22: System Monitoring Screen
11. Record the pressure calibrator reading and compare with pressure transmitter readings. Each pressure transmitter reading must not deviate with more than +/-0.3 psi from the pressure calibrator reading. Regardless of the pressure calibrator reading, the difference between the two pressure transmitter readings must be no greater than 0.3 psig. 12. Repeat the test procedure by applying 100 psig nitrogen pressure to the pressure calibrator and the two pressure transmitters. 13. If any of the pressure transmitters does not pass the check up criteria please contact Hydrogenics Customer Service (Section 1.3 Customer Assistance on page 2). 14. After test completion, turn power off, lock out electrical disconnect and tag. 15. Remove test rig. Reinstall pressure transmitters in their original location. Ensure that all fittings are properly tightened. 16. Reconnect the two pressure transmitter electrical connectors. Reconnecting contactor load wires. 17. Start up the unit and monitor for leaks. If any leaks are found, fix them according to Section 6.2.3 Gas/Water Leak Check on page 36. 18. When all leaks are fixed, disconnect unit from power, lock out disconnect and tag. Allow cell stack to electrically discharge. 19. Reconnect recirculation pump (PMP1003) electrical connector. 20. Reinstall back cover. 21. Run unit and set for automatic operation.
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6.2.13 Solenoid Valve Maintenance
Bench vise Flat head screwdriver Small adjustable wrench, open wrenches of various sizes Valve maintenance kit (O rings, seals, plunger, etc.) Shop cloth or paper towel

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6.2.13.3Solenoid Valve Maintenance

WARNING: To prevent the possibility of personal injury or property damage, turn off electrical power, depressurize valve and vent fluid to a safe area before servcing the valve.
Cleaning
All solenoid valves should be cleaned periodically. The time between cleaning will vary depending on the medium and service conditions. In general, if the hvoltage to the coil is correct, sluggish valve operation, excessive noise or leakage will indicate that cleaning is required. In the extreme case, faulty valve operation will occur and the valve may fail to shift. Clean strainer or filter when cleaning the valve.
Preventative Maintenance
Keep the medium flowing through the valve as free from dirt and foreign material as possible. While in service, the valve should be operated at least once a month to ensure proper opening and closing. Depending on the medium and service conditions, periodic inspection of internal valve parts for damage or excessive wear is recommended. Thoroughly clean all parts. If parts are worn or damaged, install a complete ASCO Rebuild Kit.
Causes of Improper Operation

Incorrrect Pressure: Check valve pressure. Pressure to valve must be within range specified on nameplate. Excessive Leakage: Disassemble valve and clean all parts. If parts are worn or damaged, install a complete ASCO Rebuild Kit.
Valve Disassembly
1. Switch power off and lock/tag out main disconnect. Cell stack must be completely depressurized and free from any residual electrical charge. 2. Remove unit back cover. 3. Remove valve to be serviced from PEM Electrolyzer. 4. Disassemble valve in an orderly fashion using exploded views for identification and placement of parts. 5. Secure valve in a bench vise and pop solenoid retention red cap and retention plate using the screwdriver (Figures 6-23 and 6-24). Some valves have solenoid retained by a nut; in this case, unscrew the nut.
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Figure 6-23: Solenoid valve disassembly
Figure 6-24: Solenoid valve disassembly (contd)
6. Remove solenoid and retention spring (if installed) (Figures 6-25, 6-26 and 6-27) and unscrew the solenoid base subassembly. Take care not to lose inside springs.
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Figure 6-25: Solenoid valve body removal
Figure 6-26: Solenoid valve retention clip removal
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Figure 6-27: Valve plunger housing loosening
7. The remaining disassembly steps depend on the solenoid type. ASCO Series 8223 1. Unscrew solenoid base subassembly from valve body. Remove body gasket and core assembly with core spring. 2. For normal valve maintenance (cleaning and/or rebuilding) it is not necessary to remove the valve seat. 3. Unscrew valve end cap from valve body. For 3/4 NPT cast stainless steel valves, remove six bolts and lockwashers using a 1/2 wrench, then remove valve bonnet. 4. Remove end cap gasket or bonnet gasket (3/4 NPT stainless steel construction), piston spring and piston assembly. To remove piston assembly, a small hole is provided through the wall of the piston assembly. Hook an appropriate tool or a bent piece of wire in hole and pull piston assembly from valve body. 5. All parts are now accessible to clean or replace. If parts are worn or damaged, install a complete ASCO Rebuild Kit. Parts included in the kit are marked with asterisks in Figure 6-28 on page 68. Clean internal passage ways in valve body. ASCO Series 8327 1. Unscrew solenoid base subassembly from valve body and remove solenoid base gasket. 2. Remove core spring from top of core/insert subassembly. 3. Pull core/insert subassembly from valve body cavity and remove insert gasket. 4. All parts are now accessible to clean or replace. If parts are worn or damaged, install a complete ASCO Rebuild Kit. Parts included in the kit are marked with asterisks in Figure 6-29 on page 69.
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ASCO Series 8262 1. Unscrew solenoid base subassembly with bonnet washer attached. 2. Remove core assembly, plugnut gasket, plugnut assembly, stem, disc, disc spring solenoid base gasket and retainer.
NOTE: On valve catalog numbers with suffix T a Teflon plugnut retainer gasket will be present under the retainer.
3. All parts are now accessible to clean or replace. If parts are worn or damaged, install a complete ASCO Rebuild Kit. Parts included in the kit are marked with asterisks in Figure 6-30 on page 70.
Valve Re-assembly
ASCO Series 8223 1. Lubricate all gaskets, piston ring, rider rings and piston and u-cups with an oxygen compatible lubricant (e.g., Castrol Braycote 601EF or Christo-Lube MCG). Apply only a thin film. 2. Assemble valve as shown in Figure 6-28. See Table ??? for required torque values. For 3/4 NPT cast stainless steel construction, hand thread screws into valve body and torque in a crisscross manner.
Table 6-2 ASCO Series 8223 Torque Values PART NAME Solenoid Base Subassembly Valve Seat End Cap Bonnet Screws TORQUE [IN-LBS] 175 +/- 25 45 +/- 5 360 144 +/- 15 TORQUE [NM] 17.8 +/- 2.8 5.1 +/- 0.6 40.7 16.3 +/- 1.7
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Figure 6-28: ASCO Series 8223 valve disassembly
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ASCO Series 8327 1. Lubricate all gaskets, piston ring, rider rings and piston and u-cups (shown in Figure 6-29) with an oxygen compatible lubricant (e.g., Castrol Braycote 601EF or Christo-Lube MCG). Apply only a thin film.
2. Snap insert gasket into the groove of the core/insert subassembly. Be sure to use the proper size gasket. 3. Install core/insert subassembly into body cavity and push it gently down until the gasket of the insert just seals in the cavity of the body. 4. Install core spring in top of core/insert subassembly. Close end of core spring protrudes from top of core. 5. Install solenoid base gasket and solenoid base subassembly. Torque solenoid base subassembly to 260 +/- 25 in-lbs [30 +/- 3 Nm] ASCO Series 8262 1. Lubricate all gaskets, piston ring, rider rings and piston and u-cups with an oxygen compatible lubricant (e.g., Castrol Braycote 601EF or Christo-Lube MCG). Apply only a thin film. 2. Replace disc spring, disc, stem, (plugnut retainer gasket on suffix T valve constructions only), solenoid base gasket and plugnut assembly.
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3. Install plugnut gasket, core (small end into solenoid base assembly) and solenoid base subassesmbly with bonnet washer. Torque solenoid base assembly to 175 +/25 in-lbs [19.830 +/- 2.8 Nm].
Common Reassembly
1. Install solenoid into body. Install assembly in PEM Electrolyzer. 2. Connect tubing to valve according to the markings on valve body. When tightening the tubing, do not use valve or solenoid as a lever. Locate wrenches applied to valve body or tubing as close as possible to connection point.
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WARNING: To prevent the possibility of death, serious injury or property damage, check valve for proper operation before returning to service. Also perform internal seat and external leakage tests with a nonhazardous, noncombustible fluid.
3. Restore line pressure and electrical power supply to valve. 4. After maintenance is completed, operate the valve a few times to be sure of proper operation. A metallic click indicates the solenoid is operating.
6.2.14 DI bed, Catalyst and Molecular Sieve Check and Replacement

The DI bed is an ion exchange resin found inside DI filter FLT1005 that helps improve water purity (see P6070061). Feed water quality and hours of operation can affect the time it takes the bed to reach saturation. The recommended replacement cycle is 3000hrs of operation (or less if saturation of the bed is suspected). Saturation is gauged by the monitoring software water conductivity reading. The catalyst is found in the Oxygen Removal Reactor (also called the Deoxo vessel, Figure 6-31). The molecular sieve is found in the drying columns VSSL2014 and VSSL2015 (also called Dryers, Figure 6-32). Recommended replacement cycle is 4 years for both catalyst and molecular sieve.
Figure 6-31: Oxygen Removal Reactor R2009 (Deoxo vessel)
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Figure 6-32: Molecular Sieves VSSL2014 and VSSL 2015 (Dryers)
Open wrench 5/16, 7/16, 9/16, 11/16, 7/8 Funnel
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Drain pan Shop cloth or paper towel Ion exchange resin (P/N 1039136) Catalyst (P/N 1011973) Molecular sieve (P/N2003448) Screen gasket (2pcs, P/N1039055) compression cap Pressure gauge, 200psig 140 psig nitrogen supply

Safety glasses Safety shoes Dust mask
6.2.14.3DI Resin Bed Replacement

1. Switch power off and lock/tag out main disconnect. Cell stack must be completely depressurized and free from any residual electrical charge. 2. Remove unit back cover. 3. Begin by draining filter FLT1005. Remove the drain compression plug on the right side of the PEM Electrolyzer (if drain port plugged). Open drain hand valve HV5002 and collect water in a drain pan. Remove the filter vessel by undoing the compression fittings and removing the securing cushion clamps. 4. Hold vessel in vertical position and undo/remove the top sanitary clamp (Figure 633).
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Figure 6-33: DI Bed Top Removal
5. Remove top screen gasket carefully (Figure 6-34). Remove bottom sanitary clamp and seal gasket only if it is suspected that the seal surface or screen are damaged. Screen gasket can be reused if in good condition, otherwise replace it.
Figure 6-34: DI Bed Screen Removal
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6. Empty the ion exchange resin and dispose of it in accordance with local environmental laws and regulations. Fill vessel with fresh resin while slightly tapping vessel to compact resin. Set the screen gasket in position. Ensure that sealing surface is clean and free of resin. Set and hand tighten the sanitary clamp, taking care not to overtighten it (Figure 6-35).
Figure 6-35: DI Bed Reassembly
7. Reinstall DI filter FLT1005, securing the cushion clamp(s) in place and reconnecting its fittings. 8. Set hand valves HV5001 HV 5002 and HV5003 for normal operation and plug the unit drain port if previously plugged (port is located on the outside bottom-left of the housing). Start unit and monitor for leaks. If any leaks are found, fix them according to Section 6.2.3 Gas/Water Leak Check on page 36.
6.2.14.4Catalyst and Molecular Sieve Replacement

1. Switch power off and lock/tag out main disconnect. Cell stack must be completely depressurized and free from any residual electrical charge. 2. Remove unit back cover. 3. Remove respective vessel(s) by undoing the compression fittings and removing the cushion clamps.
Important: Be careful not to break the heating coil ends at the bottom of oxygen removal reactor (Deoxo vessel) R2009.
4. Secure vessel in a bench vise and remove side plug. Empty vessels of old catalyst/ molecular sieve. The vessel may be gently tapped with a hammer to help displace beads. Take care not to damage the heating coil located inside oxygen removal reactor (Deoxo vessel) R2009.
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5. Fill the vessel with fresh catalyst/molecular sieve using a funnel (Figure 6-36). Tap the vessel from time to time to help beads settle .
Figure 6-36: Molecular Sieve Refill
6. Reinstall the vessel side plug. Use only Teflon tape and oxygen compatible paste. Do not use any oxygen incompatible lubricant or sealant. 7. Leak test vessels before reinstalling by pressurizing with nitrogen at 140 psig. 8. Reinstall vessel in its original location. Reconnect process fittings and secure vessel with the cushion clamp(s). 9. Set hand valves HV5001, HV 5002 and HV5003 for normal operation and plug the unit drain port if previously plugged (port is located on the outside bottom-left of the housing). Start unit and monitor for leaks. If any leaks are found, fix them according to Section 6.2.3 Gas/Water Leak Check on page 36. 10. When all leaks are fixed, disconnect unit from power, lock out disconnect and tag. Allow cell stack to electrically discharge. 11. Reinstall back cover. 12. Run unit and set for automatic operation.
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PROCESS ADJUSTMENT PROCEDURES
6.3
Process Adjustment Procedures

The dryer regeneration and shutdown depressurization metering valves, OR2017 and OR2018 respectively, are factory set. Unless it is suspected that the settings have altered, the following adjustment procedures do not need to performed.
6.3.1 Dryer Regeneration Flow Rate Check and Adjustment

Dryer regeneration flow rate is factory set to meet dry regeneration requirements when unit runs at nominal production rate. Optionally, it can be set for lower production rates in accordance with customer needs. Typically the regeneration flow rate should be 20% of production volume. A regeneration flow rate lower than this number will lead over to poor dryer performance (humid gas) ; a flow rate that is too large will waste hydrogen gas and reduce the PEM Electrolyzer efficiency. Adjustment of the regeneration flow rate is a complex tune up operation and should be done only by qualified personnel and only when absolutely necessary (e. g., if the production rate desired by customer differs significantly from the one for which the regeneration flow rate was factory tuned).

Open wrench 9/16 Precision hydrogen flow meter (0-30 L/min)

Safety glasses
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Safety shoes
6.3.1.3 Regeneration Flow Rate Check

1. Shut down unit, lock/tag power out and isolate the PEM Electrolyzer from hydrogen storage or user process by closing the respective isolation. Isolation valve must be locked out, closed and tagged. 2. Disconnect hydrogen to storage/user line and install the flow meter in place of it. Tube the flow meter outlet to the hydrogen vent. Make sure all fittings are swaged properly (Figure 6-37).
Figure 6-37: Hydrogen Flow Meter
3. Remove back cover of the unit and shut the regeneration flow completely off by closing metering valve OR2017 (Figure 6-38).
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Figure 6-38: Metering Valve OR2017
NOTE: Do not overtighten metering valve when closing. Overtightening will damage the valve.
4. Run unit and allow the flow meter reading to stabilize. With metering valve OR 2017 completely closed, adjust stack current to nominal value using the on board potentiometer (Figure 6-39). The hydrogen flow meter reading will show approximately 125% of unit nominal production rate.
Figure 6-39: Stack Current Potentiometer
5. After the flow meter reading stabilizes, slowly open the metering valve OR2017 until the hydrogen meter reading drops to nominal hydrogen-to-user production
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rate. Now the dryer regeneration flow value is set for 20% of the cell stack hydrogen output for the hydrogen production requested. 6. Shut down unit, allow time for depressurization and reconnect unit as per original configuration.
WARNING: A nitrogen purge of any hydrogen lines that have been exposed to air is required .
7. After N2 purge to applicable lines is complete, set unit for automatic operation and allow PEM Electrolyzer to run for at least 15 minutes.
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6.3.2 Shutdown Depressurization Rate Check and Adjustment

The shutdown depressurization rate is factory set and sealed. Only adjust if factory setpoint has been modified (accidentally or otherwise).

Monitoring Software Stopwatch

6.3.2.3 Shutdown Depressurization Check

1. Turn unit off and remove back cover. 2. Locate metering valve OR2018 (Figure 6-40). Turn power on and make sure that monitoring software runs on line.
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Figure 6-40: Metering Valve OR2018
3. Bring unit to run mode and allow pressure to rise to normal operating level. 4. Simultaneously press PEM Electrolyzer stop button and start stopwatch. 5. Observe the system status on the monitoring software. 6. Stop the stopwatch when PEM Electrolyzer status changes from shutdown to stand by. Record time; it must be between 3min 30 sec and 4 min 30 sec.
NOTE: Do not overtighten metering valve when closing. Overtightening will damage the valve.
7. If the recorded time is less than 3 min 30 sec, turn the metering valve (OR2018) clockwise of a turn or less (closing it). Repeat steps 3 -6 as many times as necessary to increase the depressurization time to within range. 8. If the recorded time is greater than 4 min 30 sec, turn the metering valve (OR2018) counterclockwise of a turn or less (opening it). Repeat steps 3 -6 as many times as necessary to decrease the depressurization time to within range.
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7 | Troubleshooting
This section outlines the possible fault conditions that may be encountered while operating the equipment. It describes PEM Electrolyzer responses to faults, possible causes of faults and actions that should be taken to troubleshoot the fault and bring the PEM Electrolyzer back to normal operating conditions. If further assistance is required, contact Hydrogenics Corporation for technical support (see Section 1.3 Customer Assistance on page 2).
WARNING: Before removing covers or servicing, turn off the unit and then check bus bar voltage every 10 minutes until it has fallen to less than 1Vdc. Verify voltage across the load bus bars using a voltmeter or multimeter.
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7.1
Faults
Table 7-1 7-1lists the faults displayed on the HMI, possible causes, and actions to take to correct the fault.
Table 7-1: Fault Troubleshooting FAULT MESSAGE ON SCREEN Internal Hydrogen Level High TRIP POINT >40% LEL inside enclosure SENSOR GD1000 All VALID MODES CHECK Check for leaks, check detector (Section 6.2.3 Gas/Water Leak Check on page 36). In the event that a cell stack crossover leak is found, contact Hydrogenics (Section 1.3 Customer Assistance on page 2). Check dryer BPR setting, O2 BPR setting, demand switch, hydrogen pressure transducer, PSH2100, SV2012, SV2013 and SV2023 (Section 6.2.13 Solenoid Valve Maintenance on page 62). Check filters and lines for possible blockage (Section 6.2.6 Oxygen and Hydrogen Filter Elements Replacement on page 42). Stack temperature sensor as it should have tripped first, check TSH2002, radiator fan, air inlet, ambient temp > 40oC Blocked vent (H2 or O2), OR2018 setting, SV2005 failure (Section 6.2.13 Solenoid Valve Maintenance on page 62), PRV2007 blockage
HWSS Over-Pressure
>130 psi
PSH2100
All
HWSS OverTemprature
>90C
TSH200 2
All
H2 De-Pressure Timeout
>20psi 6 minutes after shutdown
PT1100
Shutdown
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FAULTS
Table 7-1: Fault Troubleshooting FAULT MESSAGE ON SCREEN O2 De-Pressure Timeout TRIP POINT >20psi 6 minutes after shutdown SENSOR PT1010 VALID MODES Shutdown CHECK Blocked vent (O2), OR2018 setting, SV2005 failure (Section 6.2.13 Solenoid Valve Maintenance on page 62) Check FCVM connections
FCVM Cell Voltage Out of Limits FCVM Cell Voltage Offset Over Limit Water Conductivity Sensor Out of Range Stack Voltage Sensor Out of Range Stack Current Sensor Out of Range Air Flow Speed Sensor Out of Range
Cell Voltage <1.5 or >2.4 Cell Voltage > 0.4V from average cell voltage Sensor output <3mA or >20mA Sensor output <0mA or >20mA Sensor ouput <0.3V or >4.7V Sensor ouput <0.8V or >5.2V
FCVM
Run
FCVM
Run
Check FCVM connections
RT1100
Prime Pump, Polish Water, Pressurize, H2 Purge, Run Pressurize, H2 Purge, Run
Check sensor and connections Check sensor and connections Check sensor and connections Check sensor and connections, confirm sensor alignment (Section 6.2.7 Air Flow Speed Sensor Check on page 45) Check sensor and connections (Section 6.2.12 Pressure Transmitter Check on page 57) Check sensor and connections (Section 6.2.12 Pressure Transmitter Check on page 57) Check sensor and connections Check sensor and connections
VM1500
CM1500
Prime Pump, Polish Water, Pressurize, H2 Purge, Run Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run
AFS1000
H2 Pressure Sensor Out of Range
Sensor output <2.4mA or >20mA Sensor output <2.4mA or >20mA Sensor output <0V or >10V Sensor output <0V or >10V
PT1100
Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run
O2 Pressure Sensor Out of Range
PT1010
Stack Temperature Sensor Out of Range Reactor Temperature Sensor Out of Range
TE1004
TE1004
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Table 7-1: Fault Troubleshooting FAULT MESSAGE ON SCREEN Fail to Prime Pump TRIP POINT More than 15 attempts to prime pump SENSOR PMP100 3& FSL1007 VALID MODES Prime Pump CHECK Check PMP1003, check FSL1007, drain O2 separator (TK1002) and attempt restart of system. Change DI bed (Section 6.2.14.3 DI Resin Bed Replacement on page 73) Replace DI Resin in FLT1005 (Section 6.2.14.3 DI Resin Bed Replacement on page 73), check RT1100 Check PRV3004/PRV2007 setting, check SV3005 (should be closed), check DT2004 and DT3006 seals Check external shutdown signal source, check terminals 92 and 93 for 24V Check PMP1003, check FSL1007, drain O2 seperator (TK1002) and attempt restart of system Check LSL1000 & LSH1000, check for water in O2 sperator (TK1002) Check LSL4003 & LSH4003, check for water in DI water tank (tk4007) Check PMP1000, SV1127, LSL1000, check for water in O2 seperator (TK1002) Check DI water supply is on, check for water in DI tank (TK4007), check SV4003 (Section 6.2.13 Solenoid Valve Maintenance on page 62)
Fail to Polish Water
>5 minutes in polish water state
RT1100 & FLT 1005
Polish Water
Fail to Pressurize System
>15 minutes in pressurize state
PT1100
Pressurize
External Detector Fault Water Flow Switch Fault
User supplied shutdown signal False for > 5seconds
--
All
FSl1007
Polish Water, Pressurize, H2 Purge, Run
DI Tank Level Switch Malfunction Inlet Tank Level Switch Malfunction DI Water Level Low Inlet Water Level Low
LSL1000 false &LSH1000 true LSL4003 false & LSH4003 true
LSL1000 & LSH1000 LSL4003 & LSH400 3 LSL1000
Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run
False >1 minute
False >1 minute
LSL4003
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FAULTS
Table 7-1: Fault Troubleshooting FAULT MESSAGE ON SCREEN Stack Over-Temprature TRIP POINT >80C SENSOR TE1004 VALID MODES Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run CHECK Check FAHX1004 not blocked, check FAHX1004 fan (Section 6.2.4 Check/ Clean Radiator and Ventilation Fans on page 37), check TE1004 Check ambient temperature, check TE1004 Check TE2010, possible O2 crossover in stack, contact Hydrogenics (Section 1.3 Customer Assistance on page 2) Check ambient temperature, check TE2010 Replace DI Resin in FLT1005 (Section 6.2.14.3 DI Resin Bed Replacement on page 73), check RT1100 Check input voltage, check VM1500 (Section 6.2.11 Current Sensor CM1500 and Voltage Sensor VM1500 Check and Replacement on page 54) Check input voltage, check VM1500 (Section 6.2.11 Current Sensor CM1500 and Voltage Sensor VM1500 Check and Replacement on page 54) Check CR517 & CR519
Stack UnderTemprature DeOxo OverTemprature
<5C
TE1004
Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run Run
>110C
TE2010
DeOxo UnderTemprature Water Resistivity Under Limit
<5C <2MOhm for >5minutes
TE2010 RT1100
Run Pressurize, H2 Purge, Run
Stack Over-Voltage
>29V
VM1500
All
Stack UnderVoltage
<18V
VM1500
All
Wait for Stack Voltage Timeout
<18V for 10 sec
VM1500
Pressurize
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Table 7-1: Fault Troubleshooting FAULT MESSAGE ON SCREEN Stack Over-Current TRIP POINT >250A SENSOR CM1500 VALID MODES Pressurize, H2 Purge, Run CHECK Check CM1500 (Section 6.2.11 Current Sensor CM1500 and Voltage Sensor VM1500 Check and Replacement on page 54), check for short circuit Check CM1500 (Section 6.2.11 Current Sensor CM1500 and Voltage Sensor VM1500 Check and Replacement on page 54), raise input voltage, check for loose connection (Section 6.2.9 Cell Stack DC Cable Connection and Equipment Grounding/ Bonding Check on page 51) Check for blockages in ventilation holes, check FAV1000, AFS1000 (Section 6.2.7 Air Flow Speed Sensor Check on page 45) Check PRV3004/PRV2007 setting (Section 6.2.8.3 PRV3004 Setpoint Adjustment on page 48), check PRV2023 setting, check PT1100 (Section 6.2.12 Pressure Transmitter Check on page 57). Check filters and lines for possible blockage (Section 6.2.6 Oxygen and Hydrogen Filter Elements Replacement on page 42)
Stack UnderCurrent
<20A
CM1500
H2 Purge, Run
Air Flow Speed Under Limit
<0.5m/s for 1 minute
AFS1000
Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run
H2 Over-Pressure
>120psi
PT1100
Run
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FAULTS
Table 7-1: Fault Troubleshooting FAULT MESSAGE ON SCREEN O2 Over-Pressure TRIP POINT >120psi SENSOR PT1010 Run VALID MODES CHECK Check PRV3004 setting (Section 6.2.8.3 PRV3004 Setpoint Adjustment on page 48), check O2 vent for blockage, check PT1010 (Section 6.2.12 Pressure Transmitter Check on page 57). Check filters and lines for possible blockage (Section 6.2.6 Oxygen and Hydrogen Filter Elements Replacement on page 42) Check PRV2023/2007 setting, check O2 vent for blockage, check PT1100 & PT1010 (Section 6.2.12 Pressure Transmitter Check on page 57). Check DT2004/DT3006 seat seals (Section 6.2.10 Drain Traps DT 2004 and DT3006 Check on page 52), check for leaks, open lines (Section 6.2.3 Gas/Water Leak Check on page 36) Check PRV3004/2007 setting (Section 6.2.8.3 PRV3004 Setpoint Adjustment on page 48), check for leaks, open lines, check non-return valve CHK2037, check DT2004/ DT3006 seat seals (Section 6.2.10 Drain Traps DT 2004 and DT3006 Check on page 52)
Differential Pressure High
>15psi
PT1010 & PT1100
Prime Pump, Polish Water, Pressurize, H2 Purge, Run
Differential Pressure Low
<0.5psi
PT1010 & PT1100
Run
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Table 7-1: Fault Troubleshooting FAULT MESSAGE ON SCREEN H2 Under-Pressure TRIP POINT <50psi SENSOR PT1100 Run VALID MODES CHECK Check DT2004 seat seals (Section 6.2.10 Drain Traps DT 2004 and DT3006 Check on page 52), PRV3004 setting (Section 6.2.8.3 PRV3004 Setpoint Adjustment on page 48), check PT1100 (Section 6.2.12 Pressure Transmitter Check on page 57), check for leaks (Section 6.2.3 Gas/Water Leak Check on page 36) Check DT3006 seat seals (Section 6.2.10 Drain Traps DT 2004 and DT3006 Check on page 52), check PRV3004 setting, check PT1010 (Section 6.2.12 Pressure Transmitter Check on page 57), check for leaks (Section 6.2.3 Gas/ Water Leak Check on page 36) Check FCVM connections Check start button and wiring
O2 Under-Pressure
<50psi
PT1010
Run
Loss of FCVM Heart Beat Warning: Stuck Start Button Warning: FCVM Cell Voltage Slope Over Limit ESTOP (System Cannot Run) Call Hydrogenics for Assisstance
No communication for 5 seconds Start button true for > 1 minute
FCVM
Prime Pump, Polish Water, Pressurize, H2 Purge, Run Prime Pump, Polish Water, Pressurize, H2 Purge, Run Shutdown
Run
Contact Hydrogenics Customer Service (Section 1.3 Customer Assistance on page 2)
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TECHNICAL SUPPORT
7.2
Technical Support
When calling for support, the Hydrogenics technical support department may require the following information: PEM Electrolyzer serial number; Fault description (operating conditions, error type, message, etc.); Corrective actions taken, if applicable.
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Appendix A: Glossary
Ambient Temperature: Temperature outside the Charge Station enclosure, as measured at any point on the surface of the Charge Station enclosure. Anode: Electrically negative electrode at which water is split to form hydrogen. Cathode: Electrically positive electrode at which water is split to form oxygen. Cell: One complete repeating unit consisting of two bipolar plates, the diffusion/support media, electrodes and the solid polymer membrane. Charge Station Cell Stack: An assembly of single electrolyzer cells arranged in series. E-stop: Emergency Stop. ECU: Engine Control Unit. This is a microprocessor-based unit that supervises and controls all system functions for the Charge Station. HMI: Human Machine Interface. The status display on the PEM Electrolyzer front panel. kPa: Kilopascals (pressure), understood to be an absolute value unless specified otherwise. LEL: Lower Explosive Limit. LFL: Lower Flammability Limit. MOC: Minimum Oxygen Concentration. PPE: personal protective equipment, e.g. safety glasses. psi, psia vs. psig: pounds per square inch (pressure); psia absolute (includes atmospheric pressure in measurement) vs. psig gauge (pressure internal to system only). Relative Humidity: The measured partial pressure of the gas at the operating temperature process conditions divided by the theoretical partial pressure of the gas at the same temperature. SI: International System of Units. SLPM: standard litres per minutesee Standard Conditions. Stack Operation: The stack is considered to be "operating" when the current is being drawn by the stack (main DC contactor is closed). This time will be recorded by the systems hour meter HM1.
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A-1
PEM ELECTROLYZER
Standard Conditions: Hydrogenicss conventions for determining a "standard litre" vary depending on the material being measured: A standard litre of gas is referenced to 101.3 kPaabs at 0 C (except for air). A standard litre of ambient air is referenced to 101.3 kPaabs at 21 C A standard litre of water (or other liquid) is referenced to 101.3 kPaabs at 20 C.
V dc: Volts (direct current).
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Appendix B: CAN Specification

The CAN protocol is used for communication between the PEM Electrolyzer and monitoring software. It consists of operational commands and status updates from the PEM Electrolyzer. The PEM Electrolyzer uses CAN 2.0 A (11 bit) Standard, with regular ID format and a Baud rate of 250 kbits/sec. CAN 2.0 A is an ISO standard: ISO 11898/11519. Robert Bosch GmbH, the CAN spec developer, maintains a CAN information Web site at http://www.semiconductors.bosch.de/en/20/can/.
NOTE: Data flow in CAN messages is from least to most significant bit. Multi-byte values are also ordered from least to most significant.
Table B-1 lists the main CAN IDs and their functions. Details of particular CAN ID bytes are provided in Section B.2 on page 4.
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B-1
Revision 3 HYDROGENICS CORPORATION B-2
B.1
Overall CAN Specification
Table B-1: Overall CAN Specification CAN ID (Hex)

100 101
CAN ID (Dec)
256 257
SENT BY
OSC OSC
LENGTH (bytes)
1 8
PERIOD (ms)
500 500
BYTE 0
BYTE 1
BYTE 2
BYTE 3
BYTE 4
BYTE 5
BYTE 6
BYTE 7
State Stack Current (0.01A/bit Unsigned) Stack Temperature (0.01degC/bit Signed) Stack Voltage (0.01V/bit Unsigned) Reactor Temperature (0.01degC/bit Signed) Cathode (H2) Pressure (0.01psig/bit Signed) Air Flow Speed (0.001m/ s/bit Unsigned) Anode (O2) Pressure (0.01psig/bit Signed) Water Resistivity (0.001Mohm/bit Unsigned) DI Water Cooling Fan PWM (0.01%/bit Unsigned)
102
258
OSC
500
103
259
OSC
500
Digital Inputs
Digital Outputs
0x00
104
260
OSC
500
S/W Version No. (Major) 0x00 or 0xFF
S/W Version No. (Minor)
System Run Time (1min/bit Unsigned)
System Amp-Hour (1Ah/bit Unsigned)
110
272
PC
0x00 (Read System Error Records)
0xFF (Clear System Error Records)
120 140
288 320
OSC FCVM
8 8
200 FCVM Min. Voltage (0.001V/bit Signed)
System Error Record (0xFF: No Error) FCVM Avg. Voltage (0.001V/bit Signed) FCVM Max. Voltage (0.001V/bit Signed) FCVM Min. Voltage Cell No. FCVM Max. Voltage Cell #
150
336
PC
0x00 or 0xFF FCVM Error Type (1,2,3) System Estop
0x00 (Read System Error Records)
0xFF (Clear System Error Records)
160
352
OSC
Cell Group No. (0,1,2)
Total Number of Errors
Total Number of Errors System Warning
200
512
OSC
System Fault
Table B-1: Overall CAN Specification CAN ID (Hex)

540
B-3 HYDROGENICS CORPORATION Revision 3
CAN ID (Dec)
1344
SENT BY
FCVM
LENGTH (bytes)
8
PERIOD (ms) -
BYTE 0
BYTE 1
BYTE 2
BYTE 3
BYTE 4
BYTE 5
BYTE 6
BYTE 7
0x01
Cell Group No. (0, 1, 2, 3, 4, 5)
Cell Voltage (0.001V/bit Signed)
5C0
1472
OSC
0x01 (FCVM Cell Voltage Request)
PEM ELECTROLYZER
PEM ELECTROLYZER
B.2
Byte Message Details

Details on CAN ID 100 byte 0, CAN ID 103 bytes 0-4 and CAN ID 200 bytes 0-7 are given below.
B.2.1 CAN ID 100

Table B-2: CAN ID 100 (Hex) Byte 0 Values BIT 0x00 (0) 0x01 (1) 0x02 (2) 0x03 (3) 0x04 (4) 0x05 (5) 0x06 (6) 0x07 (7) 0x08 (8) 0x09 (9) 0x0A (10) 0x0B (11) 0x0C (12) 0x0D (13) Init Standby Start Ready Cabinet Purge Fill Water Prime Pump Polish Water Pressurize System H2 Purge Run Temperature Recovery Shutdown Estop MESSAGE
B-4
Revision 3
B.2.2 CAN ID 103

Table B-3: CAN ID 103 (Hex) Byte 0 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) Internal Hydrogen Level High HWSS Over-Pressure Switch Inlet Tank Low Level Switch Inlet Tank High Level Switch DI Tank Low Level Switch DI Tank High Level Switch DI Water Flow Switch Demand Switch MESSAGE
Table B-4: CAN ID 103 (Hex) Byte 1 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) Rectifier Fault HWSS Over-Temperature Switch External Detector Fault Estop Button Start Button Stop Button HWSS OK Reset Buttom MESSAGE
Revision 3
B-5
PEM ELECTROLYZER
Table B-5: CAN ID 103 (Hex) Byte 2 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) DI Water Cooling Fan (PWM) Rectifier Power Oxygen Vent Valve Hydrogen Supply valve Water Inlet Valve Enclosure Ventilation Fan Red LED Green LED MESSAGE
Table B-6: CAN ID 103 (Hex) Byte 3 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) Hydrogen Cooling Fan DI Water Circulation Pump Sensor Enable Rectifier Enable System Enable Electrical Cabinet Ventilation Fan DI Water Feed Pump Dryer Input and Output Valves MESSAGE
B-6
Revision 3
Table B-7: CAN ID 103 (Hex) Byte 4 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) Dryer Regen A Valve Dryer Regen B Valve MESSAGE
B.2.3 CAN ID 200

Table B-8: CAN ID 200 (Hex) Byte 0 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) Internal Hydrogen Level High HWSS Over-Pressure HWSS Over-Temperature Cathode De-Pressurizing Timeout Anode De-Pressurizing Timeout FCVM Cell Voltage Out of Limits FCVM Cell Voltage Offset Over Limit MESSAGE
Revision 3
B-7
PEM ELECTROLYZER
Table B-9: CAN ID 200 (Hex) Byte 1 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) Water Conductivity Sensor Out of Range Stack Voltage Sensor Out of Range Stack Current Sensor Out of Range Flow Speed Sensor Out of Range Cathode Pressure Sensor Out of Range Anode Pressure Sensor Out of Range Stack Temperature Sensor Out of Range Reactor Temperature Sensor Out of Range MESSAGE
Table B-10: CAN ID 200 (Hex) Byte 2 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) Fail to Fill DI Water Tank Fail to Fill Inlet Water Tank Fail to Prime Pump Fail to Polish Water Fail to Pressurize System External Detector Fault Rectifier Fault Water Flow Switch Fault MESSAGE
B-8
Revision 3
Table B-11: CAN ID 200 (Hex) Byte 3 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) DI Water Tank Level Switch Malfunction Inlet Water Tank Level Switch Malfunction DI Water Level Low Inlet Water Level Low Stack Over-Temperature Stack Under-Temperature Reactor Over-Temperature Reactor Under-Temperature MESSAGE
Table B-12: CAN ID 200 (Hex) Byte 4 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) Water Resisitivity Under Limit Stack Over-Voltage Stack Under-Voltage Wait for Stack Voltage Timeout Stack Over-Current Stack Under-Current Air Flow Speed Under Limit MESSAGE
Revision 3
B-9
PEM ELECTROLYZER
Table B-13: CAN ID 200 (Hex) Byte 5 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) Cathode Over-Pressure Anode Over-Pressure Differential Pressure High Differential Pressure Low Cathode Under-Pressure Anode Under-Pressure MESSAGE
Table B-14: CAN ID 200 (Hex) Byte 6 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) Loss of FCVM Heart Beat MESSAGE
B-10
Revision 3
Table B-15: CAN ID 200 (Hex) Byte 7 Values BIT 0x00 (00000000) 0x01 (00000001) 0x02 (00000010) 0x04 (00000100) 0x08 (00001000) 0x10 (00010000) 0x20 (00100000) 0x40 (01000000) 0x80 (10000000) Stuck Start Button FCVM Cell Voltage Slope Over Limit MESSAGE
Revision 3
B-11
PEM ELECTROLYZER
B-12
Revision 3
Appendix C: Material Safety Data Sheets (MSDS)
Revision 3
C-1
Safety Data Sheet Hydrogen 001A Version : 1.17 Date : 29/06/1999 1 IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY MSDS Nr 067A Product name Hydrogen Chemical formula H2 Company identification see heading and/or footer Emergency phone numbers see heading and/or footer 2 COMPOSITION/INFORMATION ON INGREDIENTS Substance/Preparation Substance. Components/Impurities Contains no other components or impurities which will influence the classification of the product. CAS Nr 01333-74-0 EEC Nr (from EINECS) 215-605-7 3 HAZARDS IDENTIFICATION Hazards identification Compressed gas Extremely flammable 4 FIRST AID MEASURES Inhalation In high concentrations may cause asphyxiation. Symptoms may include loss of mobility/consciousness. Victim may not be aware of asphyxiation. Remove victim to uncontaminated area wearing self contained breathing apparatus. Keep victim warm and rested. Call a doctor. Apply artificial respiration if breathing stopped. Ingestion Ingestion is not considered a potential route of exposure. 5 FIRE FIGHTING MEASURES Specific hazards Exposure to fire may cause containers to rupture/explode. Hazardous combustion products None Suitable extinguishing media All known extinguishants can be used. Specific methods If possible, stop flow of product. Move container away or cool with water from a protected position. Do not extinguish a leaking gas flame unless absolutely necessary. Spontaneous/explosive re-ignition may occur. Extinguish any other fire. Special protective equipment for fire fighters In confined space use self-contained breathing apparatus.
1/4
6 ACCIDENTAL RELEASE MEASURES Personal precautions Wear self-contained breathing apparatus when entering area unless atmosphere is proved to be safe. Evacuate area. Ensure adequate air ventilation. Eliminate ignition sources. Environmental precautions Try to stop release. Clean up methods Ventilate area. 7 HANDLING AND STORAGE Handling and storage Ensure equipment is adequately earthed. Suck back of water into the container must be prevented. Purge air from system before introducing gas. Do not allow backfeed into the container. Use only properly specified equipment which is suitable for this product, its supply pressure and temperature. Contact your gas supplier if in doubt. Keep away from ignition sources (including static discharges). Segregate from oxidant gases and other oxidants in store. Refer to supplier's container handling instructions. Keep container below 50C in a well ventilated place. 8 EXPOSURE CONTROLS/PERSONAL PROTECTION Personal protection Ensure adequate ventilation. Do not smoke while handling product. 9 PHYSICAL AND CHEMICAL PROPERTIES Molecular weight 2 Melting point -259 C Boiling point -253 C Critical temperature -240 C Relative density, gas 0.07 (air=1) Relative density, liquid 0.07 (water=1) Vapour Pressure 20C Not applicable. Solubility mg/l water 1.6 mg/l Appearance/Colour Colourless gas Odour None Autoignition temperature 560 C Flammability range 4-75 vol% in air. Other data Burns with a colourless invisible flame.
2/4
10 STABILITY AND REACTIVITY Stability and reactivity Can form explosive mixture with air. May react violently with oxidants. 11 TOXICOLOGICAL INFORMATION General No toxicological effects from this product. 12 ECOLOGICAL INFORMATION General No known ecological damage caused by this product. 13 DISPOSAL CONSIDERATIONS General Do not discharge into areas where there is a risk of forming an explosive mixture with air. Waste gas should be flared through a suitable burner with flash back arrestor. Do not discharge into any place where its accumulation could be dangerous. Contact supplier if guidance is required. 14 TRANSPORT INFORMATION Proper shipping name Hydrogen, compressed UN Nr 1049 Class/Div 2.1 ADR/RID Item Nr 2, 1F ADR/RID Hazard Nr 23 Labelling ADR Label 3: flammable gas Other transport information Avoid transport on vehicles where the load space is not separated from the driver's compartment. Ensure vehicle driver is aware of the potential hazards of the load and knows what to do in the event of an accident or an emergency. Before transporting product containers ensure that they are firmly secured and: - cylinder valve is closed and not leaking - valve outlet cap nut or plug (where provided) is correctly fitted - valve protection device (where provided) is correctly fitted - there is adequate ventilation. - compliance with applicable regulations. 15 REGULATORY INFORMATION Number in Annex I of Dir 67/548 001-001-00-9. EC Classification F+;R12 -Symbols F+: Extremely flammable -Risk phrases R12 Extremely flammable. -Safety phrases S9 Keep container in well ventilated place. S16 Keep away from ignition sources - No smoking. S33 Take precautionary measures against static discharges.
3/4
16 OTHER INFORMATION Ensure all national/local regulations are observed. Ensure operators understand the flammability hazard. The hazard of asphyxiation is often overlooked and must be stressed during operator training. Before using this product in any new process or experiment, a thorough material compatibility and safety study should be carried out. Details given in this document are believed to be correct at the time of going to press. Whilst proper care has been taken in the preparation of this document, no liability for injury or damage resulting from its use can be accepted.
4/4
Safety Data Sheet Oxygen 097A Version : 2.01 Date : 29/06/1999 1 IDENTIFICATION OF THE SUBSTANCE/PREPARATION AND OF THE COMPANY MSDS Nr 097A Product name Oxygen Chemical formula O2 Company identification see heading and/or footer Emergency phone numbers see heading and/or footer 2 COMPOSITION/INFORMATION ON INGREDIENTS Substance/Preparation Substance. Components/Impurities Contains no other components or impurities which will influence the classification of the product. CAS Nr 07782-44-7 EEC Nr (from EINECS) 231-956-9 3 HAZARDS IDENTIFICATION Hazards identification Compressed gas Oxidant. Strongly supports combustion. May react violently with combustible materials. 4 FIRST AID MEASURES Inhalation Continuous inhalation of concentrations higher than 75% may cause nausea, dizziness, respiratory difficulty and convulsion. 5 FIRE FIGHTING MEASURES Specific hazards Supports combustion. Exposure to fire may cause containers to rupture/explode. Non flammable Hazardous combustion products None Suitable extinguishing media All known extinguishants can be used. Specific methods If possible, stop flow of product. Move container away or cool with water from a protected position. Special protective equipment for fire fighters None.
1/4
6 ACCIDENTAL RELEASE MEASURES Personal precautions Evacuate area. Ensure adequate air ventilation. Eliminate ignition sources. Environmental precautions Try to stop release. Prevent from entering sewers, basements and workpits, or any place where its accumulation can be dangerous. Clean up methods Ventilate area. 7 HANDLING AND STORAGE Handling and storage Use no oil or grease. Open valve slowly to avoid pressure shock. Segregate from flammable gases and other flammable materials in store. Suck back of water into the container must be prevented. Do not allow backfeed into the container. Use only properly specified equipment which is suitable for this product, its supply pressure and temperature. Contact your gas supplier if in doubt. Keep away from ignition sources (including static discharges). Refer to supplier's container handling instructions. Keep container below 50C in a well ventilated place. 8 EXPOSURE CONTROLS/PERSONAL PROTECTION Personal protection Do not smoke while handling product. Wear suitable hand, body and head protection. Wear goggles with suitable filter lenses when use is cutting/welding. Avoid oxygen rich (>21%) atmospheres. Ensure adequate ventilation. 9 PHYSICAL AND CHEMICAL PROPERTIES Molecular weight 32 Melting point -219 C Boiling point -183 C Critical temperature -118 C Relative density, gas 1.1 (air=1) Relative density, liquid 1.1 (water=1) Vapour Pressure 20C Not applicable. Solubility mg/l water 39 mg/l Appearance/Colour Colourless gas Odour No odour warning properties. Autoignition temperature Not applicable
2/4
Flammability range Oxidiser. Other data Gas/vapour heavier than air. May accumulate in confined spaces, particularly at or below ground level. 10 STABILITY AND REACTIVITY Stability and reactivity May react violently with combustible materials May react violently with reducing agents. Violently oxidises organic material. 11 TOXICOLOGICAL INFORMATION General No toxicological effects from this product. 12 ECOLOGICAL INFORMATION General No ecological damage caused by this product. 13 DISPOSAL CONSIDERATIONS General To atmosphere in a well ventilated place. Do not discharge into any place where its accumulation could be dangerous. Contact supplier if guidance is required. 14 TRANSPORT INFORMATION Proper shipping name Oxygen, compressed UN Nr 1072 Class/Div 2.2 Subsidiary risk 5.1 ADR/RID Item Nr 2,1 O ADR/RID Hazard Nr 25 Labelling ADR Label 2: non flammable non toxic gas Label 05: fire intensifying risk. Other transport information Avoid transport on vehicles where the load space is not separated from the driver's compartment. Ensure vehicle driver is aware of the potential hazards of the load and knows what to do in the event of an accident or an emergency. Before transporting product containers ensure that they are firmly secured and: - cylinder valve is closed and not leaking - valve outlet cap nut or plug (where provided) is correctly fitted - valve protection device (where provided) is correctly fitted - there is adequate ventilation. - compliance with applicable regulations.
3/4
15 REGULATORY INFORMATION Number in Annex I of Dir 67/548 008-001-00-8. EC Classification O;R8 -Symbols O: Oxidising -Risk phrases R8 Contact with combustible material may cause fire. -Safety phrases S17 Keep away from combustible material. 16 OTHER INFORMATION Ensure all national/local regulations are observed. Ensure operators understand the hazard of oxygen enrichment. Before using this product in any new process or experiment, a thorough material compatibility and safety study should be carried out. Details given in this document are believed to be correct at the time of going to press. Whilst proper care has been taken in the preparation of this document, no liability for injury or damage resulting from its use can be accepted.
4/4
MATERIAL SAFETY DATA SHEET

PRODUCT NAME: ALDEX MB-1, ALDEX MB-1(SC), ALDEX MB-1(N) Product is not a controlled material. MSDS DATE: NOVEMBER 17, 2009 SUPERSEDES: AUGUST 8, 2007 SECTION I PRODUCT AND MANUFACTURER IDENTIFICATION
MANUFACTURER: Various ADDRESS: Various SUPPLIER: ALDEX CHEMICAL CO, LTD. ADDRESS: 630 Laurent St. Granby, Quebec, Canada J2G 8V1 TEL: (450) 372-8844 FAX: (450) 372-2566
TEL: Various FAX: Various + PRODUCT CHEMICAL NAME: Mixture of strong acid cation resin in H form & strong base type 1
anion resin in OH- form GENERIC FAMILY: Mixed bed ion exchange resin PRODUCT USE: Water treatment NAME OF PREPARER: Albert F. Preuss SECTION II INGREDIENTS COMPOSITION INFORMATION CAS No. 069011-20-7 069011-18-3 CHEMICAL NAME Sulfonated copolymer of styrene & divinylbenzene in hydrogen form Trimethylamine functionalized chloromethylated copolymer of styrene & divinylbenzene in hydroxide form Water % 20 30
007732-18-5
15 30 50 - 60
SECTION III PHYSICAL/CHEMICAL CHARACTERISTICS

PHYSICAL STATE: Solid SPECIFIC GRAVITY: 1.2 VAPOR PRESSURE (mm Hg): 17 @ 20C Water VAPOR DENSITY (AIR=1): 0.62 for water ODOR: Slight fishy odor APPEARANCE: Small spherical beads amber colors COEFFICIENT OF WATER/OIL DISTRIBUTION: N/A BOILING POINT (Deg. C): N/A FREEZING POINT (Deg. C): 0C SOLUBILITY IN WATER: Insoluble EVAPORATION RATE (H20=1): 1.0 ODOR THRESHOLD (ppm): N/A pH (in an aqueous slurry): 6-9
SECTION IV FIRE AND EXPLOSION HAZARD DATA

NFPA FIRE HAZARD CLASS: 1 Slight, Above 200F (93C) FLASH POINT (Deg. C)/METHOD USED: N/A AUTO IGNITION TEMPERATURE (Deg. C): >500C (932F) CONDITIONS OF FLAMMABILITY: >93C (200F) FLAMMABLE LIMITS: N/A EXTINGUISHING MEDIA: Dry chemical, carbon dioxide or water fog HAZARDOUS COMBUSTION PRODUCTS: Same as reactivity data EXPLOSION DATASENSITIVITY TO MECHANICAL IMPACT: None SPECIAL FIRE FIGHTING PROCEDURES: Wear MSHA/NIOSH approved pressure demand,
self-contained breathing apparatus. Guard against contact of the product with the eyes during salvage operation. Some sulfur oxides can be generated during combustion.
PRODUCT NAME: ALDEX MB-1(SC), ALDEX MB-1(N), ALDEX MB-1(T)
SECTION V REACTIVITY DATA

NFPA REACTIVITY RATING: 0, Stable
CONDITIONS UNDER WHICH PRODUCT IS CHEMICALLY UNSTABLE: At temperatures above 204C decomposition occurs. Explosive reactions can occur in the presence of strong oxidizing agents such as concentrated nitric acid. INCOMPATIBILITY (MATERIALS TO AVOID): Strong oxidizing agents such as nitric acid HAZARDOUS DECOMPOSITION OR BY PRODUCTS: Carbon monoxide, carbon dioxide, styrene, divinylbenzene, alkylamines, oxides of nitrogen, sulfur oxides and hydrochloric acid. HAZARDOUS POLYMERIZATION: None SECTION VI HEALTH HAZARD DATA
NFPA HEALTH HAZARD: 1, Slight ROUTE OF ENTRY: Eye contact EFFECT OF ACUTE EXPOSURE TO PRODUCT: Can produce mechanical irritation to the eyes.
May cause skin irritation of hypersensitive personnel.

EFFECT OF CHRONIC EXPOSURE TO PRODUCT: Mechanical irritation to the eyes and skin
irritation to hypersensitive personnel.

EXPOSURE LIMITS: N/A MUTAGENICITY: N/A CARCINOGENICITY: N/A REPRODUCTIVE TOXICITY: N/A TERATOGENICITY: N/A TOXICOLOGICALLY SYNERGISTIC PRODUCTS: N/A IRRITANCY OF PRODUCT: Eyes and skin SYMPTOMS OF EXPOSURE: Red, irritated eyes, itching and feeling that a particle exists
between the eyelid and eye.

EMERGENCY AND FIRST AID PROCEDURES: Flush eyes and skin with copious quantities of
water for 15 minutes. If irritation persists, see a physician.

TOXICITY DATA FOR A COMPOSITIONALLY SIMILAR MATERIAL IS: Not available
SECTION VII PRECAUTIONS FOR SAFE HANDLING AND USE

STORAGE REQUIREMENTS: Avoid freezing or prolonged storage above 50C because product
contains water which could freeze or dry-out causing physical damage to the product.
SPECIAL SHIPPING INFORMATION: Avoid freezing or drying out. IN CASE OF SPILL OR LEAK: Sweep area of product, collecting in a container for disposal. WASTE DISPOSAL METHOD: As supplied, new or unused ion exchange resins are not
hazardous and therefore are not considered as hazardous waste. They may be disposed of as ordinary trash according to local, state/provincial and federal regulations. Used resins may meet the regulatory definition of hazardous wastes as a result of their service. A representative sample of the material may be analyzed by a certified laboratory following procedures set forth in 40 CFR261, APPENDIX II, METHOD 1311 TOXICITY CHARACTERISTIC LEACHING PROCEDURE (TCLP) AND EP TOXICITY TEST PROCEDURE. Based on the results obtained from these analyses, disposal of used resin can be accomplished in accordance with applicable federal, state/provincial and municipal regulations. Avoid packing in glass columns. Product can expand and shatter the glass.
PRODUCT NAME: ALDEX MB-1(SC), ALDEX MB-1(N), ALDEX MB-1(T)
SECTION VIII FACILITY CONTROL MEASURES

PERSONAL PROTECTIVE EQUIPMENT: Wear impervious gloves and splash goggles while handling
ion exchange material.

OTHER PROTECTIVE CLOTHING OR EQUIPMENT: Long sleeve shirts and long pants are
recommended to prevent skin contact.

WORK/HYGIENIC PRACTICES: Flush product from hands with soapy water. Care should be taken
to avoid contact with eyes until hands have been completely cleaned. Product has a tendency to cling to skin. Care must be exercised to remove all product from skin. Sweep up spilled material and transfer for proper disposal as spilled product causes area to become extremely slippery and can cause falls. SECTION IX REGULATORY INFORMATION & REFERENCES SARA TITLE III REPORTING REQUIREMENTS
SECTION 302 REPORTING IF ABOVE: None SECTION 304 REPORTING IF ABOVE: None SECTION 313 REPORTING REQUIRED: No CERCLA REPORTING REQUIRED IF ABOVE: None RCRA REPORTING REQUIRED: No
Product is not WHMIS controlled in Canada and does not have a WHMIS classification. Product is considered non-hazardous under the OSHA hazard communication standard. (29CFR1910.1200)
D.O.T. HAZARD NAME: Not regulated by D.O.T. TDG CLASSIFICATION: Not regulated
REFERENCES The data and recommendations presented herein are based upon our research and the research of others and are believed to be accurate. However, no warranty is expressed or implied regarding the accuracy of these data or the results to be obtained from the use thereof. Aldex Chemical Co. Ltd. assumes no responsibility for injury to customers or third persons caused by the material if reasonable safety procedures are not adhered to as stipulated in the data sheet. Additionally, since actual use by others is beyond our control, no guarantee, expressed or implied, is made by Aldex Chemical Co. Ltd. as to the effects of such use, the results to be obtained, or the safety and toxicity of the product nor does Aldex Chemical Co. Ltd. assume any liability arising out of use, misuse, by others, of the product referred to herein. Information provided herein is provided by Aldex Chemical Co. Ltd. solely for customers assistance in complying with the Occupational Safety and Health Acts and regulations thereunder. Any other use is prohibited.
MATERIAL SAFETY DATA SHEET SNOOP 1. PRODUCT IDENTIFICATION
January 2009
SNOOP: Liquid leak detector for use on external surfaces only. Optimum usage temperatures are between
27F and 200F (-3C and 93C).
Manufactured by: Swagelok Manufacturing Company 29495 F.A. Lennon Dr. Solon, Ohio 44139 Tel: (440) 349-5600 2. INGREDIENTS Ingredients
Water Surfactant
Emergency Contact: Chemtrec (800) 424-9300
CAS #
7732-18-5 Not Available
WT%
>95 <5
PEL
Not Available Not Available
3. HEALTH HAZARD INFORMATION

European Community Danger Group............... None. Special Hazards for man or environment ........ None. LC50/LD50 ......................................................... Not available. Routes of Entry
Skin Contact
No
Skin Absorption
No
Eye Contact
Yes
Inhalation
No
Ingestion
Yes
4. FIRST AID MEASURES

If inhaled (Overexposure): After contact with skin (Overexposure): After contact with eyes: If swallowed: Medical information: Unlikely to be inhaled. Wash thoroughly with soap and water. If severe irritation develops, seek medical attention. Rinse thoroughly with water for 15 minutes, seek medical attention. Do not rub eyes. Unlikely to cause illness, seek medical attention if needed. None known.
Page 1 of 4
MATERIAL SAFETY DATA SHEET SNOOP 5. FIRE FIGHTING MEASURES

Suitable extinguishing agents: Unsuitable extinguishing agents: Special dangers caused by substance or preparation itself, by combustion products, or gases formed: Additional information: Not applicable. None known. None known.
January 2009
None.
Autoignition
Not Applicable
UEL
Not Applicable
LEL
Not Applicable
Sensitivities
Not Available
6. ACCIDENTAL RELEASE MEASURES

Measures for protection of people: Measures for protection of the environment: Cleaning measures: Additional information: Eye and hand protection as needed to minimize excessive exposure. None required. Use absorbent material to clean spills. None.
7. HANDLING AND STORAGE

Safety information: Information on protection from fire or explosion: Additional information: None. None. Store in a cool, dry place for optimal product performance.
8. EXPOSURE CONTROLS AND PERSONAL PROTECTION

Precautionary measures to protect employees: Respiratory protection: Hand protection: Eye protection: Skin protection: None required. None required. Rubber gloves are recommended to minimize exposure. Goggles are recommended when SNOOP could splash in eyes. Wash hands after use.
9. PHYSICAL AND CHEMICAL PROPERTIES Appearance

Colorless liquid
Odor
Neutral
pH
6.75 +/- 0.75
Density
1.0 gm/cm3
Vapor Pressure
Not Available
Boiling Point
212F/100C
Melting Point
Not Available
Flash Point
Not Available
Flammability
Not Available
Explosive
Not Available
Page 2 of 4
MATERIAL SAFETY DATA SHEET SNOOP 10. STABILITY AND REACTIVITY

Conditions to avoid: Materials to avoid:
January 2009
None. Strong oxidizers, alkali metals, and compounds that react exothermically with water. Hazardous decomposition products: None.
11. TOXICOLOGICAL INFORMATION

Acute toxic properties: Health effects: Additional health effects: None known. None known. None known. Reproductive Toxicity Not Available Synergistic Products Not Available
Sensitization Not Available
Teratogenicity Not Available
Mutagenicity Not Available
Carcinogenicity Listed ingredients are not suspected carcinogens according to NTP, IARC, and OSHA
12. ECOLOGICAL INFORMATION

Mobility: Degradability: Accumulation: Short/Long term effects on ecotoxicity: Comparable to water. Not established. No adverse bioaccumulation or biomagnification effects known. No known ecological affects.
13. DISPOSAL CONSIDERATIONS

Appropriate methods of disposal: European Community (EC) considerations: Unused product not considered a hazardous waste in the United States. Dispose of in a responsible manner. Use appropriate waste codes based on ingredients.
14. TRANSPORT INFORMATION
Transport precautions: Additional information:
Consult applicable regulations when transporting this product. None.
Page 3 of 4
MATERIAL SAFETY DATA SHEET SNOOP 15. REGULATORY INFORMATION

US/Canadian regulation listing: EC Relevant risk: EC Relevant safety: Additional information:
January 2009
SARA 313 - NO, Canadas Controlled Products - NO, TSCA - YES None. S: 37/39 - Wear suitable gloves and eye/face protection. S: 20 - When using do not eat or drink. Consult country codes for specific requirements.
16. OTHER INFORMATION

For further information contact: Sources of information used to compile document: Your Swagelok Distributor or the contacts listed in Section 1 of this sheet. Properties of individual ingredients were used to compile this document. This Material Safety Data Sheet was designed to give the distributors and users of SNOOP information to handle and use the product in a responsible manner. Preparation Data (440) 248-4600
Environmental and Safety Department
January 2009
Page 4 of 4
MATERIAL SAFETY DATA SHEET
Deionized Water
SECTION 1 . Product and Company Idenfication
Product Name and Synonym: Product Code: Material Uses: Manufacturer:
Deionized Water 206-00 Health: Flammability: 0 0 0

Extreme 4
Entry Date : Print Date: 24 Hour Emergency Assistance :
OFI Testing Equipment Inc. 1006 W. 34th Street Houston, TX 77018 (877) 880-9885 5/10/2010 7/30/2010
Chemtrec 800-424-9300 Canutec 613-996-6666
Reactivity:
Hazard Rating: Least Slight Moderate High 0 1 2 3
NA=Not Applicable NE=Not Established
SECTION 2 HAZARD IDENTIFICATION
Generally not hazardous in normal handling, Store away from water reactive materials.
Emergency Overview:Not Applicable. Inhalation:Not Applicable. Ingestion:Not Applicable. Skin:Not Applicable. Eye Contact:Not Applicable. Chronic Exposure:Not Applicable. Aggravated by Exposure:Not Applicable. SECTION 3 MIXTURE COMPONENTS Percent Comp. Exposure Limits
SARA 313
Component
CAS Number
Dimension
Water, Deionized ASTM Type II

SECTION 4 FIRST AID MEASURES
CAS# 7732-18-5
100%
V/V
None Established
Generally not hazardous in normal handling, Store away from water reactive materials.
SECTION 5 FIRE FIGHTING MEASURES
Fire Extinguisher Type:
Fire / Explosion Hazards:

Fire Fighting Procedure:
Any means suitable for extinguishing surrounding fire None Known. Wear self-contained breathing apparatus and protective clothing to prevent contact with skin and clothing.
SECTION 6 ACCIDENTAL RELEASE MEASURES
This material is non hazardous, wipe up and dispose of down drain. Non-Hazardous Material. Clean up of Spills Requires no Special
Deionized Water
Equipment or Procedures.
SECTION 7 HANDLING AND STORAGE
Store in a cool dry place. This Material is not considered hazardous. Store away from water reactive material.
SECTION 8 EXPOSURE CONTROLS/PERSONAL PROTECTION
Respiratory Protection: Ventilation
None required Local Exhaust Mechanical
Protective Gloves:
None required None required None required.
Eye Protection: Other Protective Equipment:
SECTION 9 PHYSICAL AND CHEMICAL PROPERTIES
Melting Point: Boiling Point:
0C 100C Information not available Information not available Soluble Colorless odorless liquid Not flammable 1
Percent Volatile by Volume:

Evaporation Rate
>99 1 Water =1 Not applicable Not applicable Not applicable
Vapor Pressure:
Vapor Density: Solubility in Water: Appearance /Odors: Flash Point: Specific Gravity:
Evaporation Standard
Auto Ignition Temp Lower Flamm. Limit in Air Upper Flamm. Limit in Air
SECTION 10 STABILITY AND REACTIVITY INFORMATION
Stability: Conditions to Avoid: Materials to Avoid: Hazardous Decomposition Products: Hazardous polymerization: Conditions to Avoid:
SECTION 11
Stable
Temperature extremes Strong Acids, Bases. Water reactive materials Not known to occur Will Not Occur None known
Toxicological Information Carcinogenic References: NTP Carcinogen - Known: No, IARC Category- None
SECTION 12
Ecological Information Not Applicable.
SECTION 13
Disposal Considerations Whatever cannot be saved for recovery or recycling should be flushed to sewer. If material
Page 2 of 4
Deionized Water
becomes contaminated during use, dispose of accordingly. Dispose of container and unused contents in accordance with federal, state and local requirements. SECTION 14 Transport Information
DOT
Classification:
Not Regulated
DOT Regulations may change from time to time. Please consult the most recent D.O.T. regulations.
SECTION 15 Regulatory Information Chemical Inventory Status Part 1:Ingrdient Water (7732-18-5) TSCA Yes EC Yes Japan YES Australia Yes Chemical Inventory Status Part 2:Ingredient Water (7732-18-5) Korea Yes DSL Yes NDSL No Phil. Yes Federal, State & International Regulations Part 1: Ingredient. Water (7732-18-5) RQ No TPQ No List NO Chemical Catg No Federal, State & International Regulations Part 2:Ingredient Water (7732-18-5) CERCLA No 261.33 No 8(d) No Chemical Weapons Convention: No TSCA 12 (b):No CDTA:No PURE/LIQUID SARA 311/312: Acute: No Chronic: No Fire: No Pressure: No Reactivity: No Australian Hazchem Code: None allocated Poison Schedule: None allocated SECTION 16 Additional Information
Conditions aggravated/Target organs: None known
Page 3 of 4
Deionized Water
Flammability
Health
Reactivity
Revisions
NFPA
7/30/2010
0.1 0
updated msds to 16 section from 10 section msds. STN
The information herein is believed to be accurate and is offered in good faith for the user's consideration and investigation. No warranty either expressed or implied is made for the completeness or accuracy of the information whether originating from the above mentioned company or not. Users of this material should satisfy themselves by independent investigation of current scientific and medical knowledge that the material can be used safely.
Page 4 of 4
Page 1/5
Material Safety Data Sheet

According to OSHA and ANSI
Printing date 05/31/2011 Reviewed on 09/28/2010
1 Identification of the substance/mixture and of the company/undertaking

Product identifier Product name: Molecular sieves, 5A Stock number: 87955 CAS Number: 69912-79-4 Relevant identified uses of the substance or mixture and uses advised against. Sector of Use SU24 Scientific research and development Details of the supplier of the safety data sheet Manufacturer/Supplier: Alfa Aesar, A Johnson Matthey Company Johnson Matthey Catalog Company, Inc. 30 Bond Street Ward Hill, MA 01835-8099 Tel: 800-343-0660 Fax: 800-322-4757 Email: tech@alfa.com www.alfa.com Information Department: Health, Safety and Environmental Department Emergency telephone number: During normal hours the Health, Safety and Environmental Department at (800) 343-0660. normal hours call Carechem 24 at (866) 928-0789.
After
2 Hazards identification
Classification of the substance or mixture The substance is not classified according to the Globally Harmonized System (GHS). Classification according to Directive 67/548/EEC or Directive 1999/45/EC Not applicable Information concerning particular hazards for human and environment: Not applicable Label elements Labelling according to EU guidelines: Observe the general safety regulations when handling chemicals Classification system HMIS ratings (scale 0-4) (Hazardous Materials Identification System)
HEALTH FIRE 0 0
Health (acute effects) = 0 Flammability = 0 Reactivity = 0
REACTIVITY 0
Other hazards Results of PBT and vPvB assessment PBT: Not applicable. vPvB: Not applicable.
3 Composition/information on ingredients
Chemical characterization: Substances (CAS#) Description: Molecular sieves (CAS# 69912-79-4)
4 First aid measures

Description of first aid measures After inhalation Supply fresh air. If required, provide artificial respiration. Keep patient warm. Seek immediate medical advice. After skin contact Immediately wash with water and soap and rinse thoroughly. Seek immediate medical advice. After eye contact Rinse opened eye for several minutes under running water. Then consult a doctor. After swallowing Seek medical treatment.
5 Firefighting measures
Extinguishing media Suitable extinguishing agents Product is not flammable. Use fire fighting measures that suit the surrounding fire.
(Contd. on page 2) USA
DR
Page 2/5

Printing date 05/31/2011 Product name: Molecular sieves, 5A
(Contd. of page 1)
Reviewed on 09/28/2010
Special hazards arising from the substance or mixture In case of fire, the following can be released: Metal oxide fume Silicon oxide Sodium oxide Advice for firefighters Protective equipment: Wear self-contained respirator. Wear fully protective impervious suit.
6 Accidental release measures

Personal precautions, protective equipment and emergency procedures Wear protective equipment. Keep unprotected persons away. Ensure adequate ventilation Environmental precautions: Do not allow material to be released to the environment without proper governmental permits. Methods and material for containment and cleaning up: Pick up mechanically. Reference to other sections See Section 7 for information on safe handling See Section 8 for information on personal protection equipment. See Section 13 for disposal information.
7 Handling and storage

Handling Precautions for safe handling Keep container tightly sealed. Store in cool, dry place in tightly closed containers. No special precautions are necessary if used correctly. Information about protection against explosions and fires: The product is not flammable Conditions for safe storage, including any incompatibilities Storage Requirements to be met by storerooms and receptacles: No special requirements. Information about storage in one common storage facility: Store away from water/moisture. Do not store together with oxidizing and acidic materials. Further information about storage conditions: This product is hygroscopic. Keep container tightly sealed. Store in cool, dry conditions in well sealed containers. Protect from humidity and water.
8 Exposure controls/personal protection

Additional information about design of technical systems: Properly operating chemical fume hood designed for hazardous chemicals and having an average face velocity of at least 100 feet per minute. Control parameters Components with limit values that require monitoring at the workplace: Not required. Additional information: No data Exposure controls Personal protective equipment General protective and hygienic measures The usual precautionary measures for handling chemicals should be followed. Keep away from foodstuffs, beverages and feed. Remove all soiled and contaminated clothing immediately. Wash hands before breaks and at the end of work. Breathing equipment: Use suitable respirator when high concentrations are present. Protection of hands: Impervious gloves Check protective gloves prior to each use for their proper condition. Material of gloves The selection of suitable gloves not only depends on the material, but also on quality. Quality will vary from manufacturer to manufacturer. Eye protection: Safety glasses Body protection: Protective work clothing.
USA (Contd. on page 3)
DR
Page 3/5

(Contd. of page 2)
9 Physical and chemical properties

Information on basic physical and chemical properties General Information Appearance: Form: Pellets Color: Light brown Odor: Not determined Odour threshold: Not determined. pH-value: Change in condition Melting point/Melting range: Boiling point/Boiling range: Sublimation temperature / start: Flammability (solid, gaseous) Ignition temperature: Decomposition temperature: Auto igniting: Danger of explosion: Explosion limits: Lower: Upper: Vapor pressure: Density: Relative density Vapour density Evaporation rate Solubility in / Miscibility with Water: Not applicable. Not determined Not determined Not determined Not determined. Not determined Not determined Not determined. Product does not present an explosion hazard. Not determined Not determined Not applicable. Not Not Not Not determined determined. applicable. applicable.
Insoluble
Segregation coefficient (n-octonol/water): Not determined. Viscosity: dynamic: kinematic: Other information Not applicable. Not applicable. No further relevant information available.
10 Stability and reactivity

Reactivity Chemical stability Thermal decomposition / conditions to be avoided: Decomposition will not occur if used and stored according to specifications. Possibility of hazardous reactions No dangerous reactions known Incompatible materials: Water/moisture Acids Oxidizing agents Hazardous decomposition products: Metal oxide fume Silicon oxide Sodium oxide
11 Toxicological information
Information on toxicological effects Acute toxicity: Primary irritant effect: on the skin: May cause irritation on the eye: May cause irritation Sensitization: No sensitizing effects known. Subacute to chronic toxicity: The toxicity of calcium compounds is generally due to the anion. The toxicity of sodium compounds is generally due to the anion. Inorganic silicon compounds may be acute inhalation irritants. Prolonged inhalation may cause pulmonary fibrosis known as silicosis.
(Contd. on page 4) USA
DR
Page 4/5

(Contd. of page 3)
Subacute to chronic toxicity: Aluminum may be implicated in Alzheimers disease. Inhalation of aluminum containing dusts may cause pulmonary disease. Additional toxicological information: To the best of our knowledge the acute and chronic toxicity of this substance is not fully known. No classification data on carcinogenic properties of this material is available from the EPA, IARC, NTP, OSHA or ACGIH.
12 Ecological information
Toxicity Acquatic toxicity: No further relevant information available. Persistence and degradability No further relevant information available. Behavior in environmental systems: Bioaccumulative potential No further relevant information available. Mobility in soil No further relevant information available. Additional ecological information: General notes: Do not allow material to be released to the environment without proper governmental permits. Results of PBT and vPvB assessment PBT: Not applicable. vPvB: Not applicable. Other adverse effects No further relevant information available.
13 Disposal considerations
Waste treatment methods Recommendation Consult state, local or national regulations to ensure proper disposal. Uncleaned packagings: Recommendation: Disposal must be made according to official regulations.
14 Transport information
Not a hazardous material for transportation. DOT regulations: Hazard class: None (cross-border)
Land transport ADR/RID ADR/RID class: None Maritime transport IMDG: IMDG Class: None Marine pollutant: No
Air transport ICAO-TI and IATA-DGR: ICAO/IATA Class: None Special precautions for user Not applicable. Transport/Additional information: Not dangerous according to the above specifications. Transport in bulk according to Annex II of MARPOL73/78 and the IBC Code Not applicable.
15 Regulatory information
Safety, health and environmental regulations/legislation specific for the substance or mixture Product related hazard informations: Observe the general safety regulations when handling chemicals National regulations This product is not listed in the U.S. Environmental Protection Agency Toxic Substances Control Act Chemical Substance Inventory. Use of this product is restricted to research and development only. Some or all of the components of this product are not listed on the Canadian Domestic Substances List (DSL) or the Canadian Non-Domestic Substances List (NDSL). Information about limitation of use: For use only by technically qualified individuals. Chemical safety assessment: A Chemical Safety Assessment has not been carried out.
USA (Contd. on page 5)
DR
Page 5/5

(Contd. of page 4)
16 Other information
Employers should use this information only as a supplement to other information gathered by them, and should make independent judgement of suitability of this information to ensure proper use and protect the health and safety of employees. This information is furnished without warranty, and any use of the product not in conformance with this Material Safety Data Sheet, or in combination with any other product or process, is the responsibility of the user. Department issuing MSDS: Health, Safety and Environmental Department. Contact: Zachariah C. Holt Global EHS Manager Abbreviations and acronyms:
ADR: Accord europen sur le transport des marchandises dangereuses par Route (European Agreement concerning the International Carriage of Dangerous Goods by Road) RID: Rglement international concernant le transport des marchandises dangereuses par chemin de fer (Regulations Concerning the International Transport of Dangerous Goods by Rail) IMDG: International Maritime Code for Dangerous Goods DOT: US Department of Transportation IATA: International Air Transport Association IATA-DGR: Dangerous Goods Regulations by the "International Air Transport Association" (IATA) ICAO: International Civil Aviation Organization ICAO-TI: Technical Instructions by the "International Civil Aviation Organization" (ICAO) CAS: Chemical Abstracts Service (division of the American Chemical Society) HMIS: Hazardous Materials Identification System (USA) USA
DR
PEM ELECTROLYZER
C- 2
Revision 3
Appendix D: P&ID
Revision 3
D-1
Appendix E: Electrical Schematics
Revision 3
E-1
201 202 203 204 205 206 207 208 209 210 211 212 213 214 215 216 217 218 219 220 221 222 223 224 225 226 227 228 229 230 231 232 233 234 235 236 237 238 239 240
WARNING !
"If any of the original wire as supplied with the electrolyzer power system must be replaced , it must be replaced with wiring material having equivalent ratings with respect to ampacity, voltage and temperature."
WIRE CODE DESIGNATION WIRE COLOUR BLACK BROWN RED ORANGE YELLOW GREEN BLUE VIOLET GRAY WHITE DESIGNATION SPECIFIED BLK BRN RED ORG YEL GRN BLU VIO GRY WHT
Hydrogenics
220 ADMIRAL BLVD. Mississauga,Ontario,Canada,L5T 2N6
Customer:
PEM ELECTROLYZER_rev2G
Project number: Project Manager: JASON LEMOS
Revision: Description:
01 02 RELEASED UPDATE
Date
01/12/10 25/02/11
Name
MS MS
Created By: Checked By: Approved By:
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
REFERENCES
Page:
Revision Number: 2 ELECTROLYZER Page Group:
Previous page: 1 Next page: 3
of 17
301 302 303 304
CUSTOMER POWER SUPPLY 0-(23.8-28.3)V DC ;230A

L1 + L2G
L1 3/0
306 307 308 309 310 311

3081 4/0
P1
CONN: 6321 ANDERSON
P1
L2 3/0
305
GRN/YEL 4AWG
1
GND CONNECTOR
3091 WHT/BLU 14AWG 3081 BLU 14AWG
312 313 314 315 316
3091 4/0
1 2
317 318
CR517
/5/517
CR519
/5/519
1L1
32110 BLU 14 AWG

3L2
5L3
3082 4/0
319 320 321 322 323 324 325 326 327 328 329 330
3092 4/0
NON-FUSIBILE DISC. SWITCH
2T1
4T2
6T3
DS307
63A/24VDC
CURRENT SENSOR
1 1
OT63FT3S
FU320
250A
FU321
2 2
250A
CNN 250
FERRAZ SHAWMUT
CNN 250
FERRAZ SHAWMUT
3211 BLU 14 AWG
ABB
PS1
4/403
FU326
3261 BLU 18AWG 1 2 BLU 3262 18AWG
DC+
/ 9/913
TO VOLTAGE MONITOR DEVICE

3281 BLU 18AWG 3
0.5A
4 BLU
3282 18AWG
DC-
/ 9/914
ATDR0.5
3221 WHT/BLU 14 AWG
CM1500
PS2
4/403
3083 3/0
3093 3/0
331 332 333
ELECTROLYZER STACK
U334
334 335 336 337 338 339 340

14CELLS;28V; 216A
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
POWER
Page:
of 17
401 402
3/323 3/323
403 404 405 406 407 408 409 410 411 412 413 414 415 416
PS1
PS2
POWER SUPPLY
4082 BLU 18AWG
+24V_1
/ 5/502
PS408
E-STOP
NO E_STOP INPUTS
FU409
1 2 4091 BLU 14AWG Vin+
FU410
A
+OUT
4081
1
15A
4082
CR504
5
/5/501
4083 BLU 14AWG
+24V_2
/ 11/1102
OUTPUTS
24VDC
ATDR15
3
20A
4111 WHT/BLU 14AWG
Vin-
ATDR20
FERRAZ SHAWMUT
104
4130 GRN/YEL 14AWG PE
GND
TB1 G
Disable+
VI-QCW31-ESY
OUTPUT 1 +24VDC
B
SENSE+
BUS_BAR
Disable-
TRIM
417 418 419 420 421 422 423 424 425 426 427 428 429 430
B A E D
SENSE-
OUT4222 WHT/BLU 14AWG
103
PE
4201 WHT/BLU
14AWG
0V_1
/ 5/502
TB1
FU424
+OUT
4241 BLU 18AWG 1
2A
2 ATDR2
4242 BLU 18AWG
12V_1
/ 9/919
FERRAZ SCHWAMUT
OUTPUT 2 +12VDC
12VDC
SENSE+
431 432 433 434 435

E D C
TRIM
SENSE-
OUT4372 BLU/WHT 18AWG
436 437 438 439 440

18V -32VDC /24VDC,12A ;12VDC,2A
105
PE
4371 BLU/WHT
18AWG
0V_2
/ 9/921
TB1
VI-QCW31-ESY
VICOR
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
24V/12V POWER SUPPLY

Page:
of 17
CR504
501
4/405
502 503 504 505 506 507 508 509 510
+24V_1
0V_1
E-STOP
TB1
4082
PB504
11
2NC
OVERTEMPERATURE
OVERPRESURE
SOFT ENABLE
RESET
3 5
4 6
8272 BLU 20AWG
4/420
DI
/ 8/827
TB1
5042
/8/816 /5/521
CR531
11
/5/531
CR535
5043 11
/5/536
CR1231
5044 11
/12/1231
CR513
5045 11
/5/514
5041 BLU 20AWG
12
94
TB1
4201 BLU/WHT 20AWG
14
14
14
14
5046
25
15A,24VDC,SPDP
EMERGENCY/ HWSS (HARDWARE SYSTEM SAFETY)
HW1E-LV4F02QD-R-24V
IDEC
LY1N-D2-DC24V
OMRON
3 /4/408
CR509
21
/5/510
24
CR509
A1 A2
24V,6A,2 PDT
511 512 513 514 515 516 517 518 519 520 521 522 523 524 525 526 527 528 529
7/707
PLC-RSC-24DC/21-21
PHOENIX CONTACT
RESET
11 11 21
12 /5/521 14 /5/517 24 /5/507
PB514
5041 BLU 20AWG c no
CR513
95
5141 A1 A2
1NO, 24VDC /11/1133
RESET
11 21 14 /5/504 24 /8/830
HW1L-M1F10QD-S-24
IDEC
24V,6A,2 PDT
PLC-RSC-24DC/21-21 x2
400V;1A GENERAL SEMICONDUCTOR
x1 V517
PHOENIX CONTACT
HWSS-OK
STACK ENABLE (PLC)

5171
CR509 11 14
/5/510
CR1225 11 14
/12/1225
P517
5172
1N 4004
CR517
A1 A2
500A,24VDC
2
STACK ENABLE
1 2 /3/317
P519
1
EV200AAANA
TYCO ELECTRONIC
CR519
A1
500A,24V
A2
2
STACK ENABLE
1 2
/3/317
E_HWSS
EV200AAANA
CR509
4082
PB504
96
5211 x1
RED /5/504 /8/816
TYCO ELECTRONICS
x2
400V;1A GENERAL SEMICONDUCTOR
x1 V519 4201 BLU/WHT 20AWG
5170 BLU 20AWG
11
/5/510
12
x2
1N 4004
26
EMERGENCY/ HWSS (LAMP)
HM529
5041 BLU 18AWG 1 2
HOUR METER
24V_PB
8/815
5170 BLU 20AWG
CR1225 21 24
/12/1225
97
5261 3
0V_PB
11/1130
OVERTEMPERATURE
701DR001O1248D2
530 531 532 533 534 535 536 537 538

6/602
24V_relay
TB1
3
5311 RED 22AWG
W531
/5/531
3x22AWG
P531
1
TSH2002
c 5312 RED 20AWG nc 5313 BLK 20AWG
P531
2
W531
/5/531
CURTIS INSTRUMENT
CR531
5314 BLK 22AWG
3x22AWG
40
TB1
5314 BLU 20AWG
A1
A2
4201 BLU/WHT 20AWG
OVERTEMPERATURE
24V,6A,2 PDT
PLC-RSC--24DC/21-21
PHOENIX CONTACT
90 C +/- 5 C, NC
RA20AB117B250CO179
CANTHERM
11 21
14 /5/504 24 /8/808
OVERPRESSURE
0V_1
6/602
W536
/5/535
3x22AWG
5361 RED 18AWG
P536
A
PSH2100
c 5362 RED 18AWG nc 5363 BLK 18AWG
P536
B
W536
/5/535
3x22AWG
TB1
5364 BLK 18AWG
CR535
5364 BLU 20AWG A1 A2 4201 BLU/WHT 20AWG
41
OVERPRESURE
24V,6A,2 PDT
PS61-19-2MNS-B-TS
GEM SENSORS
PLC-RSC-24DC/21-21
PHOENIX CONTACT
11 21
14 /5/504 24 /7/709
9/916
539 540
+24V_1
0V_Relay
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
HWSS CIRCUIT
Page:
of 17
601 602 603 604 605 606 607
5/538
5/533
+24V_1
0V_1
CONTROL SYSTEM
CS604
/7/703 /8/803 /9/903 /10/1004 /11/1103 /12/1201 /13/1304
TB1
4082
X1
6071 BLU 20AWG
/
X1 Ub CAN _L GND X1:02

6072 BLU/WHT 20AWG
TB1
27
4201
608 609
P613 13
TB199
X1:01 6081 GRN 20AWG x1 X1:03
CAN_L
CAN INTERFACE
610
/
R2
14 101
x2 6091 YEL 20AWG
120ohm
CAN_H
X1:04
611 612 613 614 615 616 617 618 619 620 621 622 623 624 625 626 627 628 629 630 631 632 633
CAN_H CAN_L CAN_H P614 DB 9 CONNECTOR GND DIP switch 8 segments ON OFF PROGRAMMING(8:ON) RUN(1:ON;2-3OFF; 5-7:OFF;8: OFF) 4:ON :CI TEMPERATURE
RS 232:05
CPC:796190-1 TYCO
X1:05 X1:06
P614
6131 RED 24AWG 6141 ORG 24AWG RS 232:02 RS 232:03 RS 232:06 RS 232:09
RxD TxD Ub TEST
W626
/6/627
RS232 6281 GRN 24AWG
1 2 3 4 5 6 7 8
CR0301
24INPUTS;18OUTPUTS
IFM
U625
LCD DISPLAY
MATRIX ORBITAL
W626
/6/615
RS232
6141 ORG 24AWG 6131 RED 24AWG
PDC1
/6/627
P/D:2 P/D:3 P/D:1
Rx Tx PWR POWER/DATA CONNECTOR
PDC1
/6/626
W628
/6/628
GND
P/D:4
6281 BLK 20AWG
W628
/6/627
6291 RED 20AWG
2 3
TxD RxD DB 9 CONNECTOR
PWR GND
634 635 636

LK204-25-WB-VPT
637 638 639 640

+24V_1
7/701
0V_1
7/702
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
CONTROL SYSTEM
Page:
of 17
+24V_1
6/638
701
6/638
702 703 704 705 706

4082
0V_1
W703 TB1
5
/7/705
GD1000
5-40V DC; OUT:0-3V
CS604 W703
/7/703
3x22AWG
TB1
28
7041 RED 20AWG 7051 BLK 20AWG
X4
/8/804
Vcc
2
Vout/Iout
5
3x22AWG
7064 WHT 20AWG
GND
4
TB1
50
7064 BLU 20AWG 01 IN00
/8/803 /9/903 /10/1004 /11/1103 /12/1201 /13/1304 /6/605
%IX1.0
H2 GAS DETECTOR
RLY1
4201
5/529
RLY2
HK-GH-A080C-W50A-05-R1-S1-E2-I2
NEODYM TECHNOLOGIES INC.
707 708 709 710 711 712 713 714 715 716 717 718 719 720 721 722 723 724 725 726 727 728 729 730 731 732 733 734 735 736 737 738 739
+24V_1
13/1303
24V_relay
CR535
5170 BLU 20AWG 21
/5/536
TB1
7081 BLU 20AWG
24
51
7081 BLU 20AWG
02 IN01
%IX1.8
OVERPRESSURE
CR735
5170 BLU 20AWG 11
/7/735
14 BLU
7131 20AWG
52
BLU
7131 20AWG
03 IN02
%IX2.0
INLET TANK LOW LEVEL
CR738
5170 BLU 20AWG 11
/7/738
14 BLU
7161 20AWG
53
BLU
7161 20AWG
04 IN03
%IX2.8
INLET TANK HIGH LEVEL
7/733
24V_relay
W720
/7/720
3x22AWG
P720
1
7202 RED 20AWG
LSL1000
C NO 7203 RED 20AWG
P720
2
W720
/7/719
3x22AWG
7204 WHT 22AWG
7201 RED 22AWG
54
7204 BLU 20AWG
05 IN04
%IX3.0
DI TANK LOW LEVEL
GEM SENSORS
164870
W724
/7/723
3x22AWG
7241 RED 22AWG
P724
1
7242 RED 20AWG
LSH1000
C NO RED
GEM SENSORS
W724 P724
7243 20AWG
/7/723
3x22AWG
7244 WHT 22AWG
55
BLU
7244 20AWG
06 IN05
%IX3.8
DI TANK HIGH LEVEL
164870
W727
/7/726
3x22AWG
P727
1
7272 RED 20AWG
FSL1007
C
177592
W727 P727
7273 RED 20AWG
/7/727
3x22AWG
7274 WHT 22AWG
7271 RED 22AWG
NO
56
BLU
7274 20AWG
07 IN06
%IX4.0
PUMP DI WATER FLOW SWITCH
GEMS SENSOR
W730
/7/730
PS2026
C NC
W730
/7/730
3x22AWG
7311 RED 22AWG
3x22AWG
7314 WHT 22AWG
57
7314 BLU 20AWG
08 IN07
%IX4.8
PRESSURE DEMAND SWITCH
PA10A/RG10A21
ASCO VALVE CANADA
24V_relay
7/718
W734
/7/734
P734
1
7352 BRN 7362 BLU
LSL4003
7353 BLK
6 29
3x22AWG
P734
3
W734
/7/734
3x22AWG
TB1
7354 WHT 22AWG
48
CR735
7354 BLU/WHT 20AWG A2 A1 5170 BLU 20AWG 10
24V,6A,1 PDT
Ub
GND
PLC-RSC-24DC/21
PHOENIX CONTACT MODE D -ON (LOW LEVEL)
INLET TANK LOW LEVEL
W738
/7/738
EX-F1
11
14 /7/713
3x22AWG
P738
1 2
7382 BRN 7392 BLU
SUNX
W738
7383 BLK
LSH4003
P738 3
/7/738
3x22AWG
TB1
7384 WHT 22AWG
49
CR738
7384 BLU/WHT 20AWG A2 A1
24V,6A,1 PDT
PLC-RSC-24DC/21
PHOENIX CONTACT MODE D-ON(HIGH LEVEL)
INLET TANK HIGH LEVEL

8/806
740
8/802
0V_1
EX-F1
SUNX
11
14 /7/716
24V_relay
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
DIGITAL INPUTS
Page:
of 17
801 802 803 804 805 806 807 808 809 810 811 812 813 814 815 816 817 818 819 820 821
7/739
+24V_1
CS604 X4 TB1
7/739 /7/705 /7/703 /9/903 /10/1004 /11/1103 /12/1201 /13/1304 /6/605
58
24V_relay
8021 BLU 20AWG
11 IN08
%IX5.0 SPARE
CR531
5170 BLU 20AWG 21 24 8081 BLU 20AWG
59
8081 BLU 20AWG
12 IN09
%IX5.8
OVERTEMPERATURE
/5/531
TB1
9
8121 BLU 20AWG
FU812
1
2A
EXTERNAL DETECTOR TB1

8122 BLU 20AWG
92
JMP
8123 BLU 20AWG
93
8123 BLU 20AWG
13 IN10
%IX6.0
OPTIONAL E-STOP
EXTERNAL DETECTOR CUSTOMER INTERFACE REMOVE JUMPER WHEN CONNECT
5/526
24V_PB
PB504
5041 BLU 20AWG 22
/5/504 /5/521
21
8161 BLU 20AWG
61
8161 BLU 20AWG
14 IN11
%IX6.8 E-STOP
START
PB820
5041 BLU 20AWG c
1NO IDEC
no
/11/1137
8201 BLU 20AWG
62
8201 BLU 20AWG
15 IN12
%IX7.0
START
HW1L-M1F10-QD-G-24
STOP
822 823 824 825 826 827 828 829 830 831 832 833 834 835 836 837 838 839 840
12/1218 5/502 /
PB822
c
1NC
nc
8231 BLU 20AWG
63
8231 BLU 20AWG
16 IN13
%IX7.8
STOP
HW1B-M1F01-R
IDEC
DI
8272 BLU 20AWG
64
8272 BLU 20AWG
17 IN14
%IX8.0
SYSTEM READY HWSS OK
RESET
CR513
5170 BLU 20AWG 21 24 8301 BLU 20AWG
65
8301 BLU 20AWG
18 IN15
%IX8.8
RESET
/5/514
+24V_1
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
DIGITAL INPUTS
Page:
of 17
SENSOR CONNECTIONS Temperature IN (WHITE ) SENSOR

902 903 904 905 906 907 908 909
3-2850-62
901
Signal RETURN (BLACK) Signal IN (RED)

9031 RED 20AWG 9041 BLK 20AWG 9051 WHT 20AWG
RIT1100
/9/903 CELL CONSTANT=0.01/CM
RIT1100
/9/902 12-24VDC,4-20mA
CS604
/7/703 /8/803 /10/1004 /11/1103 /12/1201 /13/1304 /6/605
1
12/1219
1 2 3 4
SIGNAL IN ISO GND SW2: TEMP IN SHIELD ON SW3: 1 2 3 4 Close Open V2
2 3 4
Close 1 2 3 4 Open 0-5 S
An_INPUT_CURR1
X2
/10/1005
W908 TB1
12201 BLU 20AWG
/9/908
W908
/9/908
CONDUCTIVITY MONITORING
13
3-2839-3
+GF+SIGNET
3x22AWG
9081 RED 22AWG 1
3x22AWG
3 9084 WHT 22AWG
TB1
66
9084 BLU 20AWG 01 A_IN00
V+
4-20mA
910 911 912 913 914 915 916 917 918

0V_Relay DC+ DC9151 BLU 20AWG
/ 3/326
+GF+ SIGNET
VM1500
3262 BLU 18AWG 3282 BLU 18AWG 7 8
+28V GND1 1 2 3
J/2 54V 36V 24V OUT I
TB1
12
0V_Relay
5/538
/ 3/328
13 +24VDC
9152 BLU 20AWG
67
9152 BLU 20AWG
02 A_IN01
4-20mA
STACK VOLTAGE MONITORING
An_INPUT_CURR
10/1003
4201 BLU/WHT 20AWG
15 GND3 11 GND2 MCR-VDC-UI-B-DC
12V_1
4/424 12/1223
919 920
0V_2
TB1
4242 BLU 18AWG
42
PHOENIX CONTACT
CM1500
43
9211 RED 18AWG A
921 922 923 924 925 926 927 928 929 930 931 932 933 934 935 936 937 938 939 940
4/435
+12VDC
9221 GRN 18AWG
68
4371 BLU/WHT
46
18AWG
9231 WHT 18AWG
OUTPUT
C D
SIG. GND POWER GND

InPOWER +300A/OUT:0.5-4.5VDC
9221 BLU 20AWG
03 A_IN02
0.5-4.5V
CURRENT MONITORING
12V_1
10/1019
9241 BLK 18AWG
DCS36-300-1
W927
/9/928
AFS1000 P927 1
9272 BRN 22AWG 1
3x22AWG
9271 RED 22AWG
+12VDC
9291 BLK 22AWG
P927
3
OUTPUT
2
W927
/9/926
3x22AWG
9291 WHT 22AWG
TB1
46
9301 BLK 22AWG
69
9302 BLU 22AWG
SIG. GND
9291 BLU 20AWG
04 A_IN03
AIR FLOW SENSOR 0-5V
TB1
45
D6F-W04A1
OMRON
5 Ub
6
10/1020
GND
0V_2
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
ANALOGUE INPUTS
Page:
of 17
1001 1002 1003 1004 1005 1006 1007 1008 1009 1010 1011 1012 1013 1014 1015 1016 1017 1018 1019 1020 1021 1022 1023 1024 1025 1026 1027 1028 1029 1030 1031 1032 1033 1034 1035
ASSEMBLY SENS TEMP 10351 BLK 22AWG 10311 RED 22WG
9/923 9/934
9/916
An_INPUT_CURR
CS604 PT1100
0-200PSI
W1006 TB1
12201 BLU 20AWG
/10/1006
P1006
1
10052 RED 20AWG a
P1006
+ b 10053 WHT 20AWG
W1006
/10/1006
X2
/9/906
11
3x22AWG
10051 RED 22AWG
2 3
3x22AWG
10054 WHT 22AWG
TB1
70
10054 BLU 20AWG 07 A_IN04
/7/703 /8/803 /9/903 /11/1103 /12/1201 /13/1304 /6/605
4-20mA
PRESSURE TRANSMITTER H2 STACK
not used
100.200.1.1.2.7
NOSHOK
PT1010 W1013
/10/1012 0-200PSI
P1013
A
10132 RED 20AWG a
P1013
+ b 10133 WHT 20AWG
W1013
/10/1012
3x22AWG
10131 RED 22AWG
3x22AWG
B C
TB1
71
10134 BLU 20AWG 08 A_IN05
10134 WHT 22AWG
4-20mA PRESSURE TRANSMITTER O2 STACK
not used
100.200.1.1.2.7
NOSHOK
0V_2
12V_1
TE1004 W1022
/10/1021
TB1
44
3x22AWG
10221 RED 22AWG
P1022
1
10222 1
R1024
x1
2K
P1022
10223 2
W1022
/10/1021
3x22AWG
10224 WHT 22AWG
x2
72
10224 BLU 20AWG
09 A_IN06
0-10V
TEMPERATURE TRANSMITTER O2 STACK
P1022 TB1
47
10261 BLK 22AWG
THERMISTOR
10262 3 ASSEMBLY SENS TEMP x1 x2
TE2010 W1031
/10/1030
P1031
1
10312 1
3x22AWG
R1033
x1
2K
P1031
10313 2
W1031
/10/1030
x2
3x22AWG
10314 WHT 22AWG
73
10314 BLU 20AWG
10 A_IN07
0-10V
TEMPERATURE TRANSMITTER O2 REACTOR
P1031
3
10352 3
THERMISTOR
x1 x2
1036 1037 1038 1039 1040
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
ANALOGUE INPUTS
Page:
10
of 17
1101
4/408
1102 1103 1104 1105 1106 1107 1108 1109 1110 1111
+24V_2
11/1139
CS604
/7/703 /8/803 /9/903 /10/1004 /12/1201 /13/1304 /6/605
0V_2
FAHX 1004 W1107

/11/1106
X3
4123 20
TB1
11070 BLU 18AWG 05 Ucom01 OUT00 01
P1107
A
11072 RED 18AWG 1
M
2 734SLC3A01
THERMATRON
P1107
11073 BLK 18AWG
W1107
/11/1106
TB1
%QX0.0 PWM
11071 BLU 20AWG
3x18AWG
11071 RED 18AWG
3x18AWG
11074 BLK 18AWG 11075 GRN 18AWG
74
B C
TB1
34
FAN COOLING WATER
4221 WHT/BLU 14 AWG
TB1
OUT01 02
1112 1113 1114 1115
%QX0.8 PWM
11111 BLU 20AWG
75
W1116
/11/1115
P1116
1
O2 VENT VALVE
TB1
OUT02 03
3x18AWG
11151 RED 18AWG
SV3005
X1 11152 RED 18AWG X2 X3
ASCO VALVE CANADA
P1116
11153 RED 18AWG
W1116
/11/1115
3x18AWG
1116 1117
%QX1.0
11151 BLU 20AWG
76
2 3
11155 GRN 18AWG
TB1
11154 BLK 18AWG
35
8262G134-24VDC
1118 1119 1120 1121 1122 1123 1124 1125 1126

4123 21 11241 BLU 18AWG 10 Ucom02 OUT03 04 11201 BLU 20AWG
W1120
/11/1119
3x18AWG
P1120
1
H2 SUPPLY VALVE
SV2019
X1 11202 RED 18AWG X2 X3
ASCO VALVE CANADA
P1120
2 3
W1120
/11/1119
3x18AWG
11204 BLK 18AWG 11205 GRN 18AWG
77
%QX1.8
11201 RED 18AWG
11203 RED 18AWG
8327G42-24VDC
W1124
/11/1123
TB1
OUT04 06 11251 BLU 20AWG
3x18AWG
11251 RED 18AWG
P1124
1
DI FEED WATER IN
W1124 P1124
2 3
11255 GRN 18AWG
/11/1124
SV4003
x1 X2 X3
ASCO VALVE CANADA
3x18AWG
78
TB1
11254 BLK 18AWG
36
%QX2.0
1127 1128
OUT05
W1130
/11/1128
EF8223G10-24VDC
P1130
1
3x18AWG
07 11271 BLU 20AWG
FAV1000
24V DC,250CFM
P1130
11273 BLK 18AWG
W1130
/11/1128
79
1129 1130 1131 1132 1133 1134 1135 1136 1137 1138 1139 1140
%QX2.8
11271 RED 18AWG
11272 BLK 18AWG
3x18AWG
11274 BLK 18AWG 11275 GND 18AWG
5/528
TB1
37
VENTILATION FAN PROCESS ENCLOSURE
0V_PB
M
DV6224
EBMPAPST
PB514
OUT06 08 11321 BLU 20AWG
80
11321 BLU 20AWG
x1
x2
FAULT
%QX3.0
BLU /5/514
PB820
OUT07 09
%QX3.8
12/1201
11371 BLU 20AWG
81
11371 BLU 20AWG
x1
GREEN /8/820
x2
4201
START&RUN
+24V_2
11/1103
0V_2
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
DIGITAL OUTPUTS
Page:
11
of 17
CS604
11/1138
1201 1202 1203 1204 1205 1206 1207 1208 1209 1210 1211 1212 1213 1214 1215
+24V_2
X5.1
/7/703 /8/803 /9/903 /10/1004 /11/1103 /13/1304 /6/605
FAHX 2003
/12/1204
0V_2
W1207
/12/1204
OUT08_NC
01
3x18AWG
P1207
12071 RED 18AWG
TB1
22
12061 BLU 20AWG 02 Ucom03
R0 %QX4.0 OUT08_NO
n.c.
TB1
03 04 12071 BLU 20AWG
M
12072 BLU 20AWG 1 731SLM3A02-01
THERMATRON
P1207
12073 BLU/WHT 20AWG
W1207
/12/1204
H2 COOLING FAN
3x18AWG
82
B C
TB1
38
4221
12074 BLK 18AWG 12075 BLK 18AWG
W1210
/12/1209
FAHX 2031 P1210

12101 RED 18AWG 1
3x18AWG
/12/1209
P1210
B C
W1210
/12/1209
3x18AWG
O2 COOLING FAN
12102 BLU 20AWG
1 731SLM3A02-01
THERMATRON
12103 BLU/WHT 20AWG
12104 BLK 18AWG 12105 BLK 18AWG
W1213
/12/1213
23
12121 BLU 18AWG
06 Ucom04
OUT09_NC OUT09_NO
05 07
FU1213
12130 BLU 18AWG 1
5A
3x18AWG
P1213
12131 RED 18AWG
PMP1003 M
24VDC
W1213
/12/1213
P1213
12133 BLK 18AWG
3x18AWG
R1 %QX4.8
TB1
83
2 ATDR 5
12132 RED 18AWG
1 MY2-8000.0019
SPECK PUMPEN
12134 BLK 18AWG
39
DI WATER CIRCULATION PUMP
n.c.
08
FERRAZ SCWAMUT
1216 1217 1218 1219 1220

n.c.
8/839
+24V_1
TB1
4082
12191 BLU 20AWG
10 Ucom05
OUT10_NC
09 11
R2 %QX5.0
OUT10_NO
12201 BLU 20AWG
84
An_INPUT_CURR1
/ 9/905
12
1221 1222
9/918
1223 1224 1225 1226 1227 1228 1229 1230 1231 1232
13/1303
0V_Relay
TB1
14
OUT11_NC
13
R3 %QX5.8 OUT11_NO
TB1
15 12252 BLU 20AWG
85
CR1225
A1 A2 4201 BLU/WHT 20AWG 11 21 14 /5/517 24 /5/528
ENABLE POWER STACK
24V,6A,2 PDT
PLC-RSC-24DC/21-21
PHOENIX CONTACT
TB1
10
OUT12_NC
17
R4 %QX6.0
TB1
18 12312 BLU 20AWG
CR1231
A1 A2
86
OUT12_NO
SYSTEM ENABLE (SOFT)

11 14 /5/504
24V,6A,1 PDT
PLC-RSC-24DC/21
PHOENIX CONTACT
1233 1234 1235 1236 1237 1238 1239 1240
+24V_2
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
DIGITAL OUTPUTS
Page:
12
of 17
1301 1302 1303 1304 1305 1306 1307 1308 1309 1310 1311 1312 1313 1314 1315 1316 1317
8841-2M03-B594
/7/703 /8/803 /9/903 /10/1004 /11/1103 /12/1201 /6/605 12/1232
+24V_2
MT1305 CS604
1 2
7/739
0V_1
VENTILATION FAN ELECTRICAL CABINET
X5.2 TB1
4083
MT1309
1
24VDC, 130 CFM
15
13061 BLU 20AWG
02 Ucom08
OUT13_NC
01
VENTILATION FAN ELECTRICAL CABINET
R5 %QX6.8 OUT13_NO
n.c.
TB1
03 04 13081 BLU 20AWG
87
13081 BLU 20AWG
M
4715KL-05W-B59-P00
TEHNOLOGIES CORPORATION
TB1
13082 BLU/WHT 20AWG
30
W1311
/13/1311
P1311
13121 RED 18AWG
SV1127
13122 RED 18AWG x1 x2 x3 13123 BLK 18AWG
P1311
2 3
W1311
/13/1311
3x18AWG
3x18AWG
13124 BLK 18AWG 13125 GRN 18AWG
FEED WATER VALVE
16
13121 BLU 18AWG
06 Ucom09
OUT14_NC
05 07
FU1314
13140 BLU 18AWG 1
2A
TB1
31
R6 %QX7.0
OUT14_NO
TB1
88
13141 BLK 18AWG
P1314
1
13142 RED 18AWG
ASCO VALVE CANADA
8262G86-24VDC
PMP1000
1 2
P1314
13143 BLK 18AWG
n.c.
08
W1314
/13/1314
W1314
/13/1314
13144 BLK 18AWG
PUMP FEED WATER
3x18AWG
M
AQUATEC
3x18AWG
1318 1319
9
W1321
/13/1319
3x18AWG
P1321
1
13202 RED 18AWG
SV2012
x1 x2 X3
ASCO VALVE CANADA
P1321
13203 RED 18AWG
W1321
/13/1319
3x18AWG
13204 BLK 18AWG 13205 BLK 18AWG
17
1320 1321 1322 1323 1324 1325 1326 1327 1328 1329 1330 1331
13191 BLU 20AWG
10 Ucom10
OUT15_NC
R7 %QX7.8
OUT15_NO n.c. 11 12
TB1
13201 BLU 20AWG
2 3
89
TB1
32
DRYER IN VALVE
8327G42-24VDC
W1323
/13/1325
P1323
1
13232 RED 18AWG
SV2013
x1 x2 X3 13233 RED 18AWG
P1323
2 3
W1323
/13/1325
3x18AWG
3x18AWG
13234 BLK 18AWG 13235 GRN 18AWG
DRYER UP VALVE
18
13251 BLU 20AWG
14 Ucom11
ASCO VALVE CANADA
8327G42-24VDC 13 15
R8
OUT16_NC
W1327
/13/1329
P1327
1
13272 RED 18AWG
SV2014
x1 x2 x3
ASCO VALVE CANADA
P1327
13273 RED 18AWG
W1327
/13/1329
%QX8.0 OUT16_NO
13271 BLU 20WG
90
3x18AWG
13271 RED 18AWG
2 3
3x18AWG
13274 BLK 18AWG 13275 GRN 18AWG
33
DRYER REGEN A VALVE
19
1332 1333 1334 1335 1336
8262G134 - 24VDC 13311 BLU 20AWG 16 Ucom12
W1333
OUT17_NC 17 18
/13/1334
3x18AWG
13331 BLU 20AWG
P1333
1
13332 RED 18AWG
SV2018
x1 x2 X3
ASCO VALVE CANADA
P1333
13333 RED 18AWG
W1333
/13/1334
3x18AWG
13334 BLK 18AWG 13335 GRN 18AWG
R9 %QX8.8
OUT17_NO
91
13331 RED 18AWG
2 3
DRYER REGEN B VALVE
1337 1338 1339 1340

+24V_2
8262G134 - 24VDC
0V_1
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
DIGITAL OUTPUTS
Page:
13
of 17
1401 1402 1403 1404 1405 1406 1407 1408 1409 1410 1411 1412 1413 1414 1415 1416 1417 1418 1419 1420 1421 1422 1423 1424 1425 1426 1427 1428 1429 1430 1431 1432 1433 1434 1435 1436 1437 1438 1439 1440
Hydrogenics
Customer:
Date
Name
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
SPARE
Page:
Revision Number: ELECTROLYZER Page Group:
14
of 17
1501 1502 1503 1504 1505 1506 1507 1508 1509 1510 1511 1512 1513 1514
GND
GND CONNECTOR
BACK PANEL COVER
GRN/YEL AWG 4
GRN/YEL 14AWG
DOOR RIGHT SIDE

GRN/YEL 14AWG
DOOR LEFT SIDE

1515 1516
GRN/YEL 14AWG
1517 1518 1519 1520 1521 1522 1523 1524 1525 1526 1527 1528 1529
GRN/YEL 14AWG
FRAME LEFT SIDE
FRAME RIGHT SIDE

EL PANEL GND SCREW
GRN/YEL 14AWG GRN/YEL AWG 14
CABLE SHIELDS: W927;W1006;W1013; W1022;W1031
1530 1531 1532 1533 1534 1535 1536 1537 1538 1539 1540
X1534
GROUND RAIL
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
M.SUSTAC M.XU J.L.
Date
24/02/2011
Drawing number:
1038968
Page Title:
GROUNDING
Page:
15
of 17
26 inch
ELECTRICAL PANEL-LAYOUT OF APPARRATUS

.5 inch
1 inch DUCT: G1X2LG6 COVER:C1LG6
DUCT: G.5X2LG6 COVER:C.5LG6
.5 inch 1 inch
P519
P517 RESET FAULT E-STOP

701DR001O1248D2
HOUR METER
START
USCC2I USCC2I USCC1I USCC1I USCC1I USCC1I USCC1I FT FH EV200AAANA
STOP
DISCONNECT
HM529 PB514 HW1L-M1F10QD-S-24V PB, WITH LAMP,BLUE,24V,1NO 9 DS307 PB504 HW1E-LV4F02QD-R-24V
6 inch
ATDR20 FUSE,20A, TIME DELAY 101 ATDR20
FU1213
FU1314
1 inch
FU321 CNN 250
PB820 HW1L-M1F10-QD-G-24
PB822 HW1B-M1F01-R
LCD display
OT63FT3S U625
FU409
FU326
FU410
FU424
FU812
ATDR0.5
ATDR0.5 100
ATDR15
ATDR2
ATDR2
ATDR2
ATDR5
CR519
LK204-25-WB-VPT
FU321
EV200AAANA FT FH
.5 inch
DCS36-300-1 CM1500 FU320 CNN 250
CR517
CURRENT SENSOR
PLC -RSC-24DC/21-21
PLC -RSC-24DC/21-21
CR1225 PLC -RSC-24DC/21-21 CR1231
3 inch
PLC -RSC-24DC/21-21
PLC -RSC-24DC/21-21
PLC -RSC-24DC/21 RELAY,2966171,24V,6A 110
CR504 LY1N-D2-DC24V RELAY,24V,15A,SPDP 111
MCR-VDC-UI-B-DC
PLC -RSC-24DC/21
VM1500
CR513
CR535
CR735
CR738
PLC -RSC-24DC/21
CR509
CR531
ELECTRICAL PANEL
6 inch
FU320
1 inch
VI-QCW31-ESY
28 inch
CR0301
9.5 inch
2.5 inch
P1
CS604
7 inch
PS408
P613
DUCT: F1.5X2LG6 COVER:C1.5LG6
1.5 inch
TB1
TB1 TB1 WDU 2.5 20
MT1305
107TERMINALS
LEFT SIDE: CABLES TO TERMINAL BLOCKS

inside panel
RIGHT SIDE: CABLES TO TERMINAL BLOCKS
WEI.1020000000 (WDU2,5) WDU 2.5 19
DUCT: F2.0X2LG6 COVER:C2.0LG6
2 inch
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
Date
24/02/2011
Drawing number:
M.SUSTAC M.XU J.L.
1038968
Page Title:
PANEL LAYOUT
Page:
2 Revision Number: Page Group: ELECTROLYZER
16
MT1309
7 inch
of 17
CABLE
W531
SOURCE
TSH2002
DESTINATION
TB1(3;40)
CABLE
W1107
SOURCE
FAHX1004
DESTINATION
TB1(34;74)
W536 W704
PS2100 GD703
TB1(3;41) TB1(5;28;50)
W1116 W1120
SV3005
TB1(35;76)
SV2019 SV4003
TB1(35;77)
W720
LSL1000
TB1(7;54)
W1124
TB1(36;78)
W724
LSH1000
TB1(7;55)
W1130
FAV1000
TB1(37;79)
W727
FSL1007
TB1(8;56)
W1207
FAHX2003
TB1(38;82)
W731
PS2026
TB1(8;57)
W1213
PMP1003
TB1(39;83)
W734
LSL4003
TB1(6;29;48)
W1311
SV1127
TB1(31;88)
W738
LSH4003
TB1(6;29;49)
W1314
PMP1000
TB1(31;88)
W908
RIT1100
TB1(12;66)
W1320
SV2012
TB1(32;89)
W1323
SV2013
TB1(32;89)
W927 W1006
AFS1000 PT1006
TB1(43;46;69)
W1327 W1333
SV2014
TB1(33;90)
TB1(11;70)
SV2018
TB1(33;91)
W1013
PT1010
TB1(11;71)
W1022
TE1004
TB1(44;47;72) TB1(44;47;73)
W1031
TE2010
Hydrogenics
Customer:
Date
01/12/10 25/02/11
Name
MS MS
Name
Date
24/02/2011
Drawing number:
M.SUSTAC M.XU J.L.
1038968
Page Title:
CABLE CHART
Page:
2 Revision Number: Page Group: ELECTROLYZER
Previous page: 16 Next page:
17
of 17
PEM ELECTROLYZER
E-
Revision 3
Hydrogenics Corporation 220 Admiral Boulevard Mississauga, Ontario Canada L5T 2N6 Phone: 905.361.3660 Fax: 905.361.3626 sales@hydrogenics.com www.hydrogenics.com
Hydrogenics GmbH Am Wiesenbusch 2 - Halle 5 45966 Gladbeck Germany Phone: +49.2043.944.133 Fax: +49.2043.944.146 europe@hydrogenics.com

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Hylyzer Hydrogen Generator Installation, Operation and Maintenance Manual

DOC. P/N: 1039133-03

Hylyzer Hydrogen Generator Installation, Operation and Maintenance Manual Revision 3

Warranties and Liabilities

Patents, Trademarks and Proprietary Rights

About Hydrogenics Corporation

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

Appendix A: Glossary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-1

Appendix B: CAN Specification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-1

Appendix C: Material Safety Data Sheets (MSDS) . . . . . . . . . . . . . . . . . . . . . . C-1

Appendix D: P&ID . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-1

Appendix E: Electrical Schematics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . E-1

1.1.1 Technical Terms and Abbreviations

INTENDED USE OF THE PRODUCT

Intended Use of the Product

1.4.1 Compressed Gas Association (CGA) Publications

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

1.4.2 National Fire Protection (NFPA) Association Publications

1.4.3 The Society of Automotive Engineers (SAE)

1.4.4 International Organization for Standardization (ISO)

1.4.5 International Organization for Standardization (ISO)

WARNING LABELS AND SYMBOLS

Warning Labels and Symbols

2.1.1 Typical Hazard Symbols

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

WARNING LABELS AND SYMBOLS

2.1.2 Safety Notices in the Manual

POTENTIAL HAZARDS AND SAFETY PRECAUTIONS

Potential Hazards and Safety Precautions

2.2.1 General Precautions

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

POTENTIAL HAZARDS AND SAFETY PRECAUTIONS

2.2.2 Mechanical and Handling Hazards

2.2.3 Electrical Hazards

2.2.4 High Temperatures

POTENTIAL HAZARDS AND SAFETY PRECAUTIONS

2.2.5 Flammable Gas Atmosphere and Fire/Explosion Risks

2.2.5.1 Action in the Event of Fire

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

POTENTIAL HAZARDS AND SAFETY PRECAUTIONS

2.2.6 Enriched Oxygen Atmospheres

POTENTIAL HAZARDS AND SAFETY PRECAUTIONS

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

UNCRATING AND INSPECTION INSTRUCTIONS

Uncrating and Inspection Instructions

PEM Electrolyzer Connections

4.3.1 Process Connections

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

PEM ELECTROLYZER CONNECTIONS

WARNING: All metal tubes must be connected to a common grounding system.

4.3.1.1 Hydrogen (H2) Output

4.3.1.2 Combustible Vent

4.3.1.3 DI Water Supply

PEM ELECTROLYZER CONNECTIONS

4.3.1.4 DI Water Drain

4.3.1.5 Leak Check and Nitrogen Purge

4.3.2 Power Connections

INSTALLATION, OPERATION AND MAINTENANCE MANUAL

STORING THE PEM ELECTROLYZER

4.3.3 Diagnostic Connection (for service use only)