Hydrogen Generator Model HPNM‐1

Instruction manual

166 Keystone Drive

Montgomeryville, PA 18936
Phone: 215-641-2700
Fax: 215-641-2714
Hydrogen Generator Instruction Manual Introduction

Index

INDEX ................................................................................................................................................................... 2

INTRODUCTION................................................................................................................................................. 3
SCOPE OF THE MANUAL ....................................................................................................................................... 3
SPECIFICATIONS .................................................................................................................................................. 3
NOTES ON FCC COMPLIANCE .............................................................................................................................. 4
CORRECT USE ...................................................................................................................................................... 4
PACKING LIST...................................................................................................................................................... 5
DESCRIPTION..................................................................................................................................................... 6

INSTALLATION.................................................................................................................................................. 7
RECEIVING THE GENERATOR ............................................................................................................................... 7
PLACING THE GENERATOR................................................................................................................................... 7
SYMBOLS USED ON THE GENERATOR ................................................................................................................... 7
GAS CONNECTIONS.............................................................................................................................................. 7
ELECTRICAL CONNECTIONS ................................................................................................................................. 8
REMOTE CONNECTIONS (OPTIONAL).................................................................................................................... 8
CASCADING (OPTION) ......................................................................................................................................... 9
INITIAL START-UP.......................................................................................................................................... 10
FILLING THE WATER TANK ................................................................................................................................ 10
INSTALLING THE DEIONIZER BAG ...................................................................................................................... 11
OPERATION ....................................................................................................................................................... 12
MAINTENANCE................................................................................................................................................ 16
ROUTINE MAINTENANCE ................................................................................................................................... 16
RETURNING THE UNIT........................................................................................................................................ 16
SPARE PARTS LIST ......................................................................................................................................... 17

Model HPNM-1 2
Hydrogen Generator Instruction Manual Introduction

Introduction

Scope of the manual

This manual provides operation and maintenance instructions for the following Chrysalis II
HPNM Models: HYC-HPNM-100, HYC-HPNM-160, HYC-HPNM-250 and HYC-HPNM-500
hydrogen generators.

Specifications

Table 1 Specifications of the different models of hydrogen generator

Hydrogen flow rate Model HPNM-100 0-100 cc/min at STP

Model HPNM-160 0-160 cc/min at STP
Model HPNM-250 0-250 cc/min at STP
Model HPNM-500 0-500 cc/min at STP
STP Standard temperature and pressure (STP)
68°F & 90 psig
Weight (dry) 42 lbs.

Power consumption Model HPNM-100 90VA

Model HPNM-160 115VA
Model HPNM-250 160VA
Model HPNM-500 300VA
Input voltage 110-230V / 50-60Hz
Fuse 4A (5x20)
Pressure accuracy 1.5 psig (± 0.5 %)
Microprocessor controlled display Graphic display, 128 x 256 pixels
Index of protection IP2x
Operating conditions:
- Temperature 59°F to +95°F
- Relative humidity 0-80% @ 87°F, decreasing linearly to 50% @ 95°F
-Max Altitude 6,890 ft
Over voltage category II
Pollution degree 2
Sound pressure level 46 dBA
Case dimensions 8.6”W x 9.5”L x 16”H

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Hydrogen Generator Instruction Manual Introduction

Notes on FCC compliance

This equipment has been tested and found to comply with the limits for a Class B digital
device, pursuant to part 15 of the FCC Rules. These limits are designed to provide
reasonable protection against harmful interference in a residential installation. This
equipment generates, uses and can radiate radio frequency energy and, if not installed and
used in accordance with the instructions, may cause harmful interference to radio
communications. However, there is no guarantee that interference will not occur in a
particular installation.

If this equipment does cause harmful interference to radio or television reception, which can
be determined by turning the equipment off and on, the user is encouraged to try to correct
the interference by one or more of the following measures:
• Reorient or relocate the receiving antenna.
• Increase the separation between the equipment and receiver.
• Connect the equipment into an outlet on a circuit different from that to which the re-
ceiver is connected.
• Consult the dealer or an experienced radio/TV technician for help.

WARNING!
Any changes or modifications to this equipment not expressly approved by the manufac-
turer may void the user's authority to operate the equipment.

Correct use
The Matheson Tri-Gas Chrysalis II HPNM hydrogen generator is designed to produce
hydrogen for laboratory use. The unit must only be operated for this purpose, according to
the specifications and instructions provided in this manual. In particular, the following
warnings must be observed at all times:
• Indoor use only
• Never operate the unit in freezing temperatures. This will cause irreversible damage to
the electrolysis cell.
• Only use pure water (see “Filling the water tank”)
• Only operate the unit in a room with sufficient ventilation (see “Placing the unit”).
• Always unplug the unit from the main power supply before accessing the internal
components for replacement.
• Only the parts described in the “Spare parts list” can be replaced by the user.

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Hydrogen Generator Instruction Manual Introduction

Packing list

Table 2 List of items included in the shipment

Quantity Description

1 Hydrogen generator
1 Instruction manual
1 Deionizer bag
1 Water drain with flexible tubing
1 Power cable

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Hydrogen Generator Instruction Manual Installation

Description

The hydrogen generator produces pure hydrogen (and oxygen as a by-product) by the
electrolysis of water. The key element of the generator is an electrochemical cell assembly
which contains a solid polymer electrolyte. No free acids or alkalines are used. De-ionized or
pure, distilled water is the only liquid which may come into contact with the cell. As this is
consumed it must be refilled from time to time as required.

The generated hydrogen gas is accumulated in the hydrogen/water separator and the
desiccant housing. The pressure is controlled by a pressure transducer. The outlet pressure
is indicated on the display. The hydrogen is dried by passing it through a drying tube and the
automatic dryer. The hydrogen then passes through outlet port at the rear.

Low Pressure Hydrogen

Drying Tube Pressure
Gas/Liquid Relief
Hydrogen Vent
Separator

High Pressure

Gas/Liquid
Separator
Water
Tank Automatic
Dryer

Gas/Liquid
Separator

O2 Vent
Hydrogen
Pressure
Outlet
Hydrogen Sensor
Cell

Drain Port

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Hydrogen Generator Instruction Manual Installation

Installation

Receiving the generator

All units have been carefully inspected before transport. Visual checks for damage and
functional tests should be performed upon receipt. Any damage must be immediately noted
and reported. The generator must only be returned according to the shipping instructions
provided.

Placing the generator

The hydrogen generator must be placed on a flat, level, vibration-free, shock-free surface.
Do not place the generator over a source of heat, as this may cause the device to overheat.
The unit should not be in contact with any other objects on any side, and the air inlet must
not be blocked. Leave at least 12” cm of free space at the rear for ventilation. Do not
operate the generator in a sealed or unventilated room, or in close proximity to open flame or
other sources of ignition. Do not operate the generator at below freezing temperatures.
Operation is guaranteed at operating temperatures between 45 and 95°F.

WARNING!
Normal precautions for any hydrogen supply should be taken when using the generator.
DO NOT use in sealed or unventilated rooms. DO NOT use in close proximity of open
flames or other sources of ignition.

Symbols used on the generator

Earth symbol:
This symbol marks the earth connections to the chassis of the
hydrogen generator.

Gas connections
Pure dry hydrogen at regulated pressure is available at the hydrogen outlet port at the rear of
the generator. This port must be connected to 1/8" tubing using a stainless-steel or copper
Swagelok connector. Teflon connectors are not suitable. The pressure at this port is adjusted
and shown on the display. The hydrogen relief port at the rear of the unit can be connected
to an exhaust hood or other vent system.

WARNING!
The line from the relief port should never connect in such a way that back pressure can de-
velop.

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Hydrogen Generator Instruction Manual Installation

IMPORTANT!
Remove the plugs from the oxygen vent and
hydrogen vent before operating the unit.

Keep these plugs for transporting the unit.

Electrical connections
Check the setting of the voltage selector on the rear of the unit. The set voltage is indicated
by the white arrow. To change the voltage, proceed as follows:
• Using a small screwdriver, remove the voltage selector insert.
• Replace the voltage selector insert so that the white arrow points to the correct voltage.

Remote connections (optional)

The hydrogen generators are fitted with an optional remote control feature, which allows the
user to check the status of the machine from a remote position, and to start/stop the
production of hydrogen.

The contacts used in the remote control are potentially free relay contacts. The contacts can
be configured via software as normally-open or normally-closed (see the Configuration
section). The maximum voltage and current ratings for the contacts are 1A / 48V. The pin
configuration of the remote connector is shown in the table below.

Table 3 Remote connector pin configuration

Pin Description
1+2 Start (12-30 VDC polarity not important)
3+4 Standby (System not OK)
5+6 Reaching normal pressure (Overproduction)
7+8 Refill water (Low water)
09+10 Low water level (Too low water)
11+12 Bad water
13+14 Change water (Bad water pre alarm)

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Hydrogen Generator Instruction Manual Operation

Cascading (Option)
The RS-485 interface allows up to 10 generators to be operated in parallel mode. One unit
has to be defined as the master, while the others operate in “Slave” mode. All the slaves
need to be configured with individual ID numbers. Communication between the generators
requires a standard D-sub 9 pin serial cable. The serial ports are connected as follows:

Master RS 485 port 1 Î Slave 1 RS 485 port 1 - Slave 1 RS 485 port 2 Î Slave 2 RS 485
port 2 ………

Configuration

For operation in cascading mode all generators must have an ID number. Each ID number is
unique. The master unit must also have an ID number.

Configuring the Master

1. Go into the configure menu and set the master to NO.
2. Go into the number of slaves menu and set the number off units connected to the
master.
3. Go into slave ID number and set the desired value.
4. Go back to master and set the value to yes

Configuring the Slaves

1. Go into the configure menu and set the master to NO.
2. Go into slave ID number and set the desired value.

The configuration is now complete.

Operating in Master-Slave Mode

If the configuration and the serial connection are correct, the slaves will show “Slave Mode“
when powered up.

Connect the gas outlets of all the generators to the same line.

IMPORTANT!
The cascading function will only work properly if the gas outlets on all the genera-
tors are connected to the same gas line.

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Hydrogen Generator Instruction Manual Operation

Initial start-up

Filling the Deionized Water Reservoir (Tank)

To fill the hydrogen generator with deionized water, remove the “black” plug under the sliding
arm at the top of the unit. Carefully fill the tank with deionized water to within ½” of the
“MAX” level indicator located at the sight glass on the front of the hydrogen generator. Move
the sliding arm to close the opening of the tank.

The conductivity of the water used in the generator must not exceed 2µS.

WARNING!
Do not fill the water tank higher than the marked ”max” level.

CAUTION!
To prevent contamination of the cell assembly, it is important to use only deionized water
in the generator. Water containing metallic impurities will contaminate or damage the cell,
and will void the warranty.

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Hydrogen Generator Instruction Manual Operation

Installing the deionizer bag

After having filled the tank with water, the deionizer bag (supplied) must be placed in the
tank. Inspect the bag thoroughly for holes or tears, indicated by loose deionizer beads on the
outer surface. If the bag is damaged in any way, discard and replace it with a new one. Only
use original parts (see Spare Parts). Wash the deionizer bag in deionized water before
proceeding.

Insert the free end of the “T” fastener through the hole in the centre of the water filler cap,
until it is securely fastened. The bag should not block the outlet at the bottom of the tank.
Once in place, the bag should not be allowed to dry out.

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Hydrogen Generator Instruction Manual Operation

Operation
The operating status of the unit is shown on the main screen on the graphic display.
The main screen has three options at the bottom, corresponding to the three buttons on the
unit, which are used to run the various functions and access the configuration and diagnos-
tics of the unit, following the tree structure shown in the figure below.
Status: Normal Flow
Press act: 6.2 set: 6.2 Bar
Flow
Water
Start Open Menu

Menu
Pressure adjust
Configure
Utilities
Scroll Select Exit

Pressure Adjust Configure Utilities

Pressure units Alarm list
6.2 Bar Volume units
Temp units
Diagnostics
Special functions
Exit Scroll Select Exit Scroll Select Exit

Pressure units Alarm list Diagnostics Special Functions

Select Volume units
Alarm Number: 1 Prod. Tot. : 10000 scm Dryer
Temp units
21.01.03 17:00 Oper. time : 100 H Leak Test
Pressure Rise
Pressure units Low water W. Quality: 2.5 uS Complete system test
Pressure drop delay
Auto start Exit Exit Scroll Select Exit
Bar Beeper
Master
Exit Number of slaves
Slave ID number Prod. Tot. : 10000 scm
Remote start /stop mode Oper. time : 100 H Dryer
Remote relay mode W. Quality: 2.5 uS Leak Test
Volume units
Pre alarms in alarm list Cell Volt. : 3.6 V Complete system test
Lock keyboard Cell Curr. : 33 A Toggle valve
scm Display contrast Cell Vpeak: 3.8 V
PS Temp: 40°C
Set clock

Exit PS Temp peak : 45°C

Select

Temp units Master Dryer Status Dryer

°C
Dryer Status
No
Temp col 1 : 80°C
Temp col 2 : 25 °C Select Dryer conditioning
Cycle time : 480 min Heater test
Exit Exit Exit Scroll Select Exit

Number of slaves Dryer conditioning

Pressure rise Leak Test
Time : 15000 s

0.1 Bar/min 3
Time remaining : 0s Leak test: Stop
Temp Col. 1 : 80 °C
Temp Col. 2 : 25 °C
Press Act. : 6.0 Bar
Start Stop Exit
Exit Exit Start Stop Exit

Heater test
Pressure drop delay Slave ID number Heater 1: Stop Complet system test
Heater 2: Stop Leak test: Stop
60 s ID: 1 Start Stop Exit
Heater 1: Stop
Heater 2: Stop
Exit Exit Start Stop Exit

Auto start Remote start/stop mode Pre alarms in alarm list Toggle valve
V1: open
Off Start/Stop Yes V2:
V3:
V4:
close
open
close
Exit Exit Exit Scroll Off Exit

Beeper Remote relay mode Lock Keybord Display contrast

Off Normaly closed No 5

Exit Exit Exit Exit

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Hydrogen Generator Instruction Manual Operation

Figure 1 Menu tree for the operation of the unit

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Hydrogen Generator Instruction Manual Operation

Configuration parameters

Item Description Options / Range Default

Pressure units Sets the desired unit of measure for bar / psi / kPa bar
the pressure
Volume units Sets the desired unit of measure for scm (standard cubic meters) scm
the volume scf (standard cubic feet)
Temp. units Sets the desired unit of measure for °C and °F °C
the temperature
Pressure rise Sets how fast the pressure has to in- 0.1 - 1 bar/min 0.1
crease. If the pressure increases at a 1.4 - 14 psi/min 1.4
slower rate, a low pressure alarm is
activated.
Pressure drop Sets a delay in seconds to ignore a 0 - 60 s 60
delay pressure drop (override low pressure
alarm)
Auto start Sets whether the unit automatically YES / NO NO
starts production when power is
switched on.
Beeper Sets whether the audible signal is ac- ON / OFF ON
tivated in the event of an alarm.
Master Configures the unit as the Master for YES / NO NO
cascading operation
Number of Enter the number of slaves con- 0 - 32 0
slaves nected to the master
Slave ID num- Sets the slave ID number 0 - 32 0
ber
Remote Configures the remote start/stop Start/stop, Start only, Direct start/stop
start/stop mode function control
Remote relay Configures the remote relay con- Normally open (NO) NC
mode tacts. Normally closed (NC)
Pre alarms in If set to Yes, the pre alarms are also YES / NO NO
alarm log shown in the alarm log.
Lock Keyboard If set to Yes, the keyboard will be YES / NO NO
locked automatically after the gen-
erator is in the main window for more
than 20s. To unlock the keyboard,
press the unlock button and hold for
5s.
Display contrast Adjusts the contrast of the display. 0 - 10 5

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Hydrogen Generator Instruction Manual Operation

Diagnostic display

Item Description Max.

Production Tot. Total production of hydrogen 99.999 scf
4000.00 scm
Operating time (h) Total number of hours the unit operation 99.999 hours
Wat. quality (µS) Actual water conductivity -
Cell current (A) Actual cell current -
Cell voltage (V) Actual cell voltage -
Cell voltage peak (V) The maximum cell voltage in the life of the cell -
PS. temp. (°C) Actual temperature of the power supply -
PS. temp. peak (°C) The maximum temperature of the power supply -
reached

Special functions

Item Description
Dryer Accesses the dryer functions (see below)
Dryer status Shows the temperatures of the drying columns and the position of the
cycle
Conditioning When the conditioning cycle is started, the dryer performs 4 fast cy-
cles. During this time the output valve is closed.
Heater test The heater has to show a reaction of 10°C to pass the test
Leak test The outlet valve is closed, the pressure is set to the max., when the
pressure reaches the max., production is stopped and the pressure
drop is measured over 1 minute. If the pressure drop is below the
preset value, the test is passed.
Important: The leak test will only work if the generator is in standby
mode.
Complete system test Combination of leak test and heater test
Toggle Valve Used to switch the valves manually ( for advanced diagnostics only)
Important : after exiting this window, the valves will return to the
status prior to entering the window

Normal Display

Item Description
Start/Stop Starts/Stops the production of hydrogen
Open/Close Opens/Closes the hydrogen supply valve
Menu Accesses the “Pressure Adjust”, “Configure” and “Utilities” menus

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Hydrogen Generator Instruction Manual Maintenance

Maintenance

With proper care and maintenance, your hydrogen generator should provide you with years
of trouble-free operation. There are no adjustments to be made to the generator. The only
routine service operations are those described below.

Nonetheless, the generator should be inspected approximately every 2 years. Contact your
supplier or Matheson Tri-Gas directly.

Routine maintenance
The following section describes the maintenance operations required for the correct
operation of the hydrogen generator.

Cleaning
The internal components of the hydrogen generator do not need to be cleaned and should
not be accessed by the user for cleaning. To clean the outside of the unit, only use a damp
cloth (no detergents, acids or aggressive or abrasive substances.

Water refilling
The tank must be refilled when the water level approaches the lower level, and the Refill
Water pre-alarm message appears.

Deionizer bag replacement

Rinse the water tank and replace the deionizer bag approximately every six months, or
whenever the Change Water message appears.

Installing the new deionizer bag

See page 11 (see Installing the deionizer bag)
Returning the unit
In the event of any faults or damage, first notify the agent or distributor who supplied the unit.
If this is not possible, inform Matheson Tri-Gas directly. Please also provide full details of the
problem, including the model and serial number. Instructions will then be provided for the
service or the return of the unit. Only if return authorization is provided by Matheson Tri-Gas
as per these instructions, will the device be received and repaired by Matheson Tri-Gas. If
the one year warranty has expired, or the fault is due to misuse of the unit, all repair and
shipping costs are to be paid by the customer. All other costs are borne by the customer,
except as otherwise expressly agreed upon.

WARNING!
If the unit has to be transported, make sure that the water tank is completely empty, and
place the plug (supplied with the unit) on the oxygen vent at the rear of the unit. Close the
water tank with the cap. Use suitable packaging.
The unit should be transported in an upright position; this warning should be reported on
the outside of the packaging.

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Hydrogen Generator Instruction Manual Maintenance

Spare parts list

The table below provides a list and description of the replaceable parts of the hydrogen gen-
erator. Please also refer to the corresponding figures.

Table 4 List of replaceable spare parts

Part Number Description

DI-BAG Deionizer bag

IMPORTANT!
The manufacturer reserves the right to change or modify its products without prior notice.

Model HPNM-1 17