TM

TELEDYNE TITAN EC GENERATOR SERIES

Hydrogen/Oxygen Gas Systems

OPERATION AND MAINTENANCE MANUAL

FOR THE TELEDYNE

TITANTM EC

HYDROGEN GENERATOR SYSTEM

OCTOBER 2008

iii
 TABLE OF CONTENTS

INTRODUCTION

SECTION 1: SYSTEM DESCRIPTION

SECTION 2: INSTALLATION CONSIDERATIONS AND

INSTRUCTIONS

SECTION 3: GENERATOR OPERATION

SECTION 4: MAINTENANCE AND CALIBRATION PROCEDURES

SECTION 5: TROUBLE-SHOOTING AND REPAIRS

SECTION 6: SPARE PARTS LIST

APPENDICIES:

1: DRAWINGS

ƒ GENERAL ARRANGEMENT

ƒ P & I DIAGRAM, EC GENERATOR

ƒ ELECTRICAL SCHEMATIC, EC GENERATOR

2: OPTIONAL INSTRUMENT DOCUMENTS

3: PRODUCT BROCHURES

iv
 FOREWORD

Teledyne EC series generators produce hydrogen and oxygen gas through the
electrolysis of water. The end user normally requires high purity hydrogen for an
industrial process, or is compressing hydrogen for storage and/or transport.
Many users also require high purity oxygen, which is available on the EC-C
machines. If the machine is the standard EC model, the reader should disregard
discussion of “C” system components.

This manual discusses the installation of an EC generator and power supply.

Facility considerations are discussed, followed by the specific service and interface
requirements. Installation includes many aspects pertaining to safety that must be
carefully considered by the end-user.

The EC generator system is built around the electrochemical cell stack (referred to
as the module), where mechanical, thermal, electrical and chemical actions are
occurring. The EC-750 generator platform (includes EC-500 and EC-600)
contains one module, while the EC-1000 generator contains two modules. The
purification of evolved gases occurs downstream of the module. These processes
involve supporting components that bring various technologies in to an integrated
automatically controlled system. This manual will provide an explanation of each
important machine function by describing the component(s) in terms of their
purpose and specifications, and by discussing how each is controlled and
monitored from a systems standpoint.

Machine operation is also fully covered – from initial preparation and checks
through startup, normal function, and normal or fault condition shutdown. This
manual also includes preventative maintenance procedures and the necessary
information to identify and correct problems. A component listing is provided to
help identify and request information on replacement parts. All process
components are marked with the numbers shown on diagrams and referred to in
the text of this manual.

It is important for the user to gain a good understanding of the individual

components as well as the integrated system aspects of the EC generator. The
user must also understand the various hazards present in any such process. This
can be accomplished by reading this manual and the sub-component manuals and
by taking advantage of factory training offered by Teledyne. These are important
steps in maintaining a process that provides the expected machine performance,
maintains safety, and minimizes problems and down time. INTRODUCTION TO
THE MANUAL

v
Manual Organization

This manual is divided into sections as follows. The sections are intended to be
essentially independent as regards the activities described. Sections 1 and 2 may
be useful to customers considering an EC generator and/or for planning and early
training. Sections 3 through 6 are normally not available prior to receipt of a
purchase order for an EC:

Section 1 System Description and Specifications

Basic principles, general description, and a listing of performance and other

specifications, discussion of basic safety considerations. Section 1 is useful for
introduction to the generator, quick specification reference, and training.

Section 2 Installation Considerations and Instructions

Facility considerations (including related safety information), specific interface

information and installation instructions. Section 2 concerns installation
dimensions, loads and interfaces, and is useful for facility planning as well as
specific instructions.

Section 3 Generator Operation

Preparation and pre-start checks, start-up, normal machine functions and

indications, normal shutdown and fault related automatic shutdown.

Section 4 Maintenance and Calibration Procedures

Section 5 Troubleshooting and Repairs

Section 6 Spare Parts List

Terms and Conventions Used

The generator components are located within one of two structures. The term
"gas cabinet" will be used to describe the steel frame supporting the main EC
components including the electrolysis modules, fluid and gas piping and vessels,
purification and pressure controls and an electrical enclosure which contains the
programmable logic controller (PLC) and other electrical components. FIGURE
1.1 shows the EC "gas cabinet."

The term "power supply" will be used to describe the rectifier, main 3-phase
transformer, auxiliary single phase transformers and rectifier controls, all of which
vi
are enclosed in a single cabinet normally in a different room or location from the
"gas cabinet." FIGURE 1-2 shows the power supply.

The term "feedwater" is used for purified water consumed by the EC in the
electrolysis process.

The diagrams and number references herein pertain to components located in the
gas cabinet. The power supply is manufactured separately and therefore has its
own manufacturer's manual and diagram. Connections between the power supply
and the gas cabinet are shown on the EC electrical diagram, however.

A 3-digit component numbering system is used throughout the manual, on the

Piping and Instrumentation Diagram (P&ID) and Electrical Diagram. The numbers
apply to those components located in the gas cabinet and are:

0nn - pneumatic controls (instrument air controls)

1nn - liquid portion of the hydrogen side of the system
2nn - liquid portion of the oxygen side of the system
3nn - hydrogen gas
4nn - oxygen gas
5nn - inert gas (typically nitrogen)
6nn - cooling water
7nn - pure water
9nn - electrical component without fluid or gas connection

Capital letters A through N (except the letter I) are used to denote the piping
connection points on the EC gas cabinet.

Refer to the P&ID for numbering and the key to symbols used.

Point-to-point wiring is depicted on the electrical diagram. Wiring in the gas

cabinet (and up to the power supply interface) is identified with an enclosed 3-digit
number that can be found on the electrical diagram. Other wire identification
inside the power supply can be found in the manufacturer's manual.

Abbreviations

AWG American Wire Gage (refers to wire sizes)

EPT Ethelyne, propylene terpolymer (refers to O-ring elastomer)
GPM Gallons per minute

vii
H2 Hydrogen gas
KOH Potassium hydroxide - unless otherwise stated, it refers to a solution of 25%
in water at 20°C.
LPM Liters per minute
MCM Millions of circular mils (refers to metric wire sizes)
NM3 Normal cubic meters
O2 Oxygen gas
P&ID Piping and Instrumentation Diagram
PID Proportion, Integral, Derivative (used in controls)
PLC Programmable Logic Controller
PPM Parts per million
SCF Standard cubic feet
SCFH Standard cubic feet per hour
SCFM Standard cubic feet per minute
SLM Standard liters per minute (gas flow rate)

Abbreviations (Continued)

TB Terminal board (electrical connection points)

T/C Thermocouple (temperature measurement probe)
TEFC Totally enclosed fan cooled (refers to motor enclosure)
VAC AC volts
VDC DC volts

Units

Units will be stated in standard and metric terms. If a size is given only in standard
form, it indicates an actual specification such as a pipe diameter or thread size.

Trademark Information and Copy Rights

Swagelok style connections are used in many places to connect small diameter
process tubing. Swagelok is a trademark of the Swagelok Co., Solon, OH, USA.

CPV style connections are used for process pipe and tube connections. CPV is a
trade name of CPV Manufacturing, Inc., Philadelphia, PA., USA.

Teflon is a florelastomer material used for several system gaskets. Teflon is a

trademark of E.I. Dupont, Wilmington, DE, USA.

Several sub-component manufacturers' manuals are furnished as an appendix to

this manual. These are provided in the manufacturers' original form and are not
reproduced by Teledyne. The end-user is responsible for observance of copyright
warnings in these manuals.

viii
 NOTICE

The manual contains Teledyne Energy Systems Inc. proprietary information which
may not be used for the benefit of others except by express permission.
Distribution and availability of this manual should be restricted to activities
concerned with operation and maintenance of the equipment described herein.

LIMITED WARRANTY

This equipment is covered by a limited warranty that establishes limitation of

obligations. See form ES-588 Warranty, Gas Generator System.

ALL FOREIGN CUSTOMERS AND REPRESENTATIVES

To avoid unnecessary charges and delays in U. S. Customs, any and all returned
components of the Teledyne Energy Systems Inc. equipment should be handled as
follows:

1. Notify Teledyne Energy Systems Inc. (Attention Customer Service) of the

need and reason for returning the part. Identify the part as to catalog and/or
part number, name, and the purchase order and equipment serial number
under which the part was originally purchased. Teledyne Energy Systems
Inc. will provide a Return Material Authorization (RMA) number.

2. Supply Teledyne Energy Systems Inc. with Proforma Invoices and copies of
Bills of Lading indicating the part as "Returned U. S. Goods."

3. All shipments should be made to Teledyne Energy Systems Inc., 10707

Gilroy Road, Hunt Valley, Maryland 21031, U.S.A., by way of the Port of
Baltimore, Maryland (for ocean) and Baltimore-Washington International
Airport (by air). Clearly and visibly write the RMA number provided by
Teledyne Energy Systems Inc. on the package exterior.

Failure to clear these returned components through U. S. Customs as "Returned U. S.

Goods" will result in payment of duty which will be to the customer's account.

ix
 SECTION 1 System Description

Table of Contents:

SECTION 1 System Description................................................................................... 1-1

1.1 Configuration .......................................................................................... 1-3
1.1.1 Gas Cabinet ................................................................................. 1-3
1.1.2 Electrical Power Supply ............................................................... 1-4
1.1.3 UPS.............................................................................................. 1-6
1.1.4 Interconnecting Cables ................................................................ 1-6
1.2 Principles of Operation............................................................................ 1-6
1.2.1 Electrolysis of Water .................................................................... 1-6
1.2.2 The Teledyne Cell Stack .............................................................. 1-8
1.2.3 Supporting of the Electrolysis Process....................................... 1-11
1.3 System Description............................................................................... 1-11
1.3.1 Diagrams.................................................................................... 1-11
1.3.2 Electrolyte Loop ......................................................................... 1-11
1.3.3 Cooling Water Systems.............................................................. 1-14
1.3.4 Gas Condensers and Traps (301,401 and 302,402) .................. 1-15
1.3.5 Hydrogen Gas Purification and Delivery .................................... 1-16
1.3.6 Oxygen Gas Purification and Delivery ("C" model only).............1-18
1.3.7 Feed water Supply ..................................................................... 1-19
1.3.8 Inert Gas Supply ........................................................................ 1-21
1.3.9 Instrument Air Supply................................................................. 1-22
1.3.10 Start/Stop and Monitoring Features ........................................... 1-23
1.3.11 Description of Sub-system Controls ........................................... 1-27
1.3.12 Temperature Measurement........................................................ 1-31
1.3.13 Gas Detection - Hydrogen in Oxygen, or Oxygen in Hydrogen..1-32
1.3.14 Programmable Logic Controller (PLC) ....................................... 1-33
1.3.15 Electrical System........................................................................ 1-36
1.3.16 Pipe and Tube Connections....................................................... 1-38
1.4 EC Generator Specifications................................................................. 1-40
1.5 Consumption Data ................................................................................ 1-41
1.6 Safety Warnings and Precautions......................................................... 1-42
1.6.1 Summary.................................................................................... 1-42
1.6.2 Caustic Liquid.............................................................................1-42
1.6.3 Flammable Gas.......................................................................... 1-43
1.6.4 Oxidizer...................................................................................... 1-43
1.6.5 Electrical .................................................................................... 1-43
1.6.6 Compressed Gas ....................................................................... 1-44
1.6.7 High Temperature ...................................................................... 1-44

1-1
FIGURE 1 Gas Cabinet................................................................................................ 1-4
FIGURE 2 Power Supply.............................................................................................1-5
FIGURE 3 Simple Electrochemical Cell ....................................................................... 1-7
FIGURE 4 Electrolysis Module Schematic ................................................................. 1-10
FIGURE 5 Diagram of Electrolyte Loop Components ................................................ 1-12
FIGURE 6 Cooling Water Diagram............................................................................. 1-15
FIGURE 7 Gas Purification ........................................................................................ 1-16
FIGURE 8 Catalyst Portion of Purifier ("C" Model Only)............................................. 1-19
FIGURE 9 Liquid Level Control .................................................................................. 1-20
FIGURE 10 Inert Gas Supply System ........................................................................ 1-22
FIGURE 11 Instrument Air Supply.............................................................................. 1-23
FIGURE 12 System Pressure Control ........................................................................ 1-28
FIGURE 13 Cooling Water Flow Control .................................................................... 1-28
FIGURE 14 Delta Pressure Control -Oxygen Venting................................................ 1-30
FIGURE 15 Delta Pressure Control - Hydrogen Venting ............................................ 1-31
FIGURE 16 PLC Actions ............................................................................................ 1-33
FIGURE 17 Typical Tube Connections ...................................................................... 1-39

1-2
1.1 Configuration

The EC generator system consists of two primary assemblies, the gas cabinet
and the electrical power supply, as well as the electrical cables which
interconnect these units.

1.1.1 Gas Cabinet

FIGURE 1 shows the gas cabinet, a steel frame to which the mechanical fluid
and gas components are mounted. The electrolysis cell stack (referred to as the
module) is supported on base rails at the center of the gas cabinet. The EC-750
generator platform (includes EC-500 and EC-600) contains one module, while
the EC-1000 generator contains two modules. The electrolyte liquid pumping,
cooling, and filtration components are mounted to the gas cabinet base and
connected with 1.5 inch piping.

Components supported on the gas cabinet roof and vertical stanchions are for
gas purification and system controls. These include condensers and liquid traps,
filters, adsorption gas dryers, pressure controls, pneumatic controls, and
feedwater and inert gas supply system components.

The system control touch screen, programmable logic controller (PLC) and
several electrical devices are mounted and pre-wired inside an electrical
enclosure located on the vertical stanchion (back wall) of the gas cabinet.

All components other than the electrolysis module are pre-piped and wired at the
factory. Gas and pure water piping terminations are located at the upper corners
of the gas cabinet at the back wall. The cooling water interface connections are
located at the base corners, below the gas connections. The end-user electrical
interface, a 3-phase AC connection, is inside the power supply enclosure.
Electrical connections required by the end-user such as remote enable or alarm
signals, would be made inside the electrical enclosure located on the gas
cabinet.

1-3
 FIGURE 1 Gas Cabinet

1.1.2 Electrical Power Supply

The electrical power supply is shown in FIGURE 2. It consists of a steel

enclosure with a structural base to which the system's main 3-phase transformer
is mounted. On the side of the main enclosure is a control enclosure, where most
of the inter-connecting cable connections (to the gas cabinet) are made.

The AC to DC rectifier is mounted in the upper portion of the main enclosure,

above rectifier is mounted in the upper portion of the main enclosure, above the
main transformer. Cooling fans are located below the main transformer and below
the silicon controlled rectifiers (SCR's). An uninterruptible power supply (UPS) is
mounted below the control enclosure to provide control power to the generator
when utility power is interrupted.

1-4
 FIGURE 2 Power Supply

Three auxiliary single-phase transformers are also located in the main power
supply enclosure. The rectifier control and isolation boards are mounted in the
side control enclosure. The rectifier instruments and indicating lights are found on
the front of the control enclosure.

1-5
1.1.3 UPS

An Uninterruptible Power Supply (UPS) is included to provide power to the system

controls during times of facility power outages. It will not provide power for the
electrolysis process. The most critical purpose of the UPS is to support the
Differential Pressure Control System which includes critical components that
require electrical power to function. If power to this control system is lost while the
system is pressurized, an abnormal situation could result that may include damage
to the equipment. The UPS is mounted to the side of the power supply.

1.1.4 Interconnecting Cables

The auxiliary power and control cables between the gas cabinet and the power
supply are pre-connected on the gas cabinet side. For shipment to the site, the
cables are rolled and stowed in the gas cabinet. The individual cables are
grouped and tied in harnesses according to voltage, so that the end-user can
separate voltages at installation. Figure 2-7 (in Section 2, page 2-21 of this
manual) is a representation of the cable harness configurations providing sizes
and voltages, which can be used for planning cable tray or conduit runs.

The cables that carry the DC current from the rectifier to the electrolysis module
are USA AWG size 4/0 (approximately 1 inch (25 mm) in outside diameter). Six
(6) cables are used on the positive side, and six are used on the negative side of
each module (twelve cables each side for EC 1000 systems). There is also one
(1) 4/0 structural ground cable installed between the gas cabinet structure and
the power supply structure. All of the 4/0 cable is spooled for shipment to the site
with the main EC components.

1.2 Principles of Operation

1.2.1 Electrolysis of Water

The basic process of the EC generator is the electrochemical decomposition of

water into its basic elements. The process occurs within an electrochemical cell,
or a chamber divided into positive and negative sides, wherein electrical current
flows between metal electrodes through a conductive liquid electrolyte. In
alkaline water electrolysis, the electrolyte is 30% wt potassium hydroxide (KOH).
The positive electrode is referred to as the anode and the negative electrode, the
cathode.

1-6
Refer to FIGURE 3. The cell halves are divided by a wetted membrane that
permits electrical current flow (via the electrolyte) but prevents the transfer of
evolved gases from one side to the other. When a DC voltage is applied, current
flows through the liquid in contact with the electrodes and the gases evolve.

FIGURE 3 Simple Electrochemical Cell

1-7
 At the anode, the reaction is:

4OH- > O2 + 2H2O + 4e-

At the cathode, the reaction is:

4H2O + 4e- > 2H2 + 4OH-

The overall reaction is:

2H2O > + 2H2 + O2

Pure water is consumed within the cell. Electrolyte is added to minimize

electrical resistance and to aid in the reaction by providing an excess of hydroxyl
ions (see anode reaction, above), but is not consumed in the overall process.
The amount of gas evolved on each electrode is directly related to the amount of
DC current flowing through the cell.

1.2.2 The Teledyne Cell Stack

To make the process practical, other cell components are required. Adjacent to
each electrode is a metal flow element, which acts as a conductor and provides
volume for liquid and gas flow. A cell must be adequately supported and sealed,
which is accomplished with Polysulfone frames and Teflon gaskets. Means to
introduce liquid to the cell and to carry away evolved gases and waste heat are
provided within the Polysulfone cell frames, which contain cell ports and liquid
and gas manifolds.

The Teledyne electrolysis module is a stack of individual cells through which the
electrical current flows in series, and the liquid electrolyte flows in parallel liquid
paths to each cell. FIGURE 4 shows a schematic of the basic fluid and electric
current paths. Each cell is separated from the next with a bi-polar sheet metal
disc, which isolates the liquid path and provides electrical continuity to the next
cell. The Polysulfone cell frames surround the internal components and are
stacked with interleaved Teflon gaskets to complete the process containment.
The stack components are maintained under a compressive load to assure good
electrical continuity and to achieve the desired sealing. This is accomplished
with 2.5-inch (63.5-mm) thick stainless steel endplates at each end, and 14
insulated steel tie rods.

1-8
The electrical current flow through each module is in series and is the same in all
cells. The current determines the amount of gas produced in each cell, and the
total number of cells determines the module's production rate. EC module
current, regardless of module size is between 100 and 1000 DC amperes,
depending on the user's demand.

The voltage required to flow current through one cell is, depending on operating
conditions, between 1.8 and 2.4 DC volts. Hence, the DC voltage applied to the
endplates of the module is equal to the product of the number of cells and the
individual cell voltage. Refer to section 1.4 for EC module voltage ranges versus
module size.

1-9
FIGURE 4 Electrolysis Module Schematic

1-10
 Once the module size is established based on the capacity of the end-user, the
voltage and current ranges are known and the power supply is specified
accordingly.

1.2.3 Supporting of the Electrolysis Process

A functional electrolysis process requires an electrolyte pumping system to flow

liquid into each cell and to carry evolved gases and waste heat from the module.
A feed water supply system is required to replenish water consumed in the
process. An inert gas system is required to purge air or oxygen from the system
prior to generating hydrogen. A cooling water loop is needed to remove waste
heat from the electrolyte and to supply the cooling required to condense vapor
from hydrogen and oxygen.

The electrolysis process also involves the need for several instruments and
controls to properly start, run, monitor, and stop the process. These will be
described in more detail in section 1.3.

1.3 System Description

1.3.1 Diagrams

To assist in understanding the various systems, several simplified diagrams are

included in this section. As the user becomes familiar with the machine, the
complete mechanical Piping and Instrumentation Diagram (P&ID) and the
Electrical Wiring Diagram should be utilized.

1.3.2 Electrolyte Loop

There are separate electrolyte pumping loops on the hydrogen and oxygen sides
of the system. Refer to FIGURE 5. Each loop consists of a phase separator
(which serves as a reservoir), a centrifugal pump, a heat exchanger, filter and flow
switch. Downstream of the flow switch, the electrolyte enters the respective side of
the electrolysis module. A mixture of liquid and hydrogen (or oxygen) gas flows
back to the phase separator through the module outlet pipe.

1-11
 FIGURE 5 Diagram of Electrolyte Loop Components
G AS TO TRA P
AND
PU RIFICA TION

PHASE
SE PA RA TOR

ELECTR OLYSIS M OD ULE

FLOW
FILTER SW IT C H

HEA T
EXC HANG ER
(SH ELL SIDE)

CENTR IFUG AL
PUMP

All of the electrolyte loop components are supported on the floor of the EC gas
cabinet.

The electrolyte containment materials including vessels, pipe, and fittings are
fabricated from low carbon series 316L stainless steel. Connections are seal
welded accept where access may be required. Access connection fittings are
CPV style O-ring connections. O-ring material is EPT rubber, which is
compatible with the various process fluids.

Electrolyte Pump (102, 202)

The electrolyte is circulated by means of a magnetically coupled centrifugal pump.
The centrifugal design allows for continuous and long-life operation. The use of a
magnetic coupling between the pump motor and pump impeller provides for
leak-free operation by eliminating rotating seals at the pump shaft. With the
exception of bearing surfaces, all wetted parts of the pump are stainless steel.
The impeller bearing is a carbon and thermoplastic compound that rotates on a
ceramic shaft. Periodic inspection of these bearing surfaces is recommended as
part of the preventive maintenance schedule. Nominal KOH flow rate is
1-12
approximately 19 GPM (72 LPM) for each module depending on electrolysis
module size and electrolyte filter condition.

The pump motor is a 3-phase, 1.0 HP (0.69 KW) motor which operates at the
facility input voltage to the EC's power supply. The motor is a non-sparking
design, totally enclosed fan cooled (TEFC). Motor starters with overload protection
modules are located in the power supply. The motor starters receive a control
voltage signal from the PLC when conditions are acceptable for pump starting.

Heat Exchangers (103, 203)

The heat exchanger is a standard plate-type configuration of stainless steel
construction. The heat rejection rate is controlled to maintain a stable electrolyte
temperature by varying the cooling water flow rate. The water flow rate is varied
by the temperature regulating valve 609.

Electrolyte Filters (107, 207)

The filter assembly consists of six (6) 140 micron stainless filter cartridges
arranged inside an 8 inch (203 mm) diameter stainless steel pressure vessel.
Access to the filter cartridges for cleaning is via a flat bolted flange lid.

Flow Switches (109, 209: A and B for EC1000)

The flow switch assembly consists of a stainless steel body with a removable,
fixed position, single-point, flow sensing element. Flow is monitored on the
hydrogen and oxygen sides and per module if on an EC-1000 unit. The operation
of the sensing element is based upon the thermal dispersion principle: A low-
powered heater is used to produce a temperature differential between two
Resistance Temperature Detectors (RTDs). The RTD temperature differential
varies as a function of forced convection. One RTD is heated and the other
measures the temperature of the electrolyte. A higher flow transfers more heat
away from the heated RTD, therefore creating a lower differential temperature
between the two RTDs. If flow is not adequate, one of the two relay contacts of
the flow switch will open and the PLC will stop electrolysis. This flow switch has
no moving parts and is self-diagnosing. If there is a problem with the heater or
either of the RTDs, one of the relay contacts will open and the PLC will stop
electrolysis. The flow switch is a critical machine monitor due to the importance
of removing heat from the module. Periodic inspection and functional check of
the flow switch is an important maintenance item.

Electrolysis Modules (100: A and B for EC1000)

A description of the electrolysis module internals is found in section 1.2.2. The
pipe connections to the module are located on the negative end plate. The four
connections are 1.5-inch (38 mm) stainless steel pipes with CPV style O-ring
connections. Liquid electrolyte flows from the filter and flow switch to the lower
module connections. A mixture of electrolyte and the respective gas returns to the
1-13
 phase separator via the upper module pipes.

1.3.3 Cooling Water Systems

There are two cooling water systems. Refer to FIGURE 6. The main cooling
water system consists of an inlet strainer (601), a cooling water flow control valve
(609), two heat exchangers (103, 203), and manual valve 603. On "C" model
generators, there is also a gas cooler (428) in the oxygen purification system. The
condenser cooling water system consists of two flat-plate type condensers (301,
401) with manual control valves (605 and 606) and a flat-plate condenser (385)
and manual control valve (611) down stream of the catalyst tank (381). An
additional flat-plate condenser (485) and control valve (610) are used on “C” model
generators.

All wetted process portions of the main cooling system except the strainer body
are constructed of stainless steel. The condenser cooling water lines are
connected in parallel, with stainless steel tubing and Swagelok style fittings. The
KOH heat exchangers are connected in parallel on the water side with 1.0 inch (25
mm) diameter stainless tubing and CPV style fittings.

A 40 mesh inlet strainer (601) is intended to provide a level of filtration adequate

for the EC components. The strainer can be back-flushed by opening manual
valve 608. If the user's cooling water system contains serious particulate
contamination (size or quantity), an additional strainer or filter may be required.

Refer to section 1.3.2.2 for more information on the KOH heat exchanger. Refer
to section 1.3.4 for discussion of condensers and 1.3.6 for discussion of the gas
cooler.

1-14
 FIGURE 6 Cooling Water Diagram

1.3.4 Gas Condensers and Traps (301,401 and 302,402)

Refer to FIGURE 7. On both standard and "C" system generators, water vapor is
condensed for separation from hydrogen and oxygen, and returned to the
electrolyte system. Gas exiting the phase separator (101 or 201) enters every
other plate of heat exchanger (301, 401), where the temperature is lowered
resulting in condensation of water vapor. The gas exiting the condenser next
enters a trap where moisture is collected and returned by gravity to the phase
separator.

Cooling water flows through the gas condenser in the other plates. Lower cooling
water temperatures improve the condensation process and help to minimize the
moisture load on downstream filters and dryers. A chiller is recommended for high
purity requirements in warmer climates. The operator with manual valves 605 and
606 sets the cooling water flow rates in this part of the system. As an example, if
the cooling water temperature is in the range of 15° to 20° C, the flow through
each condenser would be approximately 1-2 GPM (4-7.5 LPM). Normal variations
in site conditions do not require frequent or significant changes in this flow.

1-15
 FIGURE 7 Gas Purification

1.3.5 Hydrogen Gas Purification and Delivery

Coalescing Filters
Again referring to FIGURE 7, from the moisture trap (302), hydrogen flows to a
coalescing filters (380 and then 371) and trap assembly (372, 373 and 374). Each
coalescing filter consists of a stainless steel housing and a layered gas filter
cartridge. As the gas passes from the inside of the cartridge to the outside, vapor
carried by the gas coalesces to form water droplets on the outside of the cartridge.
The droplets then gravity drain to trap 373.

Valve 372, located between the coalescing filter drains and trap 373, is normally
open. Valve 374, which is connected to the gas vent system, is normally closed.
Every 15 minutes, valves 372 and 374 change status for 5 seconds. Valve 372
isolates the process while the pressure in trap 373 causes the small amount of
water in the trap to exit via the vent system.

For a “C” model generator, the configuration is very similar but with each
coalescing filter (480 and then 471) having its own trap assembly (482,483,484
and 472, 473 respectfully). The pressure in traps 483 and 473 causes the small
amount of water in the traps to exit via the oxygen vent system.

1-16
Catalyst Tank and Flat-Plate Condenser
After the first coalescing filter (380) the hydrogen gas flows through a vessel filled
with de-oxo catalyst, which removes any coarse amount of oxygen from the gas
stream. The catalyst in this tank (381) combines H2 and O2 and makes water in
an exothermic reaction. Flat-plate heat exchanger 385 cools the gas and
condenses any water prior to the second coalescing filter (371).

For a “C” model generator, this arrangement is very similar, but the catalyst in the
oxygen side tank must be heated. Thermocouples 486 and 487 measure the
internal temperatures for control and operation.

Adsorption Gas Dryers

Refer to FIGURE 7. Final drying of hydrogen gas, as well as removal of trace
amounts of oxygen, occurs in two sets of 5-inch (127 mm) diameter dryer vessels
downstream of coalescing filter 371. The vessels are designated 314-A and 314-
B, and 315-A and 315-B. Each vessel contains alternating layers of molecular
sieves and de-oxo catalyst. The catalyst causes the recombination of trace
oxygen with hydrogen to form water. The water, along with moisture carried in the
hydrogen, is removed in the sieve layers. The system will remove moisture to
accomplish a moisture level of less than 1 part per million at a typical operating
pressure.

For the dryers to function effectively, moisture retained by the molecular sieves
must periodically be removed. This is accomplished by taking the dryer out of
service every 6 hours, and completing an automatic regenerating process. Refer
to applicable P&ID as the following details are provided. Part of the regeneration
process involves a continuous slow purge of pure hydrogen from the on-line dryer,
through the off-dryer, and out through valves 313 and 370 to the vent system. This
purge flow crosses through orifice 304. The flow between dryer sets through 304
is constant (it reverses direction every 6 hours).

In the first hour of regeneration, heating elements inside the off-dryer tubes are
energized. This causes the sieves to expand and release trapped water vapor.
Next, the heaters are turned off and a valve (335) connected to the on-line dryer
opens for 60 minutes. This parallel path via orifice 334 increases hydrogen purge
flow and cools the dryers. After 60 minutes, valve 335 closes and, for the
remainder of the off-time, the slow purge continues. After 5.5 hours off-line
(approximately 30 minutes before switching), valve 370 closes, and valve 335
opens again. The increased flow from the on-line dryer is used to pressurize the
off-dryer in preparation for being switched back on-line. When the off-line dryer
pressure, as measured by pressure transmitter (378) is sufficient, the dryers
switch.

Three (3) minutes after a dryer switch, valve 370 is opened, causing the off-line
dryer to depressurize in preparation for the regeneration cycle.

1-17
 The above process involves the use of several pneumatic devices that are
controlled by the PLC. Pneumatic control valves are grouped in a modular
assembly with a common air pressure supply and vent port. These are located on
the back wall of the EC. A typical PLC dryer system output sends a 24 VDC signal
to a pneumatic valve. The pneumatic valve directs instrument air pressure to the
operator of a controlled valve, or vents instrument air pressure, to cause a change
in valve position. As can be seen on the P&ID, dryer switching valve 313, vent
valve 370 and bypass valve 335 are all controlled in this manner.

Final Filtration and Delivery

Upon exiting the dryer vessels, hydrogen passes through a 0.5-micron filter (316 or
317) as a final means of removing particles, for example from the dryer sieves.
From the filter, hydrogen flows through a check valve (331 or 332) and to the
delivery manifold.

At the pure hydrogen delivery manifold, pressure is indicated on gage 308.

Hydrogen passes through back pressure regulator (BPR) 309, which prevents over
demand by closing if system pressure falls too low. BPR 340 is connected
between the delivery manifold and the hydrogen vent system. If system pressure
is above the normal set point, this regulator will begin to open to vent hydrogen.

1.3.6 Oxygen Gas Purification and Delivery ("C" model only)

Adsorption Gas Dryers and Heated Catalyst

On "C" model EC generators, an oxygen purification system is included. Many
aspects of this system are identical to those of the hydrogen system. The user
should be familiar with section 1.3.5, which describes the hydrogen purification,
controls, and delivery.

Refer to FIGURE 8. A coalescing filter (471), trap (473) and trap purge valve
arrangement (472, 474) all the same as that of the hydrogen side, are used. The
dryer selection valve (413) is identical to that of the hydrogen side. Oxygen dryer
regeneration occurs on the same cycle, with the same PLC outputs and pneumatic
controls as those described in 1.3.5. For control of the oxygen dryer system
valves (406, 407, 413, 435, 470) a parallel tube is connected to the pneumatic
control outputs for the hydrogen side.

The oxygen dryer vessels are the same as those of the hydrogen side except that
the dryers contain only molecular sieves; there is no layering with a catalyst. In
order to remove trace amounts of hydrogen from the oxygen stream, a heated
catalyst is necessary. The catalyst vessel (412) is aligned with control valves 406
and 407 between dryer tubes 414-A and 414-B or between 415-A and 415-B.
Oxygen enters the first on-line dryer vessel from the coalescing filter (471) for initial
moisture removal. Next, the gas flows through the heated catalyst (412) to cause
recombination of trace hydrogen with oxygen to form water. The hot gas is then
1-18
 cooled in heat exchanger 428 and flows to the second on-line dryer vessel for final
moisture removal. Moisture removal is such that a dew point of less than -60 C is
maintained.

FIGURE 8 Catalyst Portion of Purifier ("C" Model Only)

SW ITCHING CHECK
DRYER VALVE
SW ITCHING HEATED VALVE
VALVE C ATALYST D ELIVERY
BED
.5 M ICRON
FROM
FILTER
C OALESCING G AS COO LER
FILTER
SECO ND
ADSO RPTIO N
FIRST D RYER TUB E
AD SO RPTION
DRYER TUBE SW ITCH IN G
VALVE

The heated catalyst assembly consists of a 3.5-inch (89 mm) diameter vessel with
(4) 750-watt external band heaters. The vessel is mounted in a sheet metal
housing and surrounded with thermal insulation. A thermocouple (418) is installed
in the catalyst and the signal is supplied to the PLC located inside the EC control
enclosure. The controller is set to maintain a temperature of 275 C. The controller
output is an ON/OFF signal to relay 902 supplying power to the four band heaters.

To accomplish the switching of the oxygen flow path through the catalyst, two
additional 4-way valves are used (406 and 407). These valves are physically
identical to valves 313 and 413, and are activated with the same pneumatic air
signal.

Final Filtration and Delivery

Gas filters 416 and 417 and check valves 431 and 432 are identical to those used
on the hydrogen side (refer to section 1.3.5). At the delivery manifold, pressure
gage 408 and BPR 409 are also the same as those of the hydrogen side. There is
no over pressure BPR on the oxygen side of the system because of the pressure
balancing function of the differential pressure control system.

1.3.7 Feed water Supply

Refer to Figure 1-9. To provide high purity water to the system, a displacement
rotary vane pump (701) is used. The pump is a low-volume, high-pressure pump
with a nearly constant flow characteristic. The capacity is 25 GPH (1.6 LPM). The
pump is located on the back wall structure below the electrical enclosure. The
pump motor is a 3-phase, 0.33 HP (0.25 KW) motor which operates at the facility
1-19
input voltage to the EC's power supply. The motor is a non-sparking design, totally
enclosed fan cooled (TEFC). The motor starter and overload module is located in
the power supply.

FIGURE 9 Liquid Level Control

(EC1000 levels displayed)

As the generator consumes water, the liquid level in the phase separators as
1
monitored on transmitter 113, will fall. When it reaches 52% , the PLC will
energize the motor starter and open solenoid valve (702). The pump will operate
until the liquid level reaches 62%. Check valves 703 and 707 are located in the
line leading from the pump to the hydrogen phase separator. These valves, along
with solenoid valve 702, assure that hydrogen gas will not flow in to the feedwater
system. A malfunction resulting in low liquid level (20%) or high liquid level (85%)
will cause the PLC to stop the pump and the electrolysis process.

When the system is not generating gas, feedwater can be added by the operator
at the touch screen.

1
EC500 , EC600 and EC750 generator models fill at 37%, stop at 47% and have a high level
alarm at 70%.

1-20
 All process materials except for the pump vane parts are 316 series stainless
steel.

It will be noted that water replenishment occurs only on the hydrogen side of the
system. This is due to the nature of the basic process, which tends to dilute the
electrolyte on the oxygen side (see anode reaction in section 1.2.1), and to
increase electrolyte concentration on the hydrogen side. The addition of water to
the hydrogen side tends to counteract this affect.

1.3.8 Inert Gas Supply

The hydrogen generating process cannot be initiated with oxygen (oxygen gas or
air) present in the hydrogen side of the system. This may be the case after the
system has been opened for maintenance or has been down for an extended
period. To purge oxygen from the system, an inert gas is used. Refer to FIGURE
10. The inert gas system consists of supply manifold with relief valve (530),
solenoid valve (504), manual valves (505 and 506), and four check valves (507,
508, 509, and 512).

Inert gas flow into the phase separators (101, 201) is normally added as part of an
automatic prepressurization sequence or can be initiated manually at the touch
screen when the system is in the start-up mode. The inert gas supply cannot be
energized if the EC is generating hydrogen and oxygen. When the supply is
energized, solenoid valve 504 changes position allowing inert gas to flow through
manual valves 505 and 506 to the phase separators. Inert gas pressure is
indicated on gage 503. Check valves 507 and 509 on the hydrogen phase
separator and 508 and 512 on the oxygen phase separator prevent process gases
from entering the inert gas system. When solenoid valve 510 is de-energized, the
inert gas manifold is vented to atmosphere (via third port on the valve).

1-21
 FIGURE 10 Inert Gas Supply System

Manual valves 505 and 506 are used to balance the inert gas flow rate to each
side of the system and prevent excessive differential pressure. These valves are
also useful for various maintenance and adjustment procedures.

1.3.9 Instrument Air Supply

As noted in the previous sub-system descriptions, several machine functions

require instrument air pressure. Refer to figure 1-11. There are two supply
manifolds operating at different pressures. Air is supplied to the system via
regulator 001, which is set to 80 PSIG (5.5 Bar). This is the operating pressure for
control valve actuators. In the case of valve 370, for example, a pressure of 65
PSIG (4.5 Bar) is required to overcome the return spring force of the actuator.

1-22
 FIGURE 11 Instrument Air Supply

Regulator 002 is set at 20 PSIG (1.4 Bar). This is the pneumatic instrument
supply pressure required for I/P transmitters 013, 018 and 019, which control the
cooling water valve and hydrogen and oxygen vent valves.

To assure adequate supply, pressure switch 005 is set to activate if air supply
pressure falls below 70 PSIG (4.8 Bar). This signals the PLC to stop electrolysis
and depressurize the system. Because of the critical function of pneumatic
instruments, loss of instrument air supply also causes valve 010 to energize which
temporarily supplies inert gas to the air system. This will assure that controls are
not disabled while the generator is depressurizing.

1.3.10 Start/Stop and Monitoring Features

Generator Starting and Normal Operation

When the machine has been properly set-up, filled and prepared for operation,
power is applied to the EC power supply from the facility breaker or disconnect.
When the UPS power is turned ON (on the side of the power supply enclosure) the
PLC, instruments, and touch screen will be energized. The dryer system and (for
a "C" model) the catalyst vessel heaters are enabled by turning on applicable
breakers (919, 920 and 935) inside the power cabinet electrical enclosure.

If there are no alarm conditions, the process can be started.

On the lower control panel of the generator, the EMERGENCY STOP button must
be pushed out to enable (not to start) electrolysis. This switch is in series with the
signal to supply DC power to the module and will not affect the operation of other
controls or the pumps. The EMERGENCY STOP can be used to stop electrolysis
in the event of a control or touch screen problem. If desired for maintenance or
security purposes, it may be locked.
1-23
If the system pressure at start-up is below 20 PSIG (1.4 Bar) when the operator
wants to start the generator, the PLC will initiate an automatic prepressurization
sequence, supplying inert gas to the system then depressurizing the generator
several times. The system vent valves (320, 420) will close when nitrogen is
added and open when depressurizing. Once the sequence is complete, the inert
gas will turn OFF, and an enable signal will be sent to the power supply control
board. Current will begin to flow through the module and the system pressure will
increase.

The DC module current will be limited by the PLC to a percentage of the ampere
maximum until the system has run a few minutes and the KOH temperature is in
the normal operating range. It will take several minutes for the system to reach
start delivering gas and reach the normal operating pressure. .

If the system is below the pressure set point, higher current (up to 1000 amperes
per module) will be noted until the pressure approaches the set point. If the user is
not demanding gas, the DC current will fall to approximately 100 amperes per
module, once the pressure set point has been reached.

As the KOH temperature rises, the KOH cooling system controls will become active, and
begin to flow cooling water through valve 609. After 1 to 2 hours of operation, the KOH
temperature will stabilize between 60 and 70 C, depending on demand. The
temperature should not exceed 73 C at rated output. A description of the KOH
temperature control system is found in section 1.3.11.2.

The system will function automatically after start-up. The dryer regenerating cycle
will begin and various changes in valve position will be heard periodically (typically
a hissing noise from a pneumatic valve). The traps will purge every 15 minutes.
An increase in module current will be noticed when the 335 and (for a "C" model)
435 valves are open (cool-down and pressurization) as the purge flow represents
a minor increase in demand.

Gas Purity
Upon initial gas generation, there will be a mixture of hydrogen and nitrogen (or
oxygen and nitrogen), within the system, because of the start-up purge. The user
should consider this as regards the purity of delivered gas. It is suggested that a
valve be installed in parallel with the user's delivery valve, which is piped to the
vent system. This will enable a brief purge of impure gas. After approximately 30
minutes of electrolysis, the user may open his delivery valves to receive pure
hydrogen (or oxygen).

For "C" model users requiring very low nitrogen-in-oxygen (less than 0.2 PPM),
several hours of operation may be required to bring nitrogen levels down to this
range. It is noted that the steady-state nitrogen impurity is a function of the gases
entrained in the feed water. Special feed water treatment can significantly reduce
1-24
nitrogen levels in the product gases.

Concerning the time required for typical moisture levels to be reached - a clean
system should deliver pure gas within 30 minutes or so of operation, even after
brief shut-down periods. If the system is new, has not been operated for several
weeks or has been opened for maintenance, it may take one or two days of
operation for the molecular sieves to completely dry out. The amount of time
depends on local ambient conditions and other factors.

Stopping of the Process

The electrolysis process can be stopped if the operator pushes the “POWER
SUPPLY DISABLE” button or the “SHUTDOWN/ PRESSURE RELEASE” button
available on all touch screens. The “SHUTDOWN/ PRESSURE RELEASE”
button depressurizes the generator as well as stops the electrolysis process; the
“POWER SUPPLY DISABLE” button does not. The process will also stop under
any one of several alarm conditions. Stopping results in interruption of the
enable signal from the PLC to the power supply, and in some alarm conditions,
opens the vent valves (320, 420) to depressurize the hydrogen and oxygen
sides. The KOH pumps do not normally stop when the process is stopped. The
pumps will stop, however, in low level, high level and low flow alarm conditions.

If electrical utility power is interrupted (temporary loss and recovery of power), the
UPS will go into battery back-up mode and provide 115 VAC power to the
generator control panel for approximately 100 minutes. In this case, electrolysis
will be unavailable and all pumps will be powerless. All other functions will be
active including the critical differential pressure control system. The system will
alarm and depressurize via the delivery line, down to the set point of valves 309
and 409. From this point the system will slowly depressurize via valves 330 and
430. This could take several hours depending on various other conditions. If
electrical power is not restored the UPS will send a low battery alarm signal to the
PLC when less than 15 minutes of power are remaining. This will initiate a
controlled pressure release before all power is lost. This action prevents any
pressure on the system without differential pressure control.

System Monitors and Alarms

Numerous system parameters and conditions are continuously monitored by the
PLC. Pre-programmed set points stored in the PLC's memory are used for
comparison. When an abnormal condition occurs, the PLC stops gas generation,
sounds a horn, and in some conditions opens the system vent valves. The
conditions that open the vent valves are marked with an asterisk in the table
below. The cause of the shut-down will be indicated on the touch screen. One
condition which will cause only an alarm but no shut-down is the loss of the
enclosure air purge.

In a standard EC generator, there are 20 conditions that will result in system shut-
down and alarm:

1-25
 Shutdown Set Point EC500
EC1000 EC600
EC750
Low KOH level 20% 20%
High KOH level 85% 70%
Low system pressure 51 PSIG (3.5 Bar)
High system pressure * 170 PSIG (11.7 Bar)
Low KOH flow, hydrogen side
Low KOH flow, oxygen side
High hydrogen-in-oxygen content * 180oC
High oxygen-in-hydrogen content * 180oC
Power supply trouble
Low instrument air pressure 70 PSIG (4.8 Bar)
High KOH temperature, hydrogen side 80oC
High KOH temperature, oxygen side 80oC
High H2 side catalyst tank temperature 250oC
Low feedwater purity 1 micro siemen
Loss of facility power
Hydrogen dryer fill problem 30 minutes
Loss of facility enable signal
High differential pressure, oxygen side * 10 inches water
High differential pressure, hydrogen side* 10 inches water
UPS Fault or Low Battery*

In an oxygen system "C" model, three additional alarms are possible as follows:

Shutdown Set Point

Oxygen dryer fill problem 30 minutes

High O2 side catalyst tank temperature 350oC
High catalyst bed temperature 375oC

Surveillance of the Generator

It is not necessary for personnel to be continuously present once the EC is in
normal operation. Most users check the machine once or twice during a work shift.
The user should maintain data recorded from the touch screen or other indicators
during machine checks. A suggested format for information to record is found in
section 3. This data is important in capturing trends and other information that
may be useful for problem solving.

1-26
1.3.11 Description of Sub-system Controls

Pressure Control - Response to Gas Demand

Refer to Error! Reference source not found.. The EC generator controls are
designed to react immediately to changes in user demand for hydrogen or oxygen.
This is accomplished by detecting changes in system pressure resulting from
increased or decreased flow, and altering a control signal to the power supply. The
PLC receives a 4-20 mA signal from pressure transmitter 325, corresponding to a
scale of zero to 300 PSIG (20.5 Bar). The default factory operating pressure
setting is normally 120 PSIG (8.3 Bar) but Teledyne can customize the pressure
between 90 and 160 PSIG (6.2 and 11.0 Bar). The PLC compares the actual
system pressure to the set point pressure and outputs an appropriate analog
output signal to the rectifier control board. As the signal increases, the rectifier
controls increase the firing rate of the SCRs, which results in higher DC module
amperes. As the system pressure approaches the set point, the output signal falls
and the system stabilizes at a module current corresponding to the user's demand.
This control loop utilizes proportional control with integration and derivative
features (PID).

With the system at normal operating temperature (where amperage is not limited),
a response to a change in demand will begin within a few seconds and, depending
on the magnitude of the change, will stabilize within approximately 1 to 4 minutes.

Another purpose of supplying the 4-20 mA system pressure signal to the PLC is to
monitor for high and low pressure conditions. When the pressure is above or
below set points, the generator goes into alarm.

1-27
 FIGURE 12 System Pressure Control

KOH Liquid Temperature Control

The electrolysis process creates excess heat that must be removed via the KOH
heat exchangers (103, 203). Control of the KOH temperature is a critical part of
generator operation. Refer to FIGURE 13. A cooling water flow control system
consisting of a thermocouple (232) on the heat exchanger outlet pipe, PLC,
current-to-pressure transducer (013) and air-operated water control valve (609) is
used to maintain a process temperature between 63o and 73oC.

FIGURE 13 Cooling Water Flow Control

3-15
PSIG
4-20 013 I/P
934 PLC
MA TRANSDUCER

T/C 232 AT 609 FLOW

HEAT-X 203 VALVE
OUTLET PIPE

The input is the thermocouple signal and the output is a controlled cooling water
flow through the two KOH heat exchangers. Normally, the steady state KOH
temperature at the module outlet will be between 63 and 73oC. It will vary in this
range with the output of the generator. Generator operation at too low a KOH
temperature results in lower efficiency and higher power consumption. Continuous
operation at temperatures higher than 73oC can accelerate corrosion of system
1-28
components. Failure to provide adequate cooling water flow will cause a rise in
KOH temperature and eventually an alarm shutdown. Over-cooling the module
during high current operation can also cause damage to the module since
resistance is increased.

The PLC compares the KOH heat exchanger outlet temperature (from
thermocouple 232) to the controller set point (default factory set point is normally
60oC but adjusted at commissioning). The difference is used as a basis for a 4-20
mA output signal. This output is connected to current-to-pneumatic (I/P)
transducer 013, which converts the signal to a 3-15 PSIG instrument air signal.
The air signal is provided to the diaphragm of the cooling water control valve 609,
which raises or lowers the valve stem and, hence, water flow. The PLC uses
proportional control with integration (PI).

Differential Pressure Controls

The generator is meant to operate with no pressure difference between the
hydrogen and oxygen sides. Control of the differential pressure (referred to as
Delta-P) between the hydrogen and oxygen sub-systems is an essential aspect of
operation. It is accomplished with both electrical and air-operated components.
This system is extremely critical. For this reason an Uninterruptible Power Supply
(UPS) is to provide back-up power of the Delta-P Controls in case of a utility power
failure.

CAUTION: Do Not Turn the UPS OFF while the system is pressurized.

The components used for differential pressure control are:

a differential pressure transmitter (328), which provides an output

signal of 4 to 20 mA corresponding to the difference in pressure
between the hydrogen and oxygen gases
a PLC, which takes the transmitter input and computes the proper 4-
20mA output signals for control of the delta-P system
two current to pressure transducers (018, 019), which convert the 4-20
mA signals to 3-15 PSIG for the pneumatic hydrogen and oxygen vent
vent valves 330 and 430, whose stem position is based on the air
signal from the respective I/P transducer

The control transducers 018 and 019 are such that 4 mA input creates an output of
3 PSIG, which corresponds to valve 430 or 330 being 0 percent open. 20 mA
input creates an output of 15 PSIG, which corresponds to valve 430 or 330 being
100 percent open. The range of the delta pressure transmitter is -20 to 20 inches
of H2O, equaling 4-20 mA output to the PLC. The PLC controls are set to
maintain a delta-P between -2 inches (oxygen high) and +2 inches (hydrogen
high). The PLC will shut down the generator if the delta pressure reaches either

1-29
-10 inches or +10 inches.

FIGURE 14 Delta Pressure Control -Oxygen Venting

Refer to FIGURE 14 for a typical hydrogen delivery mode. In this scenario the
oxygen pressure is typically higher than the hydrogen pressure. The oxygen side
vent valve (430) is active. The PLC control is reverse acting, which means that its
output signal to the 430 vent valve rises as its input pressure signal from
transmitter 328 falls. When the delta-P exceeds the set point (-2 inches), the
output signal from the PLC and I/P 018 to vent valve 430 will increase, causing
oxygen to be vented from the system and a corresponding reduction in oxygen
pressure.

Valve 330 functions the same way as valve 430. Referring to FIGURE 15, the
relationship between the PLC, I/P 019 and vent valve is essentially the same,
except that it is set up in the direct acting configuration, which means its output
signal increases as its input signal from 328 rises. If hydrogen pressure exceeds
the oxygen pressure by more than 2 inches of water, the PLC and I/P increase
their output signal to valve 430, thereby venting excess hydrogen. This situation
could occur in a "C" system where oxygen demand is greater than half the

1-30
 hydrogen demand. Also, during shutdown the vent rate of oxygen is typically
greater than that of hydrogen. This valve allows the hydrogen vent rate to be
increased in a controlled manner to maintain a low differential pressure.

FIGURE 15 Delta Pressure Control - Hydrogen Venting

Instrument air at a pressure of 20 PSIG (1.38 Bar) is essential for correct operation
of the differential pressure control subsystem and must always be provided while
the EC is operating. The air supply is from the instrument air manifold (80 PSIG)
via regulator 002, which reduces pressure to 20 PSIG (1.38 Bar) for these
instruments.

1.3.12 Temperature Measurement

The KOH temperature is monitored on both the hydrogen and oxygen sides of the
system at the module outlet pipes (thermocouples 111 and 211). A bayonet-style

1-31
 external pipe thermocouple arrangement is used. Thermocouple 232 is used as
the input for cooling water control and is found on the oxygen side heat exchanger
outlet pipe. It is the same type of thermocouple as 111 and 211.

Thermocouple 382 is banded to the outside of the H2 side catalyst tank and
monitors the surface temperature. If the temperature gets too high, it is an
indication that the concentration of O2 in H2 is too high coming out of the
module.

In "C" model generators, there are three other thermocouples. Two are in the
oxygen side catalyst tank. The catalyst for this tank must be heated to at least 120
degrees C to activate. Thermocouple 486 is the input to the PLC, which controls
the catalyst tank heaters. Because the reaction is also exothermic, thermocouple
487 monitors the internal temperature of the bed for alarm conditions. The third
thermocouple (418) is located inside the catalyst bed between the oxygen dryers.
This type J thermocouple connects to the PLC and functions as both the alarm and
control probe.

Two specialized probes (described in section 1.3.13) use type J thermocouples as

part of gas stream impurity monitors.

1.3.13 Gas Detection - Hydrogen in Oxygen, or Oxygen in Hydrogen

Each gas stream is monitored for the presence of the other gas using a special
probe consisting of a type J thermocouple that has been bonded to a small
catalyzed electrode. Oxygen and hydrogen will recombine on the probe surface
and cause a corresponding increase in temperature. After manufacture, the probe
is checked using a 2% hydrogen in air gas mixture. Normally, the temperature will
rise 100 to 150 C, during calibration.

The temperature signal is connected to the PLC temperature input card. If the
temperature exceeds 180 C, the generator will shut down.

Proper flow over the probe is important to its function. For the hydrogen side,
oxygen in the hydrogen stream is measured through the use of a forward pressure
regulator. The regulator (310) is in series with a rotameter (part of 310) and the
gas probe (305). The gas is sampled from a tube upstream of the dryer system,
which necessitates a filter tank (303) to remove moisture and residual KOH. The
sample stream also includes a flame trap in series with the probe.

On the opposite or oxygen side of the system, the same components are used to
detect hydrogen in the oxygen stream. The component numbers are 405 for the
probe, 410 for the regulator and rotameter, and 403 for the trap.

1-32
1.3.14 Programmable Logic Controller (PLC)

A number of automatic controls and monitors have been described that are
performed by the programmable logic controller (PLC). The PLC is a
microprocessor which takes information in various input formats such as voltage,
current or temperature, and energizes or de-energizes outputs according to the
instructions of a user-defined program. The program (referred to as ladder logic)
has comparison, timing, counting, mathematics, and other data manipulation
capabilities that enable decision making and corresponding output action. A
simple diagram of the various input and output types used on the EC generator is
shown in FIGURE 16.

FIGURE 16 PLC Actions

The information stored in the central processing unit (CPU) includes the ladder
logic, working values (information which changes), and read only data which does
not change. The read only data consists of fixed set points used for comparison
by the CPU (typically alarm set points and timing values). The program and read
only data are installed at the factory. The working values change with machine
operation, and may or may not be retained by the CPU when power is turned OFF.

An optional hand-held terminal for interface with the PLC is available, and can be
helpful in troubleshooting. It is also possible to establish personal computer
based communications with the PLC using optional software. Contact Teledyne
for more information.

The PLC is physically configured as a power supply, CPU and a number of input
and output modules. The power supply and CPU are located on the left side of the
back plane. Multiple-channel digital and analog input and output modules and
communication modules are located to the right of the CPU. Several pages of the
electrical wiring diagram are organized according to PLC inputs and outputs. An
understanding of the diagram will help clarify the details of the control system.

1-33
A listing of the input signals is as follows:

Analog Input (4-20 mA):

Liquid level from 113

System pressure from 325
Differential-pressure from 328
Hydrogen off dryer pressure from 378
Module amperes from power supply
Oxygen off dryer pressure from 478 ("C" model only)
Nitrogen pressure from 510

Digital Input (24 volts DC):

Hydrogen flow from 109

Oxygen flow from 209
Instrument air pressure from 005
Power supply trouble
External enable signal NC
High catalyst bed temp ("C" model only)
Utility Power OK from UPS
UPS Fault
Low Battery from UPS
Emergency Stop NC
External Alarm NC

Analog Input (Temperature)

Hydrogen side KOH temperature from 111

Oxygen side KOH temperature from 211
Cooling water control temperature from 232
Oxygen-in-hydrogen temperature from 305
Hydrogen-in-oxygen temperature from 405
Hydrogen side catalyst tank temperature from382
Oxygen side catalyst bed temperature from 418 ("C" model only)
Oxygen side catalyst tank temperature from 486 ("C" model only)
Oxygen side catalyst tank temperature from 487 ("C" model only)

1-34
A listing of the output modules is as follows:

Digital Output:

006 pneumatic valve dryer vent to 370/470

009 pneumatic valve system vent to 320/420
010 solenoid valve nitrogen supply
011 pneumatic valve trap purge to 372/472
003 pneumatic valve dryer switch to 315/415
014 pneumatic valve dryer switch to 314/414
016 pneumatic valve dryer purge to 335/435
504 nitrogen valve
701 feedwater pump and SV702
KOH pump motor starters
DC current enable to power supply
314 dryer heater relay
315 dryer heater relay

Analog Output (4-20 mA):

013 Cooling water I/P transducer

019 Hydrogen I/P transducer
018 Oxygen I/P Transducer
Power supply demand

The touch screen is the operator's interface with the EC generator, providing a
means of control as well as status for important machine parameters. The touch
screen is directly interfaced with the PLC and can be considered an input/output
device. Each screen is separately programmed and loaded into the touch screen
memory. During programming, PLC word addresses (where a parameter is
stored) and bit addresses (such as push button status) are placed in a
communication table, which is also loaded into the touch screen memory. This
table enables the direct communication of the touch screen inputs and display
values. The screen also has various optional set-up features, all of which are pre-
set at the factory.

The touch screen can also be used to provide the operator with information such
as programmed set point values and HELP screens that are available if an
automatic shutdown occurs.

1-35
1.3.15 Electrical System

Power Distribution
Refer to sheet 2 of applicable generator system wiring diagram and power supply
wiring diagram. Electrical power for electrolysis and associated sub-systems is
distributed from the power supply enclosure. The only input connection made by
the user is the 3-phase AC power.

This is connected on the primary side of the EC's main transformer (in the power
supply enclosure). Typically, the user will make this connection from a 3-pole
breaker located near the power supply.

From the primary side of the main transformer, 3-phase voltage is provided to the
motor starters for the EC's feedwater pump and 2 KOH pump motors; and single
phase input voltage is fed to the primary of several auxiliary transformers. These
circuits are protected by a circuit breaker located on the front of the power supply
cabinet. One transformer provides 110-120 VAC for the EC's control system
UPS. A second transformer provides 230-240 VAC for heater power in the EC's
dryer system and (for a "C" system) the oxygen side catalyst heater.

Depending on the power supply manufacturer, there are 1 or 2 110-120 VAC

transformers for power supply controls and for operation of the power supply
cooling fans.

The UPS mounted to the power supply cabinet provides the power for the EC
controls and is used to switch control power ON and OFF. This 110-120 AC
voltage is used for the programmable controller (934), instruments,
indicators/alarms, solenoid valves, and other control devices. This voltage is
also the input to a 24 volt DC power supply (966) used for the analog
instruments.

Power is provided to the EC circuits at the gas cabinet via circuit breakers inside
the power supply. These breakers can be used to switch power ON and OFF to
the applicable subsystem.

Breaker 919 provides 220-240 VAC to the hydrogen side dryers (314, 315).

For an optional "C" system, breakers 920 and 935 provide 220-240 VAC to the
oxygen side dryers (414,415) and oxygen catalyst bed heaters (412).

AC to DC Rectifier
The rectifier consists of a 6-pulse (6 SCRs) full wave bridge circuit, and various
control circuit boards. Refer to the power supply manufacturer's wiring diagram
provided in the appendix of this manual. The main control and trigger (CAT) board
1-36
receives current enable and 4-20 mA analog control signals from the EC gas
cabinet. The board also receives inputs from the 3-phase lines and feedback
current and voltage signals from the bridge output terminals. The response of the
controls is such that a DC current of 100 to 1000 amperes (200 to 2000A for EC-
1000) is supplied corresponding to the 4-20 mA input. This is accomplished by
varying the gating of the SCRs. A dampening circuit is in series with the control
signal to prevent module current from increasing too rapidly. DC current and
voltage can be limited by the operator by adjusting potentiometers on the power
supply panel. These functions are useful at start-up and for trouble-shooting.

Total module amperes and volts are displayed with meters on the front of the
power supply enclosure. Indicator lights for AC power ON, DC current ON, phase
loss and over-temperature alarms are also included on the power supply panel.

Inputs to the CAT boards are typically isolated with smaller circuit boards (referred
to as SISO or DISO boards).

The input to the rectifier bridge is from the secondary of the main 3-phase
transformer, which reduces the customer's input voltage to that corresponding to
the EC module size. The AC input is monitored for a loss of phase. The main
transformer and SCRs are monitored for high temperature. The switches of these
alarm devices are connected in series and monitored by the EC's PLC, which
looks for a complete circuit through all of the alarm switches. The power supply
CAT board also has various internal monitoring functions that will disable the
output in a fault condition.

All EC power supplies can be operated at 50 or 60 hertz. A switch or jumper wire

inside the control enclosure determines the frequency.

Electrical Wiring
The power supply and the EC gas cabinet are pre-wired, inspected, and tested at
the factory. Refer to the next section for interconnections. Cabling is approved
USA/NEC tray cable placed in covered distribution trays within the gas cabinet, or
inside rigid or liquid-tight conduit. Sealed cable connectors are used at the main
enclosure and the individual components, except at the thermocouples, where
plugs are used.

The AC input wires from the facility, electrolysis module cables, and signal/control
cables typically enter the power supply enclosure through the bottom. Control and
signal wires pass from the main cabinet to the control section on the side of the
cabinet through internal holes or conduit. Inside the power supply control
enclosure, there are several labeled terminal strips where connections to the gas
cabinet are made.

1-37
 All of the auxiliary power supply wires and control wires are pre-connected at the
factory on the gas cabinet side. A cable harness approximately 65 ft (20 meters)
long is provided. If the harness does not require trimming, final connections at the
power supply control enclosure are made with pre-installed terminals. The
harness may be trimmed, if necessary.

The DC cable for connection between the rectifier and the electrolysis module is
provided with the generator. Module and ground cable is USA NEC Type W
approved for extra hard service. The length is sufficient to make approximately a
63-ft (19-m) run, based on connecting 6 cables each at the positive and negative
sides of each module, and one cable as a ground between the gas cabinet and
power supply structures. All of the required terminal lugs and connection hardware
are included with the generator.

Inside the EC gas cabinet control enclosure, terminals are provided for a remote
signal connection. If the user desires a remote signal, for example to stop
electrolysis for facility related reasons, wires are installed to remote dry contacts
rated for 24 VDC. One connection each for normally open and normally closed
conditions is available. This function interrupts the DC enable signal only. Gas
generation will stop, and the system will depressurize.

1.3.16 Pipe and Tube Connections

Where possible in the electrolyte and cooling water loops, piping and connections
are seal welded. Where connections must be removed for access, flat-faced
fittings with EPT O-rings are used. A view of the typical fitting is shown in FIGURE
17. The fitting consists of 4 parts including the O-ring. The threaded piece
contains an O-ring groove and external threads. The tail piece contains a flat face
to mate with the O-ring. The nut slides over the tail piece and tightens the flat face
against the threaded piece. This type of connection allows the removal of pipes
and components without the need for threading space (such as with a pipe joint).

For gas tubing and condenser water tubes, Swagelok style compression fittings
are used. These are high quality, leak free fittings that can be opened and closed
repeatedly. Swagelok parts are available worldwide, and most customers can
obtain parts locally, if necessary. FIGURE 17 shows a typical connection.

The joint consists of 4 parts. The fitting with straight threads provides the tube
socket and connection point for the nut. The front and back ferrules combine to
provide proper tube compression during swaging, and the nut tightens the swaged
tube to the fitting. The nut threads are coated with silver to prevent galling. The
installation results in deformation of the tube, which then retains the parts when the
tube is removed. Many fitting sizes and styles are available. The EC incorporates
various fittings that adapt from pipe threads or socket welds to a threaded fitting.
Fittings are available to convert to metric sizes.

1-38
The connections within the EC scope of supply are made at the factory. However,
the user will need to swage a few tubes at the interface points. The user would
also consider the use of similar fittings within the facility. Although this type of
fitting is simple to install and use, a brief training course is recommended to be
sure of proper leak-free connections in the facility. Contact the local representative
for literature or training; or contact Teledyne for more information.

FIGURE 17 Typical Tube Connections

1-39
1.4 EC Generator Specifications

Hydrogen EC500 EC600 EC750 EC1000

Flow 500 SLM 600 SLM 750 SLM 1000 SLM
1060 SCFH 1270 SCFH 1590 SCFH 2120 SCFH
28 Nm3/Hr 33.5 Nm3/Hr 42 Nm3/Hr 56 Nm3/Hr
Pressure System delivery pressure is factory settable between 90 and
145 PSIG (6.2 to 10.0 BAR).
Purity 99.9998% *

Oxygen EC500 EC600 EC750 EC1000

Flow 250 SLM 300 SLM 375 SLM 500 SLM
530 SCFH 635 SCFH 795 SCFH 1059 SCFH
14 Nm3/Hr 16.8 Nm3/Hr 21 Nm3/Hr 28 Nm3/Hr
Pressure System delivery pressure is factory settable between 60 and
110 PSIG (4.2 to 7.6 BAR).
Purity 99.9993% *

Feedwater EC500 EC600 EC750 EC1000

Flow Rate 27 LPH 34 LPH 42 LPH 56 LPH
7 GPH 9 GPH 11 GPH 15 GPH
Above is with EC at rated output
Specification ASTM D1193 Type II
Minimum Resistivity 1.0 Megohm-cm
Supply pressure 0.4 to 6 BAR
5 to 100 PSIG

Electrical EC500 EC600 EC750 EC1000

Recommended 550 Amps 600A 750 A 1000 A
AC Breaker Size
(380 VAC)
(480 VAC) 450 Amps 500A 600 A 800 A
Includes auxiliary loads. See section 1.4.2.
Electrolysis 100-1100 DCA 200-2000
AMPS DC DCA
Electrolysis 150-210 178-230 215-280 150-210
VOLTS DC

* With degassing equipment for the feed water and reasonable ambient and condensing water temperatures.

1-40
 Additional specifications:

Electrolyte Approx. 265 LITERS (70 GALLONS) potassium

hydroxide (KOH)at 30% by weight for EC1000
Approx. 200 LITERS (53 GALLONS) KOH)at 30% by
weight for EC 500,600, & 750
See section 4 for KOH purity specification.

Cooling Water: Maximum flow requirement, depending on water

temperature 150 LPM (40 GPM).
Maximum Pressure Drop 2 BAR (28 PSIG)
Maximum inlet temperature 40 C
System pressure rating 10.3 BAR (150 PSIG)

Inert Gas Typically nitrogen

99.95% or greater purity
Instrument Air Minimum 5.9 BAR (85 PSIG)
Maximum 17.2 BAR (250 PSIG)
Consumption up to 1 NM3/HR (35 SCFH)
System Pressure 170 PSIG (11.7 BAR)
Rating

Ambient 5 to 50 C
temperature range

Gas Cabinet 3450 KG (7600 LB)

Base Dimensions 204 CM x 263 CM (80.2 IN x 103.6 IN)

Outline 203 CM W x 300 CM L x 203 CM H

Dimensions (80 IN W x 118 IN L x 80 IN H)
Typical Power 1390 Kg (3065 LB) for EC-500 to EC-750 1560 Kg
Supply (3440 LB) for EC-1000
Base Dimensions 122 CM x 122 CM (48 IN x 48 IN)

Outline 137 CM W x 122 CM L x 198 CM H

Dimensions (54 IN W x 48 IN L x 78 IN H)

1.5 Consumption Data

The electrical power supply input voltage and frequency are specified by the user
and the power supply is manufactured accordingly. The AC line current will
depend on facility voltage. Power factor is a function of demand. Teledyne can
furnish specific power consumption information when input conditions are known.

Cooling water specifications in the preceding section are conservative. Information

1-41
 pertaining to expected temperature rise, pressure drop, and flow rate can be
provided by Teledyne if inlet temperature is known.

1.6 Safety Warnings and Precautions

1.6.1 Summary

After a review of the EC generator in the preceding sub-sections, it is important for

the end-user to be familiar with the hazards and safety precautions of this type of
process. This section discusses these hazards and provides information for
protection against accidents or injury. The user is encouraged to review the
system and overall installation for site specific safety considerations. It is strongly
recommended that safety procedures and preparedness steps be implemented in
advance of commissioning.

This information pertains to the EC generator. The user is responsible for other
considerations such as civil works, lightning protection, hazard communication,
proper training of personnel, etc. which may impact safety.

The user is warned not to override or defeat safety or generator monitoring

features in any way.

1.6.2 Caustic Liquid

Care should be taken to avoid contact with potassium hydroxide (KOH) as it may
be harmful and is an irritant to skin and eyes. If contact does occur, neutralize the
KOH with a 3-5% solution of boric acid, wash with mild soap and rinse with potable
water. Potassium hydroxide is very slippery and minor spills in the walkway
around the generator can be hazardous. Neutralize the spill area with boric acid,
and then clean with water and dry.

Utilize goggles or a face shield when handling KOH. Standard safety glasses may
not protect against splashing. When handling KOH, use gloves that are suitable
for strong caustic applications. An apron is recommended to protect skin and
clothing in case of splashing.

Eye wash bottles or an eye washing station should be installed in the area. This is
a standard chemical safety precaution.

To neutralize any spills or drips, keep a container such as a 3 to 5 gallon (12 to 20

liter) bucket with a solution of 5% boric acid and water, in the work area.

1-42
1.6.3 Flammable Gas

Hydrogen gas when combined with oxygen gas or air can ignite with explosive
violence. Care should be taken to prevent hydrogen gas from mixing with these
gases. Conduct periodic leak checks of facility gas piping connections and valve
packing.

Hydrogen gas production can be initiated only after it is verified that standard
precautions against hydrogen accumulation and ignition have been taken. Refer
to facility related discussion in Section 2 of this manual. Verify that the building
ventilation is functioning and that all heat or spark producing equipment has been
de-energized or removed.

When the system is turned OFF, purge with inert gas to remove hydrogen from the
system. Do not open the hydrogen side of the system for maintenance without
purging hydrogen.

Maintain function of the gas cabinet electrical enclosure purge (door closed,
system ON, and alarm horn set). This assures that any leaked hydrogen cannot
enter the box where it may be exposed to ignition sources.

1.6.4 Oxidizer

Oxygen gas supports rapid combustion. Care should be taken when working with
or venting oxygen gas.

1.6.5 Electrical

There are several operating voltages in the system including the facility 3-phase
power (includes rectifier input and motor voltage), dryer heater voltage (240 VAC),
control voltage (115 VAC) and electrolysis module voltage (up to 280 VDC).
These voltages are lethal and extreme caution is required when operating the
system or performing maintenance. Keep enclosure covers in place. Keep the
control panel door closed at the gas cabinet. Never operate the EC without the
polycarbonate module shields installed. Utilize standard electrical and specific
plant safety procedures.

Be sure all equipment is properly grounded to a suitable facility ground.

1-43
 When required to perform electrical repair work or adjustments that do not require
power, lock out the main power source at the wall breaker or safety switch, using
plant safety procedures. Double check for the presence of voltage before touching
or working on high voltage circuits.

1.6.6 Compressed Gas

The hydrogen, oxygen, instrument air and inert gas sub-systems operate at up to
170 PSIG (11.7 BAR), and should be treated with the appropriate precautions for
pressurized gas. Inert gas supply is frequently from high pressure portable
cylinders. Use appropriate safety procedures (provided at site or by industrial gas
supplier) in handling cylinders and regulators. Wear safety glasses when in the
machine area.

Nitrogen and compressed air lines at the EC interface are not automatically
depressurized when the generator is off. Use appropriate precautions if
disconnecting these lines.

Never attempt to tighten a pipe thread fitting while the system is pressurized.

1.6.7 High Temperature

The EC generator contains vessels that operate above ambient temperature.

Components in the electrolyte loop and associated traps operate between 60 and
70 C. Use caution around these components.

Keep protective shields for the dryer tubes in place. Use caution around the sheet
metal enclosure of the oxygen side catalyst vessel enclosure ("C" model), and
around the gas dryer tubes. Temperatures of these surfaces can exceed 200 C.

On C-Model units, the Oxygen side catalyst tank on the roof of the generator can
also exceed 200 C since it must be heated and has an exothermic reaction.

1-44
 SECTION 2 Installation Considerations and Instructions

TABLE OF CONTENTS:

SECTION 2 Installation Considerations and Instructions......................................1

LIST OF FIGURES:...........................................................................................1
2.1 Summary ................................................................................................2
2.2 Tools, Installation Time, and Personnel Skills ........................................2
2.2.1 Tools................................................................................................2
2.2.2 Installation Time ..............................................................................3
2.2.3 Personnel Skills...............................................................................3
2.3 Installation Considerations......................................................................4
System Classification.....................................................................................4
2.3.1 Facility Inputs ..................................................................................5
2.3.2 Location...........................................................................................8
2.3.3 Ventilation......................................................................................10
2.3.4 Lighting and Other Electrical Equipment .......................................10
2.3.5 Facility Plumbing ...........................................................................11
2.3.6 Gas Vent Pass-Through Design....................................................12
2.4 Gas Cabinet and Module Installation, Pipe Connections......................13
2.4.1 Unpacking and Positioning the Gas Cabinet .................................13
2.4.2 Gas and Fluid Pipe Connections ...................................................14
2.4.3 Module Storage and Installation ....................................................15
2.5 Electrical Installation.............................................................................20
2.5.1 Power Supply Cabinet ...................................................................21
2.5.2 Interconnecting Wire and Cable ....................................................22
2.5.3 Wiring Steps ..................................................................................24
2.5.4 Signal and Control Cables.............................................................24
2.5.5 Electrolysis Module Connections (Module End Only) and Ground
Cable 27
2.5.6 Main A/C Power Input and Initial Checks ......................................30
2.5.7 Final Connection of Module Cables...............................................31
2.5.8 Final Comment ..............................................................................32

LIST OF FIGURES:

FIGURE 2-1 System Installation Diagram.............................................................6

FIGURE 2-2 EC Generator with Floor Mounting & Concrete Pad.........................9
FIGURE 2-3 Swagelok Procedure ......................................................................14
FIGURE 2-4 Module Installation .........................................................................18
FIGURE 2-5-1 Top View of Piping Installation ....................................................19
FIGURE 2-6 Power Supply with Concrete Pad...................................................22
FIGURE 2-7 CABLING FROM EC POWER SUPPLY TO GAS CABINET……….23
FIGURE 2-8 ORIENTATION OF POWER SUPPLY CABLES …………………….26
FIGURE 2-9 CONTROL CABLE ROUTING…………………………………………27

2-1
2.1 Summary
Installation of an EC generator consists of

Locating the gas cabinet and power supply structures

Installing the electrolysis module, making plumbing connections
Running the supplied control/signal and module cables between the
two structures
Connecting the control/signal cables at the power supply
Connecting the facility input power

The user's plumbing will include gas tubing (.50 inch (13 mm) maximum
outside diameter) for instrument air, inert gas supply, hydrogen delivery,
and hydrogen and oxygen vents. Gas tubes are usually best installed on
overhead supports. There will also be 1.0-inch (25.4 mm) diameter cooling
water inlet and outlet pipes.

Teledyne furnishes the interconnecting cables; however, the user will

determine and install the cable protection hardware. This may be conduit
(overhead or underground), cable trays, a cable pit, or wiring trough.
Overhead supports such as enclosed wire ways should be open or
ventilated, to prevent the possible accumulation of hydrogen. Various types
of cable seals at the entry/exit points of the machinery room may be
necessary, depending on the installation. Consult local electrical codes or
qualified plant engineer for more information.

2.2 Tools, Installation Time, and Personnel Skills

2.2.1 Tools

Most tools required for work on an EC are standard and include slotted and
Phillips head screw drivers, cutters, pliers, etc. A set of open end wrenches
in standard USA sizes from .25 to 1 inch (in 1/16 inch increments) is
required for small plumbing connections, adjustment screws, brackets, etc.
For intermediate size pipe and tube connections, an adjustable wrench up
to a 1.75-inch (45-mm) opening is suitable. For larger pipe connections in
the KOH pipe loop, a spanner up to 4.38 inches (110 mm) is required.

A set of standard size sockets and a torque wrench up to 120 FT-LB (163
N-M) is required for the filter vessel cover tightening procedure (1-1/4 inch
socket) and the KOH loop ball valve assembly torque procedure (11/16 inch
socket). A torque wrench up to 300 FT-LB (407 N-M) is required for
periodic tightening of electrolysis module tie rod hardware.

2-2
 NOTE: Torque procedures are not typically necessary
at installation. The tools are mentioned here so
as to describe mechanical tools for installation
and maintenance purposes.

Equipment supplied with the EC generator includes various special tools for
check valve disassembly and flow meter adjustment. A deep-socket is
supplied for re-torquing of the electrolysis module tie rod hardware.

Tools to cut and strip AWG 4/0 wire will be required for the DC module
cables. A standard voltmeter is required for preliminary checks. A clamp-
on inductive type AC ammeter is recommended so that current can be
checked without disconnecting wires. Refer to section 4 of this manual for
details of other equipment required for calibration or maintenance.

2.2.2 Installation Time

Assuming facility piping and wiring up to the interfaces has been completed
ahead of time and adequate lifting equipment is available, a two or 3 man
team can complete the installation in 1 to 2 days. The time will be longer
depending on the user's choices for the electrical installation, and the
condition of facility plumbing.

2.2.3 Personnel Skills

Personnel performing the gas cabinet installation require typical mechanical

skills, including lifting/handling, basic plumbing, and an understanding of
simple fluid diagrams. An understanding of the proper use of swaged tube
connections is required, in order to complete the interface connections.
Refer to section 1.3.17 for a briefing on Swagelok style connections.

The electrical power supply wiring should be completed by qualified

electrical technicians familiar with AC power distribution principals and
safety practices, and able to understand wiring diagrams. The module
cables will need to be cut to length, stripped and installed in cable lugs.
The installation of wire crimps on smaller control wiring is not necessary
unless the cables are to be cut to a shorter length.

2-3
2.3 Installation Considerations

Following is a list of considerations pertaining to planning an installation:

Area classification
Facility inputs and interfaces
Physical access for maintenance
Personnel safety
Ventilation
Floor drains
Ambient rejection of heat from the process and from the rectifier
Noise
Dust control

Further discussion of each follows as it pertains to the gas cabinet and

power supply. The user is advised to consider this information, along with
advice from site facility experts, safety personnel and insurance or other
reviewing agency requirements.

Section 1 of this manual contains safety warnings and precautions as

regards operation and maintenance. Review this material carefully. Some
safety related items such as electrical practice and ventilation must also be
carefully considered when planning the installation. These are discussed
herein.

System Classification

The EC hydrogen generator cabinet has been designed for operation in

Class I, Division 2, Group B locations as defined by the National Fire
Protection Association (NFPA), Document 70, which is the USA National
Electrical Code (NEC). The generator power supply is separate from the
generator cabinet. Unless otherwise specified, the power supply includes
standard electrical components and is intended for installation in an
UNCLASSIFIED area.

NFPA 70 definitions are provided in article 500, and equipment requirements

begin in article 501. Teledyne interprets and follows these requirements
based on a knowledge of widely accepted practices, specialized training,
and exposure to a variety of installation situations involving hazardous
materials.

Under the NFPA, Class I designates the hazardous material as a gas.

Group B pertains to the properties of hydrogen and similar materials
regarding the requirements of an explosion-containing enclosure. Division 2
defines the area as one in which flammable material is handled in closed

2-4
 systems and is not normally present in the environment. Flammable
material is present only in the event of a failure leading to leakage, and such
failures are not simultaneous with activation of exposed ignition sources.
The presence of hazardous material is assumed to be for a relatively short
time.

The above is analogous to the IEC requirements as defined in IEC 79-0.

The classification is Group IIC, Zone 2, T6. Group II refers to the application
as not mine related. The C is similar to Group B under the NFPA, and Zone
2 is defined nearly identically to Division 2. T6 refers to the ignition
temperature of the material, which is handled in the specific requirements of
the NFPA. The design philosophies of the NFPA and IEC are the same, as
are most of the equipment requirements. Teledyne follows the NFPA
requirements in detail.

In Division 2 (zone 2) locations, the hazardous gas is not normally present in

the environment. The electrical equipment is specified such that a failure is
required to expose an ignition source. Any device that can provide ignition
(arcing or hot surfaces) under normal operation is required to have isolating
or protective design feature. Devices that are not ignition sources in normal
operation are permitted in Division 2 locations within standard electrical
enclosures, and are usually not required to be especially marked. Wiring in
Division 2 locations may be in rigid conduit or via one of several cable types,
including tray cable.

2.3.1 Facility Inputs

Refer to Section 1 of this manual for pressure and flow ratings, feedwater
quality, cooling water, instrument air and nitrogen quality, conditions, and
consumption. FIGURE 2-1 contains the sizes and operating conditions of
each interface. If the facility input sources are restricted or physically far
from the EC generator, the facility pipe sizes must be increased
accordingly. The facility supply lines to the EC should be adequately rated
for the application, of compatible materials, and contain the necessary
filtration to meet these requirements. This will insure that impurities such as
oil, minerals, and particles do not enter the system.

If the facility cooling water is of poor quality in particulate size or quantity, a

duplex strainer is recommended.

Instrument air and nitrogen must be dry and oil free and appropriately
filtered. Feedwater quality must meet the requirements of Section 1.

All fluid and gas interfaces are USA tube sizes (a size refers to the outside
diameter). The user should contact Teledyne in advance of shipment if
assistance is needed in adapting to the EC tube interfaces.

2-5
FIGURE 2-1 System Installation Diagram

2-6
 INTERFACE IDENTIFICATIONS

SYSTEM INTERFACE SIZE CONDITIONS

A COOLING WATER INLET 1.00 INCH DIA. TUBE 50 TO 100 PSIG (3.5 TO 6.9
BAR), 40 GPM, 30 PSID
DROP TO EXIT, 40 C MAX
B OXYGEN VENT 0.500 INCH DIA. TUBE 0 PSIG 500 SLM O2 WITH
WATER VAPOR AT 77 C
DEW POINT
C HYDROGEN VENT 0.375 INCH DIA. TUBE 0 PSIG 1000 SLM H2 WITH
WATER VAPOR AT 77 C
DEW POINT
D HYDROGEN DELIVERY 0.500 INCH DIA. TUBE 160 PSIG (11 BAR) MAX.
1000 SLM HYDROGEN
MAX.
E COOLING WATER OUTLET 1.00 INCH DIA. TUBE 50 TO 100 PSIG (3.5 TO 6.9
BAR), 40 GPM, 63 C MAX
F OXYGEN VENT 0.375 INCH DIA. TUBE 0 PSIG, 500 SLM, WITH
WATER VAPOR AT 77 C
DEW POINT
G HYDROGEN DRYER VENT 0.500 INCH DIA. TUBE 0 PSIG, 60 SLM, H2 PLUS
WATER VAPOR AT 63 C
DEW POINT
H FEEDWATER INLET 0.500 INCH DIA. TUBE 5 TO 85 PSIG (0.4 TO 6
BAR) PURE WATER AT 20
GPH
J NITROGEN INLET 0.375 INCH DIA. TUBE 60 TO 100 PSIG (4 TO 7
BAR) NITROGEN (OIL
FREE)
L INSTRUMENT AIR 0.250 INCH DIA. TUBE 85 TO 250 PSIG (5.9 TO
17.2 BAR CLEAN
INSTRUMENT AIR AT UP
TO 60 SCFH
M OXYGEN DRYER VENT 0.500 INCH DIA. TUBE 0 PSIG, 60 SLM O2 PLUS
WATER VAPOR AT 63 C
DEW POINT
N OXYGEN DELIVERY 0.500 INCH DIA. TUBE 160 PSIG(11 BAR) MAX. 500
SLM OXYGEN MAX.
P CONDENSER COOLING 1.00 INCH DIA. TUBE 50 TO 100 PSIG (3.5 TO 6.9
WATER INLET BAR), 20 GPM, 30 PSID (2
BAR) DROP TO EXIT, 40 C
MAX
Q CONDENSER COOLING 1.00 INCH DIA. TUBE 50 TO 100 PSIG (3.5 TO 6.9
WATER OUTLET BAR), 20 GPM, 30 PSID (2
BAR) DROP FROM INLET,
63 C MAX

2-7
 The AC ampere service to the power supply is determined based on the EC
electrolysis module size and the facility 3 phase input voltage and is shown
in Table 1.4. Contact Teledyne for additional information. Unless otherwise
specified in the purchase order, the user is responsible for AC wiring
(including lugs) from a nearby 3-pole breaker or disconnect to the input
terminals located in the power supply cabinet.

2.3.2 Location

Normally, the EC gas cabinet is located in a machinery room with a cement

floor and masonry walls. It is often installed with other components
processing hydrogen such as compressors, purifiers, or instrument
manifolds. Such components are normally specially designed for areas
involving hazardous materials. Other equipment such as standard electrical
devices, instrument panels, breaker cabinets, etc. should be located in a
separate room (often called the electrical room) or area sufficiently far from
the gas equipment so as to not present ignition source hazards.

It is not recommended that the user install hydrogen-processing equipment

in an area below grade (ground level).

Many users install the EC on a raised cement pad (approx. 100 mm) to
facilitate floor cleaning. The gas cabinet contains a bracket at each of the
base corners, with provision for two anchoring screws. Refer to FIGURE
2-2, for dimensions of a recommended pad and anchor bolt locations.

The room should have at least two doorways and one of these must be
large enough for lifting equipment. It is recommended that the most
commonly used door be placed near the gas cabinet control panel. At least
3 feet (1 meter) of space along the sides of the gas cabinet is required. A
minimum of 6 feet (1.7 meters) is required on the phase separator end of
the gas cabinet for module removal. Approximately 5 feet (1.5 meters) of
clearance in front of the control enclosure is recommended, as this is where
the operator will view the touch screen.

The room and surrounding areas where hydrogen is processed should have
several obvious warning signs against smoking, open flames or sparking
devices in the area.

2-8
FIGURE 2-2 EC Generator with Floor Mounting & Concrete Pad

2-9
2.3.3 Ventilation

An essential aspect of the room design is the location of openings at the

highest point or points in the area. If hydrogen escapes, it will move upward
very rapidly and will travel to the highest points in the area. Without
ventilation, even a small hydrogen leak can accumulate with time in
stagnant areas and become an explosive mixture. This can be avoided by
assuring the locations of vents or fan exhausts are at the highest points.

The EC is designed with many special features in the electrical system such
that electrical components cannot produce ignition energy under normal
conditions. The processing of a flammable gas (hydrogen) occurs in a
closed system and leakage of hydrogen is the result of an abnormal
situation. These factors are intended to assure safe operating conditions
(as well as controlled shutdown in abnormal situations) whether or not
mechanical ventilation is used. However, Teledyne recommends forced
ventilation of any area where a flammable gas is processed.

Mechanical ventilation should be designed to draw fresh air from a location

known to be free of hazardous material, flow the air in to the machine room
at lower points, and exhaust the air at the highest points in the room. The
inlet to a mechanical ventilation system should never be from high points in
the room. Select and locate electrical components of the system (motors,
starters, switches) such that they do not present an ignition hazard. Consult
local electrical authorities for more information.

It is recommended that louvered or screened openings be located at low

points in the room which, in conjunction with openings at the high points,
will help to assure an upward flow of fresh air. This arrangement will result
in natural convective flow even if mechanical ventilation is not working.

If the location, size, and other limiting factors of an existing room or building
are a concern, the user may want to consider connecting an exhaust duct to
a square opening in the roof of the EC gas cabinet. The duct opening
dimensions are 18 X 18 inches (457 X 457 MM). This would provide
additional assurance that any leakage from EC components would be
exhausted. It is emphasized that the use of such a duct is not a mandatory
feature in the EC's design as regards electrical safety. In most situations
with adequate area ventilation, the duct is not required.

2.3.4 Lighting and Other Electrical Equipment

The typical area where hydrogen equipment is installed is specially treated

as regards potential sources of ignition. Most potential ignition sources are
from electrical devices. The EC electrical devices and wiring have been
designed and installed according to USA National Electrical Code practices
as regards both standard practice (circuit protection, grounding, enclosures,
2-10
 etc.), and those pertaining to areas processing flammable materials. These
features protect against exposed sources of ignition (sparking devices or
hot surfaces) in normal and single failure situations. The user is
responsible for such considerations in the room or building where the EC is
installed. This can be accomplished by careful consideration of local codes,
consultation with qualified engineers and good engineering judgment.

As hydrogen moves rapidly upward, if leaked, consideration should be

given to special lighting. Many standard industrial lights contain sparking
start-up devices, hot surfaces, and inadequate protection against physical
contact. Special industrial lights that do not present such hazards are
available and listed by various approving agencies.

Portable devices, plug-in extension cords, etc., should be used only for
maintenance or other temporary functions. Standard electrical devices
should not be permanently installed or operated in the machinery room.
Portable power tools and other motor driven equipment, welding equipment
and the like, should never be operated in the area when hydrogen is being
generated.

Climate control systems, if used, must be carefully designed to prevent the

induction of hydrogen and to be sure motors and controls are outside the
potentially hazardous area or are otherwise specially designed.

There may be other considerations such as the design of doors leading to

adjacent rooms, sealing areas where piping or wiring exits the room,
proximity to other processes or storage areas, etc. The user is advised to
consider all such factors prior to installation and operation of an EC.

2.3.5 Facility Plumbing

Refer to FIGURE 2-1 for a listing of the pipe connections and service. The
EC inert gas, instrument air, hydrogen and oxygen delivery and vent lines
are 0.5 inch (13 mm) or smaller in diameter. Overhead tube runs can be
easily installed at the upper rear corners of the gas cabinet. The oxygen
and feedwater inlet connections are on the same side of the gas cabinet as
the electrical enclosure. The inert gas, instrument air and hydrogen gas
lines are on the opposite side. The cooling water inlet is at the lower
oxygen side corner, below the oxygen gas connections and the cooling
water outlet is opposite, below the hydrogen gas lines.

2-11
 The user is advised to install suitable isolation valves as close as possible
to the gas cabinet, for the inert gas, instrument air, feedwater, cooling water
and gas delivery lines. Ball valves are recommended.

Valves and other restrictions should not be placed in any of the gas vent
lines. The use of a cooling water rotameter is advised if the user requires
flow data, but is not essential.

As discussed in Section 1 of this manual, users concerned about inert

purge gas in the product gas during machine start-up are advised to install
a valve in parallel with the facility delivery valve connected to the vent
system. This will enable bypassing product gas to the vent for 10 or 15
minutes at start-up, and will assure only high purity hydrogen or oxygen is
delivered. A valve for this purpose should not be a ball valve, but should be
a manual valve with a regulating type stem.

Gas vent lines will carry water vapor. Suitable precautions should be taken
against trapping moisture in gas piping. Install drain valves at system low
points, if necessary. Also, larger diameter pipe and tube may be necessary
if the distance to the vent area is very long, or if the number of fittings
causes excessive back pressure.

2.3.6 Gas Vent Pass-Through Design

Normal generator functions involve the release of hydrogen and oxygen to

the atmosphere through vent tubing connected to the EC interfaces. Dryer
regeneration vent lines carry gas and moisture purged from the off-line
dryer. Oxygen vented from a standard (hydrogen only) generator contains
an amount of water vapor that depends on cooling water temperature. The
vent lines connected to system depressurizing and pressure control valves
will also contain water vapor. The user must determine a suitable means of
passing vent gases through the building wall to the outside. The design and
location of these must be carefully considered.

It is recommended that hydrogen and oxygen vent assemblies be

separated by at least 10 feet (3 meters). In an alkaline water electrolysis
process, some of the rejected water vapor will contain trace amounts of
KOH. Locate and arrange the vent discharge piping away from walkways
or other areas where the KOH may be of concern. The discharge should
be oriented to prevent the entry of rainwater, dust, leaves, etc.

If applicable based on local weather conditions, the end-user must take

suitable precautions against the freezing of vent ports that contain moisture.
There are several methods which have been used for this function including
a simple warm water heat exchanger, pipe heating tape (must be suitable
for the area) or small fans which blow warm indoor ambient air on to the

2-12
 vent assembly. If uncertain, contact Teledyne for more information on this
subject.

CAUTION: FREEZING AND BLOCKAGE OF VENT

LINES CAN RESULT IN SERIOUS DAMAGE
TO THE GENERATOR.

Another precaution pertaining to the vent pass-through design is the

protection of stainless steel components from masonry materials. The
constituents of cement include chlorides that can attack stainless steel in
the presence of water. If the vent assembly is installed in a masonry wall,
then a PVC or polyethylene or polypropylene sleeve should be installed
between metal surfaces and the wall.

2.4 Gas Cabinet and Module Installation, Pipe Connections

2.4.1 Unpacking and Positioning the Gas Cabinet

The gas cabinet is shipped on a heavy pallet in a completely enclosed

sturdy wood crate. The machine is wrapped entirely in a heavy gage plastic
enclosure. Those items stowed within the cabinet for shipment include four
module pipes, the control cable harness, the polycarbonate module shield
kit and commissioning spare parts and tools. The electrolysis module is
shipped in a separate wood crate designed to facilitate its installation.

1. Remove the roof of the gas cabinet box.

2. Remove the four sides of the box and the plastic enclosure. Four
(4) lifting pad-eyes are furnished with the gas cabinet and are found
inside the box.

3. Install the lifting eyes if overhead equipment is to be used to move

the gas cabinet.

4. Using suitably rated lifting equipment, position the gas cabinet on

the cement pad or floor. Install the four corner brackets and anchor
to the floor, if necessary.

5. Remove the internal packaging and tie-wraps, and move stowed

devices out of the gas cabinet. Do not remove protection from pipe
connections until facility plumbing is ready for connection.

CAUTION: HANDLE THE 1.5 INCH MODULE

CONNECTION PIPES (4 PER MODULE)
VERY CAREFULLY TO AVOID DAMAGING
FITTING THREADS.

2-13
2.4.2 Gas and Fluid Pipe Connections

All connections at the top rear corners of the gas cabinet are 316 stainless
steel Swagelok style compression fittings, except brass Swagelok
condenser cooling fitting for the EC-1000. These are high quality, leak free
fittings that can be loosened and re-tightened repeatedly. It is important
that the facility side tube be properly prepared for a leak free connection.
Trim tubes to the proper length and with an even, square end. De-burr the
inside and outside diameter of the tube end. Flush the tube with water and,
if necessary to remove oil, a suitable detergent. Rinse and blow dry the
tube with nitrogen.

A connection nut and the two proper ferrules (front and back ferrules) for
each interface are provided (refer to FIGURE 2-3 below and FIGURE 1-
20, page 1-42).

FIGURE 2-3 Swagelok Procedure

1. Remove the nut and ferrules from the fitting.

2. Install the nut, back ferrule, and front ferrule in the proper
orientation over the facility tube.

3. Install the tube fully into the fitting making sure the tube bottoms out
2-14
 in the tube socket. Push the nut and ferrules down and tighten the
nut finger tight. Place a mark on the nut for reference.

4. Then using a wrench tighten the nut 1 and 1/4 (1.25) turns from the
finger tight position. This will properly swage the ferrules to the
tube.

5. Repeat the above for the nine additional connections on the

hydrogen and oxygen sides

At the lower rear corners of the EC, the cooling water pipes are
connected. The EC is furnished with a removable pipe union, which
should be welded directly to the facility cooling water pipe. Size and
service are listed on the chart of FIGURE 2-1.

2.4.3 Module Storage and Installation

Throughout this section, refer to FIGURE 2-4 and FIGURE 2-5.

CAUTION: OPEN THE MODULE CRATE INDOORS AND

OTHERWISE HANDLE THE MODULE SUCH
THAT RAIN AND MOISTURE DO NOT
CONTACT THE ENDPLATES. THIS MAY
CAUSE THE TIE ROD INSULATORS TO
ABSORB MOISTURE.

USE SUITABLE LIFTING EQUIPMENT AND

HANDLE THE MODULE WITH EXTREME
CARE TO AVOID DAMAGE.

1. Remove the plywood top and sides from the wood module crate.

2. Position the module as close as possible to the support rails on the

phase separator end of the gas cabinet.

3. Refer to FIGURE 2-4. The positive endplate (without pipe

connections) is oriented toward the rails. Place blocks under the
module pallet, if necessary, to level the module with respect to the
rails. The module wheels are at the floor level of the shipping crate.
However, the module is supported primarily by the heavy side posts
that are bolted to each endplate.

NOTE: For EC-1000, two modules are installed with the positive
endplates facing each other in the middle of the gas cabinet. Install
the first module (100B) with the negative endplate nearest the rails
and the second module (100A) with the positive endplate nearest
the rails.

2-15
4. If there is any clearance between the wood floor and the wheels,
install shims under the wheels. Slowly remove the bolts from the
module endplates and transfer the weight to the wheels and floor.

5. The module(s) can be lifted on to the rails, if a suitable lift truck or

forklift is available. Otherwise, place a small steel plate between
the support rails and the shipping pallet. Align the wheels with the
rails and push the module into the gas cabinet.

6. Each module is shipped full with demineralized water. Set up a

catch pan or bucket below the bottom connections. Loosen both
bottom ¼” fittings and connect tubing for draining the water. After
the water has been partially drained, open the top fittings to allow
the water to flow more freely.

CAUTION: HANDLE THE 1.5 INCH MODULE

CONNECTION PIPES VERY CAREFULLY TO
AVOID DAMAGING FITTING THREADS.

7. Remove the protective port covers from the module fittings.

8. Remove packing from the module connection pipes.

9. Clean the pipe threads and O-ring grooves, if necessary, and apply
fluorolube grease. A small amount of grease is needed on the O-
rings. Using the lubricant on the threads helps to prevent galling.

NOTE: The instructions below are written for EC-1000. Skip to step
19 for single module installation.

10. Carefully push module 100B against rail stops. Chalk module
wheels in place. Position Module 100A approximately 1ft (30cm)
from Module 100A, endplate to endplate.

11. Connect pipe assemblies, items 1 and 2, Fig 2-5-1 (from KOH
filters to flanged tees). Start the CPV fitting nuts at the KOH filters
and place piping in pipe supports.

12. Install tees (items 3 and 4) to flanged ends of items 1 and 2. Insert
gaskets and tighten the flange nuts finger tight.

13. Attach pipes 5, 6, 7 and 8 to the tee flanges, insert gaskets, and
tighten nuts finger tight.

14. Partially thread the CPV fittings on pipes 5, 6, 7, and 8 to the lower
ports on the negative endplates. It may be necessary to pry slightly
against the module wheel nuts, in order to start the four CPV
fittings.

2-16
 15. Tighten the CPV fittings on the KOH filter. Torque the nuts on the
flanged connections to approximately 79 ft-lbs (107 N-M). Tighten
the CPV fittings on the module negative endplates.

NOTE: It is important to tighten the fittings gradually (1/2 to one turn at a

time) to avoid galling threads or pinching O-rings. Proceed until all
fittings are wrench tight. Do not over tighten. In subsequent steps,
there will be an opportunity to check for a leak tight fit with water
and nitrogen pressure in the system.

16. The upper pipes can now be installed. Several of the pipes are
heavy, so use the pipe hangers while installing the pipes to support
and guide the installation. Loosely connect pipes 9 and 10, Figure
2-5-3, to the KOH phase separators. Loosely connect pipes 11 and
12 to top ports on the negative endplate of Module 100B.

17. Install tees (items 13 and 14) to flanged ends of pipes 9, 10, 11 and
12. Insert gaskets and tighten the flange nuts finger tight. Attach
pipes 15 and 16 to the tee flanges, insert gaskets and tighten nuts
finger tight. Connect pipes 15 and 16 to the top ports of the
negative endplate of Module 100A.

18. Once all connections have been started, torque the nuts on the
flanged tees to approximately 79 ft-lbs (107 N-M). Tighten the CPV
fittings on the module negative endplates and phase separators in
small increments.

19. For a single module installation (EC-500, EC-600, and EC-750),

the module will be placed in a position similar to 100A. Two (2)
pipes will connect the filter vessels to the module inlet ports, and
two (2) pipes will connect the module outlet ports to the phase
separators.

20. The final step is to install the polycarbonate shield kit on four
sides of the modules. PVC screws are included for attachment to
the end plates. Install the side shields first. Then install the top
and positive end shields using the special nylon screws at the
bottom of the positive end plates.

21. The generator should be filled with demineralized water or 30%

KOH shortly after the module (s) has been installed to prevent the
membrane from drying.

2-17
FIGURE 2-4 Module Installation

2-18
FIGURE 2-5-1 Top View of Piping Installation

FIGURE 2-5-2 Side View of Piping Installation

2-19
 FIGURE 2-5-3 End View of Piping Installation

2.5 Electrical Installation

The electrical installation is accomplished by positioning the power supply

cabinet, and laying out and connecting cables furnished with the EC which
interconnect the power supply and gas cabinet components. The control
cables are pre-wired on the gas cabinet side. All control cables, module
cable, ground cable, and associated mounting lugs and fasteners are
provided with the machine. Other than any user signals, there is only one
electrical interface with the facility and that is at the 3-phase input
connection inside the power supply. There are no control wire connections
made inside the gas cabinet except for any user input or alarm signals.

2-20
 WARNING: FACILITY SUPPLY, AUXILIARY AND
RECTIFIER OUTPUT VOLTAGES ARE
LETHAL. FOLLOW WARNING AND
CAUTIONS REGARDING ELECTRICAL
HAZARDS FOUND IN SECTION 1 OF THIS
MANUAL, AS WELL AS PRESCRIBED
PLANT SAFETY PROCEDURES INVOLVING
WORK ON ELECTRICAL COMPONENTS.

2.5.1 Power Supply Cabinet

1. Unpack the power supply by removing the wooden shipping

container. There should be a box of commissioning spare parts
inside the container or the power supply enclosure. This will
include such items as spare fuses, lamps, relays, etc.

2. Refer to FIGURE 2-6 for power supply installation dimensions.

Position the cabinet on the floor or cement pad in the electrical
room. Plan conduit, cable tray or cable pit runs based on
connection points in the power supply in the lower part of the
cabinet.

3. The AC input connection is at the lower front of the cabinet, the

DC at the lower rear, and the ground pad is at the bottom of the
structure. It is usually easiest to bring the cables in to the
enclosure from the bottom, as is the case with buried conduit or
a cable pit. There are various places on the cabinet surface
where cable glands can be installed, if desired by the user.

4. A 3-pole disconnect switch or manual switch in conjunction with

over current protection should be located within sight of the
power supply, preferably adjacent to the unit. Refer to the
consumption data of Section 1 of this manual for AC line current
versus module size and facility voltage.

5. The power supply contains several small cooling fans that draw
air up from the bottom and discharge warmer air through the
top. In smaller rooms, consideration should be given to free
airflow toward the bottom of the cabinet, to assure adequate
cooling. As the power supply rejects significant heat, it may be
desirable to duct the warm air from the top of the cabinet to an
outside location. Minimizing of dust in the power supply room
should also be considered.

2-21
 FIGURE 2-6 Power Supply with Concrete Pad

2.5.2 Interconnecting Wire and Cable

All of the interconnecting wire between the EC gas cabinet and the power
supply is furnished with the generator. The cabling between the power
supply and gas cabinet is multi-conductor except module and ground
cables. FIGURE 2-7 shows the cables, sizes and voltages. Control and
instrument wires are pre-connected on the gas cabinet side. The cables
are grouped according to voltage so that they can be separated by the
customer for different conduits or to otherwise comply with local codes. The
control and instrument cable used is USA National Electrical Code (NEC)
type TC tray cable. It is suitable for installation in tray cable systems or in
conduit or a cable pit.

The module cable is AWG 4/0 NEC Type W approved for extra hard
service. For the EC-1000 models two set of module cables are used (6
positive and 6 negative per module). Because of the hard service rating
and heavy insulation, the module cables are not easily pulled through
conduit. Since cable in conduit does not need to be rated Type W, users
planning conduit may wish to consider another type of 4/0 cable. Contact
Teledyne for more information.

2-22
FIGURE 2-7 CABLING FROM EC POWER SUPPLY TO GAS CABINET

2-23
2.5.3 Wiring Steps

The wiring installation is performed in five steps as follows:

1. Signal and control cable connection to power supply

2. Ground cable between power supply and gas cabinet

3. Module cables at the electrolysis module ends only

4. AC input connection, initial power, preliminary checks

5. Final module cable connection at the power supply

Performing the installation in the above sequence minimizes the chance for
a problem or error to cause damage.

To make the connections, refer to sheet 2 of the EC generator electrical

diagram. This shows terminal strip and connection points in both the gas
cabinet and power supply. Interconnecting wire numbers are also shown.

Connection terminals and wire number markers can be found on the power
supply end of all control, instrument and motor cables. If the component
separation does not require the entire cable length, the cables may be cut
to a shorter length. In this case, new terminals will need to be crimped to
the wires. Be sure to use the same wire markers.

2.5.4 Signal and Control Cables

1. Be sure any facility power to the power supply has been turned
OFF and locked. Push the Emergency Stop button, at the gas
cabinet control panel.

2. Remove the lower rear panel of the power supply enclosure.

3. Remove the side panel cover (control section of power supply).

Note the 2-inch (51 mm) conduit passage between the main
enclosure and the control circuit enclosure.

4. The instrument and control cables were wrapped in a coil for

shipment inside the gas cabinet. Loosen the wraps and unroll
the instrument and control harness. If desired, separate the
cable bundles according to the voltages listed above. As a
minimum, the two analog signal cables are to be separated from
other cables to minimize the chance for interference. The
analog cables should, for example, be placed in a separate
conduit or wiring trough.

2-24
 5. On the rear wall of the EC gas cabinet, there is a vertical cable
tray with entry points at the top and bottom of the EC. Refer to
FIGURE 2-8. This tray gives the user the option of running
cables to the power supply either above the equipment (cable
trays, for example), or below (cable pit or buried conduit).

6. When the generator is prepared for shipment, the cables were

positioned to exit the bottom of the vertical tray. This can be
changed by the installer by removing the tray covers, and
orienting the cables to the overhead end of the cable tray. Use
tie wraps to secure the cables in the vertical position.

7. Refer to FIGURE 2-9. Remove the rear panels of the power

supply cabinet.

8. Make the cable run to the power supply and bring the cables in
to the main power supply cabinet through the bottom (toward
the back of the cabinet), making sure the cables do not interfere
with the cabinet cover installation.

9. Use tie wraps to position the cables away from live components,
metal edges or fans.

10. Refer to sheet 2 of the EC generator electrical diagram. Select

the 240 VAC power cables and connect them to the transformer
terminals. Select the 115 VAC auxiliary power cable and
connect it to the proper terminals in the power supply control
cabinet.

11. Run the control and signal cables through the conduit passage
to the control section, and connect the cables to the specified
terminals.

12. Run the three motor cables to the motor starters which,
depending on the manufacturer, are located either in the main
cabinet or the control section.

13. Finally, connect the main contactor control cable (for MC1) to
the main contactor located in the main cabinet.

It is recommended that a second person perform a check of the wiring

both for correct location and a tight connection.

2-25
FIGURE 2-8 ORIENTATION OF POWER SUPPLY CABLES

2-26
 FIGURE 2-9 CONTROL CABLE ROUTING

2.5.5 Electrolysis Module Connections (Module End Only) and Ground

Cable

The EC system is supplied with 800 feet (244 meters) of AWG 4/0 cable per
module (EC-1000 has 1600 feet) intended for use as the DC current
conductor, and for a single ground cable. The wire can be cut to 13 lengths
of approximately 19 meters (or shorter): six for the positive side
connections, six for the negative side, and one for the ground cable. The
EC-1000 requires 25 lengths of approximately 19 meters (or less), six each
for the negative side of Module 100A and 100B, six each for the positive
side of Module 100A and 100B, and one for the ground cable. The length of
the positive and negative cables should be determined after considering the
location of cable entrance with respect to the end plates and rectifier. For
example, if all of the cable is brought to the gas cabinet from the end
nearest the positive end plate, the negative cables will need to be longer
than the positive cables. It is very important to trim, mark and position the
positive and negative cables such that they cannot be accidentally reversed
during installation, service or maintenance. This must be done at both the
power supply and electrolysis module ends of the cable.

2-27
 WARNING: THE DC RECTIFIER IS AN ISOLATED
OUTPUT AND REVERSAL OF THE POSITIVE
AND NEGATIVE CABLES WILL NOT INHIBIT
OPERATION. SUCH A CONDITION COULD
RESULT IN THE GENERATION OF OXYGEN
ON THE HYDROGEN SIDE AND HYDROGEN
ON THE OXYGEN SIDE, WHICH IS
EXTREMELY HAZARDOUS. TAKE STEPS
DURING FINAL TRIMMING OF CABLES,
INSTALLATION AND MARKING TO BE SURE
CABLES CANNOT BE REVERSED. BE
SURE OPERATORS AND SERVICE
PERSONNEL UNDER-STAND THIS
WARNING.

There are eight triple-barrel lugs furnished with the system, or sixteen for
the EC1000 models. Each lug takes three AWG 4/0 wires and is installed
on the module with two brass screws and copper lock washers. There are
two single-barrel lugs for use with the ground cable, which uses the same
type of fasteners. All of these items are shipped in the installed position on
the module, in the power supply and at the ground plates.

Perform the module cable installation steps in the following order:

WARNING: VERIFY THAT FACILITY POWER TO THE

POWER SUPPLY INPUT TERMINALS IS NOT
CONNECTED OR HAS BEEN LOCKED IN
THE OFF POSITION.

1. Open the front panel of the power supply to gain access to the
DC cable connection points.

2. Remove the triple barrel lugs from the rectifier output bus bars.
Temporarily replace the rear cover panel.

3. Remove the front panel, or open the front door of the power
supply to gain access to the structural ground plate.

4. Remove the single-barrel lug from the ground plate.

5. Remove the single barrel lug from the gas cabinet ground plate
located on the rear wall below the electrical enclosure.

6. Cut and strip the ends of one length of AWG 4/0 cable for the
ground connection between the structures.

7. Mark the ground cable ends with the appropriate color using
2-28
 shrink tube of electrical tape. Green (per USA practice) is
suggested to indicate ground.

8. Connect the cable to the lugs and install the lugs on the ground
plates.

9. Temporarily replace the front panel (or close the front door) of
the power supply.

WARNING: DO NOT CONNECT THE DC MODULE

CABLES TO THE RECTIFIER BUS BARS AT
THIS TIME. THIS STEP CANNOT BE TAKEN
UNTIL OTHER CHECKS HAVE BEEN
PERFORMED, AND PROPER AC POWER
INPUT HAS BEEN VERIFIED.

10. Cut the remaining cable lengths (see above discussion

regarding lengths), and strip the ends.

11. Carefully mark each cable with a suitable obvious indicator

such as colored tape, to indicate positive (+) or negative (-).
Have a second person check the marking of the cables, to be
sure positive and negative cables are not mixed.

12. Insert three cable ends in to each of the eight triple-barrel lugs
and tighten. If necessary, remove the positive endplate
polycarbonate shield.

13. Connect the lugs to the bottom of the outer surface of each
module endplate.

14. Install the polycarbonate shield. Do not connect the cables at

the power supply end at this time.

15. Be sure all connections include lock nuts and are secure.

WARNING: From this point on, the module side of these

cables should never be left disconnected
from the module. This represents a
potential shock hazard, should power
unintentionally be applied to the rectifier.
The positive endplate is a considerable
surface area that will operate at high
voltage. Keep the polycarbonate shield in
place from this point on.

2-29
2.5.6 Main A/C Power Input and Initial Checks

WARNING: FOLLOW PLANT SAFETY PRACTICES IN

LOCKING OUT FACILITY POWER BEFORE
PROCEEDING WITH THE MAIN INPUT
CONNECTION.

The main power cables will terminate in the lower or middle section of
the power supply cabinet, near the front. The terminations are lugs on
the line side of the rectifier's main contactor. Because end-user supply
wiring depends on local practices, connection lugs must be furnished by
the end-user. The connection holes on the copper input terminals are
0.68 inches (17.5 mm) diameter.

1. Make the connections to the transformer in the proper phase

sequence. Normally, L1 is connected to the left side terminal,
L2 to the center and L3 to the right.

2. At the power supply cabinet, turn OFF the control system main
circuit breaker. This will isolate the 115 and 240 VAC circuits to
the gas cabinet.

3. At the power supply panel, turn the CURRENT ADJUSTMENT

and VOLTAGE ADJUSTMENT potentiometers all the way to the
left, to a zero position. The ramp potentiometer position is not
important at this time.

4. Inside the power supply, turn OFF circuit breakers 919 and (for
C system) 920 and 935.

5. There are three motor starters inside for the EC feedwater pump
(MS1), H2 side KOH pump (MS2) and oxygen side KOH pump
(MS3). Below each starter is an overload heater pack with
adjustable set point. These were set at the factory, but should
be checked prior to operation.

6. Check the overload to be sure it matches the full load amperage

(FLA) given on the nameplate of the motors. Some adjustment
of this value may be necessary depending on the facility input
voltage.

7. There is a jumper, toggle switch or DIP switch (depending on

manufacturer) to set for operation at 50 or 60 hertz. Be sure
this device is in the correct position. Refer to the power supply
manual and diagram.

8. Make a final check of the wiring, which should be complete,

except the module cables should not be connected on the
2-30
 rectifier end.

9. Using prescribed plant safety practices, verify the following

items. Turn the input power OFF to make portable
measurement equipment connections.

10. Using plant safety procedures, close the facility breaker or

switch to supply AC power to the power supply and check:

Input phase rotation sequence is correct

Input facility voltage is within 5% of customer specified
voltage on three phases. Taps are provided on the
transformer, if necessary to correct for high or low input
voltage.
All air fans in power supply are running
Front panel power ON light is working

11. When facility input voltage has been checked, close (turn ON)
the power supply auxiliary circuit breaker located on the side or
front panel. Check for:

Auxiliary transformer at TB3 in power supply is between

110 and 125 VAC.
Change transformer taps if necessary.
Auxiliary transformer voltage at TB4 in power supply is
between 230 and 240 VAC. Change transformer taps, if
necessary.
Power supply internal transformer voltage (supplies fans
and control system) is between 110 and 125 VAC.

12. Slowly turn the voltage and current potentiometers to the right.
There should be no volts or amps indicated on the panel
meters, under these conditions. Turn the potentiometers back
to the zero position.

13. Make any changes or adjustments with the facility power turned
OFF, and re-check as necessary.

14. Turn OFF and lock out the main input power.

2.5.7 Final Connection of Module Cables

1. Be sure the Emergency Stop button at the generator is

depressed.

2. With facility power OFF and locked, remove the front panel of
the power supply.

2-31
 3. Complete the routing of the module cables and connect the
cable lugs to the correct terminals. Be sure to install lugs such
that conductors are well separated.

4. Connect the negative (-) side of the rectifier to the cables

leading to the end of the module containing the four pipe
connections.

5. The positive side (+) is connected to the end of the module with
no pipe connections.

6. Install tie wraps to separate cables from live parts or metal

edges.

7. Be sure that all fasteners include lock nuts.

WARNING: TO PREVENT THE POSSIBILITY OF

ACCIDENTAL REVERSING OF THE DC
DURING FURTHER SERVICE, TRIM, MARK
AND TIE CABLES SO IT IS NOT
PHYSICALLY POSSIBLE TO REVERSE
THEM.

8. Make a final check for correct location and tightness, and install
the power supply enclosure panels or close the door, if
applicable.

2.5.8 Final Comment

Now that power is connected and available at both the power supply
and gas cabinet, the user must take appropriate precautions regarding
safety. Turn OFF breakers for circuits not in use during pre-start
procedures. Keep the voltage and current potentiometers turned down
to zero while the system is not generating gas. Be aware of the various
voltages at points in the gas cabinet - motor circuits, heater circuits, etc.
Keep covers or doors protecting electrical circuits closed. Keep the
module shield assembly in place. Be sure others working around the
machine are aware of electrical hazards.

2-32
 SECTION 3 Generator Operation

TABLE OF CONTENTS:

SECTION 3 Generator Operation .........................................................................1

LIST OF FIGURES:...........................................................................................1
3.1 Summary ................................................................................................2
3.2 Pre-Start Checks Following Installation or Major Service .......................3
3.2.1 Electrical Power...............................................................................3
3.2.1.1 Uninterruptible Power Supply (UPS).................................................4
3.2.2 The "GENERATOR" Touch Screen.................................................6
3.2.3 Check Inert Gas Function................................................................7
3.2.4 Feed Water Input.............................................................................7
3.2.5 Manual Valve Status During Normal Operation ...............................8
3.2.6 Water Fill and Circulation ................................................................8
3.2.7 System Pressure Test .....................................................................9
3.2.8 Depressurize and Drain Water ........................................................9
3.2.9 Electrolyte Fill and Circulation .........................................................9
3.3 Normal Start-Up Procedure ....................................................................9
3.3.1 Pre-start Checks and Actions ..........................................................9
3.3.2 Generator Start Procedure ............................................................11
3.3.3 System Warm-up and Approaching of Set Point Values ...............13
3.3.4 Operating Adjustments ..................................................................15
3.3.5 Normal Cyclic Functions................................................................16
3.3.6 Stopping the Electrolysis Process .................................................22

LIST OF FIGURES:

FIGURE 3-1 Gas Generator Touch Screen - READY...........................................6

FIGURE 3-2 Gas Generator Touch Screen - GENERATING ...............................7
FIGURE 3-3 Cooling System Touch Screen.......................................................15
FIGURE 3-4 Dryer System Touch Screen ..........................................................17
FIGURE 3-5 Status Touch Screen......................................................................18
FIGURE 3-6 Gas Control Screen........................................................................19
FIGURE 3-7 Power Supply Screen.....................................................................19
FIGURE 3-8 System Information Touch Screen .................................................20
FIGURE 3-9 Data Logging Touch Screen...........................................................21
FIGURE 3-10 Graphical Data Display.................................................................21
FIGURE 3-11 Alarm Touch Screen.....................................................................24
FIGURE 3-12 EC Generator Data Sheet ............................................................26

3-1
3.1 Summary
This section will describe start-up procedures, normal machine operation,
normal shutdown, and responding to alarm situations. It is assumed that
installation of the EC and the required facility inputs, and gas vents are
complete. Once the operator has filled the generator with electrolyte and
performed simple pre-start checks, the machine can be operated from the
PLC touch screen.

Proceed to section 3.3 for a normal start-up procedure if the generator has
already been in operation. Otherwise, perform all of the checks starting
with section 3.2.

CAUTIONS: WHILE PRELIMINARY CHECKS ARE BEING

PERFORMED, TURN THE POWER SUPPLY
POTENTIOMETERS FOR VOLTAGE AND
CURRENT DOWN TO ZERO. KEEP THE
EMERGENCY STOP DEPRESSED.

SEVERAL PROCEDURES REQUIRE

OPENING THE ENCLOSURE TO ACCESS
THE DIGITAL CONTROLLERS. USE
CAUTION AS THERE IS HIGH VOLTAGE IN
THE ENCLOSURE.

DO NOT ENERGIZE THE FEEDWATER

PUMP OR THE KOH PUMPS UNTIL
PRESCRIBED BY THE PROCEDURE. THIS
WILL ASSURE THAT THE PUMP ROTATION
IS CORRECT AND THAT NEITHER PUMP IS
OPERATED IN A DRY CONDITION.

REVIEW SAFETY PRECAUTIONS AND

PREVENTATIVE MEASURES IN SECTION 1
PRIOR TO PROCEEDING. BE SURE AREA
VENTILATION IS ADEQUATE AND REMOVE
OR DE-ENERGIZE ANY IGNITION SOURCES.

USE PROTECTIVE SAFETY GLASSES IN

THE VICINITY OF THE MACHINE.

3-2
 INSTALL THE DRYER HEATER SCREENS
TO PROTECT AGAINST HOT SURFACES;
AND INSTALL THE POLYCARBONATE
SHIELD KIT ON THE ELECTROLYSIS
MODULE. NEVER OPERATE THE EC
WITHOUT THE POSITIVE ENDPLATE
SHIELD.

IF THE EC IS BEING STARTED AFTER AN

EXTENDED DOWN TIME, PERFORM AN
INERT GAS PRESSURE TEST AND
CORRECT ANY LEAKS PRIOR TO
GENERATING HYDROGEN.

CHECK THE WIRING AND THE STATUS OF

ANY EXTERNAL ENABLE SIGNALS
CONNECTED AT TB10. IF THE STATUS IS
NOT NORMAL, THE CONTROL SYSTEM
WILL ALARM.

3.2 Pre-Start Checks Following Installation or Major Service

If the system is being started after installation, or anytime it is desired to

conduct basic electrical and pressure checks, follow these steps prior to
operating the generator. If the EC has been in operation, proceed to
section 3.3 for a normal start-up procedure.

3.2.1 Electrical Power

Control power is required to conduct preliminary tests. This will energize

the PLC, touch screen and electrical instruments.

At the power supply, turn the voltage and current potentiometers down to
zero, and turn OFF the circuit breakers for the KOH pumps, Feedwater
Pump and the Dryer Heaters. (See the power supply manual for specific
information). Place the Emergency Stop button on the generator panel in
the STOP position.

Using normal plant safety procedures, establish power to the power supply
at the nearest disconnect or breaker. The power supply power light will
come ON and fans will be heard.

3-3
 CAUTION: IN THE NEXT STEP THE CONTROL SYSTEM
WILL BE ENERGIZED. THE "BUZZER
OVERRIDE" BUTTON MAY BE USED TO
TURN OFF THE HORN. DO NOT PUSH THE
RESET OR FEEDWATER ON BUTTONS AT
THIS TIME.

At the power supply cabinet, turn the UPS ON. The alarm horn will sound.
At the touch screen push the ALARM button, and push the BUZZER
OVERRIDE button.

3.2.1.1 Uninterruptible Power Supply (UPS)

The UPS features a LED display to indicate either load

percentage or battery capacity depending on the mode
of operation. It also includes self-diagnostic tests, a
combination On/Alarm Silence/Manual Battery Test
button, a Standby Button, User Configurable Program,
and two levels of alarms (Factory set by TESI) when the
unit is operating on battery.

In the unlikely event of a UPS malfunction, the UPS

automatically transfers the connected load to bypass.
Bypass operation is indicated by an alarm (which will
shut down the generator) and illuminated Bypass LED
(other LEDs may be illuminated to indicate the
diagnosed problem).

During normal operation, utility power provides energy to the UPS and the
UPS maintains the batteries in a fully charged state. The four green LEDs
indicate an approximate level of load in 25% increments.

CAUTION: Turning off the UPS while in battery mode will result in
loss of output power. Never turn the UPS OFF while the system is
pressurized. A loss of power to the system when pressurized could
result in damage to the equipment.

ON Button

This button controls output power to connected load(s) and has three
functions:

ON - Pressing this button will start up the UPS in order to provide

conditioned and protected power.
3-4
Alarm Silence - To silence alarms, press this button for at least one
second. After the alarm is silenced, the UPS will reactivate the alarm
system to alert of additional problems
Manual Battery Test – Refer to the manufacturer’s manual for details of
this test.

Manual Bypass/OFF Button

This button controls output power to connected load(s) and has dual
functions:

Manual Bypass - Pressing this button once will cause the load to be
transferred to bypass power.
OFF - Pressing this button twice within 4 seconds will turn power OFF to
the output receptacles and connected loads. Perform all necessary
shutdown procedures on connected loads before pressing this button
twice.

CAUTION

Pressing the Manual Bypass/OFF button once will cause the load to
be transferred to bypass power. Pressing the Standby/Manual
Bypass button a second time within 4 seconds will turn power OFF
to the output receptacles and connected loads. Perform all
necessary shutdown procedures on connected loads before
pressing this button twice.

The UPS provides an alternate path for utility power to the connected load
in the unlikely event of a UPS malfunction. Should the UPS have an
overload, over temperature, or UPS failure condition, the UPS
automatically transfers the connected load to bypass. This also causes
the generator to shutdown and depressurize.

Bypass operation is indicated by an alarm and illuminated Bypass LED

(other LEDs may be illuminated to indicate the diagnosed problem). An
alarm signal is sent to the PLC to initiate a pressure release. The system
cannot be restarted until the UPS is returned to normal.

To manually transfer the connected load from the inverter to bypass, press
the Standby button once.

3-5
3.2.2 The "GENERATOR" Touch Screen

Notice the GENERATOR SCREEN. The screen is the main screen and is
shown in FIGURE 3-1 and FIGURE 3-2. It provides a simplified process
flow diagram with indications of all the critical machine parameters such as:
KOH temperature, system pressure, differential pressure, liquid level, safety
temperatures, pump and valve status.

FIGURE 3-1 Gas Generator Touch Screen - READY

Various subsystem screens can be viewed by pressing buttons on the right

side of the screen. The generator status and action buttons are located at
the bottom of the screen. When the generator is in the “READY” state
(Figure 3.1) as shown in the lower left hand side, the generator is off and
the operator has the ability to turn on the KOH pumps (and add feed water
or add nitrogen from other screens) or start generation if there are no active
alarms. An ABORT button appears if START GENERATION is pushed and
disappears when pre-pressurization is completed. Figure 3.2 shows the
GAS GENERATOR TOUCH SCREEN once the generator is making
hydrogen.

3-6
 FIGURE 3-2 Gas Generator Touch Screen - GENERATING

CAUTION: DO NOT PUSH THE “KOH PUMP ON” OR

“START GENERATION” BUTTON UNTIL THE
SYSTEM HAS BEEN FILLED WITH LIQUID
(WATER OR KOH). IF THE PUMPS ARE
OPERATED WITH NO LIQUID, IT MAY
CAUSE DAMAGE.

3.2.3 Check Inert Gas Function

During normal conditions the inert gas purge is fully automatic and a
manual purge is not necessary. Nitrogen can manually be added for a
pressure test or other reasons. The function of inert gas supply should be
checked at this time. Open any facility valves for the inert gas supply.
Push the SYSTEM INFO BUTTON then the MANUAL N2 FILL AND VENT
BUTTON to access the inert gas controls. Turn the nitrogen on and the
system vent valves will close and valve 504 will change position. These
can be heard when the button is pushed. Verify that there is inert gas flow
through valves 506 and 505 into the phase separators. The system
pressure should begin to rise by a few PSIG as indicated on the touch
screen.
3-7
3.2.4 Feed Water Input

CAUTION: THE FEEDWATER PUMP WILL BE

DAMAGED IF OPERATED WITHOUT A
WATER SUPPLY FROM THE FACILITY.

At this time, the feedwater pump rotation direction must be checked. Under
the electrical enclosure at the gas cabinet back wall, locate the pump/motor
and the flow direction arrow on the pump case. Open the facility valve(s)
that supply feedwater to the EC interface. At the TEE connection near the
pump suction, loosen (do not remove) the port cap, and allow some
feedwater to drain into a bucket. This will assure the pump is wetted and
will eliminate stagnant water from the supply tube. Tighten the fitting.

Press the FEED WATER button. While looking through the pump/motor
adapter slots, push the PRIME button, and then release it. If the direction of
rotation is incorrect, two of the 3-phase leads must be reversed. This is
normally done at the power supply control enclosure. Change the leads on
the input side of motor starter MS1. Check the rotation again, and proceed.

3.2.5 Manual Valve Status During Normal Operation

Whether starting with KOH or by filling with water for a pressure test, the
manual valves in the system should be checked for correct status. The
valves listed in TABLE 3-1 are for maintenance purposes, and are not
changed during normal generator operation. Check to see that these
valves are in the proper OPEN or CLOSED position:

TABLE 3-1 Manual Valve Status

Valve Number Open or Closed
KOH filter drains 110, 210 Closed
KOH piping drains 120, 220 Closed
KOH cross-over pipe 117, 118 Open
KOH ball valves 106, 206 Open
KOH ball valves 108, 208 Open
KOH A.C.E. valve 115 Open
Cooling water strainer flush 608 Closed
Bleed valves at controller 328 Closed
Drain valves at transmitter 113 Closed

Other manual valves in the system require adjustment during start-up, and
will be discussed in the applicable procedure steps.

3-8
3.2.6 Water Fill and Circulation

After shipment or major maintenance, the generator should be filled with

either feed water or 30% KOH. This will enable checking of the pumping
loop components and a system pressure test. The use of feed water will
also help to remove any system contamination.

At the touch screen, turn ON the feedwater pump by pressing PRIME on

the FEED WATER screen. Listen at the hydrogen side phase separator for
water flow. When using demineralized water, continue filling until the liquid
level indicates approximately 40%. At this time, the operator can start the
KOH pumps. Push the KOH PUMP ON button.

On the first few attempts, the pumps will run and will force the liquid into the
electrolysis module. The redistribution of liquid will cause the liquid level to
fall below 20%, which will then cause the KOH pumps to turn OFF on a low-
level alarm. Reset the alarm and turn ON the feedwater pump and add
more water. Repeat the attempts to start the KOH pumps each time the
level reaches approximately 40%. When the liquid level is able to stay
above 20% the KOH pumps will continue to run. The operator should stop
adding feed water once the level is stable and approximately 40%.

The KOH pumps can be operated any time there is liquid in the system,
including during the pressure test.

3.2.7 System Pressure Test

If necessary at commissioning or after service, conduct a pressure test of

the system using inert gas pressure. After the functional or pressure test
turn the inert gas supply OFF at the touch screen. This is done in
accordance with the procedure in section 4.5.21.

3.2.8 Depressurize and Drain Water

When the inert gas OFF button is pressed, the gas supply is turned OFF.
Press the DEPRESSURIZE button to open the system vent valves 320, 420
and begin venting gas. If desired, close the vent valves by simply pushing
the inert gas ON button, then immediately pushing the inert gas OFF
button. At this point, the inert gas will be off and the vent valves will be
closed.

Water can be drained from the system using the same procedure as that for
KOH, in section 4.5.2

3-9
3.2.9 Electrolyte Fill and Circulation

The electrolyte fill is very similar to the water fill in section 3.2.6. Fill the
generator with KOH electrolyte in accordance with section 4.5.2. After
draining and filling, the KOH must be allowed to circulate for at least 2 hours
prior to electrolysis. If the system is new or is being started with a
replacement module, or has been drained for more than a few days, then
the KOH should be circulated for 8 hours. It is recommended that the
service be performed such that the KOH circulates overnight, then the
system is ready to operate the next day.

3.3 Normal Start-Up Procedure

3.3.1 Pre-start Checks and Actions

1. Check facility ventilation and, if applicable, any external monitors.

2. Verify that instrument air supply is at least 80 PSIG (5.5 bar) as

indicated on regulator 001 pressure gage. Verify the instrument
control pressure is 20 PSIG (1.4 bar) as indicated on regulator 002
pressure gage.

3. Verify the supply of inert gas to the generator interface. Open the
facility supply valve. Check that 505 and 506 valves are open to
permit inert gas flow to the phase separators.

4. Verify the supply of feedwater to the generator interface. Open the

facility supply valve. Loosen the cap at the TEE located at the
feedwater pump suction, and allow feedwater to purge through the
piping and to prime the pump and increase the water quality.
Tighten the cap.

5. Turn the power supply voltage and current potentiometers down to

zero.

6. Turn ON facility power to the rectifier. White light is ON and fans

are running.

7. Turn ON the UPS at the power supply cabinet. The horn may
sound and touch screen is activated. The GENERATOR screen is
shown on the touch screen.

8. Push ALARM and BUZZER OVERRIDE buttons to silence the

horn.

9. All instrument LED's and indicating lights should be ON.

Transmitter 113 indicates the KOH level. Transmitter 325 is
indicating 0%.

3-10
 10. KOH concentration has been verified within normal range (28-32%
for EC-500, 600, or 750; 28 to 32% for EC-1000).

Check condition of 310 and 410 rotameters. The regulators and needle
valves must be open to permit flow. More precise adjustment is made
with the system at normal operating pressure. If one or the other has
been disturbed since previous operation, open the needle valve 2 or 3
turns.

If the generator has been at ambient pressure for more than a few
minutes, it is recommended to purge any air that may have migrated into
the system. This purge can be performed by pressurizing the system with
inert gas up to 15 psig (1 bar) and then turning the inert gas off and
venting the system. Repeat this procedure once. As inert gas flows into
the system, the operator should carefully monitor the O2-in-H2
temperature. As the inert gas forces air through the system and over the
310 probe, the temperature will rise. If the temperature rises above 90 C,
turn the inert gas OFF and allow the system to de-pressurize. When the
temperature falls, close to ambient, start the nitrogen again.

The system is now ready for gas generation.

3.3.2 Generator Start Procedure

NOTE: ALL TOUCH SCREENS WHICH ARE

POSSIBLE DURING GAS GENERATION
CONTAIN A "SHUTDOWN/PRESSURE
RELEASE" BUTTON. THE OPERATOR CAN
DISCONTINUE THIS PROCEDURE AT ANY
STEP BY PRESSING THIS BUTTON. THE
SYSTEM WILL RESPOND BY STOPPING
THE INERT GAS PURGE OR DC CURRENT
TO THE ELECTROLYSIS MODULE AND
DEPRESSURIZING VIA VALVES 320 AND
420.

1. Establish the desired valve line-up at the facility for delivered

hydrogen or (for "C" model) oxygen. This may involve temporarily
diverting delivered gas to the vent system while the inert gas is
being purged.

2. Open the facility condenser cooling water valves at the inlet and
outlet sides. Condenser valves on the generator should already be
preset to a partially open position. If not, flow to each heat
exchanger should be approximately 1 GPM (4 LPM) or two turns
each. Flows will be adjusted again during operation.

3. Push the PRIME button on the FEED WATER screen to turn on the
3-11
 feedwater pump for about five to 10 seconds to flow fresh water
over the feedwater probe. This will update the feedwater quality
reading.

4. At the power supply panel, turn the VOLTAGE potentiometer to the

maximum setting in the clockwise direction. Turn the AMPERAGE
potentiometer between 35% - 100%, for starting a system from
ambient temperature. This will limit the start-up DC current but
maintain at least 100 amperes per module. It is best to operate the
generator in AUTOMATIC mode.

NOTE: THE AMPERAGE IS LIMITED DURING

START-UP AND RAMPED SLOWLY OVER
TIME AND WITH TEMPERATURE INCREASE.

5. Pull the Emergency Stop button out to enable electrolysis.

6. Push the START GENERATION button. This will clear any alarm
latches and begin the automated start up sequence.

7. The status on the bottom left of the touch screen will now read
PRE-PRESSURIZATION.

8. The system pressurizes and vent valves 320, 420 can be heard
going to a closed position. At a preset pressure 320 and 420 open
and pressure releases. This cycle repeats two times. While inert
gas is flowing, the operator should check for a balanced flow to
each side by observing the differential pressure reading. If the
differential pressure is high on one side (above the set value),
adjust manual valves 505 and 506 with the inert gas flowing.

9. The KOH pumps will be running. The start up sequence can be

stopped by pressing the ABORT button next to the status at any
time.

10. If the gas sensor temperatures are too high, the generator will
automatically depressurize and attempt to pressurize again. If after
15 minutes the system has not been able to start, the generator will
stay shut down.

11. After pre-pressurization is complete there will be a 15 second

delay, and then gas generation will begin. Manual inert gas and
KOH pump control are not permitted during electrolysis. The KOH
PUMP OFF, MANUAL N2 FILL AND VENT and ABORT buttons
disappear on all screens.

12. The process can be stopped anytime simply by pushing

SHUTDOWN/PRESSURE RELEASE or POWER SUPPLY
DISABLE on the touch screen or EMERGENCY STOP on the
3-12
 control panel below the touch screen. Only SHUTDOWN /
PRESSURE RELEASE releases the pressure in the generator.
When the operator hits one of these buttons on the touch screen,
he is asked for confirmation in case the button was touched
inadvertently.

13. The SYSTEM INFORMATION button will take you to the screen
shown in FIGURE 3-8.

NOTE: If instrumentation was purchased with the generator and

connected to the PLC, the display screens are accessed through the
SYSTEM INFORMATION screen. See appendix for information on
instrumentation, if applicable.

3.3.3 System Warm-up and Approaching of Set Point Values

Pressure and DC Current

During the next several minutes, the system pressure will increase and the
KOH temperature will begin to rise. When the pressure is between 70 and
80 PSIG (4.8 and 6.2 Bar), the 309 and (for a "C" model) 409 regulators will
open and gas will begin to flow to the facility.

In the first 5 to 10 minutes, the differential pressure will usually be slightly

high on the hydrogen side. This is due to the presence of the heavier inert
gas on the hydrogen side, and the various system orifices, which are sized
for hydrogen. While in a hydrogen demand situation (standard model, or
when hydrogen demand exceeds oxygen demand on a "C" model), the
change in differential pressure back to the oxygen side, is an indication that
the inert gas has been cleared from the system.

The generator will slowly ramp the current limit over the first few minutes
and operate at the maximum current allowed by the ramp and DC current
potentiometer setting on the power supply panel. When the pressure on
transmitter 325 is within one or 2 PSIG of the set point (normally 120 PSIG
or 8.3 BAR), the generator will automatically adjust production to match
facility demand.

If the pressure is below the set point, the current will rise until the set point
is reached. The current will be limited by the potentiometer setting, which is
now in terms of percentage of the power supply rating. It can take several
minutes for the pressure and current relationship to stabilize based on the
set point and a facility demand. If the demand increases, the system
pressure will fall, the current will begin to rise and, after several more
minutes, the system will stabilize at a higher current. If the demand falls,
the system pressure will increase and the current will drop down and
3-13
stabilize at a lower level.

When the facility is demanding more gas than the rated output, the gas
production will be voltage or current limited by the power supply. When the
system is fully warm and stable, the current limiting potentiometer should be
adjusted to allow full current. With no demand from the facility, the current
will drop to 10% (100A or 200A) of the rated output.

KOH Temperature Control

When the KOH temperature is cool, it also limits the allowable current.
This current limit ramp ends when the KOH inlet temperature (232) reaches
55 C. If the pressure is below the set point, the current will rise until the set
point is reached.

When the KOH temperature is within 1°C or 2 C of the set point, the cooling
water valve will begin to open to allow water flow through the KOH heat
exchanger circuit. The system will stabilize and remain within 1 C of the set
point set by Teledyne. The KOH temperature as indicated on the touch
screen from T/C's 111 and 211 will vary within a range of 60 to 73 C,
depending on system demand. When the generator is operating at full
output, the temperature should not exceed 73 C. If it does, contact
Teledyne Energy Systems for technical support.

Details of the temperature control system are shown on the COOLING

SYSTEM screen shown below.

3-14
 FIGURE 3-3 Cooling System Touch Screen

3.3.4 Operating Adjustments

Gas Probe Flow Controller Adjustment

When the system is above 60 PSIG (4.1 bar), verify that the 310 and 410
regulators are controlling the pressure to the flow meters to 7 to 10 PSIG
(~0.6 bar). Adjust the needle valves to achieve readings on the rotameter
scale (indicates cc/min air) as follows:

Hydrogen side: 20 to 30
Oxygen side: 60 to 80

Condenser Water Flow

The condenser water was initially set during the pre-start procedure. Its
final setting will depend on site conditions including cooling water
temperature. Make a final adjustment only after the machine is operating at
the normal control temperature (61 to 73 C).

Feel the tube on the gas outlet side of each condenser. It should be at or
near ambient temperature. If the tube is warm or hot to the touch, increase
the water flow in small increments. Wait two or three minutes and check
3-15
 again. Another general rule for adjustment is that the inlet and outlet tubes
on the water side of the condensers should be nearly the same. If the outlet
tube is more than a few degrees C above the inlet, increase the flow per the
above steps.

To minimize cooling water consumption, the flow can be reduced based on

the guidelines in the preceding paragraph.

3.3.5 Normal Cyclic Functions

Filter Trap Purge

Every 15 minutes, valves 372 and 374 and (for a "C" model) 482, 484, 472
and 474, will change status for 5 seconds. This will cause the traps 373
(and 483 and 473) to depressurize and remove a small amount of water
vapor via the vent system. When the valves return to the normal position,
the pneumatic control valve can be heard releasing valve operator
pressure.

Dryer Regeneration Cycle

Each time the dryers change, a regenerating cycle will occur for the off-line
dryers. The cycle is described in detail in section 1.3.5.2. It consists of a 1
hour heating followed by a 1 hour cool-down wherein valve 335 and (for a
"C" model) 435 are open. For the next 3.5 hours, there is a slow purge of
pure gas from the on-line dryer through the off-line dryer and out the vent
system. Next, valve 335 (and 435) opens and valve 370 and (for a "C"
model) 470 closes. This allows pressurizing of the off-line dryer in
preparation for switching back into service. When the system pressure and
off-dryer pressure are close enough (approximately 16 PSIG (1.1 Bar) on
the hydrogen side and 24 PSIG(1.6 Bar) on the oxygen side), the dryers
switch. Valves 313, and (for a "C" model) 406, 407, 413 change position.
The cycle is then repeated.

The operator can view all of the dryer related information by pushing the
DRYERS button. Figure 3-4 shows the DRYER STATUS SCREEN.

3-16
 FIGURE 3-4 Dryer System Touch Screen

Each change in the dryer cycle can be noticed with a noise associated with
the pneumatic controls that change valve positions.

Feedwater Addition
The PLC monitors the liquid level of the KOH with pressure transducer 113.
The system pumps feed water to the hydrogen phase separator when the
liquid level falls to the factory-set fill set point. The feed water pump will run
until the level rises to full set point. The fill time and frequency will depend
on the system demand. When the pump is started or stopped by the PLC,
the motor starter MS1 may be heard in the electrical room. Near the gas
cabinet, check valves 507 and 509 can be heard when the pump is
stopped. FIGURE 3-5 shows all of the actions, level set points and the
actual level.

3-17
 FIGURE 3-5 Status Touch Screen

Other screens that provide useful information during normal operation are
GAS CONTROL, POWER SUPPLY and SYSTEM INFO (FIGURE 3-6, FIGURE
3-7, and FIGURE 3-8.

3-18
FIGURE 3-6 Gas Control Screen

FIGURE 3-7 Power Supply Screen

3-19
 FIGURE 3-8 System Information Touch Screen

The SYSTEM INFORMATION screen contains and leads to a lot of information.

It displays the cumulative generator operating hours as well as the PLC and
screen programs. The operator can change units for the various analog signals
( C versus F, etc.). He can access and operate the manual inert gas controls and
turn the KOH pumps on and off manually when the generator is not producing gas.
He can also view and set up any optional instruments purchased with the EC
generator. For more details about the optional instrumentation, refer to the
Appendix.

Another useful feature accessed through the SYSTEM INFO screen is the
graphical data logging of important parameters. FIGURE 3-9 shows the DATA
LOGGING screen. From there the operator can choose to view graphs of different
groups of information. FIGURE 3-10 displays an example of a typical screen
showing trends of information.

3-20
FIGURE 3-9 Data Logging Touch Screen

FIGURE 3-10 Graphical Data Display

3-21
3.3.6 Stopping the Electrolysis Process

WARNING: DO NOT TURN THE UPS OFF WHILE THE

SYSTEM IS PRESSURIZED! TURNING THE
UPS OFF WILL RESULT IN A LOSS OF
POWER TO ALL DOWNSTREAM
INSTRUMENTS.

Normal Stop
The operator can push the POWER SUPPLY DISABLE button on any
touch screen, which will interrupt DC current. The operator can also push
the SHUTDOWN/PRESSURE RELEASE button on any screen. This will
interrupt DC current as well as opening the vent valves 320 and 420 to
depressurize the system. In either case, the KOH pumps will continue to
run unless the KOH PUMPS OFF button is pushed. When either button is
pushed, a confirmation screen pops up to make sure you want to stop
generation.

The operator may also use the manual push Emergency Stop switch to stop
electrolysis. This may be used if there is a control or touch screen
malfunction. The result is the same as pushing the POWER SUPPLY
DISABLE button on the touch screen.

If depressurizing, it will take five to ten minutes depending on the condition

of the facility valve(s) to complete. The generator will go through an
automated depressurization including inert gas purges before it
depressurizes completely.

If the system is going to be down for more than a few hours, the control
power should be turned OFF at the UPS.

WARNING: NEVER TURN OFF THE UPS WHILE SYSTEM

IS PRESSURIZED! THIS WILL RESULT IN A
LOSS OF POWER TO CRITICAL
INSTRUMENTS REQUIRED TO MAINTAIN
DELTA-P.

This will cause the vent valves 320, 420 and 370, 470 to close and will
minimize the chance of air being drawn into the system.

At the power supply, turn the DC voltage and amperage potentiometers

down to zero. If desired or necessary for maintenance, turn off and lock out
the facility power.

3-22
Alarm Condition

If an abnormal situation is encountered, the PLC will stop electrolysis. The

feedwater pump will stop if it was ON during the alarm. The KOH pumps
will continue to run unless the problem is low liquid level, high liquid level, or
low flow. Reference Section 1, 1.3.10, System Monitors and Alarms for
more information. The touch screen will automatically move to the ALARM
screen shown in Figure 3-11. The screen displays a list of all the alarms
with date/time stamps. The top most alarm is the most recent and active
alarm. The operator can still access other screens while in alarm, but on
each of these screens the ALARM button will be flashing red to indicate that
the alarm has not been cleared.

The alarm is reset by pressing the START GENERATION button. The

ABORT button can be pressed if the operator does not want to restart the
generator. Alarms for the optional instruments must be reset separately with
the INSTRUMENT ALARM RESET button and the horn can be silenced
with the BUZZER OVERRIDE button.

Refer to section 5 for probable causes of alarm conditions. When the

problem has been resolved, the RESET button is pushed to clear the alarm
and the system may be restarted.

3-23
 FIGURE 3-11 Alarm Touch Screen

Power Loss

During loss of power, the differential pressure control system maintains

differential pressure. If the UPS battery charge is insufficient to provide at
least 15 minutes of back up power a UPS alarm occurs. A pressure release
is initiated while there is enough back up power to safely depressurize until
a zero pressure state is reached.

CAUTION: Turning off the UPS while in battery mode will result in
loss of output power. Never turn the UPS OFF while the system is
pressurized. A loss of power to the system when pressurized could
result in damage to the equipment.

3-24
EC Monitoring and Data Collection
The EC generator is designed for automatic operation and response to
changes in user demand. It may be left unattended assuming it has been
properly commissioned and functionally checked. Normal practice is to
check the machine once or twice per 8-hour shift. It is recommended that
the operator record data at this time and the data be kept as an aid to
troubleshooting. A suggested format for data collection is shown in Figure
3-2.

A detailed service history should be kept and should include both routine
maintenance and repairs.

3-25
FIGURE 3-12 EC Generator Data Sheet

3-26
 SECTION 4 Maintenance and Calibration Procedures

TABLE OF CONTENTS:

SECTION 4 Maintenance and Calibration Procedures ................................................... 1

TABLE OF CONTENTS: ...................................................................................... 1
LIST OF FIGURES:.............................................................................................. 2
LIST OF TABLES: ................................................................................................ 2
4.1 General...................................................................................................... 3
4.1 General...................................................................................................... 3
4.2 Maintenance Schedule .............................................................................. 3
4.2.1 Weekly Checks ............................................................................... 3
4.2.2 Monthly ........................................................................................... 3
4.2.3 Every Three Months (2000 hours) .................................................. 3
4.2.4 Every Six Months (4000 hours)....................................................... 3
4.2.5 Every Year (8000 hours)................................................................. 4
4.3 Instrument Function and Calibration.......................................................... 4
4.4 Safety Warnings ........................................................................................ 5
4.5 Maintenance and Calibration Procedures.................................................. 5
4.5.1 Adjusting Instrument Air Pressure Regulators (001, 002)............... 5
4.5.2 Maintaining the Electrolyte (KOH)................................................... 6
4.5.3 Retorquing the Module ................................................................. 13
4.5.4 Inspecting the Electrolyte Pump ................................................... 14
4.5.5 Inspecting and Cleaning the Electrolyte Heat Exchanger ............. 17
4.5.6 Functional Check of the Electrolyte Flow Switch .......................... 18
4.5.7 Cleaning the Electrolyte Filter....................................................... 19
4.5.8 Replacing the Coalescing Filter .................................................... 20
4.5.9 Inspecting and Cleaning the Condenser and Gas Cooler............. 20
4.5.10 Adjusting the Pressure Switch (005)............................................. 21
4.5.11 Replacing the Product Gas Filters ................................................ 21
4.5.12 Servicing Check Valves ................................................................ 22
4.5.13 Cleaning and Inspecting Gas Orifices........................................... 25
4.5.14 Cleaning Solenoid Valves............................................................. 26
4.5.15 Replacing Gas Dryer Molecular Sieves ........................................ 29
4.5.16 Replacing Gas Sensor Molecular Sieves...................................... 30
4.5.17 Inspecting and Cleaning the Power Supply .................................. 31
4.5.18 Adjusting Overdemand Protection Valves (309, 409) ................... 31
4.5.19 Adjusting Overpressure Protection Valve (340) ............................ 32
4.5.20 Leak Testing Pneumatic Control Valves ....................................... 32
4.5.21 Checking System Leaks ............................................................... 33
4.5.22 Checking Gas Sensor Functions .................................................. 33
4.5.23 Adjusting Liquid Level Control System ........................................ 34
4.5.24 Adjusting Differential Pressure Control System ............................ 38
4.5.25 Feedwater Monitor Check............................................................. 41

4-1
LIST OF FIGURES:

FIGURE 4-1 Electrolyte Pump ...................................................................................... 16

FIGURE 4-2 Check Valves .......................................................................................... 24
FIGURE 4-3 Three-Way Solenoid Valve....................................................................... 27
FIGURE 4-4 Two-Way Solenoid Valve ......................................................................... 28
FIGURE 4-5 Liquid Level Calibration Tube................................................................... 35
FIGURE 4-6 Liquid Level Calibration Setup.................................................................. 36
FIGURE 4-7 Differential Pressure System Calibration.................................................. 39

LIST OF TABLES:

TABLE 4-1 Specific Gravity of KOH Solution at Various Temperatures........................ 10

TABLE 4-2 Diluting Concentrated Solution with Water ................................................. 12

4-2
4.1 General
This section provides information on periodic component checks, regular
maintenance such as filter changes, and procedures for adjustment of controls and
instruments.

Periodic inspection and preventative maintenance are essential to reliable

operation of the EC generator. To avoid significant down-time and repair expense,
carry out these steps and record them in a machine log. The time required for
most routine maintenance items is minimal.

Factors other than time affect maintenance. Operating output, cooling water
quality, the number of machine start-ups and other site specific factors can
influence maintenance intervals. Keep detailed records of operating data and
maintenance information in order to adjust the schedule for minimal downtime and
replacement part cost.

4.2 Maintenance Schedule

We recommend the following maintenance items at the months or machine

operating hours shown. The approximate time required for each item is shown in
parentheses along with the applicable manual section: [not shown]

4.2.1 Weekly Checks

Cooling water filters (if used)

Instrument air line filter and moisture trap
Stand-by nitrogen supply

4.2.2 Monthly

Instrument air supply pressure check/adjustment

4.2.3 Every Three Months (2000 hours)

Minor electrolyte loop service:

Electrolyte concentration check (sec 4.5.2)
Clean electrolyte filter cartridges (sec 4.5.7)
Gas sensor functional check (sec 4.5.22)
Functional check of flow switches (sec. 4.5.6)

4.2.4 Every Six Months (4000 hours)

Three-month services plus:

4-3
 Replace coalescing filter cartridge (30 minutes, sec 4.5.8)
Dryer check valve & orifice maintenance (2 hours, sec 4.5.12 and
4.5.13)
Bubble check for gas leaks (30 minutes, sec 4.5.21)
Module torque procedure (1 hour, sec 4.5.3)
Air pressure regulator adjustment (15 minutes, sec 4.5.1)

4.2.5 Every Year (8000 hours)

Three-month services plus

Six-month service plus:
Change electrolyte, (sec 4.5.2) and electrolyte heat exchanger tube
inspection/cleaning (2 hours, sec 4.5.5).
Replace molecular sieves in gas dryer tubes (4 hours, standard; 8
hours "C" model, sec 4.5.15)
Inspect air system regulator filters (15 minutes sec 4.5.1)
Inspect and clean gas condenser (1 hour, sec 4.5.9)
Replace gas sensor molecular sieve (1 hour, sec 4.5.16)
Replace product gas filter (30 minutes, sec 4.5.11)
Check valve inspection and cleaning (4 hours, sec 4.5.12)
Control valve leak checks (1 hour, sec 4.5.21)
Back pressure regulator adjustment (30 minutes, sec 4.5.19, 4.5.19)
Instrument air pressure switch check (30 minutes, sec 4.5.10)
Clean and inspect power supply internals (1 hour, sec 4.5.17)
Solenoid valve inspection and cleaning (4 hours, sec 4.5.14)
Inspect/clean trap orifice 375, 475 (30 minutes, sec 4.5.13)

4.3 Instrument Function and Calibration

Short-term maintenance intervals for some EC instruments are not prescribed.

These instruments have been demonstrated to give reliable performance for
several years without significant deviation from original set points. Inaccurate
readings and changes in performance can be noticed when machine parameters
are checked on a regular basis.

The following sections include calibration and set-up procedures for these
instruments. Unless you suspect a problem, these procedures should not be
necessary every year. As a general rule, perform calibration recommended every
two to three year for instruments exhibiting normal behavior.

The list below contains instruments with menu-driven set-ups and other types of
adjustments.

4-4
 Pressure control system (325) Refer to section 4.5.24
Electrolyte temperature control system (232, 013, 609) Refer to section
4.5.25
Liquid level control system (113) Refer to section 4.5.26
For “C” model only: catalyst vessel temperature control (418) and O2
side catalyst tank temperature control (486) Refer to section 4.5.27
Delta-pressure control system (007, 008, 017, 328, 330, 430) Refer to
section 4.5.28
Feedwater resistivity monitor (705) Refer to section 4.5.29

4.4 Safety Warnings

Various maintenance procedures require partial disassembly of the EC

subsystems. Potential hazards include retained system pressure, high voltage,
flammable gas, caustic KOH liquid and high temperature surfaces. Refer to
section 1 of this manual for warnings and precautions pertaining to these items.

Use practices recommended in this procedure as well as prescribed plant safety

procedures. Be sure the system is fully depressurized and inert gas purged to
remove hydrogen, before opening fittings. Turn off system breakers or
disconnects and lock out electrical power when performing electrical
maintenance. Use caution and personal protective gear when handling
electrolyte. Depressurize supply piping (inert gas, instrument air, and water
lines) before opening fittings.

4.5 Maintenance and Calibration Procedures

4.5.1 Adjusting Instrument Air Pressure Regulators (001, 002)

The instrument air regulator maintenance includes adjustment of the set point and
inspection of the internal filter cartridge.

Each regulator has an outlet pressure gage, which makes it a simple matter to
check the set point. If a faulty gage is suspected, verify the set point by
connecting a second gage to the regulator output plumbing.

1. Set the 001 supply pressure gage to 80 PSIG (5.5 Bar).

2. Set the 002 instrument pressure to 20 PSIG (1.38 Bar).

3. Perform the adjustment with a slight air flow through the valves. Loosen
the lock nut on the regulator bonnet and turn the adjusting screw
clockwise to raise the set pressure and counter-clockwise to lower the set
pressure. Tighten the lock nut.

4-5
 4. To be sure of the adjustment, observe the pressure gages while the
machine is in normal operation.

5. Inspect the regulator filters in accordance with the instructions and

diagrams shown in the manufacturer's manual, found in the appendix of
this manual.

4.5.2 Maintaining the Electrolyte (KOH)

WARNING: REVIEW THE WARNINGS AND PRECAUTIONS

PERTAINING TO CAUSTIC ELECTROLYTE IN
SECTION 1. USE APPROPRIATE PERSONAL
PROTECTION INCLUDING GOGGLES WHEN
HANDLING THIS LIQUID.

WHEN CONCENTRATED KOH OR SOLID KOH

PELLETS ARE MIXED WITH WATER, THE
SOLUTION TEMPERATURE WILL RISE. ADD THE
CHEMICAL SLOWLY TO AVOID EXCESSIVE HEAT.

USE ONLY 300 SERIES STAINLESS STEEL,

POLYETHYLENE OR POLYPROPYLENE
CONTAINERS, AND TUBING FOR HANDLING
ELECTROLYTE. ORDINARY STEEL, ZINC OR
CADMIUM PLATED STEEL, BRASS, BRONZE,
COPPER, ALUMINUM OR GLASS CONTAINERS
WILL BE ATTACKED BY KOH AND ARE NOT
SUITABLE.

KEEP A CONTAINER (3 OR 4 GALLONS, 12 OR 16

LITERS) OF 5% WT BORIC ACID SOLUTION TO
NEUTRALIZE SPILLED KOH.

Mixing the Electrolyte

One generator fill is approximately 70 gallons (265 liters) of 30% wt KOH solution
for an EC-1000 generator; or 53 gallons (200 liters) of 30% wt KOH solution for a
single module generator. The water used for mixing KOH solution must be from
the same high-purity source as that for generator operation.

Purchase concentrated electrolyte from chemical suppliers. The most common

method of overseas shipment is in solid pellet form, 85% wt. If a local source is
available, electrolyte can be purchased as a concentrated liquid, 45% wt in 55
gallon (208 liter) drums. To obtain 70 gallons (265 liters) of 30% solution, 261 LBS
(119 KGS) of solid 85% pellets are required, or 39.6 gallons (150 liters) of 45%
liquid are required. To obtain 53 gallons (200 liters) of 30% solution, 202 LBS (92

4-6
KGS) of solid 85% pellets are required, or 31.4 gallons (119 liters) of 45%liquid are
needed.

The specification for 85% wt pellets is:

Potassium Hydroxide (KOH) Minimum 85.0%

Impurities Not to exceed:
Potassium carbonate (K2CO30) 2.0%
Chloride (Cl) .01%
Nitrogen compounds (N) .001%
Phosphate (PO4) .0005%
Sulfate (SO4) .003%
Ammonium hydroxide precipitate .02%
Heavy metals (as Ag) .001%
Iron (Fe) .001%
Nickel (Ni) .001%
Sodium (Na) .1%
Other impurities Balance

The specification for 45% wt liquid is:

Potassium Hydroxide (KOH) Minimum 45.0%

Impurities Not to exceed:
Potassium carbonate (K2CO30) 1.1%
Chloride (Cl) .005%
Nitrogen compounds (N) .0005%
Phosphate (PO4) .0002%
Sulfate (SO4) .0015%
Ammonium hydroxide precipitate .011%
Heavy metals (as Ag) .0005%
Iron (Fe) .0005%
Nickel (Ni) .0005%
Sodium (Na) .05%
Other impurities Balance

1. When mixing electrolyte, put the pure water in the mixing container first
and add the concentrated liquid or pellets to the water.

WARNING: DO NOT POUR THE WATER INTO A CONTAINER

WITH KOH PELLETS OR CONCENTRATED LIQUID.
ADD THE KOH TO THE WATER. AS KOH IS
ADDED TO THE WATER, THE TEMPERATURE
WILL RISE SIGNIFICANTLY. ADD SLOWLY AND
MIX CONSTANTLY TO AVOID EXCESSIVE
TEMPERATURE RISE.

4-7
 2. Mix the electrolyte until it is at or near the recommended quantity.

3. Begin checking the concentration using a hydrometer or by weighing a

known volume. Refer to section 4.5.2 for the procedure for checking the
concentration.

4. Stop adding KOH when the concentration reaches 30%.

Adding the Electrolyte

There are two basic methods of adding electrolyte to the EC Generator. The
recommended method is to use a small chemical pump or barrel pump to force the
liquid into the oxygen-side phase separator. The oxygen phase separator also has
an upper connection fitting for a funnel, and the electrolyte can be poured.

For regular maintenance, consider an assembly consisting of a mixing and storage

tank mounted to a portable cart with chemical pump and tubing. Contact Teledyne
for information on optional filling equipment.

1. The EC instrument air system must be ON. The electric power to the
power supply and controls (UPS) must be ON. This energizes the liquid
level instrument and allows the operation of the electrolyte pumps.

2. If a chemical pump is used, connect the discharge tube to the oxygen side
drain port at valve 220 or to the upper CPV fitting at the phase separator.

3. At the differential pressure transducer 328 open the small manual valves
on the top. This allows gases to be displaced as the liquid is pumped into
the EC.

4. Energize the chemical pump, open valves 210 and 220, and add liquid to
the oxygen plumbing. As the liquid level reaches the phase separator,
liquid begins to flow to the hydrogen side via valve 117. As the hydrogen
phase separator fills, the liquid level instrument 113 indicates the level.

5. Continue adding liquid until instrument 113 indicates a level of

approximately 40%.

6. Energized the electrolyte pumps by pressing RESET on the touch screen.

Normally, the first few attempts to start the pumps result in redistribution of
liquid (mainly throughout the module), a decline in liquid level, and
automatic stopping of the pumps due to low level (at or below 20%).

7. Continue adding the liquid until the electrolyte pumps operate with a stable
liquid level of 35-40%.

8. Close valves 210 and 220, and turn OFF the chemical pump.

4-8
 9. Disconnect the tubing and install the drain cap.

10. Close the small manual valves on top of pressure transducer 328.

11. Refer to section 3 for recommendations pertaining to circulation of

electrolyte before operation of the EC.

Adjusting Electrolyte Concentration

Check the electrolyte concentration every three months, or when a problem with
concentration is evident. Concentration is expressed as percent weight (% wt).
An EC generator requires the KOH concentration to be 28 to 32% wt.

Determine concentration by

measuring the specific gravity of the liquid with a hydrometer (with a

minimum specific gravity range of 1.200 to 1.320), or
weighing a measured volume.

In both cases, the temperature of the liquid must be determined. For the specific
gravity method, use Error! Reference source not found.1 to measure the %wt
as a function of temperature and specific gravity. Use the weighing method if the
weighing scale is accurate to within 1 gram.

4-9
TABLE 4-1 Specific Gravity of KOH Solution at Various Temperatures
Wt.% 10oC 20oC 30oC 40oC 50oC 60oC
15 1.142 1.137 1.133 1.123 1.118 1.112
16 1.151 1.147 1.142 1.133 1.128 1.122
17 1.161 1.157 1.152 1.142 1.137 1.131
18 1.171 1.166 1.162 1.152 1.147 1.141
19 1.181 1.176 1.172 1.162 1.156 1.151
20 1.191 1.186 1.181 1.172 1.166 1.160
21 1.201 1.196 1.191 1.181 1.176 1.170
22 1.211 1.206 1.201 1.191 1.186 1.180
23 1.221 1.216 1.211 1.201 1.196 1.190
24 1.231 1.226 1.221 1.211 1.206 1.200
25 1.241 1.236 1.231 1.221 1.216 1.210
26 1.251 1.247 1.242 1.231 1.226 1.220
27 1.262 1.257 1.252 1.241 1.236 1.230
28 1.272 1.267 1.262 1.252 1.246 1.240
29 1.283 1.278 1.272 1.262 1.256 1.250
30 1.293 1.288 1.283 1.272 1.267 1.261
31 1.304 1.299 1.293 1.283 1.277 1.271
32 1.314 1.309 1.304 1.293 1.287 1.281
33 1.325 1.320 1.314 1.304 1.298 1.292
34 1.336 1.331 1.325 1.314 1.308 1.302
35 1.347 1.341 1.336 1.325 1.319 1.313
36 1.358 1.352 1.347 1.341 1.336 1.330
37 1.352 1.363 1.358 1.352 1.347 1.352
38 1.380 1.374 1.369 1.363 1.357 1.351
39 1.391 1.385 1.380 1.374 1.368 1.362
40 1.402 1.396 1.391 1.385 1.379 1.373

1. If the KOH concentration needs to be increased, refer to section 4.5.2 for

information about concentrated electrolyte received from chemical
suppliers (liquid or pellets).

2. The electrolyte must be sampled on both sides of the EC, and the results
averaged. Use a stainless steel, polyethylene, or polypropylene container
for the samples.

If using a hydrometer, collect approximately 0.5 liter of KOH in a

container with an opening wide enough for the hydrometer to float
freely.
If weighing a sample, a graduated cylinder is required and a sample
size of 100 to 200 ml is adequate.

3. With the system OFF and depressurized, remove the tube fitting caps at
4-10
 the electrolyte drain points at valves 110 and 210.

4. Slowly open valve 110 (or 210).

5. Remove and discard a small amount of KOH to be sure that the sample is
not from a stagnant area.

6. Collect the KOH, measure the temperature and then the specific gravity.

7. If the sample is being weighed, subtract the weight of the graduated

cylinder, and divide the liquid weight in grams by the volume in milliliters.
The result is the specific gravity. Refer to the chart of Error! Reference
source not found.1 above.

8. Repeat this procedure for the opposite side of the generator and average
the results.

The visual appearance of the two KOH samples will differ somewhat. This
is normal due to the difference in electrodes and corrosion characteristics
of the two sides. The normal color for used KOH is clear to a light yellow.
Both sides may exhibit some darkening due to residue from the negative
electrodes (typically a fine suspension in the hydrogen sample giving a
cloudy appearance) or due to the gradual effects on internal metal
surfaces.

9. If the average concentration is outside the normal range, you must correct
it. Usually, adjustment is required because the concentration is low. You
can increase the concentration by removing a calculated amount of KOH
and replacing that amount with a more concentrated solution (typically
45% wt). The following formula gives reasonable results if the volume at
time of measurement was within the normal operating range of the
generator. You must know the concentration of the fresh KOH whether it
is supplied as liquid or mixed using pellets.

Gallons of KOH to drain and replace for EC-750 or EC-1000:

53(1.237 measured SG ) 70(1.287 measured SG )

Gal Gal
(SG fresh KOH measured SG ) (SG fresh KOH measured SG )

or

Liters of KOH to drain and replace for EC-750 or EC-1000:

200(1.237 measured SG ) 265(1.287 measured SG )

Lit Lit
(SG fresh KOH measured SG ) (SG fresh KOH measured SG )

10. Using a funnel, you can add small quantities of KOH at the top of the
4-11
 oxygen side phase separator.

11. If the concentration is too high, dilute the solution according to the data
given in TABLE 4-22.

TABLE 4-2 Diluting Concentrated Solution with Water

Mixing Ratio
To Dilute cc Water/cc
KOH % by Existing
1% 0.050
2% 0.101
3% 0.153
4% 0.205

12. When the concentration has been corrected, clean the KOH from the pipe
connections and replace the caps.

Draining the Electrolyte

Electrolyte is easily drained from the system by connecting suitable tubes at drain
ports (valve 120, 220) and applying a slight amount of inert gas pressure.

1. The system control power must be ON, so that inert gas can be used. A
container of approximately 70 gallons (265 liters) is required.

2. Drain the system one side at a time or both sides together by connecting
tubes to both sides at the same time.

3. Connect tubing to the drain ports at valves 120 and/or 220 and place the
tubes in a suitable receptacle.

4. Secure the tubing at the receptacle due to the possibility of sudden

movement when gas bubbles enter the tube at the completion of draining.

WARNING: REDUCE FACILITY INERT GAS PRESSURE FOR

THIS PROCEDURE AS NOTED BELOW. DO NOT
LEAVE THE SYSTEM UNATTENDED WHILE
DRAINING. THE OPERATOR MUST BE READY TO
CLOSE DRAIN VALVES WHEN LIQUID IS
DRAINED, IN ORDER TO PREVENT A POSSIBLE
DIFFERENTIAL PRESSURE PROBLEM.

5. Open valve(s) 110, 210 and 120, 220.

6. Turn ON the inert gas supply and reduce the facility inert gas regulator to
less than15 PSIG (1 Bar).

4-12
 The inert gas will immediately begin forcing the electrolyte out of the
system.

7. Turn the inert gas ON and OFF at the touch screen every few minutes to
maintain within 3 to 6 PSIG (0.2 to 0.4 Bar).

8. When liquid is drained, gas bubbles cause the drain tube to move.

9. Close valves 120 and 220 and wait a few minutes. This is done because
there is typically slightly more liquid in the electrolyte filter at the time the
pump suction piping is empty. Within another few minutes of closing 120
or 220, the filter should be empty and gas will again be noted in the tube.

10. Open valves 120 and 220 again until the drain tubes move, then close110,
210, 120, 220.

11. If necessary for heat exchanger service, place a suitable pan or bucket
under the pipe between the heat exchanger and the filter vessel.

12. Remove the cap at the bottom of the pipe and drain liquid from the heat
exchanger.

13. Check the O-ring, clean it, apply Fluorolube® grease, and install the cap.

4.5.3 Retorquing the Module

Module stack load can be reduced over significant operating periods due to
thermal cycling and creep. This can lead to external leakage. Retorque the
module every six months; more often if the generator is subject to repeated
heating and cooling cycles.

This procedure should be performed even if there is no sign of external leakage.

1. Turn OFF the generator, and allow it to depressurize and cool.

2. On the power supply panel, turn the voltage and current limit
potentiometers down to the zero position.

3. Turn OFF the facility power at the input to the DC power supply.

WARNING: THE OPERATING POSITIVE ENDPLATE VOLTAGE

EXCEEDS 200 VDC AND REPRESENTS A SHOCK
HAZARD. DO NOT ATTEMPT THIS PROCEDURE
UNLESS ELECTRICAL INPUT TO THE DC POWER
SUPPLY IS OFF.

4-13
 4. Remove the polycarbonate positive endplate shield.

5. Check and tighten the tie rods in the numerical order stamped on the end
plates. It is necessary to hold one nut (typically the positive end) with a
wrench, while applying measured torque to the negative end. Use the
deep socket supplied with the generator commissioning equipment,
attached to a torque wrench with a range of at least 300 FT-LB (407 N-M).

6. Before applying measured torque, verify that the threads are not galled or
frozen. Turn the nut in both directions to verify free movement with
respect to the tie rod.

7. If the threads are tight, remove the nut, clean the threads, and apply
Fluorolube® lubricant. Loosen the nut of only one rod at a time.

8. Beginning with rod number 1, Retorque all nuts in the numerical

sequence, in 25 FT-LB (34 N-M) increments, until a torque of 250 FT-LBS
(340 N-M) is reached.

9. If electrolyte has leaked from the module, clean the exterior of the module
and the tie rods with a mild solution of boric acid in water (3-5%). Rinse
with clean water and dry thoroughly using dry air or nitrogen. Use caution
to prevent water from entering the tie-rod holes in the end plates.

10. Replace the polycarbonate positive endplate shield.

4.5.4 Inspecting the Electrolyte Pump

CAUTION: THE PUMP IMPELLER BEARING IS A CERAMIC

SPINDLE THAT CAN BE EASILY BROKEN IF THE
PUMP IS DISASSEMBLED IN THE WRONG
SEQUENCE. ALSO, THE SPINDLE IS INSTALLED
WITH A LEFT-HAND SCREW THREAD. FOLLOW
THESE INSTRUCTIONS CAREFULLY.

After the system is drained of electrolyte, the electrolyte pump may be

disconnected and disassembled for inspection. Because of the pull of the pump's
drive magnets; be cautious when separating the parts. This will prevent damaging
the drive magnet mounted to the motor shaft and the pump's ceramic spindle.

1. Refer to FIGURE 4-1. Remove the four screws that secure the
pump/motor bracket to the motor.

2. Remove the motor to base mounting screws.

3. Slide the motor away from the pump.

4-14
 The force of the drive magnet will be felt as the components are
separated.

4. Loosen the CPV fittings at the inlet and discharge.

5. Remove and place the pump/bracket assembly on a clean work surface

for disassembly.

6. Place the pump on a flat surface with the inlet of the head facing down.

7. Remove the screws that seal the liquid loop against the pump/motor
transition bracket, and separate the pump head from the impeller magnet
housing.

4-15
FIGURE 4-1 Electrolyte Pump

4-16
 8. Carefully lift the impeller off the spindle.

9. Inspect the spindle for cracks, wear or a loose fit in the pump head.

The spindle is bonded to the stainless steel fitting which is threaded into
the center of the head. The fitting is a left hand thread.

10. Inspect the impeller center bearing for wear. Replace any worn parts.

11. At the motor, check for a tight fit of the drive magnets and inspect the
magnets for breakage. If the drive magnet assembly requires removal, be
sure to mark the position on the motor shaft.

12. Assembly is the reverse of the above. Wipe the internal parts, fitting
threads, and O-ring grooves clean. Replace the O-ring seals at the pump
impeller housing and the inlet and outlet CPV fittings, using a light coating
of Fluorolube® grease. Hold the motor/drive magnet firmly when sliding
the assembly back over the impeller housing, as the magnetic forces will
be strong.

4.5.5 Inspecting and Cleaning the Electrolyte Heat Exchanger

Facility cooling water flows through one side of the electrolyte heat exchanger,
hence the flat plate’s surfaces are subject to deposits that can interfere with flow
and heat transfer. Because such conditions are strongly dependent on quality of
the facility cooling water, the maintenance interval for this procedure should be
adjusted accordingly. Teledyne recommends installing water filters on the facility
cooling water lines to reduce the amount of fouling and interval for maintenance.

1. Draining the electrolyte from the generator loop and close the facility
cooling water isolation valves.

2. Loosen the CPV fittings at the heat exchanger and remove the heat
exchanger from the gas cabinet. Be cautious of residual KOH in the heat
exchanger.

3. While the heat exchanger is out of the EC, flush water into the outlet
connection (back flush) on the water side of the heat exchanger. Any
debris should be forced out with enough flow.

4. If the fouling can’t be removed sufficiently with water, a 5% phosphoric

acid or oxalic acid solution may be used. When back flushing the
condenser, do not heat the acid solution. Flush the condenser with fresh
water after cleaning.

5. Check the KOH side for any residue and back-flush it with demineralized
water if necessary.

4-17
 6. Install the heat exchanger using new O-rings (with Fluorolube grease) at
the CPV fittings.

4.5.6 Functional Check of the Electrolyte Flow Switch

Regular checking of the flow switches is critical. If the flow switch does not detect
low flow, serious damage to the electrolysis module can result.

This check is performed while the generator is in operation at a low production rate
or when the generator is not producing gas but the pumps are operating and there
is no alarm.

Close the ball valve downstream of the electrolyte pump (108 or 208) and in the
electrolyte loop in which the flow switch is installed. Ensure that the system shuts
down and a flow switch alarm is indicated on the touch screen. Open the valve
and reset the generator and ensure that the pumps are operating for several
seconds before restarting gas generation. Repeat for the other flow switch(s).

Normally the flow switches only need to be checked. However, occasionally the
sensors may need to be adjusted to properly protect the generator. Below is a
procedure for adjusting the Flow Switch Low Flow Set-point.

1. Stop electrolysis and vent and purge the generator.

2. The generator should be at zero pressure.
3. Open the top of the flow switches and observe the lights.
a. When the KOH pumps are off then both the green and red lights
should be on.
b. When the KOH pumps are turned on then the green light should stay
on and the red light should go out after a few seconds.
4. If the red light stays on while the KOH pumps are running then do the
following:
Note: Two people are required for this operation since the adjustment must be
made quickly (the KOH pumps turn off after 15 seconds when the light is red).

a. Turn the potentiometer (R26) next to the red light to the left (counter-
clockwise) until the red light goes out. Continue turning R26
approximately 20-30 degrees further.
b. Verify that the flow switch still works by shutting off the KOH pumps
and the red light should come on.
c. Next, with the KOH pumps running, close the manual valve on the
KOH piping and the red light should come on and the alarm should
activate.
d. If the red light does not come on then turn the potentiometer (R26)
clockwise until it comes on. Then test it per the instructions above.

4-18
 5. The adjustment of the set point may take a couple of iterations of stopping
and starting the KOH pumps.
6. If the lights on the flow switch do not turn on then check the wiring.
7. If the red light won’t go out at all, then the flow switch is probably bad.

4.5.7 Cleaning the Electrolyte Filter

Clean the electrolyte filters every three months or when low flow shut downs occur
due to high filter pressure drop.

Perform this procedure when the electrolyte has been drained from the system. A
torque wrench up to 120 FT-LBS (163 N-M), and a 1-1/4 inch standard socket are
required for reassembly. A new gasket is required for the lid of the filter. Have a
container available to transport the cartridges to the place where they will be
cleaned.

1. After draining the electrolyte, place a suitable container (1 or 2 liters)

under the fitting of valve 120 (hydrogen side) or 220 (oxygen side).

2. Remove the drain cap. Open valve 110 or 210 to drain any remaining
liquid from the filter housing. Close the valve and replace the drain cap.

3. Gradually loosen the filter lid fasteners in small increments. Remove the
fasteners and lid being careful not to damage mating surfaces of the
flange or lid.

4. Loosen the filter cartridge hold-down hardware and remove the six
cartridges. Inspect the Teflon/fiber gaskets. These may be reused unless
damaged or worn. Remove the gaskets and set them aside until after
cleaning.

5. Clean the filters in a 3 to 5% wt solution of boric acid to neutralize KOH so

the filters can be handled. Gently scrub with fine stainless steel brushes
in a solution of water and detergent. Rinse thoroughly. Be sure any metal
debris (from brushes) is completely removed from the outer surface.

6. Install the clean filters and two Teflon/fiber gaskets, one each at the top
and bottom. Tighten the hold-down fasteners for the six cartridges.

WARNING: THE SCREWS AND NUTS FURNISHED WITH THE

FILTER ASSEMBLY ARE PART OF THE CERTIFIED
PRESSURE VESSEL CONTAINMENT. DO NOT
SUBSTITUTE OTHER FASTENERS.

7. Install a new Teflon gasket and place the lid on the vessel.
4-19
 8. Install the screws, lock washers, flat washers and nuts.

9. Tighten gradually to a snug condition. Using the torque wrench, tighten

each screw in 25 FT-LB (34 N-M) increments, following the numbered
sequence on the lid. Proceed until the screws have been tightened to 105
FT-LBS (142 N-M).

10. Filter cartridges may accumulate deposits that cannot be removed. In this
case, replace the cartridges.

4.5.8 Replacing the Coalescing Filter

The coalescing filter internal cartridge is a special stainless steel perforated

encased, pleated fibrous material, around a cylindrical core. Flow is from the
inside out. When the filter functions properly, water droplets can be observed on
the outer surface when the housing is removed shortly after machine operation.
Eventually the cartridge may accumulate visible darkened residue, or may clog,
creating a high pressure drop.

1. The filter cartridge is easily accessed by removing the tube fittings of the
trap assembly located below the filter housing. Remove the housing
assembly by hand or, if necessary, with the assistance of a strap wrench.

2. Remove both the nut holding the cartridge in place and the cartridge.

3. Inspect the three seals inside the housing. Two of the same size are for
the filter ends. One is a larger diameter seal for the clamped housing.

4. Replace seals if necessary. Seals are furnished in a three-piece kit. If the

large seal requires replacing, submerge it in a container of heated water to
soften it.

5. Install a new cartridge, making sure the o-rings are sitting properly.
Replace the housing and trap assembly. Leak check all components
when the system is pressurized.

4.5.9 Inspecting and Cleaning the Condenser and Gas Cooler

NOTE: A gas cooler and dehydro tank are used only in "C" model
generators.

Facility cooling water flows through the condensers and gas cooler; hence, the
inside surfaces are subject to deposits that interfere with flow and heat transfer.
Because such conditions are strongly dependent on quality of the facility cooling
water, the maintenance interval for this procedure should be adjusted accordingly.

4-20
 The system must be OFF, depressurized, and purged with nitrogen, since the
hydrogen side will be opened. Remove condenser and inspect the ports. Back
flush through the water connections. If the water ports indicate a lot of fouling,
clean with a diluted nickel scale remover solution. A 5% phosphoric acid or oxalic
acid solution may be used. When back flushing the condenser, do not heat the
acid solution. Flush the condenser with fresh water after cleaning.

4.5.10 Adjusting the Pressure Switch (005)

Pressure switch 005 signals the PLC to alarm if the facility air supply falls below 70
PSIG (4.8 Bar). The switch can be adjusted with the generator OFF and the
instrument air supply turned OFF.

1. Remove the switch adjustment cover at the top. On the back of the
switch, remove the enclosure cover and expose the electrical contacts.

2. Disconnect one of the two wires from the PLC from the connection
terminal.

3. Set up an ohm meter across the two terminals (normally open and
common). Read the nameplate on the switch to determine which direction
to turn the adjustment screw.

4. Disconnect the tubes at the switch port and connect a source of

compressed inert gas or instrument air, with accurate pressure gage.

5. Pressurize the switch to 75 to 80 PSIG (5.2-5.5 Bar) to cause the switch to

actuate.

6. Allow the pressure to fall slowly and observe the pressure as the contacts
open. The set point is 70 PSIG (4.8 Bar). Adjust if necessary and check
again.

7. Connect the wire lead, connect the tubes, and replace the cover plates.
Leak check the switch when the air system is again turned ON.

4.5.11 Replacing the Product Gas Filters

The product hydrogen product gas filters (316, 317) and, for a "C" model, the
oxygen gas filters (416, 417) can be easily replaced on a yearly basis, or when
system pressure drop indicates clogging.

1. With the system depressurized and purged to remove hydrogen, loosen

the tube fittings on the outlet of the filters and remove the check valve
manifold assembly.

4-21
 2. Remove the filter body from the dryer tube pipe fitting.

3. Remove the filter outlet tube fitting from the used filter.

WARNING: DO NOT SUBSTITUTE OTHER SEALANTS FOR

TEFLON.

4. Clean the pipe threads on the tube fitting and dryer fitting.

5. Using Teflon pipe thread tape, install the tube fitting in a new filter body,
being sure the flow arrow is properly oriented.

6. Install the new filter on the dryer tube fitting.

7. Install the remainder of the manifold tubes and tighten all fittings. Leak
check this manifold when the system is under pressure.

4.5.12 Servicing Check Valves

There are two gas delivery check valves in a standard EC generator, and 4 on a
"C" model generator. The configuration is shown in FIGURE 4-2. To assure that
internal parts move freely and that small passages do not clog and cause high
pressure drop, disassemble the valve for inspection and cleaning.

1. Remove the valve by loosening the tube fittings in the dryer discharge
manifold and then removing the valve from the manifold (pipe threads).

2. Disassemble the valve using the two special tools provided with the EC
commissioning package, while referring to FIGURE 4-2.

One tool is to hold the internal spring guide and the other is to loosen the
nut.

3. Clean internal parts and inspect for wear.

Seals are provided with the commissioning spares or can be ordered from
the factory.

4. Replace the check valve if there is any damage or binding of parts that
cannot be corrected. Install the valve, tighten all tube fittings and bubble
check the fittings when the system is pressurized.

5. Remove and inspect other check valves located at the feedwater inlet to
the phase separator (703, 707), the nitrogen inlet lines to the hydrogen
and oxygen phase separators (507, 509, 508, 512), and the hydrogen vent

4-22
 line (376) once per year for free movement, and signs of leakage or
clogging.

6. Replace these valves as a unit or disassemble them for replacement of

internal parts.

Seals for the nitrogen and water check valves are provided with the
commissioning spares kit or can be ordered from the factory.

4-23
FIGURE 4-2 Check Valves

4-24
4.5.13 Cleaning and Inspecting Gas Orifices

All gas orifices are critical maintenance items due to the very small passages
(especially on the hydrogen side) and the possibility for clogging over a period of
time.

A colored band on the orifice fitting identifies gas service. Yellow is for hydrogen
service, green for oxygen service, and white is for the trap purge line (from 374 or
474) found on either side of the system. Orifices of the same color are not always
identical in size. Use caution to avoid confusing different parts.

1. With the system depressurized and purged of hydrogen, remove the

orifice.

2. Remove dirt by blowing with compressed instrument air or inert gas. To

avoid altering the opening size and shape, do not insert metal tools into
the small opening. Use brushes or cleaning tools with caution to avoid
damaging the orifice. Clean with a suitable water/detergent solution, if
necessary, and blow dry with compressed gas.

WARNING DO NOT CLEAN WITH SOLVENTS DUE TO THE

POSSIBILITY OF CONTAMINATING PRODUCT
GASES.

3. If the orifice cannot be cleaned or appears cracked, corroded (rough

edges), or distorted, replace it.

4. Before installing new or clean orifices, check the adjacent tubes and
valves for small deposits. Blow the tubes and valve bodies with
compressed inert gas if necessary.

To protect against the possibility of Teflon pipe tape pieces from

entering gas orifices, wind the tape only to the 1st thread of the fitting
(nearest the flow path).

5. After reinstalling the orifice(s), check all tube fittings with bubble solution
while the system is pressurized.

4-25
4.5.14 Cleaning Solenoid Valves

The solenoid valves in the system include

the inert gas supply (504) and the back-up supply to the instrument air
system (010), which are of the same type
the feedwater supply valve (702)
the pneumatic control valve assembly. This assembly consists of
valves 003, 006, 009, 011, 014, and 016.

At yearly intervals, remove and inspect these valves.

1. Disassemble valves 504 and 010 according to FIGURE 4-3 and 702
according to FIGURE 4-4.

Internal part repair kits for these valves are available from the factory, as
are replacement solenoids. As the valves are relatively small, it is
generally more practical to replace as a complete assembly.

2. To remove the pneumatic valve assembly, carefully mark the location of

all tubes and electrical connectors.

3. Disconnect tubes and electrical connectors and detach from the bracket.

Removing each individual valve from the base will enable inspection of the
gasket and a partial view of the valve internals through the connection
ports.

4. Verify that the valve parts are clean and move freely, and that the gasket
is in good condition.

Individual valve/operator module disassembly is not recommended.

If necessary, replace them as complete units. A spare actuator is
supplied with the commissioning parts. When reassembling, be sure
that all connection ports are in the correct position.

5. Install the module, making sure tubes and electrical connectors are placed
on the correct operators.

6. When the air system is turned ON, leak check the operators around the
gaskets.

7. When the system is pressurized, bubble check all tube connections.

4-26
FIGURE 4-3 Three-Way Solenoid Valve

4-27
FIGURE 4-4 Two-Way Solenoid Valve

4-28
4.5.15 Replacing Gas Dryer Molecular Sieves

This procedure is part of the preventive maintenance schedule. It is also used

when the molecular sieve and catalyst material has become inactive as a water
removal agent.

NOTE: The oxygen side dryers 414 and 415 (1 and 2) do not
contain catalyst. When refilling these dryers, skip all
directions associated with catalyst in the following
procedure.

You need the following for the procedure:

a funnel or other suitable means for loading the molecular sieve and
catalyst into the dryer.
molecular sieve material - 28 pounds (12.7 KG) per vessel. Molecular
sieve material is available through Teledyne Energy Systems under
catalog number 01091 and is supplied in drums containing
approximately 300 pounds (136 KG) of material.
catalyst material - 0.7 pounds (0.32 KG) per hydrogen dryer. Catalyst
material is available through Teledyne Energy Systems under catalog
number 01017.
a scale suitable for accurate measurement of weights up to 2 LBS (1
KG), in .01 LB (5 gram) increments.
each dryer group (hydrogen or oxygen) contains four vessels.

1. With electrical power OFF at the input to the EC power supply, remove the
dryer protective shields and remove the electrical enclosure covers.

2. Disconnect all electrical leads.

3. Mark each lead pair so it will be reconnected to the proper vessel when the
procedure is completed.

4. Disconnect all tubing.

NOTE: Vessel weight is about 120 pounds (55 KG), so two or

more people are required for handling.

5. Remove the two outside vessels first, then the inside pair.

6. Remove the tube caps from the top of the dryer vessel.

7. Turn the dryer upside down and allow the old sieve material to pour into a
suitable container for disposal.

4-29
 CAUTION: The sieve may become hot on contact with
moisture or even moist air.

8. Reinvert the vessel and support the dryer in a vertical position, taking care not
to damage the 1/2-inch tube fitting at the bottom of the dryer.

9. Adapt a funnel to allow filling through the fill ports.

10. Measure out 1.3 ± 0.1 pounds (590 g) of molecular sieve material and pour
into the dryer. Use both ports and attempt to achieve an even fill.

11. For a hydrogen dryer (314 or 315), measure out 0.08 ± 0.01 pounds (36 g) of
catalyst material and pour into the dryer. Use both ports and attempt to
achieve an even fill.

12. Repeat steps 10 and 11 until a total of eight catalyst layers have been added.

13. Fill the remaining cavity with molecular sieve material until the level of fill is 7
± 2 inches (130-230 mm) below the fill port.

CAUTION: DO NOT OVERFILL. MATERIAL EXPANDS WHEN

HEATED.

14. Reinstall the tube caps and the dryers in the system.

15. Reinstall the electrical connections.

16. Leak check the installation by pressurizing the system with inert gas
(nitrogen) to 50 PSIG (3.5 Bar) and using a soap solution on all dryer fittings.
Recheck the fittings for leakage the next time the system is operated.

4.5.16 Replacing Gas Sensor Molecular Sieves

The 303 or 403 trap protects the gas sensors from moisture and residual KOH.
The internal sieves can be replaced when the system is OFF and purged to
remove hydrogen. The beads used in the filter tank should be deactivated beads
saturated to ambient moisture conditions. Deactivated beads may be prepared
from dry beads by first wetting the beads with clean water. Use caution because
dry beads become very hot when wetted. Next, spread the beads out on a clean
surface and simply allow them to dry to ambient conditions.

1. Remove the trap from the system.

2. Remove one or both end fittings in order to remove the old material.

3. Replace the fitting on one end.

4-30
 4. Fill with approximately 0.2 LBS (90 grams) of new material. Do not overfill, so
that the fittings and screens will go into place.

5. Install the fittings using new Teflon tape.

6. Install the trap in the system and bubble check threaded fittings when the
system is under pressure.

4.5.17 Inspecting and Cleaning the Power Supply

Due to the flow of cooling air through the power supply, dust can accumulate on
the inside surfaces of the power supply and interfere with proper cooling. At this
time, also check the major wire connections for loose fasteners.

1. Remove and lock out facility power following prescribed plant safety
procedures.

CAUTION: DO NOT REMOVE POWER SUPPLY ENCLOSURE

PANELS WHILE THE UNIT IS ENERGIZED.

2. Remove the power supply’s main enclosure panels.

3. Use a vacuum cleaner and light brush to remove dirt from internal
components.

4. After cleaning, check the connections of the main transformer, rectifier,

and structural ground wires.

Generally inspect internals for signs of loose connections, overheating, or

other problems.

5. Replace the main enclosure panels.

6. Open the side control enclosure panel and inspect the terminal
connections from the gas cabinet cables for tightness.

7. Inspect the terminal connections at the three pump motor starters for
tightness.

8. Replace the side control enclosure panel.

4.5.18 Adjusting Overdemand Protection Valves (309, 409)

Regulators 309 and (for a "C" model) 409 protect the EC generator against
overdemand. As system pressure falls below 70-80 PSIG (5 Bar), the regulators
should close.

4-31
 The simplest way to verify this is by observing gas flow through a facility flow meter
such as a rotameter or electronic mass flow sensor.

1. As the generator is pressurizing, open the facility delivery valves.

2. Observe the system pressure on the touch screen just as flow is indicated.

3. If necessary, loosen the lock nut and turn the adjusting screw.

4. Tighten the lock nut, and recheck the setting.

5. If facility flow meters are not available, the valve can be removed from the
generator and set using inert gas or instrument air pressure.

4.5.19 Adjusting Overpressure Protection Valve (340)

Back pressure regulator 340 is located between the hydrogen delivery pipe and
the vent system. It begins to open if the system pressure exceeds 165 PSIG (11.4
Bar). The valve has an adjusting hand-wheel.

1. One method of checking the valve is to remove it from the system and
connect to an inert gas source and pressure gage on the inlet side; and to
a tube leading to a container of water on the outlet side.

2. Apply pressure and observe the point at which the valve opens.

3. Adjust the hand-wheel so that the valve begins opening at 165 PSIG (11.4
Bar).

The adjustment can also be made with the machine in operation. However, this
requires the use of an interface with the PLC to temporarily override the high
pressure shut-down alarm, which occurs at 170 PSIG (11.7 Bar)). Contact
Teledyne Energy Systems for more information.

4.5.20 Leak Testing Pneumatic Control Valves

Perform this test once a year to be sure that instrument air is not leaking into the
system from the trap purge control, dryer bypass, and system vent valves. This
procedure applies to the following valves:

320, 420 system vent valves

372, 374 hydrogen side trap purge
482, 484 oxygen side trap purge ("C" model only)
472, 474 oxygen side trap purge ("C" model only)
335, and (for "C" model) 435 dryer bypass valve

4-32
 Depressurize the system and purge it with inert gas before performing this
procedure. The source of inert gas or instrument air must be at 80 PSIG (5.5 Bar).

1. Remove the valve to be tested from the EC by disconnecting tube or

plumbing fittings.

2. Connect the pressure source to the valve actuator port.

3. Apply pressure to the operator and look for signs of leakage into the valve
body from the actuator (submerse the body section in water, if necessary).

4. If there is no leakage, install the valve using care to clean pipe threads.
Use Teflon tape, if applicable.

5. If the valve leaks, replace the internal seals or replace the valve as a unit.

6. When the system is again under pressure, bubble check all of the
connections.

4.5.21 Checking System Leaks

A number of maintenance and repair procedures require disconnecting of

pressurized pipe or tube connections. Bubble check these connections when the
system is again under pressure.

An overall leak check is recommended once per year. Use a soap bubble solution
to check portions of the system under pressure.

In some cases, perform the check during portions of the dryer cycle. For example,
the tube between the dryer selection valve (313, 413) and the dryer vent valve
(370, 470) will be under pressure while the off-line dryer is repressurizing. The
same is true for various instrument air lines and associated fittings.

1. After electrolyte loop maintenance, perform a pressure test, if desired, by

filling the generator with water and using inert gas pressure.

2. With normal machine component status in the "generate OFF" condition,

this enables checking most connection points.

3. To pressurize and check the balance of fittings, an optional interface with

the PLC is required, to set and reset pneumatic controls. Contact
Teledyne Energy Systems for more information.

4.5.22 Checking Gas Sensor Functions

Check the combustible gas monitor probes (305, 405) by flowing a mixture of air
4-33
 with a slight concentration of hydrogen gas, and observing the rise in temperature
of the probe. This procedure requires a cylinder of calibration gas, 2% Vol.
hydrogen in air with a suitable pressure regulator, and a source of inert gas, such
as nitrogen.

Perform this test with gas generation OFF, and the system purged with inert gas,
to remove hydrogen. The control power must be ON so that the probe
temperature can be observed at the touch screen.

1. Disconnect the plumbing between the forward pressure regulator (310 or

410), and the trap (303 or 403).

2. Attach a polypropylene tube with Swagelok fittings to the inlet of the

regulator.

3. Connect the tube in parallel to both the inert gas and calibration gas
source.

4. Establish a flow of nitrogen through the regulator and adjust the rotameter
valve approximately 90% maximum flow as indicated on the 310 or 410
rotameter.

This purges the probe and should result in a temperature within 10 C of

ambient temperature, as indicated on the touch screen.

5. Turn off the nitrogen and establish the same flow of calibration gas
through the sensor.

The temperature should rise and stabilize between 110 and 160 C.

6. If the temperature cannot be maintained above 110 C, replace the probe.

7. Reassemble the trap and flow controller.

8. When the system is restarted, adjust the 310 and 410 flows as described
in section 3.

4.5.23 Adjusting Liquid Level Control System

The liquid level control loop consists of the 24-VDC (966) power supply, transmitter
113 and the PLC input card. The level signal is 4-20 mA current.

4-34
The liquid level transmitter (113) has zero and span adjustments. The instrument
is calibrated based on "0" being at the point of connection to the instrument, and
the span is 37 inches (940 mm) above 0. A simple calibration tool can be made
using a valve and plastic tube, as shown in FIGURE 4-5. FIGURE 4-6 shows the
use of the tool.

FIGURE 4-5 Liquid Level Calibration Tube

4-35
 FIGURE 4-6 Liquid Level Calibration Setup

1. The adjustments must be made with the system depressurized and

drained of electrolyte and purged with inert gas to remove hydrogen. The
control system must be ON to read indications on the touch screen.

2. Place a container suitable for KOH under the fittings to be loosened in the
next step.

4-36
3. Remove the caps and open the manual valves at transmitter 113, to drain
liquid from the sensing head.

4. Close the valves and install the caps.

5. Disconnect the tube between the bottom of the hydrogen phase separator
(101) and the transmitter instrument connection.

Use caution as some electrolyte may drip from the tube.

6. Connect the check tool to the transmitter.

7. Fill the tube with water darkened with a dye (food coloring).

8. Open the tool valve to allow the liquid level in the tube to fall to the "O"
mark.

9. Check the indication on the touch screen.

10. If an adjustment is required, remove the nameplate and expose the zero
and span adjustment screws.

11. Adjust the zero until the touch screen indicates 0% liquid level.

12. Fill the tube to the 37 inch (940mm) line.

13. The touch screen should read 96 or 97% (it will not indicate 100%).

14. If it is low, adjust the span screw until a maximum reading (96 or 97%) is
obtained.

15. Repeat the zero and span checks, as sometimes an adjustment can affect
the opposite end of the scale.

16. Remove the tool and install the tube to the phase separator.

17. Observe these fittings for signs of liquid leakage when the machine is
operational.

18. The manufacturer's manual for the transmitter is included as an appendix

to this manual, and can be consulted for more detailed information.

4-37
4.5.24 Adjusting Differential Pressure Control System

WARNING: DO NOT TURN THE UPS OFF WHILE THE SYSTEM

IS PRESSURIZED! TURNING THE UPS OFF WILL
RESULT IN A L0SS OF POWER TO ALL
DOWNSTREAM INSTRUMENTS AND CAUSE
SYSTEM DAMAGE.

These steps pertain to the pneumatic differential pressure transmitter 328 and I/P
transmitters 018 and 019. These adjustments are performed at the factory and are
normally not required at the site unless there are problems or parts are replaced.

1. The instrument air system must be ON, regulator 002 must be adjusted to
20 PSIG (1.38 Bar), and there can be no leakage in the instrument
plumbing. Hydrogen must be purged from the system using the inert gas,
because the hydrogen side phase separator will be opened.

2. If available use a signal calibrator to generate a 4-20 mA signal on the I/P

transmitter (018 or 019).

3. A 4 mA signal should leave the corresponding valve (430 or 330) closed.

A 20 mA signal should fully open the corresponding valve.

4. Eliminate any residual delta-pressure, for example, if the machine has

been cooling.

5. Verify that the two bleed valves on the 328 transmitter body are tightly
closed.

6. Loosen and remove the CPV nut from the 2 fittings at 328.

7. At the opposite end of each tube (at the respective phase separator),
loosen the CPV nut and swing the tubes out of the way of the transmitter.

8. Install a U-tube manometer on the EC frame near the transmitter, and

connect the manometer to the transmitter's oxygen side fitting and to a
portable inert gas station as shown in FIGURE 4-7.

9. Fill the manometer to at or near the midpoint zero lines, with water colored
with a few drops of food coloring.

This set-up allows the application of a differential pressure from 0 to 20

inches of water per side.

10. With the inert gas supply valve closed and the bleed valve opened 5 or 6
full turns, open the inert gas cylinder valve and adjust the bottle regulator
to no more than 15 PSIG (1 Bar).

4-38
 FIGURE 4-7 Differential Pressure System Calibration

Perform the adjustment as follows:

1. Apply 20 inches of pressure, as indicated on the manometer, to the

oxygen side of the transmitter.

2. Carefully open the inert gas supply valve until the reading is within an inch
or two of the desired reading. Then use the bleed valve to "fine tune" the
indication.

3. When there is a 20 inch indication on the manometer, the transmitter LCD

should read -20; the indicator on the touch screen should read 20 inch
oxygen side; and the oxygen vent valve 430 should be fully open.

4. If necessary, adjust the transmitter output value by entering the menu

displayed on the LCD. These buttons can be accessed by removing the
cover over the transmitter 328 LCD. See the instrument manual for more
information.

The adjustment should be to correct the pressure indication (4mA

corresponds to the zero position reading of 20 inches oxygen side).

5. When a zero adjustment is complete, turn OFF the inert gas supply valve.

6. Move the manometer tube fitting on the manometer from the oxygen side

4-39
 to the hydrogen side.

This performs a span adjustment. When the instrument is subjected to 20

inches of pressure on the hydrogen port, the LCD should read 20 inches
water (output current of 20mA). The touch screen should indicate 20
inches hydrogen side; and hydrogen vent valve 330 should be fully open.

7. To correct the output current, adjust the transmitter output value by

entering the menu displayed on the LCD. See the instrument manual for
more information.

8. Repeat steps 1 through 7 as necessary in order to ensure accuracy of

output.

9. When there is no differential pressure, the LCD should read 0 inches

water (12mA output) and the touch screen should be within one inch of
zero.

10. Apply various pressures between 0 and 20 inches water on each side in
order to verify correct LCD output

NOTE: If I/P transmitters 018 and 019 produce the correct pressure
signal according to the manometer indication and the vent valves
430 and 330 controllers do not correspond, then contact Teledyne
Energy Systems for more information.

Adjustment procedures for the Badger vent valves are found in the
manufacturer's manual in the appendix. Do not attempt adjustments
or modifications to these valves other than scheduled maintenance.

The readings should correspond. The precise value stored in the PLC can
be observed using the optional PLC hand-held interface terminal, or with a
personal computer and an optional interface card and program. The
address of the delta-p value is D0076, and is expressed on a scale of 0 to
40 inches corresponding to -20 to +20 inches on 007/008. The value will
be "20" with 0 delta pressure.

I/P transmitters 018 and 019, similar to transmitter 013, send an instrument air
output signal based on an input current between 4 and 20 mA.

When the transducers receive a 4 mA signal, as is the case with 20 inches of

water on the opposite side (20” on the hydrogen side; 4 mA on the oxygen side),
the output signal should be 3 PSIG (0.21 Bar). When demand is at a maximum
20 mA as is the case with 20 inches of water on the same side, the output signal
should be 15 PSIG (1.03 Bar).

To measure the pressure, install an accurate 0-20 PSIG or 0-2 BARG pressure
4-40
 gauge in the spare outlet port of 017.

4.5.25 Feedwater Monitor Check

The most likely cause of erratic feedwater readings is a faulty probe. A feedwater
probe that is suspected of not indicating correctly should be removed and checked.
Turn off the feedwater supply and open the feedwater drain port to drain the
feedwater plumbing. Remove the probe by unthreading it out of the plastic tee. A
dry probe in air should indicate green on the Feedwater touchscreen. If not, the
probe should be replaced. The probe is easily replaced as a unit, and there is no
calibration or adjustment.

4-41
 SECTION 5 Trouble-Shooting and Repairs

TABLE OF CONTENTS:

SECTION 5 Trouble-Shooting and Repairs ..........................................................1

5.1 General...................................................................................................2
5.2 Information on System Sub-components................................................2
5.3 Trouble Shooting According to Alarm Indication.....................................3
5.3.1 Low Electrolyte Flow........................................................................3
5.3.2 Low Electrolyte Level.......................................................................4
5.3.3 High Electrolyte Level......................................................................5
5.3.4 High Electrolyte Temperature..........................................................5
5.3.5 High Oxygen-in-Hydrogen ...............................................................5
5.3.6 High Hydrogen-in-Oxygen ...............................................................6
5.3.7 High System Pressure.....................................................................6
5.3.8 Low System Pressure......................................................................6
5.3.9 High Differential Pressure................................................................7
5.3.10 Power Supply Trouble .....................................................................7
5.3.11 Low Instrument Air Pressure ...........................................................7
5.3.12 Dryer Fill Problem............................................................................7
5.3.13 High Catalyst Bed Temperature ......................................................7
5.3.14 High H2 Side Catalyst Tank Temperature .......................................8
5.3.15 High O2 Side Catalyst Tank Temperature.......................................8
5.3.16 Low Feedwater Purity......................................................................8
5.3.17 Loss of External Enable Signal........................................................8
5.3.18 Loss of Facility Power......................................................................8
5.3.19 UPS Fault of Low Battery....................................................................8
5.4 Problems Not Indicated By Alarms .........................................................8
5.4.1 Low Gas Purity ................................................................................8
5.4.2 System Pressure or Delta Pressure Changes Excessively During
Trap Purge...................................................................................................10
5.4.3 Differential Pressure Control Not Stable........................................10
5.4.4 Control Valves 330 and 430 ..........................................................10
5.4.5 Cooling Water System Problems...................................................11
5.4.6 System Pressure or Current Control Not Stable............................11
5.4.7 Low Gas Delivery versus DC Current............................................11
5.4.8 O2 Side Catalyst Tank Can’t Be Maintained at Set Point
Temperature ................................................................................................13
5.4.9 Catalyst Vessel Cannot Be Maintained at Set Point Temperature 13
5.4.10 Combustible Gas Monitor Flow Controller Repair .........................14
5.4.11 Module Cross Leak Test Procedure ..............................................15
5.4.12 Repair of System Leaks ................................................................15

5-1
5.1 General
This section contains trouble-shooting steps and procedures for the likely
causes of malfunctions or poor machine performance.

The first section is a chart of steps versus the specific types of

EC generator alarms.
The next section discusses problems with machine performance
that may not cause an alarm and shutdown (for example, low
purity).
Procedural steps are provided for those situations not already
covered in section 4 of this manual.

The normal maintenance procedures of Section 4 contain many applicable

instructions and diagrams that apply to repairs.

Refer to P&ID and electrical diagrams supplied with the generator while
troubleshooting.

Section 6 contains a list of components available from the factory as

replacement parts. The list is indexed according to the three digit
schematic reference.

5.2 Information on System Sub-components

Sections 4 and 5 of this manual contain procedures and illustrations for

various parts of the system. In addition, several sub-component factory
manuals are included in an appendix on the CD version of the manual.
The main portions of this manual contain the operating information such
as the set points and adjustments to these components. If it is necessary
to have more details or to perform repairs, the user is referred to the
appropriate manufacturer's manual for instructions and illustrations.

The following is a list of the manuals included in the appendix:

Cooling water flow control valve 609

I/P transmitters 013, 018, 019
Pressure transmitter 325
Liquid level transmitter 113
Pressure switch 005
Pressure switch 936
Pressure regulators 309, 409
Pressure regulators 001, 002
5-2
 Back pressure regulator 340
Differential pressure transmitter 328
Control valves 330, 430
Flow Switch 109, 209 (A, B for EC-1000)

5.3 Trouble Shooting According to Alarm Indication

5.3.1 Low Electrolyte Flow

Low fluid flow

KOH filters require cleaning or replacement
KOH pump problem
Impeller bearing worn
Ceramic spindle loose, worn or broken
Drive magnets loose or broken
Impeller magnet leaking

Faulty flow switch

This flow switch is self-monitoring. There are several
possibilities of problems that can lead to a low flow
shutdown. There are two alarms associated with the flow
switch, each with an LED inside the electrical enclosure.

The lack of a green LED signifies a supposed high flow

situation. There is no real high low situation possible, this
only occurs if there is a problem with the flow switch. A red
LED indicates a low flow situation. This can be caused by a
real low flow occurrence or by a different problem with the
flow switch.

If there is a low flow shutdown, open the flow switch

electrical enclosure. If the green LED is not lit, there is a
problem with the flow switch. Contact the factory. After the
shutdown, the red LED should be lit because the electrolyte
pumps will have been shut off and there will be no flow.
Have another operator hold the reset button down to turn on
the pumps. If after 10 seconds, the red LED does not go off,
there could be a real low flow problem. At this time, follow
the other procedures in this section. If this does not correct
the situation, there is a problem with the flow switch, contact
the factory.

Loss of pump motor power:

Check motor supply voltage at MS2 or MS3 in power supply
Check supply to contactor
Check function of motor starter contactor

5-3
 Check for voltage drop across contactor
Check overload device status at motor starter
May require adjustment for facility voltage
May require resetting
Check 115 VAC signal to motor starters
Output light at PLC digital output card coming ON when
RESET is pushed
Check wiring to TB10 and to power supply and MS2 or MS3
Check voltage at drive motor
Faulty drive motor
Check for excessive current
Motor internal mechanical drag

5.3.2 Low Electrolyte Level

Check facility water supply

Excessive air in facility supply
Intermittent loss of facility supply

Differential pressure control problem

Inadequate feedwater pump performance

Pump internal relief valve set too low
Pump output pressure or flow low

Loss of pump motor power

Check motor supply voltage at MS1 in power supply
Check supply to contactor
Check function of motor starter contactor
Check for voltage drop across contactor
Check supply on 3 phases at motor
Check overload device status at motor starter
May require adjustment for facility voltage
May require resetting
Check 115 VAC signal to motor starters
Output light at PLC digital output card coming ON when
RESET is pushed
Check wiring in EC cabinet and to power supply and MS1
Check voltage at motor
Faulty drive motor
Check for excessive current
Motor internal mechanical drag
Restriction in feedwater supply line
Check suction line to pump
Solenoid valve 702 not opening or clogged
Check valve 703 or 707 restricted
Level control instrument 113 faulty or out of calibration
5-4
 PLC input card faulty or DIP switches not set

5.3.3 High Electrolyte Level

Feedwater pump motor starter contacts sticking

Level control instrument 113 faulty or out of calibration

PLC input card faulty or DIP switches not set

5.3.4 High Electrolyte Temperature

Loss of facility cooling water

Facility cooling water temperature too high

Facility supply pressure too low

Facility filter (if used) restricted

KOH temperature controls not functioning

Check function and accuracy of T/C 232
Check for open or intermittent wire in T/C circuit
Check output pressure of I/P transducer 013
Faulty or leaky control of valve 609

Cooling water piping restricted

Check strainer 601
Check for plugged control valve 609
Check heat exchanger tubes for fouling

5.3.5 High Oxygen-in-Hydrogen

Open or intermittent T/C circuit to 305

Air in hydrogen side of system

System opened without inert gas purge
Air control valve leaking actuator air into system
Leakage of air via vent lines while system is OFF
Contaminated inert gas supply

Oxygen in hydrogen side of system

Differential pressure instrument 328 leaking internally
Module cross-leakage
Hydrogen side (De-oxo) catalyst tank not removing excess oxygen

5-5
5.3.6 High Hydrogen-in-Oxygen

Open or intermittent T/C circuit to 405

Hydrogen in oxygen side of system

Differential pressure instrument 328 leaking internally
Module cross-leakage
Oxygen side (DeH2) catalyst tank not removing excess hydrogen

5.3.7 High System Pressure

Pressure control instruments faulty or require calibration

Transmitter 325 faulty or requires calibration

PLC input card faulty or DIP switches not set

Power supply problem

Check response of power supply controls versus input

5.3.8 Low System Pressure

System overdemanded by facility

Leakage of hydrogen or oxygen from system

Pressure control instruments faulty or require calibration

Transmitter 325 faulty or requires calibration

PLC input card faulty or DIP switches not set

Power supply problem
Current or voltage limited by panel control knobs
Check response of power supply controls versus input

5-6
5.3.9 High Differential Pressure

Inert gas present on H2 side of system while starting

System unable to react to transient

Differential control (328, 018, 019) mal-functioning

Restriction in H2 or O2 vent line

Valve 330 or 430 plugged or malfunctioning

Loss of pressure on one side of system

I/P transmitter mal-functioning or out of calibration

5.3.10 Power Supply Trouble

Front panel of power supply indicates problem area

Check cooling fan function

5.3.11 Low Instrument Air Pressure

Facility supply lost or intermittent; inadequate flow

001 regulator internal filter clogged

001 regulator malfunctioning or out of adjustment

Leakage in components or tube fittings

5.3.12 Dryer Fill Problem

Dryer discharge manifold components restricted

Filters (316, 317, 416, 417)
Bypass orifice (304, 334, 404, 434)
Check valves (331, 332, 431, 432)
Valve 335 or 435 mal functioning
Check output from PLC digital output card
Check function of solenoid 006
Check instrument air to valve
Dryer internal sieves contaminated/blocked

5.3.13 High Catalyst Bed Temperature

Vessel heater supply relay 902 failed closed

5-7
Thermocouple 418 failure

5.3.14 High H2 Side Catalyst Tank Temperature

Oxygen or air in hydrogen stream (See 5.3.5)

Thermocouple 382 failure

5.3.15 High O2 Side Catalyst Tank Temperature

Hydrogen in oxygen stream (see 5.3.6)

Vessel heater supply relay 981 failed closed

Thermocouple 486 or 487 failure

5.3.16 Low Feedwater Purity

Check facility supply

Check/replace feedwater resistivity probe

5.3.17 Loss of External Enable Signal

Check facility inputs

5.3.18 Loss of Facility Power

Check facility power supply

5.3.19 UPS Fault of Low Battery

Check LEDs on UPS; then review the troubleshooting section (pp. 23) in
the UPS manual for information on how to proceed.

Check UPS manual.

5.4 Problems Not Indicated By Alarms

5.4.1 Low Gas Purity

The user will install and use gas analysis equipment necessary to assure
the level of purity for his process. This may include monitoring of
moisture, nitrogen content, oxygen in hydrogen, hydrocarbon content, or
other contamination.

5-8
High moisture is the most common result of a system malfunction. Other
possible impurities are

the constituents of air that can enter the system from the facility
water supply (entrained bubbles)
the inert purge gas (usually nitrogen)
oxygen in the hydrogen
hydrogen in the oxygen

Because of the nature of the process and because the required inputs
include only water and nitrogen, it is nearly impossible to detect
hydrocarbon contamination in the product gases.

For electrolysis, one of the most common and effective means of assuring
proper generator function is to monitor gases for the presence of moisture.
When traps, filters, and dryer system components malfunction or are not
maintained the moisture content of product gases increases. Section 4
contains procedures for checking and replacing the various components.

Verify the dryer tube heaters and heater circuits (relays 922, 929, and for
a "C" model, 964 and 965). When in the heating mode, the dryer tubes
should be hot on the surface at both the top and bottom halves. The
current to each dryer heater should be 6.0 to 6.5 amperes, and the current
to each dryer tube should be above 12 amperes. If a heater is defective,
the dryer tube must be replaced.

If all components have been properly maintained and verified to operate

according to the regenerating process, and moisture levels continue to be
unacceptably high, then the dryer internal sieves must be replaced.

High nitrogen content is usually due to entrained air bubbles in the

feedwater system. Check that instrument air is not entering the system
via valve operators. A less likely cause is leakage of the inert gas system
into the generator. This may be the case if the user is operating the
system at a pressure below the nitrogen supply pressure.

Small amounts of oxygen in the hydrogen stream or hydrogen in the

oxygen stream are treated with catalyst tanks. If the catalyst in these
tanks becomes ineffective the dryers can be overwhelmed (where only
trace amounts should be present). The catalyst may need to be changed.
On a “C” model the catalyst must be heated to be effective. Normal trace
amounts of hydrogen or oxygen should be removed from product gases
with the catalyst in the dryers. Verify proper function of the dryer system
(standard model) and the catalyst vessel ("C" model) using procedures
described in this manual.
5-9
 Excessive impurity amounts may indicate leakage through transmitter 328
or from cross leakage within the module. An internal module problem
should be investigated by a cross leak test procedure.

5.4.2 System Pressure or Delta Pressure Changes Excessively During

Trap Purge

This problem can be caused by leakage at valves 372, or 472. Remove

the valve from the hydrogen or oxygen gas plumbing, and check the inlet
to outlet for leakage while the valve is closed. It can also occur if the H2
or O2 trap purge orifice becomes clogged. Inspect both orifices if the
problem continues.

5.4.3 Differential Pressure Control Not Stable

Fluctuation of the differential pressure controls, as indicated on the touch

screen, is normal and will be more noticeable with high hydrogen demand
(standard model) or when there is a large oxygen demand with little or no
hydrogen demand (on the hydrogen side of a "C" model). This is due to
the small operating range of the system (-2 to +2 inches of water).

If the differential controls continue oscillating, i.e., closing and opening

valves 330 and 430 alternately, the PLC control settings may need to be
adjusted. Call the factory for more information.

If necessary, perform the calibration procedures on the associated

components, including valves 330 and 430. Be sure vent lines are not
restricted.

Perform any further trouble-shooting by consultation with the factory.

5.4.4 Control Valves 330 and 430

Differential pressure control vent valves 330 and 430 can be

disassembled for replacement of the control section components or the
stem and seat assembly (trim set). The manual for the valves is included
as an appendix and contains the necessary service information.

There are different trim sets for the hydrogen and oxygen sides. These
are listed on the name plate. Remove one valve at a time to avoid
confusion. When the valve is installed, be sure the flow arrow points
toward the vent connection interface.

5-10
5.4.5 Cooling Water System Problems

The controller and transmitter manuals are included in the appendix. The
013 transmitter contains zero and span adjustments that are made to
precisely correlate a 4-20 mA input signal to a 3-15 PSIG (0.21-1.03 Bar)
output signal. Consult the applicable sections of the manufacturer's
manual before performing this adjustment.

The cooling water control valve can be removed for repair of the control
section (top works), stem packing, or the valve and seat assembly. The
manufacturer's manual in the appendix contains detailed procedures and
illustrations. Parts for the stem packing and control section are provided
in the commissioning spare parts with the generator.

Leakage of the condenser or heat exchanger tubes can cause bubbles in

the facility cooling water. To verify that the facility cooling water source
does not contain gas bubbles, pressure check the tubes individually, with
the condenser or heat exchanger removed from the system.

5.4.6 System Pressure or Current Control Not Stable

There will be normal fluctuation of the DC current once the system has
reached a stable operating condition. Consider the system stable if the
deviations from the pressure set point are within 0.1 to 0.5 PSIG (0.007-
0.03 Bar), and occur over a relatively slow period (once or twice per
minute). Before investigating a possible control problem, the system must
be completely stable. This means the KOH temperature must be stable
for 10 to 15 minutes with the cooling system in control at the set point;
there has been no change in demand for 10 to 15 minutes; and there has
been no change in dryer regenerating status for 10 to 15 minutes. If the
pressure does not become stable, check various system features.

Verify that disturbances are not actual pressure fluctuations, such as from
a problem with differential pressure controls or fluctuations in user
demand.

Check the power supply controls that process the signal from the PLC.
The procedure and check values depend on the type of power supply,
which is identified by its serial number. A qualified technician must
perform this procedure. Contact Teledyne Energy Systems for information
and guidance on verifying power supply controls.

5.4.7 Low Gas Delivery versus DC Current

This condition exists when module current is insufficient for the level of

5-11
user demand for hydrogen or oxygen, and the generator is unable to
supply adequate gas flow. It is caused by a loss of product gas to some
other portion of the system or to external leakage.

First, verify that there is no external leakage of hydrogen or oxygen

throughout the system. To help isolate the problem, observe the machine
conditions when the problem exists, especially the dryer status. If the
problem occurs for one of the two dryer sets, or during a specific part of
the regenerating cycle, the associated components can be checked first.

When the condition exists, check for a high flow of gas at the hydrogen
and oxygen dryer vent exits. When the dryer regenerating system is in the
PURGE or HEATING mode, this flow should be very low: 10 to 30 SLM of
hydrogen (5 to 15 SLM oxygen). When the regenerating system is in the
COOLING mode, this flow increases up to 70 SLM hydrogen (35 SLM
oxygen). When the regenerating cycle is in the FILLING mode, there
should be no flow at this vent.

Excessive flow through the dryer vent system may indicate that valve 313
(standard model) or 313, 406, 407, 413 ("C" model) is not functioning
properly. The result is unintended gas flow to the off-line dryer. Check
the operating cylinder for leakage of instrument air. Check the instrument
air supply via solenoid valve 003 or 014 to the operating cylinders. These
valves should always be in the opposite condition to one another.

Check the valve/operator assembly for binding, loose parts, or

misalignment between the operating cylinder and the ball valve sections.
A less likely cause is internal leakage in the ball valve section.

Another less likely cause of high flow in the dryer vent line is a faulty
orifice (304, 334) or, for a "C" model (404, 434).

Another cause of excessive flow through the dryer vent system is failure of
valve 335 or 435 (for a "C" model) to close properly at the correct time in
the regenerating cycle. The valve should be open for COOLING and
FILLING, and closed at other times. Remove and leak check the valve. If
necessary, check the controls for the valve, including the PLC output and
solenoid valve 006.

Potential leak points other than the dryer system include valves 374, 474
(for a "C" model), or the system vent valves 320 and 420. These can be
removed and checked. Also, check the controls of these valves: solenoids
011 for the trap vent valves and 009 for the system vent valves.

5-12
5.4.8 O2 Side Catalyst Tank Can’t Be Maintained at Set Point Temperature

Using an inductive ammeter, measure the current at the heater wire lead
at relay 981. Te current should be 4 - 5 amperes. Verify that the relay is
switching and passing current to the heater circuit.

If the supply current to the heaters is low, first check the output voltage at
TB4 in the power supply.

WARNING: USE PRESCRIBED PRECAUTIONS IN

SECTIONS 1 AND 2 IN THIS MANUAL AND
PLANT SAFETY PROCEDURES IN
WORKING IN THE POWER SUPPLY

If the current is less than 230 volts, change the taps on the transformer to
increase the voltage to 230 - 240 VAC.

If the current is low with the correct supply voltage, then one or both of the
rod heaters in the catalyst tank is damaged and must be replaced.

If a heater is not functioning, the assembly must be removed from the EC

generator. First, disconnect the AC power leads. Disconnect the gas
tubes and remove it from the generator.

Lay the assembly on a table. Remove and replace the heaters, being
careful not to spill any catalyst or damage heater leads. Re install the tank
in the generator. Reconnect the heater and thermocouple connections,
being careful that no wires are near the tank surface, which can reach
temperatures in excess of 300 degrees C.

5.4.9 Catalyst Vessel Cannot Be Maintained at Set Point Temperature

Using an inductive ammeter, measure the current at the heater wire lead
at relay 902. Te current should be 11 to 13 amperes.

If the supply current to the heaters is low, first check the output voltage at
TB4 in the power supply.

WARNING: USE PRESCRIBED PRECAUTIONS IN

SECTIONS 1 AND 2 IN THIS MANUAL AND
PLANT SAFETY PROCEDURES IN
WORKING IN THE POWER SUPPLY

If the current is less than 230 volts, change the lead connections on the
transformer to increase the voltage to 230 - 240 VAC.

5-13
 If the current is low with the correct supply voltage, then one or more of
the four band heaters around the catalyst vessel is open and must be
replaced. The problem could also be heater wire inside the catalyst
vessel's sheet metal enclosure.

The cover of the catalyst vessel enclosure may be removed. However,

insulation, which is packed around the vessel, will come out when the
cover is removed and must be replaced. To remove the cover, loosen and
remove T/C 418. Remove the cover screws, cover, and surrounding
insulation to expose the heaters and wires. Wires can be repaired in this
condition.

If a heater is not functioning, the assembly must be removed from the EC

generator. First, disconnect the AC power leads at the top heater and pull
the wires out of the enclosure. Disconnect the gas tubes, remove screws
at the mounting brackets, and remove from the generator. Use caution to
prevent the catalyst from spilling from the inlet, outlet, and T/C openings.

Lay the assembly on a table. Insulation must be temporarily removed for

access to the heaters, and then packed into place when work is complete.
Remove and replace the heaters, being careful not to damage heater
leads or the ceramic insulation. When the wires are installed, be certain
that no wires are near metal surfaces and that the ceramic insulators and
caps are carefully reinstalled.

5.4.10 Combustible Gas Monitor Flow Controller Repair

Flow over the combustible gas probe 305 or 405 is controlled by a forward
pressure regulator needle valve. Verify proper function of the controller by
observing the rotameter at controller 310 or 410. It is normal for the flow
to fluctuate somewhat with operating conditions. The probe functions
properly within a reasonable range of the recommended setting in Section
3. For the hydrogen side, the range is 20 to 30. For the oxygen side, it is
50 to 75.

If flow is erratic or if the needle valve is plugged or cannot be adjusted, it

can be disassembled for cleaning or repair. With the system OFF and
purged of hydrogen, remove the regulator and rotameter from the
generator. Clean internal parts. Replace any damaged parts. Contact
the factory about internal replacement parts or replace the entire regulator
or rotameter.

5-14
5.4.11 Module Cross Leak Test Procedure

If the presence of hydrogen in the oxygen or oxygen in the hydrogen

cannot be traced to another problem, the module must be checked for
internal cross leakage. In this procedure, the electrolyte is drained and a
slight gas pressure applied to one side of the electrolyte loop. The other
side of the loop is then observed for the presence of the gas.

Contact Teledyne Energy Systems if you think that this test is necessary.
They will provide procedures and guidance.

5.4.12 Repair of System Leaks

There are two basic non-metallic seal materials specified throughout the
EC system. Teflon is a body and stem seal in ball valves and the gasket
in the filter vessels. Teflon is also used as a pipe thread sealant.
Ethylene, propylene, ter-polymer (EPT) is used for O-rings. Both
materials are compatible with all of the process materials. Other types of
seal material may be found, depending on the component, in the gas
delivery systems.

WARNING: NEVER SUBSTITUTE OTHER O-RING OR

GASKET MATERIALS FOR TEFLON OR EPT.
THESE MAY NOT BE COMPATIBLE WITH
PROCESS MATERIALS AND COULD FAIL
RAPIDLY.

Repair immediately by draining the system (if necessary) and replacing

the leaking seal(s). The generator is provided with spare O-rings for CPV
style fittings and a number of other replacement seals. Other seals, for
example seal kits for ball valves and regulators can be obtained from
Teledyne Energy Systems.

When servicing a CPV-style fitting, thoroughly clean the connection

threads. Lubricate both the O-ring and pipe threads with a small amount
of fluorolube grease. Do not substitute other lubricants. Do not
contaminate the process plumbing with the lubricant. Use caution to
prevent damaging stainless steel pipe threads when making connections.
Because stainless steel is generally softer than carbon steel or other pipe
materials, the threads can be easily damaged and crossed.

If the 1.0-inch or 1.5 inch KOH ball valve seals are replaced, torque the

5-15
 body nuts as follows:

Body Nuts Packing Nuts

1.5 inch valve 30 FT-LBS (40 N-M) 40 FT-LBS (54 N-M)
1.0 inch valve 17 FT-LBS (23 N-M) 35 FT-LBS (48 N-M)

Leaks in the water control valve 609 can be repaired with kits provided
with the generator. These include a body gasket and a stem packing
replacement kit.

Other water components, such as the heat exchangers and condensers,

have flat head gaskets that can be replaced.

If electrolysis module external leaks are noted, perform the torque

procedure. A torque wrench must be used for this procedure. Do not over
tighten the module tie-rods.

5-16
 SECTION 6 Spare Parts List
Schematic Reference
# Part Number Part Description
001 ES-HGS143064-013 Filter Regulator (80-100 PSIG and 5- 7
002 ES-HGS143064-005 Filter Regulator (5-30 PSIG and 0.3- 2.0
ES-052450 Replacement Filter for 001, 002
Regulators
003 ES-103469 Pneumatic Solenoid, Double Acting
(Parker)
005 ES-050345 Pressure Switch, Instrument Air Supply
006 ES-103468 Pneumatic Solenoid, Single Acting
(Parker)
009 (See 006)
010 ES-050011 3-Way Solenoid Valve
ES-101425 Rebuild Kit for 50011
ES-052568 Replacement Coil for 50011 Solenoid
Valve
011 (See 006)
013 ES-103870 Current to Pressure (I/P)
014 (See 003)
016 (See 006)
018 (See 013)
019 (See 013)
100 E12100-009 Electrolysis Module, 500 SLM
E12100-019 Electrolysis Module, 600 SLM
E12100-029 Electrolysis Module, 750 SLM
E12100-039 Electrolyte Module, 500 SLM (FOR EC-
1000)
102 ES-E14072-009 KOH Pump, H2 or O2 Side, 3-Phase
Motor
ES-E14072-019 Pump Head
ES-550A1230101- Pump O-Ring Seal
031
ES-551A1400097- Insert Assembly (Spindle)
009
ES-551A1400132- Impeller Magnetic Housing
001
ES-551A1400133- Impeller Assembly
001
ES-103554 Motor, KOH Pump
103 ES-E24018-001 Heat Exchanger, KOH H2 or O2 Side
106 ES-100477 Ball Valve, 1.5 Inch KOH
ES-050733 Seal and Seat Replacement Kit for 106
107 ES-E14102 KOH Filter Vessel Assembly, H2 or O2
Side
ES-050015 Filter Cartridge for 107, 207 (6 per Side)
6-1
Schematic Reference
# Part Number Part Description
ES-050019 Teflon Gasket
108 (See 106)
109 E14177-009 Flow Switch
110 ES-050939 Ball Valve, System Drain/Fill
111 ES-052012 Thermocouple, KOH Temp
ES-052013 Pipe Clamp for 111, 211, 232 T/C
113 ES-HGS143001- Liquid Level Transmitter
007
ES-550A1230101- O-Ring Seal for 113 Transmitter
081
115 ES-050938 ACE Valve
117 ES-050734 Ball Valve, KOH Crossover
ES-050735 Repair Kit for 117 Ball Valve
118 ES-100477 Ball Valve, KOH Crossover
120 ES-050938 Ball Valve, Drain/Fill
202 (See 102)
203 (See 103)
206 (See 106)
207 (See 107)
208 (See 106)
209 (See 109)
210 (See 120)
211 (See 111)
220 (See 120)
232 (See 111)
301 ES-105196 Condenser, H2 side
302 ES-E14003-009 Trap, H2 Side
303 ES-551A1400080- Filter Tank Assembly
009
ES-551B2400007- Filter Tank Refill Kit
009
304 HGS140056-009 Orifice Assembly, .005” Diameter H2
Dryer Bypass
305 Gas Mixture Probe (E14134)
ES-M14174-009 Probe Assembly
ES-104438 Flame Arrest
308 ES-E14308-001 Pressure Gauge, H2 Delivery
309 ES-HGS140058- Back Pressure Regulator, H2 Delivery
001
310 ES-104108 Forward Pressure Regulator
ES-104367 Flow Meter
ES-104333 Pressure Gauge
313 ES-E14202-009 Ball Valve, Air Op., Dryer Switching
ES-105069 Actuating Cylinder, Double Acting
6-2
Schematic Reference
# Part Number Part Description
ES-103071 Ball Valve Body, 4-way
314 See Below Hydrogen Dryer Vessels
314-1 ES-E14081-009 Dryer Vessel w/out Chemicals, H2 Inlet
314-2 ES-E14081-010 Dryer Vessel w/out Chemicals, H2
Outlet
315-1 ES-E14081-010 Dryer Vessel w/out Chemicals, H2 Inlet
315-2 ES-E14081-009 Dryer Vessel w/out Chemicals, H2
Outlet
ES-001017 De-oxo Catalyst for H2 Dryer 1 lb per
vessel
ES-001091 Molecular Seive for h2 Dryer 28 lbs
(12.7 KG) per vessel
316 ES-001377 Product Gas Filter, H2
317 (See 316)
320 ES-050949 Valve, Air Operated, Normally Closed
325 ES-HGS143000- Total Pressure Transmitter
007
same as seal for 113
328 ES-102034 Differential Pressure Transmitter (4-20
mA output)
329 (See 308)
330 ES-HGS143063- Control Valve, H2 side Delta-P
003
ES-050922 Valve Trim Kit G
331 ES-050295 Check Valve, Dryer Delivery
ES-050296 Quad Seal for 331 Check Valve
ES-050297 Adjusting Tool
ES-050298 Nut Driver (Tool)
332 (See 331)
334 ES-HGS140056- Orifice Assembly, .017” Diameter H2
029 Dryer SV Bypass
335 ES-050900 Air Operated Valve, NO, Dryer Bypass
336 ES-HGS140056- Orifice Assy, .040, Shut-down Flow
059
340 ES-103235 Back Pressure Regulator, H2 Vent
370 ES-E14096-009 Valve, 2-way NC Air Operated
ES-050938 Valve Portion of 370 Assy
ES-050936 Actuator, Spring Return
371 ES-104022 Coalescing Filter Housing
ES-104023 Replacement Filter Cartridge
372 ES-050944 Valve, 2-way NO, Air Actuated
ES-050293 Replacement Seal
373 ES-551A1400080- Trap, Coal Filter, H2
039
374 (See 320)
6-3
Schematic Reference
# Part Number Part Description
375 ES-E14028-009 Orifice Assembly, .080” Diameter Filter
Drain
376 ES-050159 Check Valve, H2 Vent System
378 ES-050507 Pressure Transmitter, off-line Dryer
380 (See 371)
381 ES-E14200-009 Catalyst Tank, H2 Side
382 ES-052012 Thermocouple
385 (See 301)
401 (See 301)
402 ES-14003-010 Trap, O2 Side
403 (See 303)
404 ES-HGS140056- Orifice Assy, .005” dia, O2 Dryer
019 Bypass
405 (See 305)
406 (See 313)
407 (See 313)
408 (See 308)
409 (See 309)
410 (See 310)
ES-104366 Flow Meter
412 ES-HGS140070- Catalyst Vessel Assy
009
ES-050542 Replacement Band Heater
ES-052570 Catalyst, 10 lbs (4.5 KG) required per
change
413 (See 313)
414 See Below Dryer Vessel, O2 Side
414-1 ES-E14081-009
414-2 ES-E14081-010
415-1 ES-E14081-009
415-2 ES-E14081-010
416 (See 316)
417 (See 316)
418 ES-001025 Thermocouple, Catalyst Vessel
ES-052010 Quick Disconnect for 418
Thermocouple
ES-052011 Rubber Boot for 418 Thermocouple
Plug
ES-001089 Reducing Fitting for 418 Thermocouple
420 (See 320)
426 (See 308)
427 ES-HGS140056- Orifice, .040", O2 Side Vent
069
428 ES-E14073-009 Gas Cooler, O2 Side Catalyst Outlet

6-4
Schematic Reference
# Part Number Part Description
429 (See 308)
430 ES-HGS1430063- Control Valve, O2 Side Delta-P
005
ES-050923 Valve Trim Kit F
431 (See 331)
432 (See 331)
434 ES-HGS140056- Orifice, .028”, O2 Dryer SV Bypass
039
435 (See 335)
470 (See 370)
471 (See 371)
472 (See 372)
473 (See 373)
474 (See 320)
475 (See 375)
478 (See 378)
480 (See 371)
481 M14078-019 O2 Side Catalyst Tank
ES-002764 Replacement Heater Rod
Catalyst (See 412)
482 (See 372)
483 (See 373)
484 (See 320)
485 (See 385)
486 ES-105271 Thermocouple, Cat Tank Control
487 ES-001025 Thermocouple, Cat Tank Alarm
503 (See 308)
504 (See 010)
505 ES-050943 Manual Valve, N2 Supply
506 (See 505)
507 ES-001507 Check Valve, Nitrogen & Feedwater
ES-001124 Quad Ring
ES-001156 Adjusting Tool
ES-001159 Nut Driver (Tool)
508 (See 507)
509 (See 507)
510 ES-103073 Nitrogen Pressure Tranducer
512 (See 507)
530 ES-050021 Relief Valve, Inert Gas Supply
601 ES-050649 Strainer, Cooling Water Inlet
603 ES-050940 Valve, Manual Cooling Water
608 (See 603)
609 ES-050926 Control Valve, Cooling Water Flow
6-5
Schematic Reference
# Part Number Part Description
610 ES-105045 Manual Globe Valve
611 (See 610)
701 ES-HGS140073- Pump Assembly, Feedwater Supply
009
702 ES-050007 Solenoid Valve, 2-way NC Feedwater
ES-101425 Rebuild Kit for 702 Solenoid Valve
ES-052568 Replacement Coil for 702 Solenoid
Valve
703 (See 507)
705 ES-101124 Conductivity Sensor, Feedwater
System
ES-101552 Conductivity Transmitter
707 (See 507)
Operator Interface Box ES-104521 Programmable Memory
Components
ES-105138 Ethernet Switch
ES-105140 Module CPU, Ethernet
ES-105139 Touch screen
ES-103121 Power supply, 60W
ES-103098 Module, Devicenet
ES-103097 Power Supply, PLC
ES-100067 121 Ohm Resistor
Control Box Components ES-104207 Relay, 25 Amp Solid State
ES-103447 Module, Output, AC
ES-103478 Field Bus Coupler
ES-103476 Supply Module
ES-103480 Temperature Analog Input Card
ES-103102 Remote Output Terminal
ES-103101 Analog Input Terminal
ES-103100 Analog Output Terminal
ES-103096 Remote Input Terminal
972 ES-101552 Conductivity Transmitter
PS1 ES-103121 Power supply, 60W
E-Stop ES-103540 Switch Contacts, 2-button, Electrolysis
Enable

6-6