LAUPER INSTRUMENTS 0020-03 Hydroxychrom User Manual

LAUPER INSTRUMENTS 0020-03 Hydroxychrom User Manual

Historic

Revision

N°

| Modification nature| Application date| Modified chapters
---|---|---|---
0| Creation| 24/10/2012| All
1| Revision| 25/10/2012| Ch.3 & 4
2| Revision| 22/04/2015| Ch.4.6.2
3| Revision| 14/12/2018| Ch. 3.1 & 4.3
 |  |  |
Editor: S. GUTIERREZ, JP.AMIET, K.TRAULLE| Checked by:| Approved by:
---|---|---
Visa :| Visa :| Visa :

WARNING

The described material in this manual contains one or several confidential computer programs that are the property of CHROMATO-SUD.
CHROMATO-SUD authorize the instrument owner to use the program (s) for what it has been designed to the exclusive of any other use.
The total or partial copyright, the dismantle, the retro-compilation or transcription or the above mentioned program for the use of the owner of a third party are strictly forbidden.

GENERAL WARRANTY

CHROMATO-SUD guarantees these instruments against the manufacturing defaults during a twelve month period from the delivery date. The replacement of the defective components will be free except the transport or travel fees that will be invoiced according the current tariffs.
CHROMATO-SUD accepts no liability for damages or possible incurred losses.
CHROMATO-SUD provides a spare part service and After Sales Service. Please contact the service engineer responsible for the repair or the spare part repair. The serial number of the instrument as well as the description of the trials done and the estimated reasons of the breakdown should be given to provide you the quickest service.

CHROMATO-SUD reserves the right to modify the prices and the characteristics of these products. Copyright – © 2005, CHROMATO-SUD 15 Rue d’Artiguelongue, 33 240 SAINT ANTOINE, FRANCE

In case of warranty particular conditions, the general warranty will not be applied.

CHAPTER 1. INTRODUCTION

**** This document provides all necessary information for the installation and operation of your HYDROXYCHROM High Purity Hydrogen generator; it also describes the simple maintenance operations, alarms as well as troubleshooting.
It is applicable to the below generation models and software HYDROXYCHROM Viewer Version 1.0 produced since October 2012:

• HYDROXYCHROM-100
• HYDROXYCHROM-160

The operating manual considers and describes an instrument generally equipped with the most complex configuration ; should the explanation concerning the most complex instrument be too different from the simpler instrument, both cases will be described.

__ CHAPTER 2. GENERAL INFORMATION & COMPATIBILITY TO NORMALISATIONS

**CE C ONFORMITY**

This equipment was built in compliance and is compatible with EC recommendations concerning electrical safety and electromagnetic emissions. It complies with 89/336/EWG, 93/98/EWG, standards EN 50 081-1, in 50 081-2, EN 50 082 – 1 and EN 50 082 –

Note

Any modifications on the instrument which have not been approved in writing by the manufacturer will automatically cancel the manufacturer warranty. If such modifications are nevertheless undertaken, they are under the user responsibility; the manufacturer will under no circumstances be responsible for any damages direct or indirect which they would cause

E.E.E. PRODUCT R ECYCLING DECLARATION

In agreement with the European EC/2002/96 directive on electrical and electronic equipment recycling, this product may not be disposed in the garbage. For recycling information, contact the company who sold this product. If you want to get rid of this instrument, identify it as such and direct it to a certified recycling centre.

 SECURITY INSTRUCTIONS AND CORRECT USE

This Hydrogen generator has been designed in order to produce small quantities of Hydrogen for instrumentation applications. This device must only be used for such applications respecting the specifications and recommendations for its proper use described in this operating manual. The main recommendations are:

• Instrument can only be use indoors, at temperatures above 4°C and in a well-ventilated room.
• In case of maintenance inside the instrument, always unplug it before opening the casing(s). HIGH VOLTAGE

CHAPTER 3. SPECIFICATIONS AND DESCRIPTION

**** SPECIFICATIONS

Models| HYDROXYCHROM-100

HYDROXYCHROM-160

---|---
H2 Outflow

@ 1013/20°C

| HYDROXYCHROM-100 = 100 Nml/min

HYDROXYCHROM-160 = 160 Nml/min

H2 purity| Maximum Hydrocarbon content: 0.1ppm
Dew point| -40°C / -40°F
Outlet Pressure| From 0.5 to 7 bar (7 to 102 psig), adjustable by software.
Pressure resolution| 10 mbar
Pressure stability| Better than ±10 mbar
H2 generation technology| Proton Exchange Membrane (PEM), Solid Polymer Membrane
Drying technology| No maintenance static dryer
Water quality| High purity distilled & filtered water. TOC free. Conductivity < 0.20 µS/cm
Water capacity| 5L tank outside, 0.4L tank inside.
Water consumption| 5L water generates about 6000L Hydrogen
Safety| Low H2 stored volume; over pressure valve; internal leak test; automatic shut down; maximum current limit, water quality.
Manual control| ON-OFF power switch
Display| By Hydroxychrom Viewer
Communications| USB
H2 outlet fitting| Stainless steel 1/8″ OD compression
Functioning conditions :

·       Temperature

·       Humidity

| ****

+10°C to +35°C

max 80%, non condensing

Transport        and                          storage conditions:

·       Temperature

·       Humidity

·       Duration

| ****

+4°C to +40°C

Max 90%

Maximum 30 days. Instrument should run 5 minutes every month

Power supply| Automatic switching from 90VAC to 260VAC, 47 to 63 Hz
Power consumption

(max at full flow)

| HYDROXYCHROM-100 and HYDROXYCHROM-160: maximum 150W
Sound pressure| < 40dB (A)

**** INSTRUMENT PRESENTATIO

The front panel contains a functioning LED (see chapter 5 for the signification). The rear panel’ left side has:

• Mains plug

with fuse and switch

• DB9 interface connectors for RS485, remote control USB, dry relay. The rear panel’ in the center has:
• ZEROWATER input from external tank, fitting for 6mm tube
• Output hydrogen by dual ring fitting stainless steel 1/8″
• Dry air inlet, fitting brass 1/8”
• O2 output fitting, fitting for 8mm tube
• Mild Air outlet after cooling internal structures View of rear’s face:

FUNCTIONING PRINCIPLE

The self-priming water pump1 sucks water from the ZEROWATER tank (external tank), and keep the internal tank filled up between the two Infra-Red water level detectors. The internal tank contains a circular deionization cartridge with minimum 1 year lifetime.

The circulating water pump2 aspires ZERO WATER from the internal tank, and make water circulating through the electrolysis cell with PME membrane. Mixed with oxygen generated by electrolysis, the water return to the internal tank. O2 is separated and flows outside the instrument through a 8mm exhaust fitting.
After creation during the electrolysis, hydrocarbon free wet hydrogen passes through the membrane and is dried a first time in the liquid-gas separator, then a second time by a static dryer without maintenance.
The Hydrogen pressure is measured and regulated to the desired value by a current feedback to the H2-cell. HYDROXYCHROM-100 and HYDROXYCHROM-160 are equipped with a single layer H2-cell.

H2 GENERATION MODULE

CHAPTER 4. INSTALLATION AND OPERATION

**** RECEIPT OF INSTRUMENT AND CHECK

Each instrument is inspected and packaged prior to transport with great attention. Immediately after receipt, we recommend to perform a quick visual inspection of the package. If the package is damaged, report it in writing to the carrier at the time of delivery.

The HYDROXYCHROM is packed in a wood box with protection and maintaining foams placed above and below the instrument.

The HYDROXYCHROM packaging extraction begins with the opening of the wood box; at this stage, it is possible to verify the visual integrity of the instrument.

Any damages must be immediately identified and photographed; it should be reported to the carrier as well as to your local Distributor or to CHROMATOTEC.

For major damages, the HYDROXYCHROM shall be returned to the manufacturer after synchronization with the service department, which can be reached by e-mail at:

support@chromatotec.com.

In case of non-respect of this procedure, CHROMATOTEC cannot be kept in charge of the caused damage and cost will be charged to the customer.

It is well recommended to keep the wood box for future shipments.

DELIVERY CONTENT

assembled
1| Connection tube from ZEROWATER tank to HYDROXYCHROM.
1| ZEROWATER tank (5L)
1| USB key including operating manual and HYDROXYCHROM Viewer software. If the generator is supplied with an analyzer, these elements are supplied with the USB key of the analyzer.
1| QC and verification certificate
1| USB cable for connecting the device to a PC
1| Power cable 230V, CE or according to your country
1| Shipping box

****  GENERATOR INSTALLATION

• The HYDROXYCHROM generator must be installed on a flat surface, without vibrations, avoiding potential shocks and excessive heat source; it should not be in contact with other devices on any of its walls.
• Operate the instrument in an open and well-ventilated area, in which the temperature does not go below +4°C. Good functioning of the instrument is guaranteed for a temperature between +10 and +35°C.
• To ensure proper ventilation, a clear space of at least 5 cm is required on the top of the instrument and around the ventilation outlet. The cooling air intake is located directly on the top and the rear of the instrument; under no circumstances this part should be

**** CONNECTIONS

F LUIDIC CONNECTIONS

ZEROWATER Inlet:

• Disconnect the tube assembly which connects the inlet and outlet of the water circulation This assembly is made for transport.
• Place the ZEROWATER tank close to the H2-generator
• Connect the tube to the Lubricate the end of tube with distilled water and introduce it in the fitting, (labeled ZEROWATER INLET), push it firmly and screw the nut.

REMARK

The ZEROWATER tank has been designed to be placed on the floor at a maximum distance of 1.2 m from the generator. It can, nevertheless, be placed at the same level or above the instrument. The maximum difference in height between the generator and the ZEROWATER tank is 1m.

Hydrogen Outlet : Hydrogen pressure is available at the OUTLET H2 output on the back of the instrument. This outlet is equipped with a stainless steel Swagelok 1/8” fitting.
Oxygen outlet: remove the 8mm tube from the transport tube assembly and connect it to the O2 Outlet. The O2 outlet must be kept at atmospheric pressure and without restriction. Some droplets of water condensation are sometime present at the tube’s end. This is normal; water could be collected by a small plastic glass.

Air inlet: Air inlet must be dry air at 3 bar.

Warnings:

1)  Oxygen outlet must be maintained at atmospheric pressure.
2) If H 2 outlet under pressure is suddenly opened, in certain circumstances H2 could be mixed with water. Switch OFF device before disconnecting H2 Outlet.
CAUTION : your HYDROXYCHROM generator has been tested for several hours at the factory and all its tubes have been cleaned of ambient air contaminants. After a break of several days to several weeks of operation, Air ambient has slightly dirt the circuit of the instrument. The walls of the tubes need again to be cleaned. Before connecting to the consumer, please let your H2-generator running during a couple of hours to the atmosphere.

E LECTRIC CONNECTIONS

Mains: Connect the HYDROXYCHROM generator with the electrical cable provided; if it was not possible, verify that the cable use has a sufficient section and has a ground wire (3X1 mm2 minimum). Make sure laboratory differential circuit breaker can absorb an inrush current of at least 6A without switching off.

FACTORY SETTINGS

During one of the last phases of QC, your HYDROXYCHROM has been programmed with a set of values called “factory settings”. Those settings will help you to start the generator without troubles:

• Set H2 Pressure: 2000mbar
• Timeout Pressure Alarm: 0 second (timeout disabled)
• Functioning Mode: Continuous on

At this step, the HYDROXYCHROM is ready for startup.

• Switch power ON
• After a few seconds due to generator initialization, the water pump1 sucks ZEROWATER and fill up the internal tank
• When upper water level is reached, current is applied to the hydrogen Electrolysis process is initiated and some H2 is available at the H2 outlet.

The H2 generator’s configuration could be modified according to your needs via its USB connection and a PC with HYDROXYCHROM Viewer software.

REMOTE CONTROL S OFTWARE : HYDROXYCHROM V IEWER FOR

USB

OVERVIEW

HYDROXYCHROM Viewer software provides User Interface to control Gas Generator Network through USB interface

SPECIFICATIONS

Requirements

PC or Laptop under WinXP SP2 or higher / Win Vista / Win 7 At least 5Mb of free space on the Hard drive USB port

Performance

Reporting Instrument Status, Parameters and Setting

Connection

The Instrument is connected to a PC using USB port.

INSTALLATION PROCEDURE

HYDROXYCHROM VIEWER :

**** To install HYDROXYCHROM Viewer you must log the computer in

“administrator”

Remark:

If you want work with HydroxychromViewer in Russian start by installing the “Cyrillic code page” (procedure below) and then come back here (only available with HydroxychromViewer V2.0).
Step 1: Run “install_hydroxychromviewer.exe”
Step 2: Select your preferred language for this installation

Step 3: Choose destination folder or use default.

Step 4: Complete installation

Remarks:

• If you just installed Hydroxychrom Viewer V1.0, when the installation is complete you have to do a “commit cf” (procedure below).
• If you just installed Hydroxychrom Viewer V2.0, when the installation is complete, this window will appear: click on “yes”, the computer will restart automatically saving the modification you just
  

CYRILLIC CODE PAGE INSTALATION:

**** Step 1: Run “install_cyrillic_codepage.exe”
Step 2: Select your preferred language for this installation

Step 3: Complete installation

When the installation is complete, this window will appear: clic on “yes”, the computer will restart automatically saving the modification you just made.

Remark:

After the computer restarted you can install the HydroxychromViewer software (go back to the procedure above).

COMMIT CF PROCEDURE FOR COMPUTER UNDER EMBEDDED WINDOWS:

Open the program named “command prompt” in the toollbar

In this program, write “commitcf” as shown in the picture below and press enter.

The program asks you to restart, write “Y” for yes as shown in the picture below and press enter.

CHANGING LANGUAGE:

**** Step 1: Open Application partition.

Step 2: Open Hydroxychrom folder.

Step 3: Open Hydroxychrom_v2.ini file with “Notepad”.

Step 4: Modify the second line of the code:

• LanguageFile=Hydroxychrom_UK.lng for English language
• LanguageFile=Hydroxychrom_FR.lng for French language
• LanguageFile=Hydroxychrom_RU.lng for Russian language

And then save the file.

Step 5: Exit Hydroxychrom viewer:

And open it again:

USAGE:

Step 1: Connect USB
Step 2: Start HYDROXYCHROM Viewer

Step 3: Adjust the COM port number that is associated with USB port

Step 4: Left Click on Connect

INSTRUMENT INFORMATION STATUS AND OPERATION MODE

MODE:

Instrument working mode could be chosen from one of following

Off – No gas generation;
On – Gas generation is running but will be stopped after power off;
Continuous On – Gas generation is running but will be automatically started every time after power on;
Remote control – Gas generation Started/Stopped depending on the Digital Input signal at the rear side of the instrument.
Leak check – allows to check internal H2 leaks

INSTRUMENT INFORMATION:

Instrument information section provides Firmware Version, Instrument Serial Number, Run time and Cell total current.

PRESSURE INFORMATION AND SETTINGS:

Actual Pressure shows the pressure measured at the outlet of the instrument;
Set Pressure is a parameter, where user could see and/or modify desired value of the pressure; Timeout is time in seconds showing for how long the Actual Pressure does not match the Set Pressure ; Timeout Alarm is time in seconds given to the instrument after start to reach the Set Pressure.

IMPORTANT NOTE: For security reasons, the Instrument stops generation when the Timeout value became equal to Timeout Alarm.

FLOW INFORMATION

Consumption shows current water consumption in ml/h;
Production shows actual production of H2 in percentage from the maximum capacity
Estimated Flow shows actual H2 flow in ml/min. Please note that this value is not directly measured but calculated inside the instrument. Use it only for estimation purposes.

CELL INFORMATION:

Cell information section provides Run time and Cell total current.

REGULAR MAINTENANCE

The Hydrogen generator HYDROXYCHROM does not need regular maintenance; it needs ZEROWATER and electrical power. If the instrument is used according to recommendations made by the constructor, the deionizing bags (internal and external tanks) should be exchanged once every 1 year and the internal tank filter should be exchanged once every 3 years. In order to keep the instrument in its original conditions, please use exclusively distilled and filtered water.

LED AND BUZZER INDICATIONS

Green| Red| Buzzer|
---|---|---|---
ON| OFF| OFF| STBY (by user), REMOTE – STBY, ON, CONTINEOUS ON, REMOTE – ON
FAST| OFF| OFF| STBY with Warning
FAST| OFF| FLASH| ON with Warning, CONTINEOUS ON with Warning, REMOTE – ON with Warning
OFF| FAST| FAST| STBY with Error
FLASH| OFF| SLOW| LeakTest in process
FLASH| OFF| OFF| LeakTest success
FLASH| SLOW| FAST| LeakTest Fail
FAST| FAST| OFF| USB-CABLE-CONNECTED
Variable| OFF| OFF| H2 Flow Production indication versus maximum capacity

STBY = STAND-BY

ALARMS + TROUBLESHOOTING

detector.

·      Tube between external tank and device is leaky.

| ·      External tank is empty, add water.

·      Push    tube    in    the             INLET WATER quick connector.

2| H2 Output pressure| ·      Actual H2 pressure could not reach set value, because there is a leak inside your generator or on the line between generator and GC.

·      H2 flow consumed by your GC is superior to the generator’s capacity.

| ·      Proceed to a leak check with HYDROXYCHROM Viewer software and verify if fittings are screwed correctly.

·      Volume between H2 generator and consumer too big. Pressure value could not be reached on time. Increase value of timeout.

·      Verify          capacity                          and consumption, reduce consumption of GC.

3| H2-Cell Voltage| ·      Bad quality of water.

·      Deionisant bags inside internal and external tank are not any more efficient.

·      H2-cell is dry.

| ·      Replace actual water exclusively by distilled and filtered water.

·      Exchange deionisant bags.

·      Verify if water is correctly circulating. Circulating pump should not be stopped.

4| Internal communication| ·      One or several cable(s) inside device is(are) disconnected or damaged

·      One board inside device is damaged.

| ·      If a cable is simply disconnected due to vibrations during shipment, please switch of the device and reconnect simply the cable.

·      If one board is damaged, please call your local distributor for repair.

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References

• suche.ch
• Home | Lauper Instruments

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