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UHP hydrogen generator

UHP Laboratory Hydrogen Gas Generators

All Models

NITROX

dh, domnick hunter and NITROX are registered trademarks of domnick hunter limitedCopyright: domnick hunter limited 2000 Publication Ref: GG 06/00-H2I-E Rev.7 Stock No. 17 497 0050

HYDROGEN ICOM CONTENTS

1) Installation 3

1.1) Safety Warning 31.2) General Information 31.3) Technical Specification 4

1.3.1) Key Features 51.4) Location of the Generator 5

1.4.1) Recommended Location for a domnick hunter 6Hydrogen Generator

1.5) Installation Procedure 71.6) Recommended System Layout 8

1.6.1) Basic Layout 81.6.2) Installation with Back-up Supply 81.6.3) Installation with Multiple Generators 8

1.7) Power Connection and Sequence of Operation 91.8) Shutdown Procedure 10

2) Commissioning 11

2.1) External Instruments and Connections 11/122.2) Commissioning Procedure 13

3) Maintenance 14

3.1) Water Indicators 143.2) Water Conductivity Indicators 143.3) Deioniser Bags 153.4) Desiccant Cartridge Indicator 153.5) Service Kits 163.6) Maintenance Procedures 17

3.6.1) Replacing Water 173.6.2) Filling Water Containers 173.6.3) Maintaining Non-Interrupted Operation 17

4) Service Instructions 18

4.1) Shutdown Procedure 184.2) Maintenance Procedure - Replace Water 18-204.3) Maintenance Procedure - Deioniser Bag Change 214.4) Maintenance Procedure - Desiccant Cartridge Change 224.5) Restart Procedure 264.6) Service Record Log 27


5) Fault Finding 28

5.1) Troubleshooting 285.2) Displayed Errors 295.3) Alarm Modes 305.4) Errors and their Meanings 30-34

6) External Connections 35

6.1) Remote Start/Stop 356.1.1) Inputs 1&2 and 3&4 35/366.1.2) Production – Stop (1&2) 366.1.3) Production – Hold (3&4) 36

6.2) Outputs 366.2.1) Alarm Out (1&2&3) 366.2.2) Water Fill (1&2&3) 376.2.3) Auto – Remote Select 37

7) Installation Errors 38

7.1) General 387.2) Outlet Connection 387.3) Electrical 38

8) Warranty 39

9) Declaration of Conformity 40

10) Notes 41

11) Contact Addresses 42


1 - INSTALLATION

1.1) Safety Warning

Do not operate the generator until the information contained in this documenthas been read and understood by all personnel concerned. Hydrogen is not apoisonous gas but, in a concentrated form, there is a risk of asphyxiation. Thegenerator produces a small flow of hydrogen that quickly disperses in theatmosphere, therefore minimising this risk. However, do not inhale the outputgas from the outlet pipe. Oxygen is also liberated during operation of the unit.This is vented into the rear water tank.

Although, during operation, the volume of hydrogen within the generator isvery small, it is essential to keep the generator away from excessive heat andnaked flames as there is the possibility of explosion if safety warnings are notadhered to.

Position equipment to ensure unobstructed access to rear.

All personnel handling, using or maintaining this generator must employ safeworking practices and observe all relevant local health and safety regulations.

If the equipment is not used in the manner specified by this manual then theprotection afforded by the equipment may be impaired

1.2) General Information

The generator will produce a constant stream of hydrogen gas at apre-determined flow rate when connected to a suitable power supply and fedwith a suitable quality of deionised water. These units are suitable for use inlaboratories and light industrial environments and are non-hazardous fortransportation purposes.

It should be noted that the Hydrogen generator must be installed andrunning within three months of despatch from domnick hunter limited,to ensure the optimum efficiency of the SPE cell. If this is not adheredto this will invalidate the warranty.

Note: Any interference with the calibration warning labels and internal partswill also invalidate the generator’s warranty and may incur costs for rework orrecalibration of the generator.

If the unit needs to be returned to domnick hunter for any reason, youmust drain all the water from the tanks and remove the desiccantcartridge and deioniser bags. The unit must be properly packed andshipped in an upright position.


1.3) Technical Specification

• Models: UHP-20H, UHP-40H, UHP-60H

• Dimensions: 680mm x 345mm x 300mm (HxWxD)

• Weight: 26kg

• Water Specification: >1 MΩ cm

• Flow Rates:UHP-20H 160cc/min hydrogenUHP-40H 250cc/min hydrogenUHP-60H 500cc/min hydrogen

• Outlet Pressure: 0.1-90 psi g

• Hydrogen Gas Purity: 99.99999%

• Mains Supply: 100 -230 VAC50-60 Hz

• Fuse Rating: Input Mains Fuses –

• Manufacturer, Bussmann, Type S505, Rated 250V, F5AT.• Manufacturer, Littelfuse, Type Series 215, Rated 250V, F5AT• Alternate Input Mains Fuses Listed, Rated 250V, F5AT

• Power Consumption: UHP-20H - 185 WattsUHP-40H - 285 WattsUHP-60H - 285 Watts

• Water Consumption (approximate) UHP-20H: 128cc per day/0.9 litres per week UHP-40H: 256cc per day/1.8 litres per week UHP-60H: 511cc per day/3.6 litres per week

Figures based on full flow with 24 hour operation at 22ºC ambient.

• Gas Drying: Refillable molecular sieve

• Ambient Temperature: +5 to +40°C


1.3.1) Key Features

• Start-up system check

• Automatic leak test

• Automatic calibration

• Remote start/stop facility

• Water full indicator

• Water low indicator

• Water empty indicator and alarm

• Flow indicator

• Conductivity sensor/alarm

• Maintenance indicator

• Automatic pressure sensing

• Safety shutdown on rapid pressure loss

• Audible alarm warning

1.4) Location of the Generator

• Locate indoors in a clean environment with good ventilation.

• Protect from water spillage.

• Keep well away from static electricity and naked flames.

• Install on a level site.

• Allow minimum clearance of 50mm around the generator for ventilationpurposes.

• Ensure mains supply corresponds with the generator rating plate and isfully earthed to ground.


1.4.1) Recommended Location for a domnick hunter HydrogenGenerator

Environmental conditions:

This equipment is designed to be safe at least under the followingconditions:

• indoor use - bench mounted• altitude up to 2,000m• temperature 5°C to 40°C• maximum relative humidity 80% for temperatures up to 31°C

decreasing linearly to 50% relative humidity at 40°C• mains supply voltage fluctuations not to exceed ±10% of the nominal

voltage

INSTALLATION CATEGORIES II;POLLUTION DEGREE 2


1.5) Installation Procedure

1) Locate the generator in the position it will normally be sited. Site thegenerator as close to the application as possible, but do not connectgas supply pipework until the recommended system layout has beenread and understood.

2) After reading the recommended system layout (page 8), install the unitas follows:

• Remove the fitting cover from the Hydrogen outlet port

• Connect to application (using pipework recommended for hydrogengas). NB. Purge the outlet pipework for at least 15 minutes toremove trapped oxygen before connecting to the application.

3) Obtain a supply of deionised water (see specification on page 4) andfill the water container to the “FULL” mark on the visual window on thefront of the generator.

4) Remove deioniser bags from the packaging; locate the ‘T’ fastener on

the top of each bag through the centre hole on the top cap of the watercontainer. Put one bag into each top cap, then place bags into thewater containers and fit caps securely.

5) Open the door on the front of the generator. Remove the plastic caps

from the top of the desiccant cartridge and fitting as shown andconnect the flexible tubing to the desiccant cartridge.

Plastic caps


1.6) Recommended System Layout

1.6.1) Basic Layout

1.6.2) Installation with Back-up Supply

1.6.3) Installation with Multiple Generators


1.7) Power Connection and Sequence of Operation

1) The generator operating voltage is marked on the rating plate on therear panel.

2) Make sure that the power switch is in the OFF position.

3) Connect the power cord to the rear panel of the generator.

4) Connect the free end of the power cord to an appropriate powersource.

6) Switch generator on. The generator will give audible indication of thestart up process, and all LEDs will illuminate for approximately twoseconds.

7) During start-up, the unit may automatically revert to the last error modeit experienced. Press the black reset button to clear it and continuewith the start up procedure. If it cannot be cleared by this methodfollow the fault-finding procedure in section 5.

8) The start-up builds internal cell pressure up to 7.2 bar g. (indicated onthe main display panel) using maximum current. This takesapproximately ten minutes during which the system check LED willflash.

9) The generator will continue the system check and a leak test takes place for twoseconds. The system check LED will continue to flash.

10) Outlet solenoid valve opens. The system check is now complete and if successfulthe LED becomes constantly lit.

11) Set the outlet pressure regulator to give desired pressure.

The generator will now run maintaining flow at the set pressure. We advisethat the outlet pipework is purged for 15 minutes to remove oxygen beforeconnecting to the application.


1.8) Shutdown Procedure

If a service or fault-finding procedure requires the generator to be shut down,it is imperative that the following service shutdown instructions are followedcarefully.

1) Ensure that the application supplied by the generator no longerrequires gas.

2) Switch the generator off at the on/off switch and isolate from mainssupply by removing the appliance connector from the appliance inlet.

3) Slowly depressurise the system. Watch the outlet pressure gauge onthe front of the generator. Once the gauge shows zero, the valve canbe fully opened. The generator is now shut down.


2- COMMISSIONING

2.1) External Instruments and Connections

Front and rear panels

Key:

1) Display screen (see page 12)2) Water level3) Desiccant cartridge4) Hydrogen outlet port (on side panel)5) Reset switch6) Hydrogen outlet pressure gauge7) Hydrogen pressure regulator8) On/Off switch9) Water drain port10) Hydrogen relief vent11) Excess Hydrogen vent12) Mains connection13) Water Tanks14) External Connection Panel

1 2

3

4

5

6

7

8 9

10 11

12

13

14


Display Screen

Key:

a) SPE Cell Pressure LED displayb) Alarm (general)c) Maintenance alarmd) Water level indicatore) Remote stop alarmf) System checkg) Hydrogen flowh) Water conductivity indicator


2.2) Commissioning Procedure

1) Ensure that the generator is connected to a suitable electricity supplyusing the mains lead supplied, the water bottles have been filled withthe correct grade of distilled/deionised water, the desiccant bags areput in the water tanks and the desiccant dryer cartridge is connected.

2) Turn the generator on by pushing the “on/off” switch on the front of thegenerator.

• Observe all the LEDs on the front panel illuminate for approximatelytwo seconds.

• The generator will go into a system check mode for severalminutes. Observe the green flashing LED illuminate while pressurein the system builds up to 7.2 bar g.

• Observe the red display as the pressure builds up to 7.2 bar g.

• Once the system check LED illuminates continuously, the systemcheck is complete and an internal leak test will now take place.

3) At this stage the outlet valve on the generator will open. Now set thedesired output pressure by opening the door on the front of thegenerator and turn the pressure regulator clockwise to a maximum of90 psi g, which will be indicated on the analogue pressure gaugeabove the regulator.

The green LEDs on the scale at the bottom of the display panel willgive an indication of flow rate in %. It is recommended that ahydrogen-calibrated flow meter is used to verify the required flow ratein cases where this is likely to be within 10% of the max. capacity of thegenerator.


3 - MAINTENANCE

3.1) Water Indicators

To ensure continuous operation, regularly check the water level and top up ifnecessary.

There are four water level indicators on the front of the generator:

• Top green LED illuminated constantly: Water level full

• Central green LED illuminated constantly: Water acceptable level

• Central green LED flashing: Water low, refill as soon as possible

• Red LED illuminated: Water empty, alarm condition, refill to restart

Before filling the water containers, always check the quality of the deionisedwater and ensure it falls between the tolerances outlined in the technicalspecification on page 4.

3.2) Water Conductivity Indicators

The hydrogen generator has a built-in conductivity meter with alarm to ensurethe correct quality of deionised water is used at all times. There are ten LEDslocated on the right hand side of the front display panel indicating thefollowing:

• Seven green LEDs indicating good quality water

• Two amber LEDs indicating that the quality of water is near the limit foroperation

• One red LED indicating that the quality of water could cause damage tothe process. At this point the generator will shut down on alarm

The conductivity meter is there for two reasons:

1) To ensure good quality water is used at all times.

2) To give an indication of when the deioniser bags should be changed.


3.3) Deioniser Bags

There are two deioniser bags for each generator (one for each watercontainer). The deioniser resin scavenges any remaining ions from the waterand helps to stop the conductivity from rising during operation.

The bags should be replaced:

1) If the conductivity is rising to alarm level when the same quality water isbeing used consistently.

2) Every six months.

3.4) Desiccant Cartridge Indicator

The internally mounted desiccant cartridge is in the system to dry thehydrogen gas before feeding to the application. The life of the cartridge willdepend on the gas usage.

When the cartridge is new, the desiccant will be a mixture of orange and whitematerial. Regularly check the window on the right hand side of the front doorto see any colour change. The flow of gas runs from top to bottom, thereforethe colour change (which turns the material to clear) will start from the top.Once the change is visible, order a refill kit (see page 16).

The desiccant does not need changing until the colour change reaches thebottom of the window.

There are two ways of replacing the desiccant:

1) Order the whole cartridge assembly.

2) Order the refill kit and follow instructions in section 4.4.


3.5) Service Kits

Deioniser Bags: Replace once every six months or if conductivity increaseswhen using good quality water as outlined in the technical specification onpage 4.

Deioniser bag kit: Contains two bags.

Kit number: 60 497 0010

Desiccant Cartridge Assembly: Replace when colour change reaches thebottom of the viewing window. Do not regenerate the desiccant material. Thecartridge housing is plastic and not suitable for regeneration.

Desiccant kit: Contains one full assembly including fittings.

Kit number: 60 497 0050

Desiccant Refill Kit: Replace when colour change reaches the bottom of theviewing window.

Refill kit: Contains enough desiccant to refill one cartridge.

Kit number: 60 497 0020.


3.6) Maintenance Procedure

3.6.1) Replacing Water

If it becomes necessary to replace the water in the hydrogen generator,first switch off the unit by using the shutdown procedure on page 18.Find a watertight container that has a minimum volume of 4 litres andplace it at a level that is below the base of the generator. Take the tubeand drain connector supplied with generator, open the door on the frontof the generator and push the connector into the drain bulkhead. Drainall of the water into the container and dispose of the contents. Neverrefill the generator with contaminated water that has been drained fromthe generator.

Remove the drain and tube from the bulkhead, take approximately 3-4litres of fresh deionised water and refill both water containers to the fullmark on the level indicator.

Follow restart procedure on page 27.

3.6.2) Filling Water Containers

If the illuminated water indicators are showing either the static green orflashing green LEDs illuminated, the water can be filled simply byleaving the generator running and removing the top caps from thecontainers. Top up the containers with fresh deionised water to thedesired level ensuring not to exceed the maximum level shown in thewater level window. Replace the container caps securely.

3.6.3) Maintaining Non-Interrupted Operation

To ensure that the hydrogen generator runs continuously and toprevent alarm conditions occurring, regularly check the following:

Water quality

Water level

Desiccant cartridge

Flow indication LEDs


4 - SERVICE INSTRUCTIONS

4.1) Shutdown Procedure

If a service or fault finding procedure requires the generator to be shut down,it is imperative that the service shutdown instructions (also on page 10) arefollowed carefully.

Access within the equipment must be limited to suitably skilled andcompetent technicians.

1) Ensure that the application the generator is supplying no longerrequires gas.

2) Switch the generator off at the on/off switch, then isolate from mainssupply by removing the appliance connector from the appliance inlet.

3) Slowly depressurise the system. Watch the outlet pressure gauge onthe front of the generator. Once the gauge shows zero the valve can befully opened.

4) The generator is now shut down.

4.2) Maintenance Procedure - Replace Water

Draining Water Tanks

1) Place a water container of volume 4 litres or more in front of thegenerator at a lower level than that of the generator drain port shown.Open the door on the front of the generator and locate the drain fittingand tube supplied into the drain port. Push drain fitting securely intothe drain bulkhead to start draining the tanks.


3) Once the tanks are completely drained, push the button on the top ofthe bulkhead down to release the fitting and pull away.

4) Remove tube and fitting, dispose of drained water. DO NOT re-usedrained water.


Filling Water Tanks

1) Locate the front water tank cap that is at the top of the generator asshown.

2) Take your suitable de-ionised water (check specification on page4)and fill the container as shown in the diagram. While filling, look at the

water level window on the front of the generator door and fill to theFULL mark.

Note: The two water containers are joined in parallel internally and, therefore,when you have filled the front bottle to the top, the level will drop. Wait for thewater level to settle before filling again to the FULL mark. Repeat this untilthe level in both tanks is near the top.

3) Replace cap securely.


4.3) Maintenance Procedure - Deioniser Bag Change Installing Deioniser Bags

1) Remove both water tank caps. Take the two deioniser bags out of theirpackaging and push the locating ‘T’ piece through the hole in thecentre of each cap (one deioniser bag in each cap).

2) Pull locating ‘T’ fully through and hang bag onto the cap as shown.

3) Place one deioniser bag into each water container and replace capssecurely.


4.4) Maintenance Procedure - Desiccant Cartridge Change

Note: It is imperative that the service shutdown instructions are followedcarefully PRIOR to commencement of any maintenance procedures.

Ensure that the generator has been fully depressurised beforeproceeding.

Replacing Desiccant/Dryer Cartridge

1) Open the door on the front of the generator. Loosen the tubing nutfrom the top of the desiccant cartridge by turning anti-clockwise andpull the tubing free.

2) Repeat the process with the tube fitting at the bottom of the cartridge.


3) Pull cartridge free from the mounting clips.

Note: If you are changing the whole cartridge assembly, then go to point 10. 5) While holding the cartridge firmly and upright, remove one end by

turning the end cap anti-clockwise.

6) Completely remove end cap and keep in a safe place. Discard all ofthe used desiccant material. Do not regenerate the desiccant material.The cartridge housing is plastic and not suitable for regeneration.


7) Using a clean cloth, carefully wipe the inside of the cartridge to removeany dust. Remove the cap from the desiccant refill kit and slowly pourthe material into the cartridge.

8) Fill to the top but be careful not to over fill.

9) Replace cap firmly by turning clockwise. Ensure that the desiccantdoes not get trapped under the ‘O’ ring seal on the end cap. Ifdesiccant does get trapped, unscrew cap and remove some desiccant.Re-seal.


10) Push the cartridge forward to locate into mounting clips.

11) Re-connect the flexible tubing to the top and bottom fittings on thedesiccant cartridge.

12) The desiccant cartridge is now connected.


4.5) Restart Procedure

1) Ensure that any spare parts or covers have been replaced and fixedsecurely into position.

2) Reconnect pipework from the outlet of the recommended isolation shutoff valve to the application and turn valve to the closed position.

3) Reconnect mains supply to the back of the generator.

4) Switch ON using the on/off switch.

5) Once the green flashing system check LED illuminates continuously,the generator is ready to use.

6) Purge the system for 10 to 15 minutes to ensure purity and begin tosupply application with gas.


4.6) Service Record Log

Date Deioniser DesiccantChanged Bags Cartridge


5 - FAULT FINDING

5.1) Troubleshooting

Access within the equipment must be limited to suitably skilled andcompetent technicians.

Fault Found Probable cause RemedyDisplay will not illuminate • Wrong input voltage

• Fuse blown

• Power supply failure• On/Off switch failure

• Check mains voltage andserial number plate forvoltage spec.

• Check fuse, replace ifnecessary.

• Contact local distributor.• Check operation, order a

new one if necessary.LED failure on LED systemcheck

• LED failed • Contact local distributor foradvice.

Generator will not start up onsystem check

• EPROM failure • Contact local distributor foradvice.

Error 2Remote stopRemote stop fails to operate

• Input signal activated

• Volt free signal notactivated

• Remove input signal,replace jumper bar andpress reset.

• Check external electrics.

Error 3Water empty

• Water container empty

• Conductivity circuit fault

• Refill container to a suitablelevel with water specified.

• Check connections on watercontainers. Contact localdistributor for advice.

Error 5Up to pressure time out

• Internal leak

• Power supply fault

• Remove side panels andcheck all fittings with asuitable leak test fluid,tighten if necessary.

• Check outlet fitting for gason start up.

• Contact local distributor.Error 6Pressure decrease above limit

• Massive pressure loss • Check external pipework,repair if necessary.Remove side panels andcheck internal pipework.Contact local distributor ifnecessary.

Error 7Pressure leak above limit

• Internal leak

• Outlet valve leaking

• Remove side panels andcheck all fittings with asuitable leak test fluid,tighten if necessary.

• Check outlet fitting for gason start up. If leaking

• Contact local distributor forreplacement.


Fault Found Probable cause Remedy

Error 8Voltage too high

• Power supply fault • Contact local distributor foradvice.

Error 9Voltage too low


Error ACurrent too high


Error BCurrent too low


Error CConductivity too high

• Water quality not to spec

• Deioniser bags saturated

• Switch off, drain water fromcontainers and refill withnew supply.

• Remove bags fromcontainers and replace.

Error EEPROM or calibration fault

• Software fault • Contact local distributor foradvice.

Error FWatchdog

• Software fault • Contact local distributor foradvice.

Remote start/stop fails tooperate

• Volt free signal notactivated

• Check external electrics.

5.2) Displayed Errors

Error Message Cause Remedy

Err 2 Remote Stop Ref: 5.4.1Err 3 Water Empty Ref: 5.4.2

Err 5 Up to pressure time out Ref: 5.4.4Err 6 Pressure decrease above limit Ref: 5.4.5Err 7 Pressure leak above limit Ref: 5.4.6Err 8 Voltage too high Ref: 5.4.7Err 9 Voltage too low Ref: 5.4.8Err A Current too high Ref: 5.4.9Err B Current too low Ref: 5.4.10Err C Conductivity too high Ref: 5.4.11Err E Eprom or calibration fault Ref: 5.4.13Err F Watchdog Ref: 5.4.14


5.3) Alarm Modes

If an alarm condition occurs, the electronic display on the front of thegenerator will show “Err” followed by a number or letter. With every alarmcondition there will be an audible alarm at different frequencies. The higherthe frequency, the more urgent the alarm condition will be.

Although under most alarm conditions the generator will stop producing gas, itis important that the fault is looked into promptly and thoroughly to preventimmediate or long-term damage to the generator. Persistent alarm conditionsshould be reported to the place of purchase immediately for advice.

5.4) Errors and their Meanings

In all alarm conditions, the ALARM LED will be illuminated. Where referenceis made in italics to an alarm symbol, please refer to the External Instrumentsand Connections diagram, section 2.1 pages 11 and 12.

5.4.1) Err 2 - Remote Stop

At the rear of the generator is a connection, which allows a volt-freesignal to be used to automatically shut down the generator. When thisoccurs, a low frequency audible alarm sounds, “Err 2” is displayed andthe production of hydrogen gas stops. Note: the Remote Stop LEDilluminates. To activate the remote stop function, open the volt-freecontacts. Before the generator can be restarted the contacts must beclosed. To re-set this alarm condition, remove the volt-free signal from the backof the generator and either press the re-set button or switch thegenerator off and then back on again.

5.4.2) Err 3 - Water Empty

Although there is a visual display on the front of the generator showingthe level of water, there is also a sensor to detect the water level. Ifthis level drops below the permitted level to produce hydrogen withoutdamaging the unit, then Err 3 is displayed and an audible alarmsounds. Note: the Water Empty LED illuminates.

To re-set this alarm condition, refill the water containers to the refill orfull marks. Once the water is to a suitable level, the generator willautomatically restart and will go into the re-start mode.


5.4.4) Err 5 - Up to pressure time out

When the generator is in start-up phase it has a set time to reach themaximum pressure of 7.2 bar g. If the generator does not reachpressure in the allotted time, then Err 5 will be displayed, the ALARMLED will illuminate and a high frequency audible alarm will sound.

This alarm condition will occur if there is a leak internally or if the outlet

shut-off valve is passing gas. It is also possible that the current/flowcould be low which can be seen on the Flow Display LEDs on thefront of the unit. To locate a leak, remove side panels and use asuitable leak testing fluid on the push-in and Swagelok fittings. If aleak is found, tighten carefully with a suitable spanner. If gas is leakingout of the outlet on start-up while the system check LED isilluminated, contact local distributor or domnick hunter forreplacement part. If the fault is caused by low current/flow on start-up,it may be caused by a power supply fault. If this occurs, contact localdistributor or domnick hunter direct for replacement part.

5.4.5) Err 6 - Pressure decrease above limit

This is a safety alarm condition that occurs if there is a break in thepipework, either internally or externally, which results in rapid pressureloss. When this alarm condition occurs, the Alarm and MaintenanceLEDs are illuminated, a high frequency audible alarm sounds and theproduction of hydrogen stops.

If this occurs, check external pipework first and repair any leaks

immediately, then check internal pipework and fittings by removing sidepanels and checking for faults. If an internal fault is found, report itimmediately to your local distributor or domnick hunter direct foradvice and replacement part.


5.4.6) Err 7 - Pressure leak above limit At the end of the start-up procedure, before the outlet valve opens, a

system leak check takes place for 2.5 seconds. At this time, productionof hydrogen stops and the internal pressure is monitored. If thepressure loss over the 2.5 second check is more than the set limit thenthe alarm is activated. At this time Err 7 is displayed, the Alarm andMaintenance LEDs are illuminated and a high frequency audiblealarm sounds.

As this condition can only occur on start-up, the two causes of this arean internal leak or the outlet valve is leaking. To remedy this problem,remove the side panels and use a suitable leak test fluid to check allpush-in and Swagelok fittings. If a leak is found, tighten the fittingcarefully with a suitable spanner or if the push-in fitting is leaking,remove and re-cut the end with a tube cutter before re-fitting.

5.4.7) Err 8 - Voltage too high

This alarm condition protects the process within the generator fromhigh voltage. When this occurs, the Alarm and Maintenance LEDsilluminate and production of hydrogen stops.

If this fault occurs, do not attempt to re-start the generator in case ofdamage. Contact your local distributor or domnick hunter direct foradvice and replacement part.

5.4.8) Err 9 – Voltage too low

This alarm condition protects the process within the generator from lowvoltage. When this occurs, the Alarm and Maintenance LEDsilluminate and the production of hydrogen stops.

If this fault occurs, do not attempt to re-start the generator in case of

damage.

Contact your local distributor or domnick hunter direct for advice andreplacement part.

5.4.9) Err A - Current too high

This alarm condition protects the process within the generator fromhigh current. When this occurs, the Alarm and Maintenance LEDsilluminate and the production of hydrogen stops.

If this fault occurs do not attempt to re-start the generator in case ofdamage. Contact your local distributor or domnick hunter direct foradvice and replacement part.


5.4.10) Err B - Current too low

This alarm condition protects the process within the generator from lowcurrent. When this occurs, the Alarm and Maintenance LEDsilluminate and the production of hydrogen stops.

If this fault occurs, do not attempt to re-start the generator in case of

damage. Contact your local distributor or domnick hunter direct foradvice and replacement part.

5.4.11) Err C - Conductivity too high

The generator monitors the quality of deionised water that is fed intothe system. If the water is not to the minimum quality domnick hunterrecommends, the life of the electrolytic cell could be reduced. Thesystem is also able to record the number of times the generator hasbeen into a ‘conductivity too high’ alarm. This can be down loaded andviewed by domnick hunter engineers. This information could be usedin a warranty claim situation where it is evident that the water fed intothe system had been of consistently poor quality.

To prevent a conductivity alarm, monitor the indicators on the front ofthe generator and replace deioniser bags when necessary. If the unitshows an alarm condition, the Alarm LED will illuminate, theproduction of hydrogen stops, and all the Conductivity indicators willbe illuminated.

To remedy this, isolate the generator from the mains supply, drain allthe water from the unit through the drain port and flush and refill withgood quality water. If the indicators still light, check the quality of thewater being used.

5.4.12) Err E - EEPROM or calibration fault

The EEPROM holds the software that calibrates all the necessaryinternal parts. If the software and memory are unable to read thesystem’s operation, the generator will go into alarm. When thishappens, Alarm and Maintenance LEDs are illuminated, a lowfrequency audible alarm sounds and the production of hydrogen stops.If this occurs, contact your local distributor or domnick hunter directfor advice and a replacement part.


5.4.13) Err F – Watchdog The Watchdog monitors the system’s electronic operation and will shut

down the generator if an internal fault occurs with software.

If this occurs, do not attempt to re-start the generator in case ofdamage to other parts of the generator. In an alarm condition, theAlarm and Maintenance LEDs will be illuminated, a low frequencyaudible alarm will sound and the production of hydrogen will stop.Switch the generator off and contact your local distributor or domnickhunter direct for advice.

If the unit needs to be returned to domnick hunter for any reason, youmust drain all the water from the tanks and remove deioniser bags. Theunit must be properly packed and shipped in an upright positioncomplete with mains cable and deioniser bags.


6 - EXTERNAL CONNECTIONS

Rear Panel External SELV Connections

6.1) Remote Start/Stop

The remote start/stop function is an additional feature fitted as standard to thegenerator. This feature allows the user to shut the generator down remotelyat a specific time or following a specific event, and then restart the systemautomatically.

The terminal board features two inputs (Stop, Hold) and two outputs (Alarm,Water Fill).

There is also a link arrangement which, if set, will either stop or temporarilyhalt production upon the alarm output being actuated.

6.1.1) Inputs 1&2 and 3&4

The inputs are provided for users who wish to remotely control theoperation of the generator.

RemoteStart/Stop

Connections1 2 3 4

Alarm OutConnections

1 2 3

Water FillConnections

1 2 3

Auto – RemoteSelection Links


The inputs are suitable only for connection to volt-free contacts (15 mA,12V DC rated) for example normally open push-button contacts, ornormally open relay contacts available in some other relatedequipment.

If either input is activated, then the front panel Remote Start/Stop LEDwill illuminate.

If remote operation is not required then no connection should be madeto the inputs.

6.1.2) Production – Stop (1&2)

Connecting input terminals 1 and 2 together via a remote push buttonor relay will stop Hydrogen production. This is a latched condition.The remote push button must be released and the front panel resetbutton must be operated to restart production.

6.1.3) Production – Hold (3&4)

Connecting input terminals 3 and 4 together via a remote push buttonor relay will cause Hydrogen production to “pause” whilst theconnection is made. Once the remote connection is broken productionwill recommence.

6.2) Outputs

The outputs are provided for those users who wish to connect externalequipment to the generator to monitor operation and/or to provide anautomatic water replenishment scheme.

The outputs consist of single pole change over relay contact outputsrated at 10A max. – for connection to SELV systems only:

Maximum 30V r.m.s. or 42.4V peak or 60 V d.c.

The legend on the terminal board shows the state of the contacts whenthe unit is powered off.

6.2.1) Alarm Out (1&2&3)

When the unit is powered up, and there is no alarm, the alarm relay isenergised so that 1&2 are connected. When the unit is either off orpowered up and in alarm then 1&3 are connected.


Example:

The user requires a remote bell to sound if the generator enters analarm condition. The remote bell power supply and bell is connected toAlarm Out terminals 1 and 3. On entering an alarm condition or losingmains power the relay will switch, connecting Alarm Out terminals 1and 3, completing the circuit and sounding the remote bell.

6.2.2) Water Fill (1&2&3)

When the unit is powered up and the water level is below “Full” thenthe Water Fill relay is energised and 1&2 are connected. If the waterlevel is “Full” or the unit is switched off then 1&3 are connected.

Example:

The user has a low voltage water pump for transferring deionised waterto the water reservoir. The low voltage supply and pump circuit iswired to Water Fill terminals 1 and 2. When the water level dropsbelow the full sensor the relay will pull in and connect Water Fillterminals 1 and 2 together, completing the circuit and operating thepump. Once the water full sensor is covered with water the relay willdrop out and stop the pump. A minimum on time is employed to ensurethat the relay does not constantly turn on and off.

6.2.3) Auto - Remote Select

The link arrangement allows the alarm output to automatically Stop orhold off production.

To enable this function the link for the required operation is fittedhorizontally using the centre socket, either Stop or Hold. Once fitted, ifthe unit goes into alarm then production will cease. Depending uponwhich link was placed in the auto position, production will either startagain once the alarm has been cleared (Hold) or the reset button onthe front panel will require actuation (Stop).

Placing a link in the auto position disconnects the associated remoteterminals. i.e. If the Stop link is put in Auto mode then connectingterminals 1&2 will have no effect.


7 - INSTALLATION ERRORS

7.1) General

• Failure to observe recommended actions in this manual causing thewarranty to be invalidated

• Insufficient ventilation around the generator causing heat build-up

• Use of non-genuine or non-recommended domnick hunter spare parts

• The application requires more gas than can be supplied by the generatorwhich means the wrong generator has been requested or the generator isbeing used for too many applications at the same time

• Leaks on external hydrogen pipework causing decreased performance

• Use of poor quality deionised water 7.2) Outlet Connection

• Use of porous or ferrous pipework allowing ingress of oxygen

• Outlet pipe diameter incorrect

7.3) Electrical

• Incorrect supply cable other than that supplied causing over heating andpotential fire risk

• Lack of suitable earth connection causing potential electric shock risk

• Incorrect mains voltage other than that given on the serial number plate,causing the generator to malfunction


8- WARRANTY

This warranty applies to HYDROGEN GENERATORS and associated parts (theEquipment) manufactured and supplied by domnick hunter ltd (domnick hunter).

Use of the HYDROGEN GENERATORS without the recommended water quality(see page 4) or genuine parts will expressly invalidate the warranty. It should also benoted that the Hydrogen generator must be installed and running within threemonths of despatch from domnick hunter limited, to ensure the optimum efficiencyof the SPE cell. If this is not adhered to this will invalidate the warranty.

Should the Equipment be defective as to materials or workmanship, domnick hunterwarrants that it will remedy such defect. Where the Equipment is a HYDROGENGENERATOR, the warranty period will be 12 months from date of commissioning or18 months from date of manufacture, whichever is the earlier. In the case ofEquipment other than a HYDROGEN GENERATOR the warranty period shallcommence from the date of despatch. Should any defect occur during the warrantyperiod and be notified in writing to domnick hunter or its authorised distributorwithin the said period, domnick hunter will, as its sole option, remedy such defectby repair or provision of a replacement part, provided that the Equipment has beenused strictly in accordance with the instructions provided with each item ofEquipment and has been stored, installed, commissioned, operated and maintainedin accordance with such instruction and with good practice. domnick hunter shallnot be under any liability whatsoever under the warranty, if, before giving notificationin writing to domnick hunter as aforesaid, the Customer or any third party meddles,interferes, tampers with or carries out work whatsoever (apart from normalmaintenance as specified in the said instructions) in relation to the Equipment or anypart thereof.

Any accessories, parts and equipment supplied by domnick hunter but notmanufactured by domnick hunter shall carry whatever warranty the manufacturerhas given domnick hunter providing it is possible for domnick hunter to pass onsuch warranty to the customer.

To claim under the warranty, the goods must have been installed and continuouslymaintained in the manner specified in the ICOM. Our product support engineers arequalified and equipped to assist you in this respect. They are also available to makerepairs that may become necessary in which event they will require an official orderbefore carrying out the work. If such work is to be the subject of a warranty claim,the order should be endorsed for consideration under warranty.

Where Equipment is sold outside the UK mainland direct to the end user thewarranty will cover parts only. Any substitution of parts not manufactured orapproved by domnick hunter will expressly invalidate the warranty.


9 – DECLARATION OF CONFORMITY

DECLARATION OF CONFORMITY

98/37/EC 89/336/EEC 73/23/EEC

Name of manufacturer or supplier:

domnick hunter ltd

Address:

Dukesway, Team Valley Trading Estate, Gateshead,

Tyne and Wear, England, NE11 0PZ

Description of Product: Laboratory Hydrogen Generator

Model Number

UHP-20H UHP-40H UHP-60H

Place of issue:

GATESHEAD, TYNE AND WEAR, ENGLAND

Name of authorised representative:

DAVID KEAY

Position of authorised representative:

MANAGING DIRECTOR (GAS GENERATION DIVISION)

Declaration:

I declare that, as the authorised representative, the above

information in relation to the supply/manufacture of this product is in

conformity with the standards and other related documents following

the provisions of the 98/37/EC, 89/336/EEC, 73/23/EEC directives.

Signature of

authorised representative

a member of the domnick hunter group plc

pure innovation


10 – NOTES


11 – CONTACT ADDRESSES

domnick hunter pty ltdBoronia Victoria AustraliaTel: +61 (0)3 9762 9922Telefax: +61 (0)3 9762 9911

domnick hunter Canada incOntario CanadaTel: +1 905 820 7146Telefax: +1 905 820 5463

domnick hunter (China) Beijing OfficeBeijing ChinaTel: +86 10 646 33523Telefax: +86 10 646 33521

domnick hunter (China) Shanghai OfficeShanghai ChinaTel: +86 21 6294 7792Telefax: +86 21 628 38311

domnick hunter SkandinaviaSlangerup DenmarkTel: +45 (0)47 38 0644Telefax: +45 (0)47 38 0643

domnick hunter France SAVillefranche sur Saône FranceTel: +33 (0)4 74 62 34 51Telefax: +33 (0)4 74 62 35 44

domnick hunter GmbHKrefeld GermanyTel: +49 (0)2151 83660Telefax: +49 (0)2151 395779

PT domnick hunter IndonesiaJakarta 14240 IndonesiaTel: +62 21 458 40488Telefax: +62 21 452 4323

domnick hunter NihonKobe JapanTel: +81 (0)78 391 8055Telefax: +81 (0)78 391 8056

domnick hunter NihonYokohama JapanTel: +81 (0)45 250 1522Telefax: +81 (0)45 250 1523

domnick hunter-RL (Malaysia) SDN BHDPetaling Jaya MalaysiaTel: +60 3 733 3415Telefax: +60 3 735 1699

domnick hunter Group Pte LtdSingaporeTel: +65 744 4088Telefax: +65 744 9959

domnick hunter IbericaBarcelona SpainTel: +34 (0)93 351 4807Telefax: +34 (0)93 351 7102

domnick hunter SweTec ABGothenburg SwedenTel: +46 (0)31 748 0610Telefax: +46 (0)31 748 0621

domnick hunter-RL (Thailand) Co LtdBangkok ThailandTel: +66 2 255 5305-8Telefax: +66 2 255 5340

domnick hunter LtdGateshead EnglandTel: +44 (0)191 402 9000Telefax: +44 (0)191 497 1216e-mail: [email protected] site: www.domnickhunter.com

domnick hunter incCharlotte NC 28269 USATel: +1 704 921 9303Telefax: +1 704 921 1960Toll Free: +1 800 345 8462Web site: www.domnickhunter.com

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