Manual Hidrigeneradora

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PEM ElectrolyzerHylyzer Hydrogen Generator

Hylyzer Hydrogen Generator Installation, Operation and Maintenance Manual

Revision 3This 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

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PEM ElectrolyzerHylyzer Hydrogen Generator

Hylyzer Hydrogen Generator Installation, Operation and Maintenance ManualRevision 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.

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Revision History

Warranties and LiabilitiesGuarantees, 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 Hydro-genics Corporation reserves the right to revise the included information at any time, without notice.

Patents, Trademarks and Proprietary RightsThis 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 Corpo-ration 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 CorporationHydrogenics Corporation is a leading global developer of clean energy solutions, advancing the Hydro-gen Economy by commercializing hydrogen and fuel cell products. The company has a portfolio of prod-ucts and capabilities to serve the hydrogen and energy markets of today and tomorrow.

Contact Information:220 Admiral BoulevardMississauga, 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

REV. LEVEL

CHANGE DESCRIPTION DATE

2 Initial Release 14 December 2010

3 Installation, Operation, Maintenance and Troubleshooting sections expanded

12 July 2011

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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

Revision 3 HYDROGENICS CORPORATION v


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


6.2.3.3 Leak Check Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 36

6.2.4 Check/Clean Radiator and Ventilation Fans . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

6.2.4.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37


6.2.4.3 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


6.2.5.3 Hydrogen Gas Detector Check Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

6.2.6 Oxygen and Hydrogen Filter Elements Replacement . . . . . . . . . . . . . . . . . . . 42

6.2.6.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42


6.2.6.3 Filter Replacement Steps . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

6.2.7 Air Flow Speed Sensor Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

6.2.7.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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


6.2.8.3 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


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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 Replacement54

6.2.11.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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


6.2.12.3 Pressure Transmitter Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 58

6.2.13 Solenoid Valve Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 62

6.2.13.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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


6.2.14.3 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


6.3.1.3 Regeneration Flow Rate Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 78

6.3.2 Shutdown Depressurization Rate Check and Adjustment . . . . . . . . . . . . . . . . 81

6.3.2.1 Tools Required . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81


6.3.2.3 Shutdown Depressurization Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . 81

7 | 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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Revision 3 HYDROGENICS CORPORATION 1

1 | IntroductionThis is the Installation, Operation and Maintenance manual for the Hydrogenics Hylyzer Hydrogen Generator, part number 1039008.

1.1 Intended AudienceThis 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 AbbreviationsFor definition of the potentially unfamiliar terms and abbreviations used in this man-ual, refer to Appendix A:“Glossary” on p. 1.

Some terms that do not appear in the manual have been included to help gain a gen-eral understanding of Hydrogenics’ electrolyzer technology.

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INTENDED USE OF THE PRODUCT PEM ELECTROLYZER

The terms “user” or “operator” in this manual refer to the party who will oversee the Charge Station’s (automatic) operation. In most cases, the direct “operator” will be a system control device, which must be programmed to respond to the Charge Station’s fault messages and other feedback safely and appropriately for the intended applica-tion.

1.2 Intended Use of the ProductThe Hylyzer Hydrogen Generator uses clean de-ionized water and electricity to produce hydrogen and oxygen.

1.3 Customer AssistanceFor technical assistance with the installation, operation or maintenance of this product contact:

Hydrogenics CorporationService Department220 Admiral BoulevardMississauga, Ontario Canada, L5T 2N6Main: (905) 361-3660Customer Service: (905) 298-3328Fax: (905) 361-3626

1.4 Reference DocumentsA 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 applica-ble regulations of their local authorities.

1.4.1 Compressed Gas Association (CGA) PublicationsCompressed Gas Association Inc.4221 Walney Road, 5th FloorChantilly, VA 20151Phone: 703-788-2700Fax: 703-961-1831www.cganet.com


INSTALLATION, OPERATION AND MAINTENANCE MANUAL 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 Com-pressed Gases

S-1.3 Pressure Relief Device Standards-Part 3 - Stationary Storage Containers for Com-pressed Gases

1.4.2 National Fire Protection (NFPA) Association PublicationsNational Fire Protection Association1 Batterymarch Park,PO Box 9101,Quincy, MA 02269-9101, USAPhone: 617-770-3000Fax: 617-770-0700www.nfpa.org

NFPA 1 Uniform Fire Code

NFPA 55 Standard for the Storage, Use, and Handling of Compressed Gases and Cryo-genic Fluids in Portable and Stationary Containers, Cylinders, and Tanks.

NFPA 70 National Electric Code

1.4.3 The Society of Automotive Engineers (SAE)SAE International400 Commonwealth DriveWarrendale, PA 15096-0001Phone: 1-877-606-7323Fax: 724-774-0790www.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-CreuseCase postale 56

CH-1211 Geneva 20Switzerland


REFERENCE DOCUMENTS PEM ELECTROLYZER

Phone: +41 22 749 01 11Fax: +41 22 733 34 30www.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 Quebec333, rue FranquetQuébec, QC G1P 4C7Phone: 1-418-652-2238Fax: 1-418-652-2292www.bnq.qc.ca

1784-000 CAN/BNQ - Canadian Hydrogen Installation Code


2 | SafetyInstallations 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.


WARNING LABELS AND SYMBOLS PEM ELECTROLYZER

2.1 Warning Labels and SymbolsBe 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 SymbolsMake 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 DocumentsThis symbol indicates important instructions accompanying the product or, used within a document, indicates potential hazards of a general nature.

WARNING: Electrical HazardThis symbol indicates the potential for high voltages within the product that may present a risk of electric shock.

WARNING: Hot SurfaceThis symbol indicates that the product may be hot enough in some areas to cause burns to the skin if touched.

WARNING: FlammableThis 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 AtmosphereThis 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.


INSTALLATION, OPERATION AND MAINTENANCE MANUAL 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 PressureThis 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 ManualSeveral 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 dam-age the equipment.


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 applica-ble 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 modifi-cations can result in a dangerous shock hazard and can void the warranty

Inspect the equipment periodically: ensure that cables and wiring have not loos-ened 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 equip-ment, injury to persons or even death. Unauthorized modifications will void the warranty.


INSTALLATION, OPERATION AND MAINTENANCE MANUAL POTENTIAL HAZARDS AND SAFETY PRECAUTIONS

2.2.2 Mechanical and Handling Hazards

WARNING: Improper handling, operation, or maintenance of the equipment may cause per-sonal 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 nitro-gen before any service is performed.

Do not touch the potentially high-voltage areas, such as the wiring harness, the stack termi-nals 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.



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, colour-less, odourless and tasteless gas. Hydrogen is non-toxic and cannot be detected by human senses. Hydrogen and air mixtures are highly combustible/explosive. A hydro-gen 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 FireThe most effective method to fight a hydrogen fire is to extinguish the source of hydro-gen supply, provided this can be done safely.

WARNING: Risk of explosion. Extinguishing a hydrogen fire while the source of hydrogen con-tinues 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.


INSTALLATION, OPERATION AND MAINTENANCE MANUAL POTENTIAL HAZARDS AND SAFETY PRECAUTIONS

2.2.6 Enriched Oxygen Atmospheres

WARNING: The product produces oxygen as it operates. An oxygen enriched atmosphere rep-resents 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 explo-sions , 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.




3 | Product OverviewThe 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 mem-brane (PEM) cells. The Hylyzer Hydrogen Generator is built into a sturdy equipment cabi-net, 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.


TECHNICAL SPECIFICATIONS PEM ELECTROLYZER

3.1 Technical Specifications

Table 3-1: Charge Station Technical Specifications

PROPERTY UNIT VALUE

PRODUCT INFORMATION

Model Number Hylyzer Hydrogen Generator

Part Number 1039008

Stack Technology Proton Exchange MembraneElectrolyzer

Stack Size - number of cells 17

Maximum Current A 202

PHYSICAL

Overall Dimensions (L x W x H) mm 660 x 740 x 1170

Mass kg 250

PERFORMANCE

Hydrogen Production Nm3/h ≤ 1.1

System Operating Pressure kPa (psig) 101.4–894 (0–115)

Ambient Operating Temperature °C 5–40

Hydrogen Purity % > 99.995

Water Content ppm < 15

Oxygen ppm < 2

Nitrogen ppm < 2

DI WATER REQUIREMENTS

Inlet Water Consumption L/h ~ 1.2

Resistivity MΩ ·cm 2

Water Supply Temperature °C 5–45

Water Supply Pressure kPa (psig) 170–791 (10–100)


INSTALLATION, OPERATION AND MAINTENANCE MANUAL TECHNICAL SPECIFICATIONS

ELECTRICAL POWER REQUIREMENTS

Maximum Power Consumption kW 6.8

Maximum Current Draw A 40

Stack Operating Voltage Vdc 38

MAIN SAFETIES

Internal Hydrogen Level High O2/H2Differential Pressure

HWSS Over-Pressure Water Flow Low

HWSS Over-Temperature Overvoltage / Undervoltage

H2 De-Pressurizing Timeout Overcurrent / Undercurrent

O2 De-Pressurizing Timeout Water Level Low

FCVM Cell Voltage Out of Limits (optional) De-oxo Overtemperature

FCVM Cell Voltage Offset Over-Limit (optional)

Air Flow

H2 in O2 detection Automatic Purge

Table 3-1: Charge Station Technical Specifications

PROPERTY UNIT VALUE


TECHNICAL SPECIFICATIONS PEM ELECTROLYZER


4 | InstallationThis section details the steps for receiving and installating the PEM Electrolyzer.

4.1 Environmental RequirementsThe PEM Electrolyzer is designed for indoor use. Please observe the following installation requirements:

It should be installed in a dry, clean, temperature-controlled environment ( 5–40°C).

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 Electrolyzer’s 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 venti-lated environment.


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 InstructionsInspect the shipping container for damage. If the PEM Electrolyzer container has been dam-aged during shipment, immediately report it to Hydrogenics Corporation and the shipping per-sonnel. 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 transporta-tion.

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 tem-peratures 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 ConnectionsThe unit connections can be divided into 3 main categories: process, power and diagnostic.

4.3.1 Process ConnectionsIn 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 recom-mended. Process Interconnect tubing must be equal to or larger than the process interface fit-tings (no downsizing allowed)

Figure 4-1: Process Connections (typical)


INSTALLATION, OPERATION AND MAINTENANCE MANUAL 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 oper-ation of the PEM Electrolyzer.

4.3.1.1 Hydrogen (H2) OutputA ¼” 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 VentA ¼” 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 ventila-tion 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 SupplyThe 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 ¼” 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: 10–100 psig

Temperature: 5 to 45 °C


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 Mohm•cm.

4.3.1.4 DI Water DrainDI water is generally consumed by the electrolysis process. There is no need to drain water dur-ing operation; a permanent drain connection is optional.

When required for maintenance, the customer may drain the water into a pan or vessel. A ¼” bulkhead compression fitting, 316SS, has been provided to connect to the gravity fed DI water drain.

4.3.1.5 Leak Check and Nitrogen PurgeAfter 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 suc-cessful purge requires a dilution of oxygen content below the level at which a potentially flam-mable 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. Dur-ing or after the pressurizing/ venting cycle, the pressure should never be allowed to drop to ambient.

4.3.2 Power ConnectionsThe PEM Electrolyzer must be supplied with a 200-250 VAC, 60 A, 1 phase 50/60Hz electri-cal 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 nitro-gen 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


INSTALLATION, OPERATION AND MAINTENANCE MANUAL 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 ElectrolyzerAlways store the PEM Electrolyzer in a heated (> 5°C) 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.


STORING THE PEM ELECTROLYZER PEM ELECTROLYZER


5 | OperationThis 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 ChecksPrior 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 radia-tor fan housing.


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)


INSTALLATION, OPERATION AND MAINTENANCE MANUAL PRE-OPERATION CHECKS

Figure 5-2: Cell Stack Drain Valve (HV5002)

Figure 5-3: De-oxo Heating Coil Valve (HV5001)


CONTROL INTERFACE PEM ELECTROLYZER

5.2 Control InterfaceThe 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

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.

Table 5-1 LED Legend

Control Function

Start Button (green)

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 set-point).

Stop Button (red)

The stop button shuts down the PEM Electrolyzer and returns the sys-tem to Standby State. It will not produce hydrogen again until Start is pressed.

Reset Button (blue)

Clears past faults and prepares system for initial operation. The Start button will not function until Reset has occured. Press Reset to put sys-tem in Standby state.

E-Stop (Emer-gency Stop, red)

The e-stop button shuts down the system as if there were a fault (to pre-Standby state) This button latches, and must be turned to be released before system will operate again

Hour Meter This counter indicates hours the system has been in operation.

Status Display The status display (HMI) will indicate the system’s current state or dis-play a fault message if any are in effect

On/Off Switch Main power switch. When this switch is off, all functions of the system are disabled. Turn On to initialize system.


INSTALLATION, OPERATION AND MAINTENANCE MANUAL CONTROL INTERFACE

Figure 5-5: State Transition Diagram

Init

Standby

Fill Water

Prime Pump

Polish Water Pressurize System

H2 Purge

Run

Estop

Temperature

Recovery

DI Water Tank Full(DI Water Tank High Level Switch = True &

Inlet Water Tank High Level Switch = True)

DI Water Flow OK

(DI Water Flow Switch = True for 10s)

Water Resistivity > 2MÙ

Cathode (H2) Pressure > 85psig

60s

Demand Switch = False

Anode/Cathode

Pressure < 20psig

& 30 more seconds

1036215 State Machine

& HWSS OK=True

2

1

5

6

7 8

9

1011

12

13

Start Ready

Cabinet Purge

3

4

Demand Switch = True

15s

Stack Temperature < 50°C

Stack

Temperature

> 65°C

30s & Anode/Cathode

Pressure < 20psig

Shutdown

Stop

Button

Pressed?

Yes

No

Power On

Reset ButtonEstop Button or Fault

Stop ButtonStart Button

Stop Button


OPERATING PROCEDURE PEM ELECTROLYZER

5.3 Operating ProcedurePlease refer to the operational schematic in Figure 5-6 for the discussions in Sections 5.3.1 - 5.3.3.

Figure 5-6: Operational Schematic

5.3.1 InitializationTo 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.

DI Water tank

DI WATER INDI WATER PUMP

RECIRCULATION PUMP

O2 SEPARATORDRYER A DRYER B

DEOXOCELL STACKDC POWER SUPPLY

H2 BACKPRESS REG

O2 O2 BACKPRESS REGULATORREG

COOLING FAN

REGEN FLOW 20%

LIVE

SYSTEM INITIALIZINGPRESS RESETPRESS STARTCABINET PURGEPRIME PUMPPRESSURIZINGHYDROGEN PURGERUNFILL WATERWATER POLISHING

HYDROGENICS

STSSTORAGE TANK

START STOP RESET E-STOP

PURGE FAN

H2 VENT

FAN CYCLE

SEPARATOR CYCLE

DI TANK CYCLE

SW DRY

O2 VENTNEXT SLIDE


INSTALLATION, OPERATION AND MAINTENANCE MANUAL 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 air-speed 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 separa-tor 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 MΩ ·cm, 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 MΩ ·cm then this step is skipped.

Pressurization: Once DI water resistivity is > 2 MΩ ·cm, the cell stack is energized, gener-ating 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 oth-erwise 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 back-pressure regulating valve PRV2007, ensuring the set point of the two PRVs is actively bal-anced.-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) "DIFFEREN-TIAL 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.


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 pro-duction. The HMI displays “SYSTEM RUNNING”. Hydrogen and oxygen pressure is bal-anced as described above with hydrogen pressure 0.5-5psig higher than oxygen pressure. This prevents oxygen from migrating into the hydrogen stream. Conversely, hydrogen-in-oxygen 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 OperationDrying 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 mois-ture trapped during the active phase.

The 3-way valve SV2012 initially directs hydrogen towards dryer VSSL2014. The hydro-gen 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 adsorp-tion 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 regen-eration) via metering valve OR2017 and then out to the vent stack via open (de-ener-gized) 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


INSTALLATION, OPERATION AND MAINTENANCE MANUAL 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 pro-duced 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 atmo-sphere.

Zone B: Drying column A is active and fully pressurized. 100% of hydrogen pro-duced 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 pro-duced by the cellsatck flows through. Drying column B is pressurized at full pres-sure 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 respec-tively)

Zone D: Drying column B is active and fully pressurized. 100% of hydrogen pro-duced 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 atmo-sphere.


SHUTDOWN PROCEDURE PEM ELECTROLYZER

Zone E: Drying column B is active and fully pressurized. 100% of hydrogen pro-duced 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 pro-duced by the cellsatck flows through. Drying column A is pressurized at full pres-sure and in standby.

5.3.3 Continuous OperationAfter 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 pres-sure 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 Procedure1. 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.


6 | General MaintenanceRegular inspection and maintenance must be performed to maintain the PEM Elec-trolyzer in optimal working condition and prolong the life of its components. Addi-tionally, 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.


MAINTENANCE INTERVALS AND SPARE PARTS PEM ELECTROLYZER

6.1 Maintenance Intervals and Spare PartsInspection and service intervals are specified below.

Table 6-1Maintenance Intervals

MAINTENANCE ITEM SECTION HYG P/N JAN

FEB

MA

R

AP

R

MA

Y

JUN

JUL

AU

G

SEP

OC

T

NO

V

DEC

Check H2 vent stack X X X X X X X X X X X X

Check E-stop operation 6.2.2 X X X X X X X X X X X X

Check Fault Log for past month X X X X X X X X X X X X

Check for Gas leaks 6.2.3 X X

Clean / check rad fan operation 6.2.4 X X

Check tubing and pipe supports X X

Check H2 area detector 6.2.5 1031226 X X

Check equipment (connected to a common ground)

6.2.9 X X

Replace FLT2004filter element 6.2.6 1005300 X

Check air flow switch 6.2.7 X

Replace H2 area detector 6.2.5 1031226 X

Check all regulator settings 6.2.8 X

Check AC and DC power cables / connections

6.2.9 X

Check drain trap DT2004 6.2.10 1018604 X

Check DC voltage / current sensors 6.2.11 2000902/1027409

X

Check pressure transducers 6.2.12 2000075 X

Check / replace solenoid valvesa See Note a X

Check / replace DI bed 6.2.14 1020583 3000 hoursb

Check / replace dryer desiccant 6.2.14 2003448 4 years

Run test X X X X X X X X X X X X

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


INSTALLATION, OPERATION AND MAINTENANCE MANUAL MAINTENANCE PROCEDURES

6.2 Maintenance ProceduresThe 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 CleaningUse 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 CheckIn 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 but-tons 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 auto-matic restart set point the PEM Electrolyzer will not run. The HMI display will show the "Wait for demand switch" message.


MAINTENANCE PROCEDURES PEM ELECTROLYZER

6.2.3 Gas/Water Leak Check

WARNING: Before removing covers or servicing, turn off the unit and then check bus bar volt-age 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 depres-surize and for the electrolyzer stack to electrically discharge. Proceed with tighten-ing 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.



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 FansRadiator 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 volt-age 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



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






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



Figure 6-2: Span Gas Cylinder Hose


Safety glasses

Safety shoes

6.2.5.3 Hydrogen Gas Detector Check Steps


2. Remove tube connection between PRV3004 and OR2018 (PID dwg 1038516 rev 3)

Figure 6-3: Hydrogen Tube Disconnection



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



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 ¼ 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 auto-matic operation.

6.2.6 Oxygen and Hydrogen Filter Elements Replacement






Open wrench (9/16”, 11/16”, 7/8”)

Strap wrench

Shop cloth or paper towel


Safety glasses



6.2.6.3 Filter Replacement StepsThe 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 ori-entations.

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.



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 fit-tings. 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



6.2.7 Air Flow Speed Sensor Check





None


Safety glasses

Safety shoes

6.2.7.3 Air Flow Speed Sensor Check Steps


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 6-10)

3. Air speed sensor is located behind the cabinet purge fan (see Figure 6-11)



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 auto-matic operation



6.2.8 Pressure Regulators Check






Monitoring software

0-150psig pressure gauge

Open wrench 9/16”

¼” compression union cross (Swagelock P/N SS-400-4)

¼” SS316 compression nuts and ferrules (2 sets)

¼” SS316 x 0.035 tube (0.3meters)


Safety glasses

Safety shoes



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 ¼“ compression "T" union (Figure 6-12) and replace with ¼“ union cross compression (Figure 6-13). Reconnect adja-cent 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 ¼“ Compression "T" Union



Figure 6-13: Pressure Gauge Connection to ¼“ 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 clock-wise 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 AdjustmentPRV 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.



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 adjust-ment 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



6.2.9 Cell Stack DC Cable Connection and Equipment Grounding/Bonding Check





None


Safety glasses

Safety shoes

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 con-tact, oxidized contacts/wire, loose cable strands, broken wire, insulation conditions, signs of overheating, etc.

3. Check all electrical connections for tightness.



6.2.10 Drain Traps DT 2004 and DT3006 Check





6.2.10.1Tools Required

None

6.2.10.2Personal Protective Equipment

Safety glasses

Safety shoes

6.2.10.3Drain Trap Check

1. Confirm that the PEM Electrolyzer has run for at least 100 hours total (not necessar-ily 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



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.



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


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.



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.

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.

Voltage Measurement

Current Measurement



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.



6.2.12 Pressure Transmitter Check






Monitoring software

0-100psi pressure gauge

Open wrench 9/16”, 11/16”, 7/8”

100 psi nitrogen supply


Flexible tubing and fittings rated for 200 psi


Safety glasses

Safety shoes



6.2.12.3Pressure Transmitter Check


2. Remove load side wires of contactor CT318 and isolate. This is to prevent cell stack for being accidentally energized during test.


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 6-20). Label transmitters and their corresponding electrical connectors (socket) accordingly.



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).



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 con-trol 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).



Figure 6-22: System Monitoring Screen

11. Record the pressure calibrator reading and compare with pressure transmitter read-ings. 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 con-tactor 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.



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.)



Safety glasses

Safety shoes



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.

CleaningAll 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 dam-aged, install a complete ASCO Rebuild Kit.

Valve Disassembly



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.



Figure 6-23: Solenoid valve disassembly

Figure 6-24: Solenoid valve disassembly (cont’d)

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.



Figure 6-25: Solenoid valve body removal

Figure 6-26: Solenoid valve retention clip removal



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 pro-vided 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 aster-isks 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 aster-isks in Figure 6-29 on page 69.



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 pres-ent 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 aster-isks 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 TORQUE [IN-LBS] TORQUE [NM]

Solenoid Base Subassembly 175 +/- 25 17.8 +/- 2.8

Valve Seat 45 +/- 5 5.1 +/- 0.6

End Cap 360 40.7

Bonnet Screws 144 +/- 15 16.3 +/- 1.7



Figure 6-28: ASCO Series 8223 valve disassembly



ASCO Series 8327

1. Lubricate all gaskets, piston ring, rider rings and piston and u-cups (shown in Fig-ure 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 pro-trudes 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 con-structions only), solenoid base gasket and plugnut assembly.



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 tighten-ing 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.



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 ReplacementThe 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, Fig-ure 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)



Figure 6-32: Molecular Sieves VSSL2014 and VSSL 2015 (Dryers)






Open wrench 5/16”, 7/16”, 9/16”, 11/16”, 7/8”

Funnel



Drain pan


Ion exchange resin (P/N 1039136)

Catalyst (P/N 1011973)

Molecular sieve (P/N2003448)

Screen gasket (2pcs, P/N1039055)

¼” compression cap

Pressure gauge, 200psig

140 psig nitrogen supply


Safety glasses

Safety shoes

Dust mask

6.2.14.3DI Resin Bed Replacement



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 compres-sion fittings and removing the securing cushion clamps.

4. Hold vessel in vertical position and undo/remove the top sanitary clamp (Figure 6-33).



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



6. Empty the ion exchange resin and dispose of it in accordance with local environ-mental 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



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 reac-tor (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.



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.


INSTALLATION, OPERATION AND MAINTENANCE MANUAL PROCESS ADJUSTMENT PROCEDURES

6.3 Process Adjustment ProceduresThe 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 AdjustmentDryer 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 pro-duction rate desired by customer differs significantly from the one for which the regen-eration flow rate was factory tuned).





Open wrench 9/16”

Precision hydrogen flow meter (0-30 L/min)


Safety glasses


PROCESS ADJUSTMENT PROCEDURES PEM ELECTROLYZER

Safety shoes

6.3.1.3 Regeneration Flow Rate Check

1. Shut down unit, lock/tag power out and isolate the PEM Electrolyzer from hydro-gen 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).



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 approxi-mately 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



rate. Now the dryer regeneration flow value is set for 20% of the cell stack hydro-gen 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.



6.3.2 Shutdown Depressurization Rate Check and AdjustmentThe shutdown depressurization rate is factory set and sealed. Only adjust if factory set-point has been modified (accidentally or otherwise).





Monitoring Software

Stopwatch


Safety glasses

Safety shoes

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.



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 ¼ of a turn or less (closing it). Repeat steps 3 -6 as many times as neces-sary 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 ¼ of a turn or less (opening it). Repeat steps 3 -6 as many times as necessary to decrease the depressurization time to within range.


7 | TroubleshootingThis 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.


FAULTS PEM ELECTROLYZER

7.1 FaultsTable 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

TRIP POINT SENSOR VALID MODES CHECK

Internal Hydro-gen Level High

>40% LEL inside enclosure

GD1000 All 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).

HWSS Over-Pres-sure

>130 psi PSH2100 All Check dryer BPR setting, O2 BPR setting, demand switch, hydrogen pres-sure transducer, PSH2100, SV2012, SV2013 and SV2023 (Section 6.2.13 Solenoid Valve Mainte-nance on page 62). Check filters and lines for possible blockage (Sec-tion 6.2.6 Oxygen and Hydrogen Filter Elements Replacement on page 42).

HWSS Over-Temprature

>90°C TSH2002

All Stack temperature sensor as it should have tripped first, check TSH2002, radi-ator fan, air inlet, ambient temp > 40oC

H2 De-Pressure Timeout

>20psi 6 minutes after shutdown

PT1100 Shutdown Blocked vent (H2 or O2), OR2018 setting, SV2005 failure (Section 6.2.13 Solenoid Valve Mainte-nance on page 62), PRV2007 blockage


INSTALLATION, OPERATION AND MAINTENANCE MANUAL FAULTS

O2 De-Pressure Timeout

>20psi 6 minutes after shutdown

PT1010 Shutdown Blocked vent (O2), OR2018 setting, SV2005 failure (Section 6.2.13 Solenoid Valve Mainte-nance on page 62)

FCVM Cell Volt-age Out of Lim-its

Cell Voltage <1.5 or >2.4

FCVM Run Check FCVM connections

FCVM Cell Volt-age Offset Over Limit

Cell Voltage > 0.4V from average cell voltage

FCVM Run Check FCVM connections

Water Conduc-tivity Sensor Out of Range

Sensor output <3mA or >20mA

RT1100 Prime Pump, Polish Water, Pressurize, H2 Purge, Run

Check sensor and connec-tions

Stack Voltage Sensor Out of Range

Sensor output <0mA or >20mA

VM1500 Pressurize, H2 Purge, Run Check sensor and connec-tions

Stack Current Sensor Out of Range

Sensor ouput <0.3V or >4.7V

CM1500 Prime Pump, Polish Water, Pressurize, H2 Purge, Run


Air Flow Speed Sensor Out of Range

Sensor ouput <0.8V or >5.2V

AFS1000 Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run

Check sensor and connec-tions, confirm sensor alignment (Section 6.2.7 Air Flow Speed Sensor Check on page 45)

H2 Pressure Sen-sor Out of Range

Sensor output <2.4mA or >20mA

PT1100 Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run

Check sensor and connec-tions (Section 6.2.12 Pres-sure Transmitter Check on page 57)

O2 Pressure Sen-sor Out of Range

Sensor output <2.4mA or >20mA

PT1010 Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run

Check sensor and connec-tions (Section 6.2.12 Pres-sure Transmitter Check on page 57)

Stack Tempera-ture Sensor Out of Range

Sensor output <0V or >10V

TE1004 Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run


Reactor Temper-ature Sensor Out of Range

Sensor output <0V or >10V

TE1004 Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run







Fail to Prime Pump

More than 15 attempts to prime pump

PMP1003 & FSL1007

Prime Pump Check PMP1003, check FSL1007, drain O2 separa-tor (TK1002) and attempt restart of system. Change DI bed (Section 6.2.14.3 DI Resin Bed Replacement on page 73)

Fail to Polish Water

>5 minutes in pol-ish water state

RT1100 & FLT 1005

Polish Water Replace DI Resin in FLT1005 (Section 6.2.14.3 DI Resin Bed Replacement on page 73), check RT1100

Fail to Pressurize System

>15 minutes in pressurize state

PT1100 Pressurize Check PRV3004/PRV2007 setting, check SV3005 (should be closed), check DT2004 and DT3006 seals

External Detec-tor Fault

User supplied shutdown signal

-- All Check external shutdown signal source, check ter-minals 92 and 93 for 24V

Water Flow Switch Fault

False for > 5seconds

FSl1007 Polish Water, Pressurize, H2 Purge, Run

Check PMP1003, check FSL1007, drain O2 sepera-tor (TK1002) and attempt restart of system

DI Tank Level Switch Malfunc-tion

LSL1000 false &LSH1000 true

LSL1000 & LSH1000

Fill Water, Prime Pump, Pol-ish Water, Pressurize, H2 Purge, Run

Check LSL1000 & LSH1000, check for water in O2 sperator (TK1002)

Inlet Tank Level Switch Malfunc-tion

LSL4003 false & LSH4003 true

LSL4003 & LSH4003

Fill Water, Prime Pump, Pol-ish Water, Pressurize, H2 Purge, Run

Check LSL4003 & LSH4003, check for water in DI water tank (tk4007)

DI Water Level Low

False >1 minute LSL1000 Fill Water, Prime Pump, Pol-ish Water, Pressurize, H2 Purge, Run

Check PMP1000, SV1127, LSL1000, check for water in O2 seperator (TK1002)

Inlet Water Level Low

False >1 minute LSL4003 Fill Water, Prime Pump, Pol-ish Water, Pressurize, H2 Purge, Run

Check DI water supply is on, check for water in DI tank (TK4007), check SV4003 (Section 6.2.13 Solenoid Valve Mainte-nance on page 62)






Stack Over-Tem-prature

>80°C TE1004 Fill Water, Prime Pump, Pol-ish Water, Pressurize, H2 Purge, Run

Check FAHX1004 not blocked, check FAHX1004 fan (Section 6.2.4 Check/Clean Radiator and Venti-lation Fans on page 37), check TE1004

Stack Under-Temprature

<5°C TE1004 Fill Water, Prime Pump, Pol-ish Water, Pressurize, H2 Purge, Run

Check ambient tempera-ture, check TE1004

DeOxo Over-Temprature

>110°C TE2010 Run Check TE2010, possible O2 crossover in stack, contact Hydrogenics (Sec-tion 1.3 Customer Assis-tance on page 2)

DeOxo Under-Temprature

<5°C TE2010 Run Check ambient tempera-ture, check TE2010

Water Resistivity Under Limit

<2MOhm for >5minutes

RT1100 Pressurize, H2 Purge, Run Replace DI Resin in FLT1005 (Section 6.2.14.3 DI Resin Bed Replacement on page 73), check RT1100

Stack Over-Volt-age

>29V VM1500 All Check input voltage, check VM1500 (Section 6.2.11 Current Sensor CM1500 and Voltage Sen-sor VM1500 Check and Replacement on page 54)

Stack Under-Voltage

<18V VM1500 All Check input voltage, check VM1500 (Section 6.2.11 Current Sensor CM1500 and Voltage Sen-sor VM1500 Check and Replacement on page 54)

Wait for Stack Voltage Timeout

<18V for 10 sec VM1500 Pressurize Check CR517 & CR519






Stack Over-Cur-rent

>250A CM1500 Pressurize, H2 Purge, Run Check CM1500 (Section 6.2.11 Current Sensor CM1500 and Voltage Sen-sor VM1500 Check and Replacement on page 54), check for short circuit

Stack Under-Current

<20A CM1500 H2 Purge, Run Check CM1500 (Section 6.2.11 Current Sensor CM1500 and Voltage Sen-sor VM1500 Check and Replacement on page 54), raise input voltage, check for loose connection (Sec-tion 6.2.9 Cell Stack DC Cable Connection and Equipment Grounding/Bonding Check on page 51)

Air Flow Speed Under Limit

<0.5m/s for 1 min-ute

AFS1000 Cabinet Purge, Fill Water, Prime Pump, Polish Water, Pressurize, H2 Purge, Run

Check for blockages in ventilation holes, check FAV1000, AFS1000 (Sec-tion 6.2.7 Air Flow Speed Sensor Check on page 45)

H2 Over-Pres-sure

>120psi PT1100 Run Check PRV3004/PRV2007 setting (Section 6.2.8.3 PRV3004 Setpoint Adjust-ment 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 Fil-ter Elements Replacement on page 42)






O2 Over-Pres-sure

>120psi PT1010 Run 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 Fil-ter Elements Replacement on page 42)

Differential Pres-sure High

>15psi PT1010 & PT1100

Prime Pump, Polish Water, Pressurize, H2 Purge, Run

Check PRV2023/2007 set-ting, 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 (Sec-tion 6.2.3 Gas/Water Leak Check on page 36)

Differential Pres-sure Low

<0.5psi PT1010 & PT1100

Run Check PRV3004/2007 set-ting (Section 6.2.8.3 PRV3004 Setpoint Adjust-ment on page 48), check for leaks, open lines, check non-return valve CHK2037, check DT2004/DT3006 seat seals (Sec-tion 6.2.10 Drain Traps DT 2004 and DT3006 Check on page 52)






H2 Under-Pres-sure

<50psi PT1100 Run 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 Transmit-ter Check on page 57), check for leaks (Section 6.2.3 Gas/Water Leak Check on page 36)

O2 Under-Pres-sure

<50psi PT1010 Run 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)

Loss of FCVM Heart Beat

No communica-tion for 5 seconds

FCVM Prime Pump, Polish Water, Pressurize, H2 Purge, Run

Check FCVM connections

Warning: Stuck Start Button

Start button true for > 1 minute

Prime Pump, Polish Water, Pressurize, H2 Purge, Run

Check start button and wiring

Warning: FCVM Cell Voltage Slope Over Limit

Shutdown

ESTOP (System Cannot Run) Call Hydrogen-ics for Assis-stance

Run Contact Hydrogenics Cus-tomer Service (Section 1.3 Customer Assistance on page 2)





INSTALLATION, OPERATION AND MAINTENANCE MANUAL TECHNICAL SUPPORT

7.2 Technical SupportWhen 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.


TECHNICAL SUPPORT PEM ELECTROLYZER

Revision 3 HYDROGENICS CORPORATION A-1


Appendix A: Glossary

Ambient Temperature: Temperature outside the Charge Station enclosure, as mea-sured 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/sup-port 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 con-trols 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 other-wise.

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 atmo-spheric pressure in measurement) vs. psig “gauge” (pressure internal to system only).

Relative Humidity: The measured partial pressure of the gas at the operating temper-ature process conditions divided by the theoretical partial pressure of the gas at the same temperature.

SI: International System of Units.

SLPM: standard litres per minute—see “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 sys-tem’s hour meter HM1.

A-2 HYDROGENICS CORPORATION Revision 3

PEM ELECTROLYZER

Standard Conditions: Hydrogenics’s 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.

Vdc: Volts (direct current).

Revision 3 HYDROGENICS CORPORATION B-1


Appendix B: CAN Specification

The CAN protocol is used for communication between the PEM Electrolyzer and moni-toring 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.semiconduc-tors.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.

INSTA

LLATIO

N, OPERA

TION A

ND M

AIN

TENA

NC

E MA

NU

AL

Revision 3H

YDRO

GEN

ICS C

ORPO

RATIO

NB-2

B.1 Overall CAN Specification

Table B-1: Overall CAN Specification

CAN ID (Hex)

CAN ID (Dec)

SENT BY

LENGTH (bytes)

PERIOD (ms)

BYTE 0 BYTE 1 BYTE 2 BYTE 3 BYTE 4 BYTE 5 BYTE 6 BYTE 7

100 256 OSC 1 500 State

101 257 OSC 8 500 Stack Current (0.01A/bit Unsigned)

Stack Voltage (0.01V/bit Unsigned)

Cathode (H2) Pressure (0.01psig/bit Signed)

Anode (O2) Pressure (0.01psig/bit Signed)

102 258 OSC 8 500 Stack Temperature (0.01degC/bit Signed)

Reactor Temperature (0.01degC/bit Signed)

Air Flow Speed (0.001m/s/bit Unsigned)

Water Resistivity (0.001Mohm/bit Unsigned)

103 259 OSC 8 500 Digital Inputs Digital Outputs 0x00 DI Water Cooling Fan PWM (0.01%/bit Unsigned)

104 260 OSC 8 500 S/W Ver-sion No. (Major)

S/W Ver-sion No. (Minor)

System Run Time (1min/bit Unsigned) System Amp-Hour (1Ah/bit Unsigned)

110 272 PC 1 - 0x00 or 0xFF

0x00 (Read System Error Records) 0xFF (Clear System Error Records)

120 288 OSC 8 - System Error Record (0xFF: No Error)

140 320 FCVM 8 200 FCVM Min. Voltage (0.001V/bit Signed)

FCVM Avg. Voltage (0.001V/bit Signed)

FCVM Max. Voltage (0.001V/bit Signed)

FCVM Min. Voltage Cell No.

FCVM Max. Volt-age Cell #

150 336 PC 1 - 0x00 or 0xFF

0x00 (Read System Error Records) 0xFF (Clear System Error Records)

160 352 OSC 8 - FCVM Error Type (1,2,3)

Cell Group No. (0,1,2)

Total Num-ber of Errors






200 512 OSC 8 - System Estop

System Fault System Warning

PEM E

LECTRO

LYZER

B-3H

YDRO

GEN

ICS C

ORPO

RATIO

NRevision 3

540 1344 FCVM 8 - 0x01 Cell Group No. (0, 1, 2, 3, 4, 5)

Cell Voltage (0.001V/bit Signed)



5C0 1472 OSC 1 - 0x01 (FCVM Cell Voltage Request)

Table B-1: Overall CAN Specification

CAN ID (Hex)

CAN ID (Dec)

SENT BY

LENGTH (bytes)

PERIOD (ms)

BYTE 0 BYTE 1 BYTE 2 BYTE 3 BYTE 4 BYTE 5 BYTE 6 BYTE 7

B-4 HYDROGENICS CORPORATION Revision 3

PEM ELECTROLYZER

B.2 Byte Message DetailsDetails 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 MESSAGE

0x00 (0) -

0x01 (1) Init

0x02 (2) Standby

0x03 (3) Start Ready

0x04 (4) Cabinet Purge

0x05 (5) Fill Water

0x06 (6) Prime Pump

0x07 (7) Polish Water

0x08 (8) Pressurize System

0x09 (9) H2 Purge

0x0A (10) Run

0x0B (11) Temperature Recovery

0x0C (12) Shutdown

0x0D (13) Estop



B.2.2 CAN ID 103


BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) Internal Hydrogen Level High

0x02 (00000010) HWSS Over-Pressure Switch

0x04 (00000100) Inlet Tank Low Level Switch

0x08 (00001000) Inlet Tank High Level Switch

0x10 (00010000) DI Tank Low Level Switch

0x20 (00100000) DI Tank High Level Switch

0x40 (01000000) DI Water Flow Switch

0x80 (10000000) Demand Switch


BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) Rectifier Fault

0x02 (00000010) HWSS Over-Temperature Switch

0x04 (00000100) External Detector Fault

0x08 (00001000) Estop Button

0x10 (00010000) Start Button

0x20 (00100000) Stop Button

0x40 (01000000) HWSS OK

0x80 (10000000) Reset Buttom


PEM ELECTROLYZER


BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) DI Water Cooling Fan (PWM)

0x02 (00000010) Rectifier Power

0x04 (00000100) Oxygen Vent Valve

0x08 (00001000) Hydrogen Supply valve

0x10 (00010000) Water Inlet Valve

0x20 (00100000) Enclosure Ventilation Fan

0x40 (01000000) Red LED

0x80 (10000000) Green LED


BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) Hydrogen Cooling Fan

0x02 (00000010) DI Water Circulation Pump

0x04 (00000100) Sensor Enable

0x08 (00001000) Rectifier Enable

0x10 (00010000) System Enable

0x20 (00100000) Electrical Cabinet Ventilation Fan

0x40 (01000000) DI Water Feed Pump

0x80 (10000000) Dryer Input and Output Valves



B.2.3 CAN ID 200


BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) Dryer Regen A Valve

0x02 (00000010) Dryer Regen B Valve

0x04 (00000100) -

0x08 (00001000) -

0x10 (00010000) -

0x20 (00100000) -

0x40 (01000000) -

0x80 (10000000) -


BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) Internal Hydrogen Level High

0x02 (00000010) HWSS Over-Pressure

0x04 (00000100) HWSS Over-Temperature

0x08 (00001000) Cathode De-Pressurizing Timeout

0x10 (00010000) Anode De-Pressurizing Timeout

0x20 (00100000) FCVM Cell Voltage Out of Limits

0x40 (01000000) FCVM Cell Voltage Offset Over Limit

0x80 (10000000) -


PEM ELECTROLYZER


BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) Water Conductivity Sensor Out of Range

0x02 (00000010) Stack Voltage Sensor Out of Range

0x04 (00000100) Stack Current Sensor Out of Range

0x08 (00001000) Flow Speed Sensor Out of Range

0x10 (00010000) Cathode Pressure Sensor Out of Range

0x20 (00100000) Anode Pressure Sensor Out of Range

0x40 (01000000) Stack Temperature Sensor Out of Range

0x80 (10000000) Reactor Temperature Sensor Out of Range


BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) Fail to Fill DI Water Tank

0x02 (00000010) Fail to Fill Inlet Water Tank

0x04 (00000100) Fail to Prime Pump

0x08 (00001000) Fail to Polish Water

0x10 (00010000) Fail to Pressurize System

0x20 (00100000) External Detector Fault

0x40 (01000000) Rectifier Fault

0x80 (10000000) Water Flow Switch Fault




BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) DI Water Tank Level Switch Malfunction

0x02 (00000010) Inlet Water Tank Level Switch Malfunction

0x04 (00000100) DI Water Level Low

0x08 (00001000) Inlet Water Level Low

0x10 (00010000) Stack Over-Temperature

0x20 (00100000) Stack Under-Temperature

0x40 (01000000) Reactor Over-Temperature

0x80 (10000000) Reactor Under-Temperature


BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) Water Resisitivity Under Limit

0x02 (00000010) Stack Over-Voltage

0x04 (00000100) Stack Under-Voltage

0x08 (00001000) Wait for Stack Voltage Timeout

0x10 (00010000) Stack Over-Current

0x20 (00100000) Stack Under-Current

0x40 (01000000) -

0x80 (10000000) Air Flow Speed Under Limit


PEM ELECTROLYZER


BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) Cathode Over-Pressure

0x02 (00000010) Anode Over-Pressure

0x04 (00000100) Differential Pressure High

0x08 (00001000) Differential Pressure Low

0x10 (00010000) Cathode Under-Pressure

0x20 (00100000) Anode Under-Pressure

0x40 (01000000) -

0x80 (10000000) -


BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) Loss of FCVM Heart Beat

0x02 (00000010) -

0x04 (00000100) -

0x08 (00001000) -

0x10 (00010000) -

0x20 (00100000) -

0x40 (01000000) -

0x80 (10000000) -




BIT MESSAGE

0x00 (00000000) -

0x01 (00000001) Stuck Start Button

0x02 (00000010) FCVM Cell Voltage Slope Over Limit

0x04 (00000100) -

0x08 (00001000) -

0x10 (00010000) -

0x20 (00100000) -

0x40 (01000000) -

0x80 (10000000) -


PEM ELECTROLYZER

Revision 3 HYDROGENICS CORPORATION C-1


Appendix C: Material Safety Data Sheets (MSDS)

1/4

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.

2/4

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 50°C 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 20°C 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.

3/4

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, 1°F

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.

4/4

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.

1/4

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.

2/4

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 50°C 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 20°C Not applicable.

Solubility mg/l water 39 mg/l

Appearance/Colour Colourless gas

Odour No odour warning properties.

Autoignition temperature Not applicable

3/4

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.

4/4

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.

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 SUPPLIER: ALDEX CHEMICAL CO, LTD.

ADDRESS: Various ADDRESS: 630 Laurent St.

Granby, Quebec, Canada J2G 8V1 TEL: Various TEL: (450) 372-8844

FAX: Various FAX: (450) 372-2566

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. CHEMICAL NAME %

069011-20-7 Sulfonated copolymer of styrene & divinylbenzene

in hydrogen form 20 – 30

069011-18-3 Trimethylamine functionalized chloromethylated

copolymer of styrene & divinylbenzene in

hydroxide form 15 – 30

007732-18-5 Water 50 - 60

SECTION III – PHYSICAL/CHEMICAL CHARACTERISTICS

PHYSICAL STATE: Solid BOILING POINT (Deg. C): N/A SPECIFIC GRAVITY: 1.2 FREEZING POINT (Deg. C): 0°C VAPOR PRESSURE (mm Hg): 17 @ 20°C Water SOLUBILITY IN WATER: Insoluble

VAPOR DENSITY (AIR=1): 0.62 for water EVAPORATION RATE (H20=1): 1.0

ODOR: Slight fishy odor ODOR THRESHOLD (ppm): N/A

APPEARANCE: Small spherical beads amber colors pH (in an aqueous slurry): 6-9 COEFFICIENT OF WATER/OIL DISTRIBUTION: N/A

SECTION IV – FIRE AND EXPLOSION HAZARD DATA

NFPA FIRE HAZARD CLASS: 1 Slight, Above 200°F (93°C)

FLASH POINT (Deg. C)/METHOD USED: N/A AUTO IGNITION TEMPERATURE (Deg. C): >500°C (932°F) CONDITIONS OF FLAMMABILITY: >93°C (200°F) FLAMMABLE LIMITS: N/A

EXTINGUISHING MEDIA: Dry chemical, carbon dioxide or water fog

HAZARDOUS COMBUSTION PRODUCTS: Same as reactivity data EXPLOSION DATA- SENSITIVITY 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 204°C 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 50°C 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 customer’s

assistance in complying with the Occupational Safety and Health Acts and regulations

thereunder. Any other use is prohibited.


SNOOP® January 2009

Page 1 of 4

1. PRODUCT IDENTIFICATION SNOOP®: Liquid leak detector for use on external surfaces only. Optimum usage temperatures are between 27°F and 200°F (-3°C and 93°C). Manufactured by: Emergency Contact: Swagelok Manufacturing Company Chemtrec (800) 424-9300 29495 F.A. Lennon Dr. Solon, Ohio 44139 Tel: (440) 349-5600 2. INGREDIENTS

Ingredients CAS # WT% PEL Water 7732-18-5 >95 Not Available

Surfactant Not Available <5 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 Skin Absorption Eye Contact Inhalation Ingestion

No No Yes No Yes 4. FIRST AID MEASURES • If inhaled (Overexposure): Unlikely to be inhaled. • After contact with skin (Overexposure): Wash thoroughly with soap and water. If severe irritation

develops, seek medical attention. • After contact with eyes: Rinse thoroughly with water for 15 minutes, seek medical attention. Do not rub eyes. • If swallowed: Unlikely to cause illness, seek medical attention if needed. • Medical information: None known.



Page 2 of 4

5. FIRE FIGHTING MEASURES • Suitable extinguishing agents: Not applicable. • Unsuitable extinguishing agents: None known. • Special dangers caused by substance None known.

or preparation itself, by combustion products, or gases formed:

• Additional information: None.

Autoignition UEL LEL Sensitivities Not Applicable Not Applicable Not Applicable Not Available

6. ACCIDENTAL RELEASE MEASURES • Measures for protection of people: Eye and hand protection as needed to minimize excessive exposure. • Measures for protection of the

environment: None required. • Cleaning measures: Use absorbent material to clean spills. • Additional information: None. 7. HANDLING AND STORAGE • Safety information: None. • Information on protection from fire

or explosion: None. • Additional information: Store in a cool, dry place for optimal product performance. 8. EXPOSURE CONTROLS AND PERSONAL PROTECTION • Precautionary measures to protect

employees: None required. • Respiratory protection: None required. • Hand protection: Rubber gloves are recommended to minimize exposure. • Eye protection: Goggles are recommended when SNOOP® could splash in eyes. • Skin protection: Wash hands after use.

9. PHYSICAL AND CHEMICAL PROPERTIES

Appearance Odor pH Density Vapor Pressure Colorless liquid Neutral 6.75 +/- 0.75 1.0 gm/cm3 Not Available Boiling Point Melting Point Flash Point Flammability Explosive

212°F/100°C Not Available Not Available Not Available Not Available



Page 3 of 4

10. STABILITY AND REACTIVITY • Conditions to avoid: None. • Materials to avoid: Strong oxidizers, alkali metals, and compounds that react exothermically with water. • Hazardous decomposition products: None. 11. TOXICOLOGICAL INFORMATION • Acute toxic properties: None known. • Health effects: None known. • Additional health effects: None known.

Sensitization

Teratogenicity

Reproductive Toxicity

Mutagenicity

Synergistic Products

Carcinogenicity

Not Available Not Available Not Available Not Available Not Available Listed ingredients are not suspected

carcinogens according to NTP, IARC, and OSHA

12. ECOLOGICAL INFORMATION • Mobility: Comparable to water. • Degradability: Not established. • Accumulation: No adverse bioaccumulation or biomagnification effects known. • Short/Long term effects

on ecotoxicity: No known ecological affects. 13. DISPOSAL CONSIDERATIONS • Appropriate methods of disposal: Unused product not considered a hazardous waste in the United States. Dispose of in a responsible manner. • European Community (EC) considerations: Use appropriate waste codes based on ingredients. 14. TRANSPORT INFORMATION • Transport precautions: Consult applicable regulations when transporting this product. • Additional information: None.



Page 4 of 4

15. REGULATORY INFORMATION • US/Canadian regulation listing: SARA 313 - NO, Canada’s Controlled Products - NO, TSCA - YES • EC Relevant risk: None. • EC Relevant safety: S: 37/39 - Wear suitable gloves and eye/face protection.

S: 20 - When using do not eat or drink. • Additional information: Consult country codes for specific requirements. 16. OTHER INFORMATION • For further information contact: Your Swagelok Distributor or the contacts listed in Section 1 of this sheet. • Sources of information used Properties of individual ingredients were used to compile this document.

to compile 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

Environmental and Safety Department (440) 248-4600 January 2009


Deionized Water

SECTION 3 MIXTURE COMPONENTS

SECTION 1 . Product and Company Idenfication

Product Code:

Product Name and Synonym:

206-00

Deionized Water

SECTION 2 HAZARD IDENTIFICATION

Health: 0

Flammability: 0

Reactivity: 0

Hazard Rating:

Least Slight Moderate High Extreme

0 1 2 3 4

NA=Not Applicable NE=Not Established

OFI Testing Equipment Inc.

1006 W. 34th Street

Houston, TX 77018

(877) 880-9885

Material Uses:

Manufacturer:

Entry Date : 5/10/2010

Chemtrec 800-424-9300 Canutec 613-996-6666

24 Hour Emergency Assistance :

Print Date: 7/30/2010

Component

Percent

Comp. DimensionSARA 313 CAS Number

Exposure

Limits

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 4 FIRST AID MEASURES

SECTION 5 FIRE FIGHTING MEASURES

Fire Extinguisher Type: Any means suitable for extinguishing surrounding fire

Fire Fighting Procedure: Wear self-contained breathing apparatus and protective clothing to prevent contact with skin and clothing.

Fire / Explosion Hazards:None Known.

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

Generally not hazardous in normal handling, Store away from water reactive materials.

Generally not hazardous in normal handling, Store away from water reactive materials.

Water, Deionized ASTM Type II 100% V/VCAS# 7732-18-5 None Established

Deionized Water

Equipment or Procedures.

SECTION 8 EXPOSURE CONTROLS/PERSONAL PROTECTION

Respiratory Protection: None required

Mechanical

Local ExhaustVentilation

Protective Gloves: None required

Eye Protection: None required

Other Protective Equipment: None required.

Store in a cool dry place. This Material is not considered hazardous. Store away from water reactive material.

SECTION 7 HANDLING AND STORAGE

SECTION 9 PHYSICAL AND CHEMICAL PROPERTIES

Melting Point: 0°C

Boiling Point: 100°C

Vapor Pressure: Information

not available

Vapor Density: Information

not available

Solubility in Water: Soluble

Appearance /Odors: Colorless

odorless liquid

Flash Point: Not flammable

Specific Gravity: 1

Percent Volatile by Volume: >99

Evaporation Rate 1

Auto Ignition Temp Not applicable

Lower Flamm. Limit in Air Not applicable

Upper Flamm. Limit in Air Not applicable

Evaporation Standard Water =1

SECTION 10 STABILITY AND REACTIVITY INFORMATION

Stability: Stable

Conditions to Avoid: Temperature extremes

Materials to Avoid: Strong Acids, Bases. Water reactive materials

Hazardous DecompositionProducts:

Not known to occur

Hazardous polymerization: Will Not Occur

Conditions to Avoid: None known

SECTION 11 Toxicological Information

SECTION 12 Ecological Information

SECTION 13 Disposal Considerations

Carcinogenic References: NTP Carcinogen - Known: No, IARC Category- None

Not Applicable.

Whatever cannot be saved for recovery or recycling should be flushed to sewer. If material

Page 2 of 4

Deionized Water

SECTION 14 Transport Information

SECTION 15 Regulatory Information

SECTION 16 Additional Information

becomes contaminated during use, dispose of accordingly. Dispose of container and unusedcontents in accordance with federal, state and local requirements.

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: NoTSCA 12 (b):NoCDTA:No PURE/LIQUIDSARA 311/312: Acute: NoChronic: No Fire: NoPressure: No Reactivity: NoAustralian Hazchem Code: None allocatedPoison Schedule: None allocated

Conditions aggravated/Target organs: None known

DOT Classification: Not Regulated

DOT Regulations may change from time to time. Please consult the most recent D.O.T. regulations.

Page 3 of 4

Deionized Water

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.

Health Reactivity

Flammability

NFPARevisions

0.17/30/2010 updated msds to 16 section from 10 section msds. STN

0

Page 4 of 4

Page 1/5

Material Safety Data SheetAccording to OSHA and ANSI

Printing date 05/31/2011 Reviewed on 09/28/2010

DR

1 Identification of the substance/mixture and of the company/undertaking

Product identifier

Product name: Molecular sieves, 5A

Stock number: 87955CAS Number:69912-79-4Relevant 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 sheetManufacturer/Supplier:Alfa Aesar, A Johnson Matthey CompanyJohnson Matthey Catalog Company, Inc.30 Bond StreetWard Hill, MA 01835-8099Tel: 800-343-0660Fax: 800-322-4757Email: [email protected]

Information Department: Health, Safety and Environmental DepartmentEmergency telephone number:During normal hours the Health, Safety and Environmental Department at (800) 343-0660. Afternormal hours call Carechem 24 at (866) 928-0789.

2 Hazards identification

Classification of the substance or mixtureThe substance is not classified according to the Globally Harmonized System (GHS).

Classification according to Directive 67/548/EEC or Directive 1999/45/EC Not applicableInformation concerning particular hazards for human and environment: Not applicable

Label elements

Labelling according to EU guidelines:Observe the general safety regulations when handling chemicalsClassification systemHMIS ratings (scale 0-4)(Hazardous Materials Identification System)

HEALTH

FIRE

REACTIVITY

0

0

0

Health (acute effects) = 0Flammability = 0Reactivity = 0

Other hazardsResults of PBT and vPvB assessmentPBT: 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 measuresAfter inhalationSupply fresh air. If required, provide artificial respiration. Keep patient warm.Seek immediate medical advice.After skin contactImmediately wash with water and soap and rinse thoroughly.Seek immediate medical advice.After eye contactRinse opened eye for several minutes under running water. Then consult a doctor.After swallowing Seek medical treatment.

5 Firefighting measures

Extinguishing mediaSuitable extinguishing agentsProduct is not flammable. Use fire fighting measures that suit the surrounding fire.

(Contd. on page 2) USA

Page 2/5




(Contd. of page 1)

DR

Special hazards arising from the substance or mixtureIn case of fire, the following can be released:Metal oxide fumeSilicon oxideSodium oxideAdvice for firefightersProtective equipment:Wear self-contained respirator.Wear fully protective impervious suit.

6 Accidental release measures

Personal precautions, protective equipment and emergency proceduresWear protective equipment. Keep unprotected persons away.Ensure adequate ventilationEnvironmental 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 sectionsSee Section 7 for information on safe handlingSee Section 8 for information on personal protection equipment.See Section 13 for disposal information.

7 Handling and storage

HandlingPrecautions for safe handlingKeep 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 incompatibilitiesStorageRequirements 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 averageface velocity of at least 100 feet per minute.

Control parametersComponents with limit values that require monitoring at the workplace: Not required.Additional information: No data

Exposure controlsPersonal protective equipmentGeneral protective and hygienic measuresThe 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 glovesCheck protective gloves prior to each use for their proper condition.Material of glovesThe selection of suitable gloves not only depends on the material, but also on quality.Quality will vary from manufacturer to manufacturer.Eye protection: Safety glassesBody protection: Protective work clothing.

USA(Contd. on page 3)

Page 3/5




(Contd. of page 2)

DR

9 Physical and chemical properties

Information on basic physical and chemical propertiesGeneral InformationAppearance:

Form: PelletsColor: Light brown

Odor: Not determinedOdour threshold: Not determined.

pH-value: Not applicable.

Change in conditionMelting point/Melting range: Not determinedBoiling point/Boiling range: Not determinedSublimation temperature / start: Not determined

Flammability (solid, gaseous) Not determined.

Ignition temperature: Not determined

Decomposition temperature: Not determined

Auto igniting: Not determined.

Danger of explosion: Product does not present an explosion hazard.

Explosion limits:Lower: Not determinedUpper: Not determined

Vapor pressure: Not applicable.

Density: Not determinedRelative density Not determined.Vapour density Not applicable.Evaporation rate Not applicable.

Solubility in / Miscibility withWater: Insoluble

Segregation coefficient (n-octonol/water): Not determined.

Viscosity:dynamic: Not applicable.kinematic: Not applicable.

Other information No further relevant information available.

10 Stability and reactivity

ReactivityChemical stabilityThermal decomposition / conditions to be avoided:Decomposition will not occur if used and stored according to specifications.Possibility of hazardous reactions No dangerous reactions knownIncompatible materials:Water/moistureAcidsOxidizing agentsHazardous decomposition products:Metal oxide fumeSilicon oxideSodium oxide

11 Toxicological information

Information on toxicological effectsAcute toxicity:Primary irritant effect:on the skin: May cause irritationon the eye: May cause irritationSensitization: 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 maycause pulmonary fibrosis known as silicosis.

(Contd. on page 4) USA

Page 4/5




(Contd. of page 3)

DR

Subacute to chronic toxicity:Aluminum may be implicated in Alzheimers disease. Inhalation of aluminum containing dustsmay cause pulmonary disease.Additional toxicological information:To the best of our knowledge the acute and chronic toxicity of this substance is not fullyknown.No classification data on carcinogenic properties of this material is available from the EPA,IARC, NTP, OSHA or ACGIH.

12 Ecological information

ToxicityAcquatic 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 assessmentPBT: Not applicable.vPvB: Not applicable.Other adverse effects No further relevant information available.

13 Disposal considerations

Waste treatment methodsRecommendation Consult state, local or national regulations to ensure proper disposal.

Uncleaned packagings:Recommendation: Disposal must be made according to official regulations.

14 Transport informationNot a hazardous material for transportation.

DOT regulations:Hazard class: None

Land transport ADR/RID (cross-border)ADR/RID class: None

Maritime transport IMDG:IMDG Class: NoneMarine 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 ormixture

Product related hazard informations:Observe the general safety regulations when handling chemicals

National regulationsThis product is not listed in the U.S. Environmental Protection Agency Toxic SubstancesControl Act Chemical Substance Inventory. Use of this product is restricted to research anddevelopment only.Some or all of the components of this product are not listed on the Canadian DomesticSubstances 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)

Page 5/5




(Contd. of page 4)

DR

16 Other informationEmployers should use this information only as a supplement to other information gathered bythem, and should make independent judgement of suitability of this information to ensureproper use and protect the health and safety of employees. This information is furnishedwithout warranty, and any use of the product not in conformance with this Material SafetyData Sheet, or in combination with any other product or process, is the responsibility of theuser.

Department issuing MSDS: Health, Safety and Environmental Department.Contact:Zachariah C. HoltGlobal EHS ManagerAbbreviations and acronyms:ADR: Accord européen sur le transport des marchandises dangereuses par Route (European Agreement concerning the InternationalCarriage of Dangerous Goods by Road)RID: Règlement international concernant le transport des marchandises dangereuses par chemin de fer (Regulations Concerningthe International Transport of Dangerous Goods by Rail)IMDG: International Maritime Code for Dangerous GoodsDOT: US Department of TransportationIATA: International Air Transport AssociationIATA-DGR: Dangerous Goods Regulations by the "International Air Transport Association" (IATA)ICAO: International Civil Aviation OrganizationICAO-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

C- 2 HYDROGENICS CORPORATION Revision 3

INSTALLATION, OPERATION AND MAINTENANCE MANUAL PEM ELECTROLYZER

Revision 3 HYDROGENICS CORPORATION D-1


Appendix D: P&ID

Revision 3 HYDROGENICS CORPORATION E-1


Appendix E: Electrical Schematics

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

JASON LEMOS Next page:Page Group:Previous page:

1713

Page:2

REFERENCES

of

Date NameRevision: Drawing number:HydrogenicsMississauga,Ontario,Canada,L5T 2N6

PEM ELECTROLYZER_rev2G

Project Manager: ELECTROLYZER

24/02/2011M.SUSTAC

Name Date

Approved By:

Created By:

Project number:220 ADMIRAL BLVD.

1038968Page Title:

Revision Number:

Customer: Description:

Checked By: M.XU

J.L.

"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."

WARNING !

ORANGE

RED

BLACK

BROWN

GREEN

BLUE

WIRE CODE DESIGNATION

VIOLET

GRAY

WIRE COLOUR

BRN

YELLOW

WHITE WHT

GRY

VIO

BLU

GRN

YEL

ORG

RED

BLK

DESIGNATION SPECIFIED

201 RELEASED 01/12/10 MS

02 UPDATE 25/02/11 MS

301

302

303

304

305

306

307

308

309

310

311

312

313

314

315

316

317

318

319

320

321

322

323

324

325

326

327

328

329

330

331

332

333

334

335

336

337

338

339

340


1724

Page:3

POWER

of




24/02/2011M.SUSTAC

Name Date

Approved By:

Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

0-(23.8-28.3)V DC ;230A

CUSTOMERPOWER SUPPLY

TO VOLTAGE MONITOR DEVICE

CONN: 6321 ANDERSON

2

CM1500CURRENT SENSOR


02 UPDATE 25/02/11 MS

1 GGND CONNECTOR

U334

14CELLS;28V; 216A

ELECTROLYZER STACK

-

+

4AW

GG

RN

/YEL

3/0

L1 3/0

L2

1

2CR517

/5/517

+P1 -P1

14AWGWHT/BLU3091

14AWGBLU3081

18AWGBLU3262

18AWGBLU3282

4/0

3081

4/0

3091

1

2CR519

/5/519

3/0

3083

3/0

3093

1 2

3 4

0.5AATDR0.5

FU326

2

1

FU320250A

CNN 250FERRAZ SHAWMUT

2

1

FU321250A

CNN 250FERRAZ SHAWMUT

18AWGBLU3261

18AWGBLU3281

BLU

14

AWG

3211

WH

T/BL

U 1

4 AW

G32

21

BLU

14

AWG

3211

0

1L1

2T1

3L2

4T2

5L3

6T3

DS30763A/24VDC

NON-FUSIBILE DISC. SWITCH

OT63FT3SABB

4/0

3082

4/0

3092

PS14/403

PS24/403

DC+ / 9/913

DC- / 9/914

L1 + L2- G

401

402

403

404

405

406

407

408

409

410

411

412

413

414

415

416

417

418

419

420

421

422

423

424

425

426

427

428

429

430

431

432

433

434

435

436

437

438

439

440


1735

Page:4

24V/12V POWER SUPPLY

of




24/02/2011M.SUSTAC

Name Date

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Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

OUTPUTS

NO E_STOPINPUTS

OU

TPU

T 1

+24

VDC

OU

TPU

T 2

+12

VDC

24VDC

12VDC


02 UPDATE 25/02/11 MS

A+OUT 1 2

15AATDR15

FU410

Vin-

Vin+

PS408

18V -32VDC /24VDC,12A ;12VDC,2A

POWER SUPPLY

VI-QCW31-ESYVICOR

VI-QCW31-ESY

GND

2 GBUS_BAR

5 3CR504E-STOP

/5/501

4081 4082

18AWGBLU4082

14AWGBLU4083

14AWGBLU4091

14AWGWHT/BLU4111

TB1PE

10414AWGGRN/YEL

4130

Disable+

Disable-

BSENSE+

CTRIM

DSENSE-

EOUT-

A+OUT

BSENSE+

CTRIM

DSENSE-

EOUT-

1 2

2A

FERRAZ SCHWAMUTATDR2

FU424

1 2

3 4

20A

FERRAZ SHAWMUT

ATDR20

FU409

18AWGBLU/WHT4371

14AWGWHT/BLU4201

18AWGBLU4242

18AWGBLU4241

1TB1PE

103

1TB1PE

105

14AWGWHT/BLU4222

18AWGBLU/WHT4372

PS23/323

+24V_1 / 5/502

PS13/323

+24V_2 / 11/1102

0V_1 / 5/502

12V_1 / 9/919

0V_2 / 9/921

501

502

503

504

505

506

507

508

509

510

511

512

513

514

515

516

517

518

519

520

521

522

523

524

525

526

527

528

529

530

531

532

533

534

535

536

537

538

539

540


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HWSS CIRCUIT

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24/02/2011M.SUSTAC

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Created By:


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Revision Number:


Checked By: M.XU

J.L.

HOUR METER

2

(HARDWARE SYSTEM SAFETY)


02 UPDATE 25/02/11 MS

11 14

CR513RESET

/5/514

11 12

CR509E_HWSS

/5/510

2

c no1NO, 24VDC

IDECHW1L-M1F10QD-S-24

/11/1133

PB514RESET

TB125

TB11 11 12

PB504E-STOP

2NC

IDECHW1E-LV4F02QD-R-24V

/8/816/5/521

8 7

15A,24VDC,SPDP

OMRONLY1N-D2-DC24V

CR504

EMERGENCY/ HWSS

5 3 /4/408

x1 x2

RED/5/504/8/816

PB504

EMERGENCY/ HWSS (LAMP)

A1 A2

24V,6A,2 PDT

PHOENIX CONTACTPLC-RSC-24DC/21-21

CR513

RESET

11 14 /5/504

21 24 /8/830

5141

5211

504650435042 5044

A1 A2

24V,6A,2 PDT


CR509

11 12 /5/521

11 14 /5/517

21 24 /5/507

HM529

701DR001O1248D2CURTIS INSTRUMENT

1 2

4082

4082 26

TB1

40

TB141

TB13

321 24

CR1225

/12/1225

5261

11 14

CR1231SOFT ENABLE

/12/1231

ncc

TSH2002OVERTEMPERATURE

90 C +/- 5 C, NC

CANTHERMRA20AB117B250CO179

ncc

PSH2100OVERPRESSURE

GEM SENSORSPS61-19-2MNS-B-TS

A1 A2

24V,6A,2 PDT

PHOENIX CONTACTPLC-RSC--24DC/21-21

CR531

OVERTEMPERATURE

11 14 /5/504

21 24 /8/808

A1 A2

24V,6A,2 PDT


CR535

OVERPRESURE

11 14 /5/504

21 24 /7/709

11 14

CR531OVERTEMPERATURE

/5/531

11 14

CR535OVERPRESURE

/5/536

5045

22AWGRED5311

22AWGBLK5314

20AWGBLU5314

18AWGRED5361

18AWGBLK5364

20AWGBLU5364

20AWGBLU5041

20AWGBLU5041

20AWGBLU/WHT4201

20AWGBLU/WHT4201

18AWGBLU5041

11 14CR1225

STACK ENABLE (PLC)

/12/1225

11 14CR509HWSS-OK

/5/510

P5311

P531

2

A1 A2

500A,24V

TYCO ELECTRONICSEV200AAANA

CR519STACK ENABLE

1 2 /3/317

A1 A2

500A,24VDC

TYCO ELECTRONICEV200AAANA

CR517STACK ENABLE

1 2 /3/317

x1x2V517400V;1A

GENERAL SEMICONDUCTOR1N 4004

x1x2V519400V;1A

GENERAL SEMICONDUCTOR1N 4004

P5171

P5191

2

2

5171 5172

20AWGBLU5170

20AWGBLU5170

TB194

95

96

97

20AWGBLU/WHT4201

20AWGBLU/WHT4201

3x22AWG/5/531

W5313x22AWG

/5/531W531

3x22AWG/5/535

W5363x22AWG

/5/535W536

20AWGRED5312

20AWGBLK5313

18AWGRED5362

18AWGBLK5363

21 24

CR509

/5/510

1 2

3 4

56

20AWGBLU8272

P536A

P536B

+24V_14/405

+24V_16/602

0V_14/420

0V_16/602

0V_Relay9/916

24V_PB8/815

0V_PB11/1130

24V_relay7/707

DI / 8/827

601

602

603

604

605

606

607

608

609

610

611

612

613

614

615

616

617

618

619

620

621

622

623

624

625

626

627

628

629

630

631

632

633

634

635

636

637

638

639

640


1757

Page:6

CONTROL SYSTEM

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Approved By:

Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

DB 9 CONNECTOR

DB 9 CONNECTOR

POWER/DATA CONNECTOR

CAN INTERFACE

CPC:796190-1TYCO

P614P614

X1 X1

ON

1 2 3 4

RUN(1:ON;2-3OFF; 5-7:OFF;8: OFF)

PROGRAMMING(8:ON)

5 6 7 8OFF

DIP switch 8 segments


02 UPDATE 25/02/11 MS

4:ON :CI TEMPERATURE

U625LCD DISPLAY

MATRIX ORBITAL

LK204-25-WB-VPT

CS604/7/703/8/803/9/903

/10/1004/11/1103/12/1201/13/1304

24INPUTS;18OUTPUTS

CONTROL SYSTEM

IFMCR0301

X1:01 Ub

X1:03 CAN _L

X1:04 CAN_H

X1:05 CAN_L

X1:06 CAN_H

X1:02GND

RS 232:02 RxD

RS 232:03 TxDRS 232:05GND

RS 232:06 UbRS 232:09 TEST

2 TxD

3 RxD

P/D:4GND

9 PWR

P/D:1 PWR

5 GND

P/D:3 Tx

P/D:2 Rx

TB14

TB1274082

20AWGBLU6071

20AWGBLU/WHT6072

24AWGRED6131

24AWGORG6141

20AWGBLK6281

4201

20AWGRED6291

20AWGGRN6081

20AWGYEL6091

x1

x2

R2120ohm

TB199

101

PDC1/6/627

PDC1/6/626

24AWGGRN6281

24AWGRED6131

24AWGORG6141

RS232/6/615

W626

RS232/6/627

W626

/6/627W628

/6/628W628

P61313

14

+24V_15/538

0V_15/533

+24V_17/701 0V_1

7/702

CAN_H /

CAN_L /

701

702

703

704

705

706

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

740


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DIGITAL INPUTS

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24/02/2011M.SUSTAC

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Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

%IX1.0

%IX1.8

%IX2.0

%IX2.8

%IX3.0

%IX3.8

%IX4.0

%IX4.8

OVERPRESSURE

INLET TANK LOW LEVEL

INLET TANK HIGH LEVEL

H2 GAS DETECTOR

C NO

C NC


02 UPDATE 25/02/11 MS 2

CS604

/8/803/9/903

/10/1004/11/1103/12/1201/13/1304

/6/605

Ub9

IN0001

IN0102

IN0203

IN0304

IN0506

IN0607

IN0708

LSH4003

INLET TANK HIGH LEVEL

MODE D-ON(HIGH LEVEL)

SUNXEX-F1

IN0405

2GND

1

Vcc

GD10005-40V DC; OUT:0-3V

HK-GH-A080C-W50A-05-R1-S1-E2-I2NEODYM TECHNOLOGIES INC.

29

P7341

5

RLY2

2

P7343

P7381

6

2

P7241

P7202

4

RLY1

3

Vout/Iout

X4/8/804

P7383

P7201

P7272

P7271

P7242

TB128

TB15

42014082

BLU7362

BLU7392

BRN7382

BRN7352

22AWGWHT7314

FSL1007

PUMP DI WATER FLOW SWITCH

GEMS SENSOR177592

22AWGWHT7274

20AWGRED7273

22AWGWHT7244

20AWGRED7243

22AWGWHT7204

20AWGRED7203

20AWGBLU7161

BLK7383

20AWGBLU7131

BLK7353

22AWGRED7311

20AWGRED7272

22AWGRED7271

20AWGRED7242

22AWGRED7241

20AWGRED7202

22AWGRED7201

22AWGRED7351

22AWGBLK7361

22AWGRED7381

22AWGBLK7391

20AWGBLK7051

20AWGRED7041

PS2026

PRESSURE DEMAND SWITCH

ASCO VALVE CANADAPA10A/RG10A21

20AWGWHT7064

7

8

TB150

52

53

54

55

56

57

20AWGBLU7064

20AWGBLU7131

20AWGBLU7161

20AWGBLU7314

20AWGBLU7274

20AWGBLU7244

20AWGBLU7204

GND10

21 24

CR535

/5/536

TB151

20AWGBLU5170

20AWGBLU7081

A2 A1

CR735

24V,6A,1 PDT

PHOENIX CONTACTPLC-RSC-24DC/21

11 14 /7/713

A2 A1

CR738

24V,6A,1 PDT


11 14 /7/716

11 14

CR735

/7/735

11 14

CR738

/7/738

20AWGBLU/WHT7354

20AWGBLU/WHT7384

TB148

TB149

22AWGWHT7354

22AWGWHT7384

20AWGBLU7081

20AWGBLU5170

20AWGBLU5170

20AWGBLU5170

3x22AWG/7/720

W720

3x22AWG/7/719

W720

3x22AWG/7/723

W7243x22AWG

/7/723W724

3x22AWG/7/726

W7273x22AWG

/7/727W727

3x22AWG/7/730

W7303x22AWG

/7/730W730

3x22AWG/7/734

W7343x22AWG

/7/734W734

3x22AWG/7/738

W7383x22AWG

/7/738W738

NOC

GEM SENSORS164870

LSL1000DI TANK LOW LEVEL

NOC

GEM SENSORS164870

LSH1000

DI TANK HIGH LEVEL

3x22AWG/7/705

W703

3x22AWG/7/703

W703

LSL4003

INLET TANK LOW LEVEL

MODE D -ON (LOW LEVEL)

SUNXEX-F1

+24V_18/802

+24V_16/638

0V_16/638

0V_113/1303

24V_relay5/529

24V_relay7/733

24V_relay7/718

24V_relay8/806

801

802

803

804

805

806

807

808

809

810

811

812

813

814

815

816

817

818

819

820

821

822

823

824

825

826

827

828

829

830

831

832

833

834

835

836

837

838

839

840


1779

Page:8

DIGITAL INPUTS

of




24/02/2011M.SUSTAC

Name Date

Approved By:

Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

SYSTEM READYHWSS OK

SPARE

E-STOP

RESET

CUSTOMER INTERFACE

%IX5.0

%IX5.8

%IX6.0

%IX6.8

%IX7.0

%IX7.8

%IX8.0

%IX8.8

OVERTEMPERATURE

START

STOP

OPTIONALREMOVE JUMPER WHEN CONNECT

JMP


02 UPDATE 25/02/11 MS 2

22 21

PB504E-STOP

/5/504/5/521

IN0811

IN0912

CS604

/7/703/9/903

/10/1004/11/1103/12/1201/13/1304

/6/605

IN1013

IN1114

IN1215c no

1NO

IDECHW1L-M1F10-QD-G-24

/11/1137

PB820START

IN1316

IN1417

IN1518

X4/7/705

c nc

1NC

IDECHW1B-M1F01-R

PB822STOP

20AWGBLU8272

20AWGBLU8231

20AWGBLU8201

20AWGBLU8161

20AWGBLU5041

20AWGBLU5041

EXTERNAL DETECTOR

EXTERNAL DETECTOR

TB158

59

93

61

62

63

64

TB19 1 2

2A

FU812

20AWGBLU8121

20AWGBLU8122

20AWGBLU8123

21 24

CR513RESET

/5/514

21 24

CR531

/5/531

6520AWGBLU

8301

TB192

20AWGBLU8081

20AWGBLU5170

20AWGBLU5170

20AWGBLU8021

20AWGBLU8272

20AWGBLU8231

20AWGBLU8201

20AWGBLU8161

20AWGBLU8123

20AWGBLU8301

20AWGBLU8081

+24V_112/1218

+24V_17/739

24V_relay7/739

24V_PB5/526

DI /5/502

901

902

903

904

905

906

907

908

909

910

911

912

913

914

915

916

917

918

919

920

921

922

923

924

925

926

927

928

929

930

931

932

933

934

935

936

937

938

939

940


17810

Page:9

ANALOGUE INPUTS

of




24/02/2011M.SUSTAC

Name Date

Approved By:

Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

4-20mA

4-20mA

0.5-4.5V

0-5V

SW2:

SW3: ON

1 2 3 4 OpenClose

1 2CloseOpen3 4

0-5 S


02 UPDATE 25/02/11 MS

J/2123

54V36V24V

SENSOR CONNECTIONS

Signal IN (RED)Signal RETURN (BLACK)Temperature IN (WHITE )

A_IN0001

RIT1100/9/903

CELL CONSTANT=0.01/CM

SENSOR

3-2839-3+GF+SIGNET

1

3V-

A_IN0102

1 V+

CS604

/7/703/8/803

/10/1004/11/1103/12/1201/13/1304

/6/605

A_IN0203

A_IN0304

4 SHIELD

3 TEMP IN

2 ISO GND

VM1500

STACK VOLTAGE MONITORING

MCR-VDC-UI-B-DC

PHOENIX CONTACT

1 SIGNAL IN

2

3

4

RIT1100/9/902

12-24VDC,4-20mA

CONDUCTIVITY MONITORING

3-2850-62+GF+ SIGNET

2

CM1500

+300A/OUT:0.5-4.5VDC

CURRENT MONITORING

DCS36-300-1InPOWER

BOUTPUT

A +12VDC

C SIG. GND

D POWER GND

X2/10/1005

13+24VDC

15GND3

7 +28V

8 GND1

9OUT I

11GND2

22AWGWHT9291

18AWGBLK9241

18AWGBLU3262

18AWGBLU3282

20AWGBLU9151

22AWGRED9081

20AWGRED9031

20AWGBLK9041

20AWGWHT9051

TB112

TB166

67

68

69

AFS1000

AIR FLOW SENSOR

D6F-W04A1OMRON

2OUTPUT

1 +12VDC

3 SIG. GND

TB146

22AWGBRN9272

22AWGBLK9301

P9271

2

P927

3

4318AWGRED

9211

22AWGRED9271

22AWGBLU9302 20AWGBLU

9291

Ub5

GND6

20AWGBLU/WHT4201

4618AWGWHT

9231

22AWGBLK9291

18AWGBLU/WHT4371

20AWGBLU12201

22AWGWHT9084

20AWGBLU9152

20AWGBLU9152

20AWGBLU9084

18AWGGRN9221

20AWGBLU9221

3x22AWG/9/928

W927

3x22AWG/9/926

W927

3x22AWG/9/908

W9083x22AWG

/9/908W908

TB142

18AWGBLU4242

TB145

TB113

12V_14/424

0V_24/435

0V_210/1020

DC+ / 3/326

DC- / 3/328

0V_Relay5/538

0V_Relay12/1223

12V_110/1019

An_INPUT_CURR112/1219

An_INPUT_CURR10/1003

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

1036

1037

1038

1039

1040


17911

Page:10

ANALOGUE INPUTS

of




24/02/2011M.SUSTAC

Name Date

Approved By:

Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

4-20mA

4-20mA

0-10V

0-10V


02 UPDATE 25/02/11 MS

P1013

A

P1013

B

P1022

1

P1022

3

P1006

1

X2/9/906

A_IN0407

A_IN0508

CS604

/7/703/8/803/9/903

/11/1103/12/1201/13/1304

/6/605

A_IN0609

TE2010

TEMPERATURE TRANSMITTER O2 REACTOR

ASSEMBLY SENS TEMP

2

21

x2x1

R1033

2K

TE1004

TEMPERATURE TRANSMITTER O2 STACK

ASSEMBLY SENS TEMP

x2x1

R1024

2K

3

PT10100-200PSI

PRESSURE TRANSMITTER O2 STACK

100.200.1.1.2.7NOSHOK

a + b-

c not used

b-

1

a +

A_IN0710

3

c not used

PT11000-200PSI

PRESSURE TRANSMITTER H2 STACK

100.200.1.1.2.7NOSHOK

P1031

3

P1031

1

P1031

2

P1022

2

P1006

2

10222 10223

10262

10312

10352

10313

22AWGBLK10351

22WGRED10311

22AWGRED10221

22AWGBLK10261

20AWGWHT10133

20AWGRED10132

22AWGRED10131

22AWGWHT10054

20AWGWHT10053

20AWGRED10052

22AWGRED10051

TB111

TB147

TB144

TB170

TB171

72

73

20AWGBLU12201

20AWGBLU10054

20AWGBLU10134

20AWGBLU10224

20AWGBLU10314

22AWGWHT10134

22AWGWHT10224

22AWGWHT10314

3x22AWG/10/1006

W10063x22AWG

/10/1006W1006

3x22AWG/10/1012

W10133x22AWG

/10/1012W1013

3x22AWG/10/1021

W10223x22AWG

/10/1021W1022

3x22AWG/10/1030

W10313x22AWG

/10/1030W1031

x1 x2

THERMISTOR

x1 x2

THERMISTOR

3

C

0V_29/934 12V_1

9/923

An_INPUT_CURR9/916

1101

1102

1103

1104

1105

1106

1107

1108

1109

1110

1111

1112

1113

1114

1115

1116

1117

1118

1119

1120

1121

1122

1123

1124

1125

1126

1127

1128

1129

1130

1131

1132

1133

1134

1135

1136

1137

1138

1139

1140


171012

Page:11

DIGITAL OUTPUTS

of




24/02/2011M.SUSTAC

Name Date

Approved By:

Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

%QX0.0

%QX0.8

%QX1.0

%QX1.8

%QX2.0

%QX2.8

%QX3.0

%QX3.8

PWM

PWM


02 UPDATE 25/02/11 MS

P1120

1

P1116

2

P1120

2

OUT0203

OUT0102

OUT0001

CS604

/7/703/8/803/9/903

/10/1004/12/1201/13/1304

/6/605

OUT0304

X3

Ucom0210

OUT0406

OUT0507

OUT0608

OUT0709

Ucom0105

X2x1

X3

SV4003DI FEED WATER IN

ASCO VALVE CANADAEF8223G10-24VDC

X2X1

X3

SV3005O2 VENT VALVE

ASCO VALVE CANADA8262G134-24VDC

X2X1

X3

SV2019H2 SUPPLY VALVE


P1116

1

TB120

21

TB135

4123

4123

14 AWG WHT/BLU4221

18AWGRED11151

18AWGRED11152

18AWGRED11153

18AWGBLK11154

18AWGRED11201

18AWGRED11202

18AWGRED11203

18AWGBLK11204

18AWGRED11251

18AWGBLK11254

18AWGRED11071

18AWGBLU11070

18AWGBLU11241

1 2

FAV100024V DC,250CFM

VENTILATION FAN PROCESS ENCLOSURE

DV6224EBMPAPST

M

P1130

1

P1130

218AWGBLK

1127218AWGBLK

1127318AWGBLK

11274

TB137

TB136

TB175

TB176

77

TB178

20AWGBLU11271

20AWGBLU11251

20AWGBLU11201

20AWGBLU11151

18AWGRED11271

x1 x2

GREEN/8/820

PB820

START&RUN4201

20AWGBLU11321

20AWGBLU11371

80

81

x1 x2

BLU/5/514

PB514

FAULT

P1107

A 21

FAHX 1004

FAN COOLING WATER 734SLC3A01

THERMATRON

M P1107

B18AWGBLK

1107318AWGRED

11072

TB134

TB174

79

20AWGBLU11071

20AWGBLU11111

18AWGBLK11074

20AWGBLU11321

20AWGBLU11371

3x18AWG/11/1106

W11073x18AWG

/11/1106W1107

3x18AWG/11/1115

W11163x18AWG

/11/1115W1116

3x18AWG/11/1119

W11203x18AWG

/11/1119W1120

3x18AWG/11/1123

W11243x18AWG

/11/1124W1124

3x18AWG/11/1128

W11303x18AWG

/11/1128W1130

C18AWGGRN

11075

318AWGGRN

11155

318AWGGRN

11205

18AWGGRN11255

18AWGGND11275

P1124

1

P1124

2

3

+24V_212/1201

+24V_24/408

0V_211/1139

0V_211/1103

0V_PB5/528

1201

1202

1203

1204

1205

1206

1207

1208

1209

1210

1211

1212

1213

1214

1215

1216

1217

1218

1219

1220

1221

1222

1223

1224

1225

1226

1227

1228

1229

1230

1231

1232

1233

1234

1235

1236

1237

1238

1239

1240


171113

Page:12

DIGITAL OUTPUTS

of




24/02/2011M.SUSTAC

Name Date

Approved By:

Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

R4

R3

R0

R2

R1

%QX4.0

%QX4.8

%QX5.0

%QX5.8

%QX6.0


02 UPDATE 25/02/11 MS

P1207

A

P1213

1

P1207

B21

H2 COOLING FAN

731SLM3A02-01THERMATRON

M

P1213

2

CS604

/7/703/8/803/9/903

/10/1004/11/1103/13/1304

/6/605

OUT08_NC01

OUT10_NC09

n.c.12

n.c.04

X5.1

Ucom0302

n.c.08

Ucom0406

OUT09_NO07

OUT09_NC05

OUT08_NO03

OUT11_NC13

OUT12_NC17

Ucom0510

OUT10_NO11

TB19

OUT11_NO15

Ucom0614

21

PMP1003 24VDC

DI WATER CIRCULATION PUMPMY2-8000.0019

SPECK PUMPEN

M

OUT12_NO18

Ucom1216

TB114

TB110

TB122

23

4082

18AWGBLK12074

20AWGBLU/WHT12073

20AWGBLU12072

18AWGRED12071

18AWGBLK12134

18AWGBLK12133

18AWGRED12132

18AWGRED12131

20AWGBLU12311

20AWGBLU12251

20AWGBLU12191

18AWGBLU12121

20AWGBLU12061

TB138

39

TB182

84

1 2

5A

FERRAZ SCWAMUTATDR 5

FU1213

18AWGBLU12130

20AWGBLU12201

A1 A2

24V,6A,1 PDT


CR1231

SYSTEM ENABLE (SOFT)

11 14 /5/504

A1 A2

CR1225

ENABLE POWER STACK24V,6A,2 PDT


11 14 /5/517

21 24 /5/528

TB185

TB186

20AWGBLU12071

20AWGBLU12252

20AWGBLU12312

20AWGBLU/WHT4201

21

FAHX 2003/12/1204

M

TB183

4221

3x18AWG/12/1204

W12073x18AWG

/12/1204W1207

3x18AWG/12/1213

W12133x18AWG

/12/1213W1213

C18AWGBLK

12075

21731SLM3A02-01

THERMATRON

M21FAHX 2031

/12/1209

O2 COOLING FAN

M

3x18AWG/12/1209

W12103x18AWG

/12/1209W1210

18AWGBLK12104

20AWGBLU/WHT12103

20AWGBLU12102

18AWGRED12101

18AWGBLK12105

P1210

A

P1210

B

C

+24V_211/1138

+24V_213/1303

0V_2

0V_Relay9/918

+24V_18/839

An_INPUT_CURR1 / 9/905

1301

1302

1303

1304

1305

1306

1307

1308

1309

1310

1311

1312

1313

1314

1315

1316

1317

1318

1319

1320

1321

1322

1323

1324

1325

1326

1327

1328

1329

1330

1331

1332

1333

1334

1335

1336

1337

1338

1339

1340


171214

Page:13

DIGITAL OUTPUTS

of




24/02/2011M.SUSTAC

Name Date

Approved By:

Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

R9

R8

R7

R6

R5%QX6.8

%QX7.0

%QX7.8

%QX8.0

%QX8.8


02 UPDATE 25/02/11 MS

1 2

PMP1000PUMP FEED WATER

8841-2M03-B594AQUATEC

M

CS604

/7/703/8/803/9/903

/10/1004/11/1103/12/1201

/6/605

OUT13_NC01

n.c.04

X5.2

OUT13_NO03

Ucom0802

x2x1

X3

SV2013

DRYER UP VALVE


x2x1

X3

SV2018DRYER REGEN B VALVE

ASCO VALVE CANADA 8262G134 - 24VDC

OUT14_NC05

OUT14_NO07

Ucom0906

n.c.08

x2x1

x3

SV2014

DRYER REGEN A VALVE

ASCO VALVE CANADA 8262G134 - 24VDC

n.c.12

OUT15_NC9

OUT15_NO11

Ucom1010

x2x1

X3

SV2012

DRYER IN VALVE


OUT16_NC13

OUT16_NO15

Ucom1114

1 2

MT130924VDC, 130 CFM VENTILATION FAN ELECTRICAL CABINET

4715KL-05W-B59-P00TEHNOLOGIES CORPORATION

M

OUT17_NC17

OUT17_NO18

Ucom1216

P1314

1

P1321

1

P1323

1

P1327

1

P1333

1

P13142

P1321

2

P1323

2

P1327

2

P1333

2

TB115

16

17

18

19

TB132

TB130

4083

20AWGBLU13081

18AWGBLK13141

18AWGRED13271

18AWGRED13331

20AWGBLU/WHT13082

18AWGRED13142

18AWGBLK13143

18AWGBLK13144

18AWGRED13202

18AWGRED13203

18AWGRED13232

18AWGRED13233

18AWGBLK13204

18AWGBLK13234

18AWGRED13272

18AWGRED13273

18AWGBLK13274

18AWGRED13332

18AWGRED13333

18AWGBLK13334

20AWGBLU13061

18AWGBLU13121

20AWGBLU13251

20AWGBLU13191

20AWGBLU13311

1 2

MT1305

VENTILATION FAN ELECTRICAL CABINET

M

33

TB187

TB188

TB189

90

91

1 2

2A

FU1314

20AWGBLU13201

20WGBLU13271

20AWGBLU13331

18AWGBLU13140

x2x1

x3

SV1127

FEED WATER VALVE


P1311

2

P1311

1

TB131

20AWGBLU13081

18AWGRED13122

18AWGBLK13123

18AWGBLK13124

18AWGRED13121

3x18AWG/13/1311

W13113x18AWG

/13/1311W1311

3x18AWG/13/1314

W13143x18AWG

/13/1314W1314

3x18AWG/13/1325

W1323

3x18AWG/13/1319

W13213x18AWG

/13/1319W1321

3x18AWG/13/1325

W1323

3x18AWG/13/1329

W13273x18AWG

/13/1329W1327

3x18AWG/13/1334

W13333x18AWG

/13/1334W1333

318AWGGRN

13125

3

3

318AWGGRN

13275

318AWGGRN

13335

18AWGGRN13235

18AWGBLK13205

+24V_212/1232

+24V_2

0V_17/739

0V_1

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

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Name Date

Approved By:

Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

1501

1502

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GROUNDING

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24/02/2011M.SUSTAC

Name Date

Approved By:

Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

GROUND RAIL

2

CABLE SHIELDS:W927;W1006;W1013;W1022;W1031

GND CONNECTOR

EL PANEL GND SCREW


02 UPDATE 25/02/11 MS

X1534

BACK PANEL COVER

FRAME RIGHT SIDE

AWG 4GRN/YEL

AWG 14GRN/YEL

FRAME LEFT SIDE

14AWGGRN/YEL

DOOR LEFT SIDE

DOOR RIGHT SIDE

14AWGGRN/YEL

14AWGGRN/YEL

14AWGGRN/YEL

14AWGGRN/YEL

GND


171517

Page:16

PANEL LAYOUT

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24/02/2011M.SUSTAC

Name Date

Approved By:

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J.L.

26 inch

28 in

ch

107TERMINALS

START RESET E-STOP DISCONNECTHOUR METER

LCD display

CURRENT SENSOR

STOPFAULT

inside panel

MT1

305

MT1

309

P1

P613

P517P519

ELECTRICAL PANEL

RIGHT SIDE: CABLES TO TERMINAL BLOCKS

ELECTRICAL PANEL-LAYOUT OF APPARRATUS

LEFT SIDE: CABLES TO TERMINAL BLOCKS

2

TB1

DUCT: G.5X2LG6COVER:C.5LG6

.5 inch DUCT: G.5X2LG6COVER:C.5LG6

.5 inch

DUCT: G.5X2LG6COVER:C.5LG6

.5 inch

6 in

ch6

inch

7 in

ch

7 in

ch

DUCT: F1.5X2LG6COVER:C1.5LG6

1.5 inch

DUCT: F2.0X2LG6COVER:C2.0LG6 2 inch

DUCT: G1X2LG6COVER:C1LG6

1 inch

1 inch

1 inch

2.5 inch

9.5

inch

3 in

ch


1 inch

02 UPDATE 25/02/11 MS

CS604

CR0301

CR50

9PL

C -R

SC-2

4DC/

21-2

1

CR51

3PL

C -R

SC-2

4DC/

21-2

1

TB1

WEI.1020000000 (WDU2,5)WDU 2.5

19

TB1WDU 2.5

20

PB504HW1E-LV4F02QD-R-24V

PB820HW1L-M1F10-QD-G-24

HM529

701DR001O1248D2

VM15

00M

CR-V

DC-

UI-

B-D

C

U625

LK204-25-WB-VPT

CM1500

DCS36-300-1

PB822

HW1B-M1F01-R

FU12

13

USCC1I

FU13

14

USCC1I

CR53

1PL

C -R

SC-2

4DC/

21-2

1

CR53

5PL

C -R

SC-2

4DC/

21-2

1

CR12

25PL

C -R

SC-2

4DC/

21-2

1

CR73

5PL

C -R

SC-2

4DC/

21

CR73

8PL

C -R

SC-2

4DC/

21

DS307

OT63FT3S

FU41

0

USCC1I

FU42

4

USCC1I

FU81

2

USCC1I

FU40

9

USCC2I

CR519

EV200AAANA

PS408

VI-QCW31-ESY

CR517

EV200AAANA

FU320

FT FH

FU32

0CN

N 2

50

FU321

FT FH

FU32

1CN

N 2

50

FU32

6

USCC2I

ATD

R0.

5

ATD

R0.

510

0

ATD

R20

FUSE

,20A

, TIM

E D

ELAY

101

ATD

R20

ATD

R15

ATD

R2

ATD

R5

ATD

R2

ATD

R2

PB514HW1L-M1F10QD-S-24V

PB, WITH LAMP,BLUE,24V,1NO9

CR12

31PL

C -R

SC-2

4DC/

21REL

AY,2

9661

71,2

4V,6

A11

0

CR50

4LY

1N-D

2-D

C24V

REL

AY,2

4V,1

5A,S

PDP

111


1716 Page:

17

CABLE CHART

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24/02/2011M.SUSTAC

Name Date

Approved By:

Created By:


1038968Page Title:

Revision Number:


Checked By: M.XU

J.L.

CABLE SOURCE DESTINATION

W531

W536

W704

W720

W724

W727

W731

W734

W738

W908

W927

W1006

W1013

W1022

W1031

CABLE SOURCE DESTINATION

W1107

W1116

W1120

W1124

W1130

W1207

W1213

W1311

W1314

W1320

W1323

W1327

W1333

TSH2002 TB1(3;40)

PS2100 TB1(3;41)

GD703 TB1(5;28;50)

LSL1000

LSH1000

TB1(7;54)

TB1(7;55)

FSL1007

PS2026

TB1(8;56)

TB1(8;57)

LSL4003

LSH4003

TB1(6;29;48)

TB1(6;29;49)

RIT1100 TB1(12;66)

AFS1000 TB1(43;46;69)

PT1006

PT1010

TB1(11;70)

TB1(11;71)

TE1004

TE2010

TB1(44;47;72)

TB1(44;47;73)

FAHX1004 TB1(34;74)

SV3005 TB1(35;76)

SV2019

SV4003

TB1(35;77)

TB1(36;78)

FAV1000 TB1(37;79)

FAHX2003 TB1(38;82)

PMP1003 TB1(39;83)

SV1127 TB1(31;88)

PMP1000 TB1(31;88)

SV2012

SV2013

SV2014

SV2018

TB1(32;89)

TB1(32;89)

TB1(33;90)

TB1(33;91)

2


02 UPDATE 25/02/11 MS

E- HYDROGENICS CORPORATION Revision 3

INSTALLATION, OPERATION AND MAINTENANCE MANUAL PEM ELECTROLYZER

Hydrogenics Corporation220 Admiral BoulevardMississauga, OntarioCanada L5T 2N6Phone: 905.361.3660Fax: [email protected]

Hydrogenics GmbHAm Wiesenbusch 2 - Halle 545966 GladbeckGermanyPhone: +49.2043.944.133Fax: [email protected]

Manual Hidrigeneradora

Documents

castrol braycote

hydrogenics220

load bus bars

cnn 250ferraz

oxygen compatible

strong oxidizing

1a general

proper governmental