dh

domnick hunter
scientific

HYDROGEN GAS GENERATORS

20H/40H/60H Models

User Guide

GB NL D F FI SV NO DK HE ES PO IT
 GB
This Product is designed and built in compliance with
the ATEX directive. It is not suitable and must not under
any circumstances be used in any Hazardous,
Flammable or Explosive environments.

Location of the Gas Generator

GB
Environmental conditions:
This equipment is designed to be safe at
least under the following conditions:
INSTALLATION CATEGORIES II;
POLLUTION DEGREE 2

2
HYDROGEN USER GUIDE CONTENTS

1.1) Safety Warning 4

1.2) General Information 5

1.3) Dimensions 5

1.4) Technical Specification 7

1.5) Recommended System Layout 8

1.6) Installation Procedure 9

1.7) Shutdown Procedure 13

1.8) Operating 14

2) Maintenance Schedule 20

3) Trouble Shooting 25

4) Warranty 27

5) Notes 28

3
General Warning.
This product must be installed and maintained by competent and authorised personnel only, under strict
observance of this user guide, and any relevant standards and legal requirements where appropriate.

Read and understand this user guide before using, installing or undertaking any maintenance of this product.

Failure to correctly perform procedures detailed within this user guide can result in an unplanned release of
pressure, which may cause serious personal injury or damage.

Replacement parts must be disposed of in accordance with local laws or regulations.

Retain this user guide for future reference

Symbol Warning.
Warning: Highlights actions or procedures which, if not performed correctly, will lead to personal injury, a safety
hazard or damage to this product.

1.1) Safety Warning.

Do not operate this gas generator until the information contained in this document has been read and understood
by all personnel concerned.

Hydrogen is a highly flammable gas. Safe working practices and all relevant local health and safety regulations
should be observed by personnel operating and maintaining this generator. It is essential to keep the gas generator
away from excessive heat and naked flames as there is the possibility of explosion if safety warnings are not
adhered to. All connections to the generator should be periodically checked to minimise the risk of leaking hydrogen
and potential ignition.

In addition to the flammability danger, the accumulation of hydrogen can displace oxygen, thereby creating an
asphyxiation hazard.

The generator produces a small flow of product oxygen & H2 slightly above atmospheric pressure, which is vented
at the rear of the generator. All vent ports at the rear of the unit must be kept clear and free from blockage to ensure
safe operation.

Position equipment to ensure easy access to rear.

4
1.2) General Information
The gas generator will produce a constant stream of hydrogen at a pre-determined flow rate when connected to a
suitable power supply and fed with a suitable quality of deionised water. These units are suitable for use in
laboratories and light industrial environments and are non-hazardous for transportation purposes.

It should be noted that the Hydrogen generator must be installed and running within three months of
despatch from domnick hunter limited, to ensure the optimum efficiency of the PEM cell. Failure to do
this will invalidate the warranty.

Note: Any interference with calibration warning labels and tampering with internal parts will also invalidate the
warranty and may incur costs for rework or recalibration of the gas generator.

Cleaning Requirements: Only use damp cloth, no detergent or solvents to be used

1.3) Dimensions

5
1.3) Dimensions Cont.

6
1.4) Technical Specification
Models: 20H, 40H, 60H

Water Specification: Deionised, ASTM Type II, >1 megohm-cm

Flow Rates:

20H 160cc/min hydrogen

40H 250cc/min hydrogen
60H 500cc/min hydrogen

Outlet Pressure: 0 – 7 barg (0 – 100 psig)

+/- 0.07barg (1psi)

Hydrogen Gas Purity: >99.999%

Mains Supply: 110-230 Vac

50-60 Hz

Fuse Rating: Input Mains Fuses –

Manufacturer, Bussmann, Type S505, Rated 250V, F5AT.

Manufacturer, Littelfuse, Type Series 215, Rated 250V, F5AT
Alternate Input Mains Fuses Listed, Rated 250V, F5AT

Power Consumption:

20H 125 Watts

40H 185 Watts
60H 235 Watts

Gas Drying: Molecular sieve

Ambient Temperature: +5 to +40ºC

Water Consumption (approximate):

20H 1.25L / Week

40H 2L / Week
60H 4L / Week

Figures based on full flow with 24 hour 7 day operation at 22˚C ambient

7
1.5) Recommended System Layout

8
1.6) Installation Procedure
1) Locate the generator in the position it will normally be used and as close to the application as possible. Do not
connect gas supply piping until the recommended system layout has been read and understood.

Note: Care should always be taken when lifting equipment. It is recommended that 2 people should lift the
equipment, from the base only, or use a suitable lifting device. Local procedures for lifting should be adhered to at
all times

2) After reading the recommended system layout (page , install the unit as follows:

Remove the fitting cover from the Hydrogen outlet port

Remove the three transit plugs from the rear of the generator

9
Installation Procedure Cont.
Connect to application (using pipework recommended for hydrogen gas). NB: Purge the outlet pipework for
at least 15 minutes to remove trapped oxygen before connecting to the application.

3) Obtain a supply of deionised water (see specification on page ) and fill the water container to the “FULL”
mark on the water reservoir

10
Installation Procedure Cont
4) Remove cartridge from the packaging

Cartridge
Insert into water reservoir fill neck and fit cap securely.

NOTE
It is recommended that the generator is not flowing hydrogen when the water bottle cap is removed. Place into
standby mode or isolate power.

11
Installation Procedure Cont
Power Connection and Sequence of Operation
1) The generator operating voltage is marked on the rating plate.
2) Connect the power cord to the rear panel of the generator.
3) Connect the free end of the power cord to an appropriate power source.

1. 100 – 230 Vac 50 – 60 Hz

250V, F5AT

5) Switch on power source. The generator will give audible indication of the start up process. The unit serial
number and model will be briefly displayed.

6) The Generator will now start to produce hydrogen, the outlet valve will remain shut until the unit has reached
operating pressure. Operating pressure or set pressure (shown as SET on the display) is set via the keypad
located on the front of the generator, the generator will revert to the last known setting when restarted. During
start-up, the unit may automatically revert to the last error mode it experienced, if it does press the reset button to
clear it (Centre button on keypad) and continue with the start up procedure. If it cannot be cleared by this method
follow the faultfinding procedure at the end of this manual.

7) The start-up builds internal pressure or Actual pressure (shown as ACT on the display) until it reaches the SET
pressure. (Indicated on the main display panel) using maximum current. This takes 5 – 10 minutes, depending on
the model, during which the system check LED will flash. This is the LED located in the front display panel.

8) The generator will continue the system check and a leak test takes place for two seconds when the generators
reach desired pressure. The system check LED will continue to flash.

9) Outlet solenoid valve opens. The system check is now complete and if successful the system check LED
becomes constantly lit. The generator is now on line and supplying gas

The generator will now run maintaining flow at the set pressure. We advise that the outlet pipework be purged for
15 minutes to remove oxygen before connecting to the application.

12
1.7) Shutdown Procedure
If a service or faultfinding procedure requires the generator to be shut down, it is imperative that the following
service shutdown instructions are followed carefully.

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

2) Switch the generator off at the mains switch and

isolate from the supply by removing the
appliance connector from the appliance inlet.

3) Slowly disconnect the Hydrogen outlet connection pipe from the side of the generator allowing the system to
de-pressurise

1 Warning Hydrogen Gas will be released at pressure, ensure generator is fully depressurised before
starting any maintenance

4) The generator is now shut down.

13
1.8) Operating

Controller Interface

14
Controller Interface Cont.

Default Operating Screen

This is the screen that will be displayed under normal operating conditions

SET Set Pressure

User adjustable outlet pressure control, use up and down keys to increment and decrement set pressure.

ACT Actual Pressure

Current actual internal / outlet pressure of the generator

X/ Status of generator outlet. X = outlet valve is shut and generator is NOT currently on line.
= Outlet valve is open and generator is on line and flowing hydrogen.

% Percentage of max flow currently being supplied. Each block indicates 20%, during initial pressure up or
after a massive pressure drop the flow indicator will show 100% and the flow status will be X indicating
the generator is building internal pressure and not currently on line.

15
Controller Interface Cont.

Water Quality Screen

The conductivity bar graph will count down from full illumination if water quality degrades, when Four blocks are
left illuminated the “Change Water” error message will be displayed, this will not interrupt the flow of hydrogen
from the generator. The water bottle will flash red (if option fitted) and an intermittent alarm will sound, at the
earliest convenient time the bottle should be drained and refilled with deionised water >1 megohm-cm. Should the
water quality degrade to the point at which all the blocks are extinguished the generator will shut down via a
conductivity error. The water bottle will light red (if option fitted) and a continuous alarm will sound, the flow of
hydrogen will be stopped at this point.

Pressure units of measurement

By using the up and down keys the unit of pressure measurement can be changed between bar, psi & Mpa.

16
Controller Interface Cont.

Run time screen

Run Time Time in hours the generator has been producing hydrogen.

Amp Hours Number of amp hours the hydrogen cell has seen i.e. if the cell has been running for 1 hour @
20amps then the Amp Hours will increase by 20.

Controller Interface Cont.

5
Flow screen
Flow cc/min Current flow in cc/min being produced by the generator. This is for indication only and we
recommend the use of a flow meter to gain an accurate measurement.

Litres Total amount of Hydrogen produced by the generator, measured in litres

17
Controller Interface Cont.

Self-Test screen
Pressing and holding both arrow keys while in this screen enters the self-test mode, the outlet fitting must be
removed before testing can begin. The steps are as follows

Pressure release All pressure in the generator is released the test will not proceed until 0
bar is achieved.
Pressure build The unit will build pressure to 100psi while monitoring the time taken.
Pressure Hold The generator will perform a pressure decay test for a pre-determined time.
Pressure Release The outlet solenoid is opened and the pressure released. The test will not progress
unless 0 bar is achieve
Test Passed / Failed If all criteria are meet then a pass is displayed, else fail

NOTE
It is recommended that the self-test feature be used when a part of the pressure circuit is serviced, such
as a desiccant cartridge change.

18
Controller Interface Cont.

Standby Screen
If the enter key (middle key) on the keypad is held the generator will enter standby mode. The generation of
hydrogen is stopped and the outlet valve is closed. Pressing this key again will return the generator to start up
mode and then to online delivery.

8
Reset Screen
Pressing the enter key (middle key) during an error condition will reset the system

NOTE
Hard Reset
If an overpressure, O2 vent blocked error is seen the system will need to be hard reset once the problem has
been resolved. This is also the case if the same error is reset 3 times consecutively.

How to perform a Hard Reset

The initial problem must first be resolved, then the power be removed from the unit. On reapplying power the
enter key (middle key) must be held, then the enter key must be pressed again as with a normal reset.

19
2) MAINTENANCE SCHEDULE

Recommended
Recommended
Description of
Description of Service
Service Requirement
Requirements ServiceInterval
Service Interval

24 Monthly
6 Monthly
Weekly
Daily
Operation
Operation

Check
Check POWER
POWERON ONindicator
indicatorisisilluminated
illuminated C - - -
Check STATUS/FAULT
Check STATUS/FAULT indicators
indicators locatedlocated
on on
control panel
C - - -
control panel
Check
Check Water
WaterLevel
Level C - - -
Check
Check Water
Water Quality
Quality(Conductivity)
(Conductivity) C - - -
Check
Check Drying
DryingCartridge
Cartridge - C - -
66 Month
MonthService
ServiceKit
Kit - - R -
24
24 Month
MonthService
ServiceKit
Kit - - - R

Key:
Key: C (Check)R (Replace)
C (Check) R (Replace)

This product should be installed in accordance with the recommendations outlined in this manual. Commissioning
and service should be undertaken by a domnick hunter trained, qualified and approved service engineer to
maintain warranty.

Extended warranty, tailored service contracts, and optional extras are available for this product. Please contact
your local domnick hunter sales office for a tailored service agreement to meet your specific requirements.

20
MAINTENANCE CONT.
Replacing De-ioniser Cartridge

It is recommended that the generator is placed in standby before replacing the cartridge / bags

Remove the exhausted cartridge / bags and discard. Replace with new

3. Water bottle cap must be fitted when the generator is in operation

21
MAINTENANCE CONT.

Replacing Enironmental Filters

22
MAINTENANCE CONT.
Replacing Drying Cartridge

Switch off and isolate from the main supply

Depressurise the unit by removing the outlet fitting

1. Ensure generator is fully depressurised

23
MAINTENANCE CONT.
Replacing Drying Cartridge Cont.
Remove the exhausted desiccant cartridge by rotating anti-clockwise and withdrawing.

2. Hand tighten then 1/8 turn. Do not over tighten, Risk of damage and leakage if over tightened

3 Perform system self check after replacing the drying cartridge. See operating section

16000 hour Service Interval

At 16000 hours run time the generator will alarm and indicate the service interval has been reached. The
generator can be reset at this point but the message “Service Reqd” will continue to alternate with the parameter
set pressure on the top line of the LCD. At this point the 24 month service should be carried out using the 24
month PM Kit.

24
 Water Level and Quality
If Fitted Water
Bottle LED Status
3) Trouble Shooting

Pressure Errors

25
If Fitted Water
Bottle LED Status
 Internal Electrical Faults
If Fitted Water
Bottle LED Status

Sensor Faults
If Fitted Water
Trouble Shooting Cont.

Bottle LED Status

26
Other Faults
If Fitted Water
Bottle LED Status
4- WARRANTY
This warranty applies to HYDROGEN GENERATORS and associated parts (the Equipment)
manufactured and supplied by domnick hunter ltd (domnick hunter).

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

Should the Equipment be defective as to materials or workmanship, domnick hunter warrants that it
will remedy such defect. Where the Equipment is a HYDROGEN GENERATOR, the warranty period
will be 12 months from date of commissioning or 18 months from date of manufacture, whichever is the
earlier. In the case of Equipment other than a HYDROGEN GENERATOR the warranty period shall
commence from the date of despatch. Should any defect occur during the warranty period and be
notified in writing to domnick hunter or its authorised distributor within the said period, domnick
hunter will, as its sole option, remedy such defect by repair or provision of a replacement part,
provided that the Equipment has been used strictly in accordance with the instructions provided with
each item of Equipment and has been stored, installed, commissioned, operated and maintained in
accordance with such instruction and with good practice. domnick hunter shall not be under any
liability whatsoever under the warranty, if, before giving notification in writing to domnick hunter as
aforesaid, the Customer or any third party meddles, interferes, tampers with or carries out work
whatsoever (apart from normal maintenance as specified in the said instructions) in relation to the
Equipment or any part thereof.

Any accessories, parts and equipment supplied by domnick hunter but not manufactured by domnick
hunter shall carry whatever warranty the manufacturer has given domnick hunter providing it is
possible for domnick hunter to pass on such warranty to the customer.

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

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

27
5 – NOTES

28
5 – NOTES Cont.

29
 DECLARATION OF CONFORMITY FOR GB
20H, 40H, 60H

IEC 1010-1:90+A1:92+A2:95

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

Name of manufacturer or supplier: domnick hunter ltd.

Full postal address including country of origin:

Dukesway, TVTE, Gateshead, Tyne & Wear, NE11 0PZ
United Kingdom

Place of issue: Gateshead

Description of product: Laboratory Hydrogen Generator

Name, type or model, batch or serial number: 20H, 40H, 60H

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

Name of authorised representative

B.Wade

Position of authorised representative

Business Systems Improvements Manager

Full postal address if different from above

As Above

Declaration
I declare that as the authorised representative, the above information in relation to the supply /
manufacture of this product, is in conformity with the standards and other documents following the
provisions of the above Directives.

Signature of authorised representative

30
dh, domnick hunter, OIL-X and Pneudri are
registered trademarks of domnick hunter limited.

domnick hunter limited has a continuous policy of

dh
product development and although the Company
reserves the right to change specifications, it attempts to domnick hunter
keep customers informed of any alterations. This
publication is for general information only and customers
scientific
are requested to contact our Industrial Division Sales
domnick hunter limited
Department for detailed information and advice on a
Dukesway, Team Valley Trading Estate,
products suitability for specific applications. All products
Gateshead, Tyne and Wear,
are sold subject to the Company’s standard conditions
England NE11 0PZ
of sale.
Tel: +44 (0)191 402 9000
Telefax: +44 (0)191 482 6296

www.domnickhunter.com Copyright domnick hunter limited 2004

a member of the domnick hunter group plc Stock No: 174970180 Rev 000