HySTAT Indoor (10 Bar) Manual Book

HySTAT Manual
Revision: 09
Revision date: 25/01/2011

WARNING AND DISCLAIMER
This manual is designed to provide tutorial information about the HySTAT electrolyzer. While
every effort has been made to make this manual complete and as accurate as possible, no guar-
antee of its suitability is given.
Hydrogenics Europe NV shall have neither liability nor responsibility to any person or entity with
respect to any loss or damage in connection with or arising from the information contained in
this manual. In case of doubt, please contact us.
Hydrogenics Europe NV
Nijverheidsstraat 48c
B-2260 Oevel, Belgium
Tel.: +32.14.46.21.10
Fax.: +32.14.46.21.11
www.hydrogenics.com
CONFIDENTIALITY
The information contained herein is proprietary information of Hydrogenics Europe NV and shall
not be copied and/or reproduced in any matter, nor used in any purpose whatsoever except as
specifically permitted pursuant to a written agreement with Hydrogenics Europe NV.
Page 4
HySTAT MANUAL
Revision: 09 - Revision date: 25/01/2011

Page 1
HySTAT MANUAL
Chapter 1: Safety .............................................................................................................8

1.1. Conventions used in this publication ................................................................... 8
1.2. Registered trademarks ........................................................................................ 8
1.3. The Hydrogenics Safety Philosophy ...................................................................9
1.4. Hydrogenics general safety guidelines ..............................................................10
1.5. First aid equipment ............................................................................................11
1.5.1. First aid kit................................................................................................... 11
1.5.2. Eye wash station ......................................................................................... 11
1.5.3. Emergency shower ..................................................................................... 11
1.6. Hydrogen properties ..........................................................................................12
1.7. Oxygen properties .............................................................................................13
1.8. Explosion hazard ...............................................................................................14
1.8.1. Hydrogen risks ............................................................................................ 14
1.8.2. HySTAT hazardous area classification ....................................................... 14
1.8.3. Safety guidelines......................................................................................... 14
1.9. Fire hazard ........................................................................................................16
1.9.1. Hydrogen risks ............................................................................................ 16
1.9.2. Oxygen risks ............................................................................................... 16
1.9.3. Safety guidelines – prevention .................................................................... 16
1.9.4. Safety guidelines – effect mitigation ........................................................... 17
1.10. Chemical corrosion hazard ..............................................................................18
1.10.1. KOH risks.................................................................................................. 18
1.10.2. Safety guidelines – prevention.................................................................. 18
1.10.3. Safety guidelines – effect mitigation ......................................................... 19
1.11. Asphyxia hazard ..............................................................................................20
1.11.1. Inert gases risks ........................................................................................ 20
1.11.2. Oxygen risks ............................................................................................. 20
1.11.3. Safety guidelines....................................................................................... 20
1.12. Skin burn hazard .............................................................................................21
1.12.1. Hot surfaces risks ..................................................................................... 21
1.13. Electrocution hazard........................................................................................ 21
1.13.1. General ..................................................................................................... 21
1.13.2. Residual voltage risk ................................................................................. 21
1.14. Power outage .................................................................................................. 23
Chapter 2: Environmental information ............................................................................26

2.1. Environmental, Health & Safety policy .............................................................. 26
2.2. Material safety datasheets ................................................................................26
2.3. Vented gases ....................................................................................................27
2.3.1. Oxygen........................................................................................................ 27
2.3.2. Hydrogen .................................................................................................... 27
2.3.3. Nitrogen ...................................................................................................... 27
2.4. KOH ...................................................................................................................27
2.4.1. Loss during normal operation ..................................................................... 27
2.4.2. KOH spills ................................................................................................... 27
2.5. Chemicals disposal ...........................................................................................27

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HySTAT MANUAL
Chapter 3: Installation (indoor units) ..............................................................................30

3.1. General.............................................................................................................. 30
3.1.1. Checklist ..................................................................................................... 30
3.2. Reception and handling .....................................................................................31
3.2.1. Reception.................................................................................................... 31
3.2.2. Handling...................................................................................................... 31
3.3. Site preparation ................................................................................................. 35
3.3.1. Structural..................................................................................................... 35
3.3.2. Floor trays for cabling ................................................................................. 38
3.3.3. Drains - gully traps ...................................................................................... 39
3.3.4. Connections ................................................................................................ 39
3.3.5. Heating and ventilation ............................................................................... 43
3.3.6. Storage ....................................................................................................... 43
3.3.7. Dehydro dryer ............................................................................................. 44
3.4. Mechanical connections ....................................................................................45
3.4.1. General ....................................................................................................... 45
3.4.2. Hydrogen user line...................................................................................... 45
3.4.3. Hydrogen vent to atmosphere..................................................................... 45
3.4.4. Oxygen vent to atmosphere........................................................................ 46
3.4.5. Feed water connection................................................................................ 47
3.4.6. Water locks ................................................................................................. 47
3.4.7. Drain connections ....................................................................................... 48
3.5. Electrical connections ........................................................................................49
3.5.1. General ....................................................................................................... 49
3.5.2. Cables......................................................................................................... 49
3.5.3. Earthing and bonding.................................................................................. 49
3.5.4. Cable trays.................................................................................................. 50
3.5.5. Lightning protection..................................................................................... 50
3.6. ATEX enclosure ventilation system................................................................... 50
3.6.1. Design flow & pressure ............................................................................... 51
3.6.2. Layout ......................................................................................................... 51
3.7. Electrolyte ..........................................................................................................52
3.7.1. General ....................................................................................................... 52
3.7.2. Specifications.............................................................................................. 52
3.7.3. Filling........................................................................................................... 52
3.8. Utilities............................................................................................................... 52
3.8.1. Purge installation ........................................................................................ 52
3.8.2. Cooling water .............................................................................................. 52
3.8.3. Closed loop cooling water........................................................................... 52
3.8.4. Other ........................................................................................................... 53
Chapter 4: Operation ......................................................................................................56

4.1. Introduction to the HySTAT system................................................................... 56
4.1.1. Product code............................................................................................... 56
4.1.2. Process description..................................................................................... 56
4.1.3. Process flow................................................................................................ 56
4.1.4. System overview......................................................................................... 56
4.1.5. Main components........................................................................................ 58
4.2. HySTAT Electrolyzer operation .........................................................................71

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HySTAT MANUAL
4.2.1. General ....................................................................................................... 71

4.2.2. HySTAT human-machine interface ............................................................. 71
4.2.3. HySTAT basic operation principles ............................................................. 71
4.2.4. HySTAT start conditions ............................................................................. 71
4.2.5. HySTAT operational phases ....................................................................... 72
4.2.6. Level control, pressure control and current control ..................................... 75
4.2.7. Starting the HySTAT ................................................................................... 75
4.2.8. Stopping the HySTAT ................................................................................. 77
4.2.9. Depressurizing the HySTAT ....................................................................... 77
4.3. Deoxo dryer operation .......................................................................................79
4.3.1. Deoxo dryer operational phases ................................................................. 79
4.3.2. Nitrogen purge of the deoxo dryer .............................................................. 80
4.3.3. Depressurization of the deoxo dryer ........................................................... 81
4.3.4. Deoxo dryer into production ........................................................................ 81
4.4. Critical alarms ....................................................................................................82
Chapter 5: Maintenance and troubleshooting ................................................................86

5.1. Introduction........................................................................................................ 86
5.2. Generator status ................................................................................................87
5.2.1. Status for maintenance procedures ............................................................ 87
5.3. Inspection of the HySTAT system .....................................................................89
5.3.1. Definitions of inspections ............................................................................ 89
5.3.2. Overview of inspections – HySTAT ............................................................ 90
5.3.3. Overview of inspections – Dryer systems ................................................... 92
5.3.4. Overview of inspections – Auxiliaries.......................................................... 93
5.4. Scheduled maintenance – HySTAT ..................................................................94
5.4.1. Maintenance schedule ................................................................................ 94
5.4.2. Power- and control cabinet maintenance.................................................... 97
5.4.3. Cleaning the outdoor housing ..................................................................... 99
5.4.4. Checking and replacing the 24V UPS batteries ........................................ 100
5.4.5. Checking the fixing of the power cables ................................................... 101
5.4.6. Replacing the thyristor cooling fans .......................................................... 103
5.4.7. Replacing the complete thyristor stack ..................................................... 105
5.4.8. Checking the torque on the cell stack ....................................................... 107
5.4.9. Checking leak tightness ............................................................................ 109
5.4.10. Checking the concentration of the electrolyte ......................................... 111
5.4.11. Removing the electrolyte ........................................................................ 114
5.4.12. Filling with electrolyte .............................................................................. 116
5.4.13. Checking the functionality of the temperature switches.......................... 120
5.4.14. Checking the functionality of the level switches...................................... 122
5.4.15. Replacing the level switch floats ............................................................. 124
5.4.16. Replacing the level transmitter floats ...................................................... 127
5.4.17. Checking the level transmitter................................................................. 129
5.4.18. Replacing or recalibrating the safety relief valves................................... 131
5.4.19. Inspecting pressure vessels.................................................................... 132
5.4.20. Checking and cleaning the electrolyzer solenoid valves......................... 134
5.4.21. Replacing solenoid & pneumatic valves ................................................. 136
5.4.22. Cleaning the break tank .......................................................................... 147
5.4.23. The HTO analyzer................................................................................... 148
5.4.24. Cleaning the HTO panel ......................................................................... 153
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HySTAT MANUAL
5.4.25. The HTA analyzer ................................................................................... 154

5.4.26. The OTA analyzer................................................................................... 161
5.4.27. The OTH Analyzer .................................................................................. 163
5.4.28. Replacing the dewpoint transmitter......................................................... 170
5.4.29. Check functionality of door switch power rack ........................................ 171
5.4.30. Check functionality of flooding detection device ..................................... 172
5.4.31. Check functionality of air flow switch ...................................................... 173
5.4.32. Check functionality of current switch for process fan.............................. 174
5.4.33. Changing taps of transformer in power rack ........................................... 175
5.5. Scheduled maintenance – Deoxo dryer ..........................................................178
5.5.1. Purging the deoxo dryer............................................................................ 179
5.5.2. Replacement of the coalescing filter after deoxo vessel........................... 180
5.5.3. Check instrument air supply...................................................................... 181
5.5.4. Check/Replace filter on instrument air supply........................................... 182
5.5.5. Replacement of the coarse particle filter element..................................... 183
5.5.6. Replacement of the solenoid valves ......................................................... 184
5.5.7. Replacement of the pneumatic valves ...................................................... 185
5.5.8. Exchange catalyst in deoxo dryer ............................................................. 186
5.5.9. Exchange molecular sieve in deoxo/dehydro dryer .................................. 187
5.6. Troubleshooting ...............................................................................................189
5.6.1. The events table ....................................................................................... 190
5.6.2. Investigating start conditions..................................................................... 191
5.6.3. Troubleshooting ........................................................................................ 192
Appendix A: HMI display terminal .................... .........................................................2

A.1.Getting Started..................................................................................................... 2
A.1.1.General ..........................................................................................................2
A.1.2.Using the display terminal .............................................................................3
A.1.3.Screen headers .............................................................................................3
A.2.Electrolyzer screens............................................................................................. 7
A.2.1.GGS1 screen .................................................................................................7
A.2.2.Trending Process screen ...............................................................................8
A.2.3.Power screen .................................................................................................9
A.2.4.Enable/Disable cell stacks screen ...............................................................10
A.2.5.Cell stack details screen ..............................................................................11
A.2.6.Production counters screen .........................................................................12
A.2.7.Electrolyzer actions screen ..........................................................................13
A.2.8.Electrolyzer start conditions screens ...........................................................14
A.3.Utility screens..................................................................................................... 15
A.3.1.Closed loop cooling screen .........................................................................15
A.3.2.RO System screen ......................................................................................16
A.3.3.Fill calculation screen ..................................................................................17
A.3.4.Outdoor housing screen ..............................................................................18
A.4.Deoxo drier screens........................................................................................... 19
A.4.1.HPS screen .................................................................................................19
A.4.2.HPS Nitrogen purge screen .........................................................................21
A.5.Information screens ........................................................................................... 22
A.5.1.Info overview screen ....................................................................................22
A.5.2.Clock & Language screen ...........................................................................23

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HySTAT MANUAL
A.5.3.Start conditions overview screen .................................................................24

A.5.4.Basic start conditions screens .....................................................................25
A.5.5.Basic delayed start conditions screens .......................................................26
A.5.6.Events screen ..............................................................................................27
A.5.7.Analog alarms overview screen ...................................................................28
A.5.8.Analog basic alarms screen ........................................................................29
A.6.Debugging screens ............................................................................................ 30
A.6.1.Debug overview screen ...............................................................................30
A.6.2.Diagnostics screen ......................................................................................31
A.6.3.Counters actuators screen ..........................................................................32
A.6.4.Production limitations screen .......................................................................33
A.6.5.Profisafe overview screen ...........................................................................34
A.6.6.Profisafe UTx screen ...................................................................................35
A.6.7.Profisafe GGS1 screen ................................................................................36
A.6.8.Profisafe HPS screen ..................................................................................37
Appendix B: Tag reference ............................. .........................................................40

B.1.General .............................................................................................................. 40
B.2.HySTAT process................................................................................................ 40
B.3.Deoxo dryer ....................................................................................................... 44
B.4.Deoxo dryer: Full Flow Zero Loss (optional) ...................................................... 46
B.5.Deoxo dryer: Booster pump (optional) ............................................................... 47
B.6.Dehydro dryer .................................................................................................... 47
B.7.Analyzer panel deoxo dryer ............................................................................... 49
B.8.Analyzer panel dehydro dryer ............................................................................ 49
B.9.Instrument air panel ........................................................................................... 50
B.10.Conductivity measurement panel..................................................................... 50
B.11.Frit sparger....................................................................................................... 51
B.12.Chiller............................................................................................................... 51
B.13.Closed loop cooling.......................................................................................... 51
B.14.Cooling water from customer ........................................................................... 53
B.15.Total gas counter ............................................................................................. 53
B.16.Reverse osmosis system ................................................................................. 54
B.17.Hydrogen Cylinder Filling Station..................................................................... 55
B.18.Vacuum Pump for Hydrogen Cylinder ............................................................. 55
Appendix C: Start conditions .......................... .........................................................58

C.1.General Remarks............................................................................................... 58
C.2.Basic start conditions ......................................................................................... 58
C.3.Common hydrogen production basic start conditions ........................................ 59
C.4.Nitrogen purge start conditions .......................................................................... 61
C.5.Hydrogen deoxo dryer start conditions .............................................................. 62
C.6.Oxygen dehydro dryer start conditions .............................................................. 64
C.7.Hydrogen production start conditions ................................................................ 67
C.8.Cell stack 1 start conditions ............................................................................... 68
C.9.Cell stack 2 start conditions ............................................................................... 70
C.10.Cell stack 3 start conditions ............................................................................. 71
C.11.Cell stack 4 start conditions ............................................................................. 72

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HySTAT MANUAL
Appendix D: Specifications utilities ................ .........................................................76

D.1.Electrolyte .......................................................................................................... 76
D.2.Demineralized water .......................................................................................... 77
D.3.Supply water to reverse osmosis system .......................................................... 77
D.4.Cooling water..................................................................................................... 78
D.4.1.Cooling water purity .....................................................................................79
D.4.2.Ethylene glycol – water solution ..................................................................79
D.4.3.Cooling system capacity ..............................................................................79
D.4.4.Chiller coolant ..............................................................................................80
D.5.Nitrogen gas ...................................................................................................... 80
D.6.instrument air ..................................................................................................... 80
D.7.Calibration gases ............................................................................................... 80
D.8.Electrical power supply ...................................................................................... 81
D.8.1.Grid specifications .......................................................................................81
D.8.2.Power specifications ....................................................................................81
Appendix E: Remote access and data-logging ........................................................84

E.1.Getting started ................................................................................................... 84
E.2.Remote Access Viewer...................................................................................... 84
E.2.1.Introduction ..................................................................................................84
E.2.2.Installation ...................................................................................................85
E.2.3.Connecting to the Operator Terminal ..........................................................85
E.2.4.Using a Web Browser as a Viewer ..............................................................87
E.3.Beijer Electronics Data Collector (Optional)....................................................... 89
E.3.1.Introduction ..................................................................................................89
E.3.2.System requirements ...................................................................................89
E.3.3.Installation ...................................................................................................91
E.3.4.Using Beijer Electronics Data Collector .......................................................92
E.3.5.Database Tables .......................................................................................102
E.4.Beijer Electronics Viewer (Optional) ................................................................ 103
E.4.1.The Main Window ......................................................................................103
E.4.2.Settings ......................................................................................................103
E.4.3.View Trend ................................................................................................104

HYSTAT MANUAL
SECTION 1: SAFETY
Page 8 Section 1
HySTAT MANUAL SAFETY
Section 1: SAFETY
1.1 Conventions used in this publication

For simplicity and consistency, this manual uses the following conventions.
Note sign. Notes call attention to information that is especially significant to

understanding and operating the equipment.
Caution sign. Caution notices are used where equipment might be damaged if
care is not taken.
Warning sign. Warning notices are used to emphasize hazardous conditions that
may cause serious personal injury if care is not taken.
1.2 Registered trademarks

A IMET® www.hydrogenics.com (Inorganic Membrane Electrolysis Technology)
A HySTAT® www.hydrogenics.com (Hydrogen Station)
A Swagelok® www.swagelok.com
A Snoop® www.swagelok.com
A Ham-let® www.ham-let.com
A Siemens® www.siemens.com
A Simatic NET® www.siemens.com
A Microsoft® www.microsoft.com
A Windows® www.microsoft.com
A Exter® www.beijerelectronics.com
A Exter T70® www.beijerelectronics.com

Section 1 Page 9
SAFETY HySTAT MANUAL
1.3 The Hydrogenics Safety Philosophy

The standard “ISO 22734-1 – Hydrogen generators using water electrolysis process” is used as a
starting-point for the HySTAT systems. This International Standard defines the construction, safety and
performance requirements of packaged or factory matched hydrogen gas generation appliances.
Every HySTAT is designed from an “integrated safety” perspective:
1st priority: elimination of actions likely to create a hazardous situation;

2nd priority: prevention of hazardous situations by integrated safety features;
3rd priority: mitigation of the effects of an occurring incident.
Hydrogenics Europe NV has performed a risk assessment for all standard equipment, taking into
account the following standards:
A EN ISO 12100:2010 Safety of machinery. General principles for design. Risk assessment and
risk reduction.
A IEC 61508: Functional safety of electrical/electronic/programmable electronic safety-related

systems
A IEC 62061: Safety of Machinery - Functional safety of safety-related electrical, electronic and
programmable electronic control systems
A IEC 61511: Function safety: safety instrumented systems for the process industry sector
Alltough Hydrogenics Europe NV has chosen widely accepted design criteria,

it’s important to note that the customer should review wether the tolerable risk
that Hydrogenics Europe NV has used in the design of the generators is also
acceptable for this application. In case of doubt, please contact Hydrogenics
Europe NV.
A complete overview of all HySTAT hazards and safety guidelines can be found in the following
chapters. Read them carefully prior to operating the HySTAT installation.

Page 10 Section 1
1.4 Hydrogenics general safety guidelines

Keep a copy of this manual, a set of electrical drawings, and a set of P&ID’s in a
designated place inside or near the HySTAT, so that this valuable information is
accessible to operators and engineers at all times.
Make sure that all personnel involved in the installation, operation, or maintenance of
the HySTAT is trained accordingly.
Do not allow unsupervised work on or around the HySTAT installation.
Always wear personal protective equipment: minimum recommendations are safety

shoes and safety goggles. When handling electrolyte or other chemicals, wear face
protection, suitable gloves, and protective clothing.
Make sure the area where the HySTAT is installed, all entrances to it, and all escape
routes from it, are properly labeled and kept free at all times.
Do not make any constructional changes to the unit without contacting Hydrogenics
Europe NV first.
Do not allow any spark generating equipment around the HySTAT during operation.
Prohibit smoking in and around the HySTAT.

Section 1 Page 11
1.5 First aid equipment

1.5.1 First aid kit
Make sure that a first aid kit is available and easily accessible in or near the HySTAT
unit. Check its contents on a regular basis.
Hydrogenics Europe NV recommends the following items to be present inside the kit:
A cambric bandage (5 cm x 5 m and 7 cm x 5 m)

A triangulated bandage (96 x 96 x 36 cm)
A wound plaster (6 cm x 1 m)
A adhesive plaster (1,25 cm x 5 m)
A adhesive plaster (2,50 cm x 5 m)
A easy-application bandage (8 x 10 cm and 12 x 12 cm)
A hybin, hygienic solution (30 ml)

A stainless safety pins - 10 pc
A medicated cotton-wool (25 gr)
A waterproof woundbandage (7 x 2 cm) - 12 pc
A compress (1/16)
A isothermal blanket (1,6 x 2,2 m)
A packet of latex gloves (powder free) - 4 pc
A elastic squeezing bandage
A pair of scissors
A Diphoterine aerosol can (www.prevor.com)
1.5.2 Eye wash station
Install an eye wash station in or near the HySTAT unit, at a clearly marked and easily
accessible location.
Hydrogenics Europe NV recommends an eye wash station containing Diphoterine® as active

component. Refer to the customer checklist or contact Hydrogenics Europe NV for more information.
1.5.3 Emergency shower

Hydrogenics Europe NV recommends to install an emergency shower station if possible. This is a device
specifically designed and intended to deliver flushing fluid in sufficient volume to cause that fluid to
cascade over the entire body, to prevent or mitigate injuries caused by fire, abrasive substances, etc.
The shower needs to be easy to handle, view and access. The water should be of adequate quality and
temperature so that any danger for the health of the employees is avoided.

Page 12 Section 1
1.6 Hydrogen properties

At standard temperature and pressure, hydrogen is a colorless, odorless, nonmetallic, tasteless, highly
flammable diatomic gas (H2). With an atomic mass of 1.00794 g/mol, hydrogen is the lightest element.
Hydrogen is non toxic, but does not support life.
Hydrogen gas is highly flammable and will burn violently at concentrations as low as
4% H2 in air. Its auto-ignition temperature is 844,3K (571,2°C).
Pure hydrogen-oxygen flames are invisible to the naked eye, thus it is difficult to detect if a hydrogen
leak is burning.
Hydrogen flames tend to ascend rapidly with the gas in air.
When mixed with oxygen across a wide range of concentrations, hydrogen explodes upon ignition.

Section 1 Page 13
1.7 Oxygen properties

At standard temperature and pressure, oxygen is a colorless, odorless, nonmetallic, tasteless diatomic
gas (O2). The atomic mass of oxygen is 15.9994 g/mol.
Concentrated sources of oxygen promote rapid combustion and therefore are fire and
explosion hazards in the presence of fuels.
Oxygen is no actual fuel, but as a reactant, concentrated oxygen allows combustion to proceed rapidly.
Some materials may auto-combust in a concentrated oxygen environment.

Page 14 Section 1
1.8 Explosion hazard

1.8.1 Hydrogen risks
When mixed with oxygen, hydrogen combusts or explodes when ignited.
The concentration limits between which a hydrogen-air mixture combustion (or explosion) is supported
are defined in ISO 22734-1 as follows:
LFL*: 4.0% *Lower Flammability Limit, considered as LEL
UFL*: 75.0% *Upper Flammability Limit, considered as UEL

Upon ignition, a hydrogen-air mixture concentrated within these limits combusts or explodes. The
minimum ignition energy is 0.02mJ.
The range of volume for a ratio of hydrogen in air that will form a flammable atmosphere is more
extensive than the range that will form an explosive atmosphere. The LFL and UFL are used to
provide the maximum protective measures.
1.8.2 HySTAT hazardous area classification
EU US/CA
ATEX Zone 2 Class I Div II
Gas Group IIC Gas Group B
Temperature class T1 Temperature class T1
Information related to the Ex-zone boundaries can be found in the HySTAT Explosion Protection
Document.
Each HySTAT complies with the applicable codes & standards for the region in which it is installed. In
principle, the differences these may imply (i.e. CE vs. NRTL), affect nor the safety nor the reliability of the
installation.
It is of utmost importance that a full risk assessment is carried out for the
HySTAT and its surroundings. Please review project documentation (P&ID’s,
electrical drawings, zoning drawings, etc.). If something is not clear, please
contact Hydrogenics Europe NV.
1.8.3 Safety guidelines

A Provide clear identification of all hazards and hazardous areas
Keep activities not related to the HySTAT remote from it. Refer to the explosion
protection document. No exceptions can be allowed within the Ex-zone.

Section 1 Page 15
Ventilate hazardous areas sufficiently, so that, in case of a gas leak, the escaped gas is
vented to the outside of the building immediately.
Install continuous atmosphere monitoring equipment so that hydrogen and if

applicable oxygen leaks can be detected.

Page 16 Section 1
1.9 Fire hazard

1.9.1 Hydrogen risks
Hydrogen burns violently in air. Pure hydrogen-oxygen flames are invisible to the naked eye, thus it is
difficult to visually detect a burning hydrogen leak. A cloth on a rod can be used to detect a hydrogen
flame boundary.
Extinguishing a hydrogen fire while the leak is not stopped may cause an explosion
worse than the fire itself.
1.9.2 Oxygen risks
Oxygen vigorously accelerates combustion. Some materials that will not burn in air will
burn in an oxygen rich atmosphere (>23 %). Fire resistant clothing may burn and offer
no protection.
Oxygen may also form explosive mixtures when exposed to combustible materials such as oil, grease
and other hydrocarbons.
During maintenance, no grease or oil can be applied to parts that are in contact with
oxygen during normal operation.
A standard HySTAT does not include a transmitter to detect an in- or decreased

concentration of oxygen in the atmosphere. Depending on site conditions, it may be
recommended to include one. Another approach is for operators to verify the oxygen
concentration with a portable oxygen analyzer before entering the process part.
1.9.3 Safety guidelines – prevention

A Minimize potential leaks of hydrogen and oxygen
A Eliminate ignition sources

A Prohibit smoking and open flames near the HySTAT
A Keep the HySTAT area free of dry vegetation and combustible matter
A Provide hydrogen and oxygen isolation procedures
A Provide a fire detection- and alarm installation
A Provide warning signs and escape routes
A Consult local fire authorities for appropriate fire-fighting equipment

Section 1 Page 17
1.9.4 Safety guidelines – effect mitigation
Always consult local authorities for correct fire fighting instructions.
If you hear a hissing sound from a pressurized vessel at or about the HySTAT, assume the possibility of
a hydrogen fire.
Never attempt to put out a hydrogen fire.
What you should do:

A Press an emergency shutdown button unless it appears unsafe to approach one
A Evacuate the area and raise the alarm if possible
A Summon help and call the fire fighting services
A Attempt to cut off the flow of hydrogen and/or oxygen
1.9.5 Non-hydrogen fires

Standard, non-hydrogen fires have visible flames and will not be preceded by alarms from a hydrogen
leak detection. Note that a hydrogen fire may also produce a visible flame and/or smoke if there is a
combustible material near.
It is a mistake to assume that a fire in or around the HySTAT is not hydrogen-fed

based on the presence of a visible flame.
What you should do:

A Press an emergency shutdown button unless it appears unsafe to approach one
A Evacuate the area and raise the alarm if possible
A Summon help and call the fire fighting services

A Use a fire extinguisher to fight small fires only, and only after notifying the fire fighting services
A standard HySTAT does not include a fire alarm to detect a standard fire.

Page 18 Section 1
1.10 Chemical corrosion hazard

1.10.1 KOH risks
The HySTAT uses a 30% w/v solution of KOH (Potassium Hydroxide) in water.
KOH is highly corrosive and causes severe burns. The risk is enlarged by the nominal
working temperatures of 70°C – 75°C and elevated pressure.
Hydrogenics Europe NV service engineers are not allowed to, and therefore will not,
prepare KOH solutions on site.
When an aqueous solution is being prepared, an exothermic reaction takes place.
KOH solution skin contact may go unnoticed at first, but will cause severe skin burns within 48 hours.
Even under normal operating conditions, due to KOH presence, the pH values of the gases and liquids
inside the user lines, water locks and drains can rise to pH14.
1.10.2 Safety guidelines – prevention
For additional information, refer to the KOH MSDS sheet.
A Provide a KOH handling kit that consists of safety shoes, fase protection, protective gloves and
a chemical overall
A Install an emergency shower and eye wash station, and provide Diphoterine® rinsing systems
(refer to chapter 1.5: ‘First aid equipment’ for more information)
A Label all containers containing KOH solution
NEVER perform work involving electrolyte without the presence of someone else.
Avoid skin contact or swallowing.

Section 1 Page 19
Avoid vapor inhaling.
Wash hands and face thoroughly after handling a KOH solution.
A Use a suitable container and well-ventilated room for mixture preparation
1.10.3 Safety guidelines – effect mitigation

In case of eye- or skin contact:
A Always summon for medical assistance.

A Apply Diphoterine® immediately, or rinse with plenty of water.
A Use the eye wash station in case of eye contact.

Page 20 Section 1
1.11 Asphyxia hazard

1.11.1 Inert gases risks
Inert gases are non-toxic, but may act as an asphyxiate by replacing the oxygen content in a confined
space.
1.11.2 Oxygen risks

If the concentration of oxygen in air drops below 19.5% or rises above 23.5%, respectively there is a risk
of asphyxia or hypoxia.
A standard HySTAT does not include a transmitter to detect an in- or decreased

concentration of oxygen in the atmosphere. Depending on site conditions, it may be
recommended to include one. Another approach is for operators to verify the oxygen
concentration with a portable oxygen concentration analyzer before entering the process
part.

A Provide adequate ventilation
A Install continuous atmosphere monitoring equipment
A Provide observers outside the hazardous area during work

Section 1 Page 21
1.12 Skin burn hazard

1.12.1 Hot surfaces risks
The nominal operating temperature of the HySTAT is 70°C.
During operation, some of the process equipment reaches temperatures high enough
to cause skin burns if touched.
The dryer vessels' internal temperature can rise up to 250°C during their regeneration phase. Connected
piping and tubing may reach temperatures far over 100°C.
Wear protective equipment entering the process part during operation.
Always allow the unit to cool down sufficiently before servicing.
1.13 Electrocution hazard

1.13.1 General
In general, the nominal three-phase AC voltage that is applied to the HySTAT is 400Vac, 50Hz for
European installations, and 480Vac, 60Hz for North American installations.
The AC voltage is converted to a DC voltage of around 170Vdc to power the cell stack.
Both the AC and DC voltages are life-threatening if touched directly.
1.13.2 Residual voltage risk

The cell stack holds a considerable residual voltage after shutdown.
Great care must be taken approaching the cell stack for over one hour after shutdown
to avoid the risk of electric shock. ALWAYS check for residual voltage using a voltage
tester.

Page 22 Section 1

an
A All electrical equipment used must comply with local codes & standards
Isolate the power supply before servicing electrical parts of the unit. ALWAYS check
for voltage using a voltage tester before servicing any electrical part.
A Mind the residual cell stack voltage
A Provide earthing according local codes & regulations
A Organize periodical detailed inspections and keep their recordings
A Perform maintenance
Refer to ‘Section 5: Maintenance and troubleshooting’ for maintenance instructions.

Section 1 Page 23
1.14 Power outage

While the loss of utilities, especially electricity, may pose an inconvenience, it will not cause a safety
problem. If electricity service fails, the HySTAT will stop and depressurize in a safe way. The backup
battery makes sure the PLC is powered long enough to be able to control this process.
Although power outage does not cause an immediate safety problem, in case
environmental temperatures drop below 0°C, irrepairable damage may be
caused to the HySTAT if the unit is not powered within a certain time. If sub-zero
temperatures are likely to occur and if the power supply is not supervised locally
(on site), it is advised to install one or more separate heaters, connected to an
emergency power supply, inside the HySTAT. Contact Hydrogenics Europe NV
for more information.
Refer to ‘Section 5: Maintenance and troubleshooting’ for PLC and UPS battery
maintenance instructions.

Page 24 Section 1

HYSTAT MANUAL
SECTION 2: ENVIRONMENTAL INFORMATION

Page 26 Section 2
HySTAT MANUAL ENVIRONMENTAL INFORMATION
Section 2: ENVIRONMENTAL INFORMATION
2.1 Environmental, Health & Safety policy

The Hydrogenics' on-site generation division believes that employees working safely in a healthy work
place are part of our good business practice. We are committed to the protection of the environment and
the welfare of the communities in which we do business.
We operate in the manufacturing sector, where we recognize that our activities can have an impact on
the environment. This also enables us to provide our customers with products and services that will con-
tribute to the overall health & safety and respect for the environment.
We will identify and minimize the environmental, health & safety impacts of our operations, products and
services by means of pollution prevention and health & safety programs.
We recognize that good environmental, health & safety programs will only succeed when we provide
proper training and education to our management team and employees and inform our other stakehold-
ers about the impact inherent to their activities.
We will encourage contractors to manage their environmental, health & safety performance in line with
this policy.
We will comply with all applicable regulatory requirements and other commitments to which Hydrogenics
Europe NV has made a commitment as a minimum.
We will continuously strive for improvement of our environmental, health & safety performance and insist
that each employee and member of the management team contributes to this performance.
2.2 Material safety datasheets

Each MSDS contains an environmental section. Study them thoroughly prior to handling any chemical
substance. These material safety datasheets must be delivered with the products by your local supplier.

Section 2 Page 27
ENVIRONMENTAL INFORMATION HySTAT MANUAL
2.3 Vented gases

2.3.1 Oxygen
The oxygen vented to atmosphere during the production process, is a diatomic gas (O2), and as such
one of the two major components of air. Thus it immediately dissolves into the surrounding air, without
forming any threat to the environment.
2.3.2 Hydrogen
The hydrogen vented to atmosphere during purge or bleed phases, is a diatomic gas (H2). Once in con-
tact with the surrounding air, it combines with the oxygen present in the air to form H2O or water.
2.3.3 Nitrogen
The nitrogen vented to atmosphere during purge phases, is a diatomic gas (N2), and as such one of the
two major components of air. Thus it immediately dissolves into the surrounding air, without forming any
threat to the environment.
2.4 KOH
2.4.1 Loss during normal operation
Even during normal operation, the HySTAT loses a small amount of KOH. In those very low concentra-
tions, it is dissolved in the drained liquids, in the water locks and in the gas to the user line.
If you have any doubts, questions or concerns, feel free to contact Hydrogenics Europe
NV.
2.4.2 KOH spills

KOH leaks or spills must be dealt with in accordance with the MSDS instructions and the local codes and
standards. In general, make sure a KOH spill kit, containing at least a neutralizing acid, spill pads, and
garbage bags, is present on site.
2.5 Chemicals disposal

Always consult the MSDS and the local codes & standards for instructions on disposal of chemicals such
as electrolyte, cooling water etc.

Page 28 Section 2
HySTAT MANUAL ENVIRONMENTAL INFORMATION

HYSTAT MANUAL
SECTION 3: INSTALLATION (INDOOR UNITS)

Page 30 Section 3
HySTAT MANUAL INSTALLATION (INDOOR UNITS)
Section 3: INSTALLATION (INDOOR UNITS)
3.1 General
This section describes the installation of an indoor HySTAT unit.
The installation of the HySTAT, its peripheral equipment and the necessary interconnection piping and
cabling is the responsibility of the customer. Make sure that only properly trained personnel are involved
in the electrical and mechanical works that need to be performed to complete the installation.
Hydrogenics Europe NV cannot be held responsible for any damage to the HySTAT caused by improper
handling or abnormal actions during installation.
3.1.1 Checklist
The start-up and commissioning document ‘SHEQF 03-01-02 Customer checklist’ is sent to you upon
arrival of your HySTAT. It contains valuable information necessary to complete the installation of your
unit. Read it carefully and follow the instructions given, and complete the checklist for further reference.
Once completed, a signed copy of the customer checklist should be sent to Hydrogenics Europe NV.
Always take pictures of the installed equipment and send them to Hydrogenics Europe
NV along with the completed customer checklist. These pictures enable the project
manager to verify the successful completion of the installation.

Section 3 Page 31
INSTALLATION (INDOOR UNITS) HySTAT MANUAL
3.2 Reception and handling

3.2.1 Reception
Make sure the carrier hands over the cargo documents after delivery.
Upon reception, inspect the HySTAT and all its accompanying equipment for damage. Before the pack-
ing is removed, check the outside of the enclosures for marks of tilting or bumping. A temperature log-
ging device is present inside the control cabinet, and will be taken out and checked by a Hydrogenics
Europe NV service engineer during startup.
Note that the dry cooler, if present, is always shipped separately.
Packing removal
The HySTAT and all its accompanying equipment is carefully packed for transportation. Inside the equip-
ment, wooden beams and planks may be used to fix material that is prone to movement during transport.
Carefully remove all the packing wood, and dispose of it properly.
Nails are used to fix the packing wood. Wear suitable personal protective equipment
while removing it.
Transport damage
If damage is detected it needs to be reported to the carrier within five working days, and to Hydrogenics
Europe NV as soon as possible, so that timely repair is not compromised. Always take photographs of
the damaged parts immediately.
Ignoring transport damage, or not reporting damage to Hydrogenics Europe NV

immediately, may significantly increase the time needed for repair.
3.2.2 Handling
After delivery, the HySTAT and all its accompanying equipment needs to be lifted and moved to its des-
tination. The use of the included lifting device is recommended. The weight of the (unfilled) unit is stated
in the cargo documents.
Avoid tilting and shocking of the equipment. This may cause serious damage to
internal parts.
To prevent severe damage while moving the equipment, always make sure that the
cell stack(s) is (are) tightened to the frame, and that all equipment is properly fixed.

Page 32 Section 3
Make sure that lifting equipment is operated by qualified personnel, and within its
rated lifting capacity only.
Note that the process skid of a HySTAT-Q cannot be lifted with a forklift when the cell
stacks are installed.
Handling the process skid with forklifts

The HySTAT process skid can be lifted using a forklift with extended lifting forks. To lift the process skid,
the forks must be positioned underneath the gas separator, as indicated by the red forks on the figure
below.
Figure 1 – HySTAT-Q process part - forklift fork positioning
A HySTAT-Q unit cannot be lifted with a forklift when the cell stacks are installed in
the skid. Doing so may cause severe damage to the unit.

Section 3 Page 33
Handling the process skid with lifting device

The HySTAT process skid can be lifted using a lifting device. To lift the process skid, the lifting device
must be attached to the process skid, as indicated on the figures below.
Figure 2 – HySTAT-Q process part lifting device attachement

Page 34 Section 3
Figure 3 – HySTAT-D process part lifting device attachement
After installation, unscrew the cell stacks at the ends of their frame, not at the mid-flange. So
it’s possible for the cell stacks to move freely during operation
Handling the HPS skid

The HPS or dryer skid can be lifted with a forklift. Position the lifting forks underneath the skid, and take
appropriate measures to prevent the skid from tilting over.
Handling the electrical cabinets

The electrical cabinets can be lifted with a forklift or similar hoisting device. Use shackles in combination
with appropriate chains or hoisting belts, to lift the cabinets by the lifting lugs that are mounted at the top
of the cabinet.
Make sure to keep the electrical cabinets positioned vertically (never lay down).

Section 3 Page 35
3.3 Site preparation

Hydrogenics Europe NV reserves the right to review and approve the utility plans in
advance. Deviation from the approved connections must be approved in writing by
Hydrogenics Europe NV.
3.3.1 Structural
For installation of the HySTAT and all of its accompanying equipment, take the dimensions in the follow-
ing drawings into account. Typically, the electrical cabinets are placed back-to-wall. The dimensions in
between and around the equipment, are to be considered as minimum dimensions for routine mainte-
nance.
The setups shown in the following drawings, are for units that have an ATEX
enclosure. If this is not the case, then, as indicated by the blue dashed lines
( ), nor the electrical cabinets nor the chiller can be installed near the
HySTAT process- or HPS skids. Refer to the explosion protection document for
details on zoning.
Note that in case the interconnection cables are supplied with your HySTAT, the length of
these cables is limited to a standard value. Take these values into account when creating the
site layout. Refer to your contract and contact Hydrogenics Europe NV in case of doubt.

Page 36 Section 3
Figure 4 – Layout requirements for a typical HySTAT-S setup

Section 3 Page 37
Figure 5 – Layout requirements for a typical HySTAT-D setup

Page 38 Section 3
Figure 6 – Layout requirements for a typical HySTAT-Q setup
3.3.2 Floor trays for cabling

All interconnection cabling (DC- and control cabling) is standard designed to exit the electrical cabinet at
the cabinet bottom. Therefore all cabling is preferably guided through floor trays. Make sure to incorpo-
rate these in the building design.

Section 3 Page 39
Refer to the electrical drawing set for detailed information on cable types and sizes, and the
amount of cables to be routed through the floor trays.
3.3.3 Drains - gully traps

The HySTAT system has three drain connections in total; i.e. one at each water lock (for condensate
removal), and one at the CT (conductivity transmitter) panel (for feed water rejection in case of insuffi-
cient water quality). As each drain connection is to be routed to the drainage system externally, it is
advised to install one or more gully traps in the floor, near both the water lock connections, and the reject
feed water to drain connection. Thus the drained water can easily be guided to the sewer system by
means of a permanent flexible hose.
Note that the CT panel is supplied with the HySTAT, but not incorporated in the process skid.
It is to be mounted near the skid; the location can be chosen as preferred as long as the
panel is mounted outside the Ex-zone. Make sure to have a gully trap near the CT panel’s
location, in order to be able to drain rejected feed water.
Both the water lock to drain connections can be routed downward only from the
drain connection point in the HySTAT. Therefore make sure that one or more gully
traps are installed near the process skid.
3.3.4 Connections
The following three drawings show the main connection locations on the three different HySTAT sys-
tems. All piping and tubing lines are internally routed to couplings that are mounted on connection plates
in the equipment’s side walls.
Note that the connection points shown are merely indicative; for detailed information refer to
the mechanical drawing set supplied with your HySTAT.
Refer to the electrical and mechanical drawing sets and the P&ID’s supplied with your
HySTAT for type and size of each connection.

Page 40 Section 3
11
10
11
10
7
2
3 8
4
5
10 9
Figure 7 – Top view - overview of connection points for a typical HySTAT-S setup
1 Electrical connection (entry at cabinet top) 7 Hydrogen vent line

2 Oxygen vent line 8 Hydrogen to user
3 Utilities: N2, demin water 9 Water lock to drain (hydrogen)
4 Water lock to drain (oxygen) 10 (+) and (-) DC Cables to cell stack (floor routing)
5 Gas cooling from chiller to process 11 Control cables (floor routing)
6 Cooling water feed + return

Section 3 Page 41
12
10 11
10 12 11 12
7
2 8
3
13 13-14
4
5 14
6
10 11 9
Figure 8 – Top view - overview of connection points for a typical HySTAT-D setup
1 Electrical connection (top of cabinet) 8 Hydrogen to user

2 Oxygen vent line 9 Water lock to drain (hydrogen)
3 Utilities: instrument air, N2, demin water 10 (+) and (-) DC Cables to cell stack 1 (floor routing)
4 Water lock to drain (oxygen) 11 (+) and (-) DC Cables to cell stack 2 (floor routing)
5 Gas cooling from chiller to process 12 Control cables (floor routing)
6 Cooling water feed + return 13 Interconnections process - HPS
7 Hydrogen vent line 14 Gas cooling to HPS

Page 42 Section 3
14
8
15-16
7
16
15 9
14 13 13
13
12 12
12
14
11 11 11
1 10
10 10
3
6
4 5
2
Figure 9 – Top view - overview of connection points fora typical HySTAT-Q setup
1 Electrical connection (top of cabinet) 9 Water lock to drain (oxygen)

2 Oxygen vent line 10 (+) and (-) DC Cables to cell stack 1 (floor routing)
3 Utilities: instrument air, N2, demin water 11 (+) and (-) DC Cables to cell stack 2 (floor routing)
4 Water lock to drain (hydrogen) 12 (+) and (-) DC Cables to cell stack 3 (floor routing)
5 Gas cooling from chiller to process 13 (+) and (-) DC Cables to cell stack 4 (floor routing)
6 Cooling water feed + return 14 Control cables (floor routing)
7 Hydrogen vent line 15 Interconnections process - HPS
8 Hydrogen to user 16 Gas cooling to HPS

Section 3 Page 43
3.3.5 Heating and ventilation

An indoor HySTAT unit must be installed in a frost-free room. Make sure the heating system of the room
is dimensioned accordingly.
The maximum design temperature for a standard indoor HySTAT unit is 40°C. Appropriate measures are
to be taken so that the room temperature does not exceed this value. Make sure to take the additional
heat generated by the HySTAT equipment into account. Use the following table as a reference:
Equipment Dissipated heat (at 100% production)

HySTAT-S Process* 2,5 kW
HySTAT-D Process* 5 kW
HySTAT-Q Process* 10 kW
Deoxo dryer (standard)* 2 kW
Deoxo dryer (large scale)* project dependent, contact Hydrogenics Europe NV
Dehydro dryer (standard)* 2 kW
Dehydro dryer (large scale)* project dependent, contact Hydrogenics Europe NV
Chiller (liquid cooled) 0,5 kW
Chiller (air cooled) project dependent, contact Hydrogenics Europe NV
Reversed osmosis system 0,2 kW
Compressor project dependent, contact Hydrogenics Europe NV
HySTAT-S Power rack* 7,5 kW
HySTAT-D/Q Power rack 15 kW
Control panel 1 kW
* The process- and HPS’ dissipated heat is to b

extracted to the outside of the building in case an
ATEX enclosure is installed.
In case an ATEX enclosure is installed, please take the additional airflows given in chapter 3.6.1: Design
flow & pressure into account when dimensioning the HVAC system. These airflows are taken from the
room and extracted to the outside of the building, and as a consequence, the intake airflow needs to be
heated or cooled.
3.3.6 Storage
If the HySTAT is temporarily stored at a location other than its final installation location, make sure the
place is dry and clean, protected from weather, and frost-free. For accessibility reasons, leave at least 1
meter (3 feet) buffer area around the equipment. Keeping the HySTAT inside its transportation package
gives sufficient protection, and is recommended for longer storage periods.
The HySTAT is delivered without liquid inside the system. In case it is to be stored for a
period of 2 months or more prior to installation, please contact Hydrogenics Europe NV for
instructions.
The Cell Stack should be disconnected from the rest of the unit and the openings
should be capped (air tight) at both top and bottom. It doesn’t need to be filled with
any liquid.

Page 44 Section 3
3.3.7 Dehydro dryer
If an optional dehydro oxygen dryer system is present, be aware that it cannot be

installed inside an Ex-zone. Refer to the explosion protection document for detailed
information.

Section 3 Page 45
3.4 Mechanical connections

3.4.1 General
Always carry out a risk assessment and carefully abide by its rules and obligations.
Refer to the process and instrumentation diagrams for material, piping, tubing and
connection specifications.
Always refer to the mechanical drawing set for details!
A Use stainless steel 316L for all hydrogen and oxygen piping, including the vent stacks.
A Make sure that all external piping is done ensuring condensate water to flow back into the
HySTAT.
A All hydrogen piping and tubing must be clearly color-coded and labeled. The piping/tubing has
to be mounted such that there is no mechanical stress on any connection.
A All piping and equipment in oxygen lines must be cleaned for oxygen service.
A If hydrogen lines run in the same duct as electrical cables, all joints on the hydrogen line in the
ducted section must be welded. A minimum distance of 50 mm between cables and hydrogen
piping/tubing must be maintained. Make sure the hydrogen line is located higher than other
piping/tubing.
A If oxygen lines run in the same duct as electrical cables, all joints on the oxygen line in the
ducted section must be welded. A minimum distance of 50 mm between cables and oxygen
piping/tubing must be maintained. Make sure the oxygen line is located lower than other piping/
tubing.
A Provide isolation valves at strategic points in your network, so that the hydrogen and/ or oxygen
source can be shut off in a safe way for maintenance, or in case of an emergency. Clearly mark
those valves.
A Locate the vents of pressure relief devices so that moisture cannot collect inside the line.
A Make sure the vent stacks are installed completely frost-free. Apply tracing if necessary.
3.4.2 Hydrogen user line

Connect the hydrogen user line with the appropriate connector to the designated connections plate.
Refer to your set of mechanical and interconnection drawings for details.
3.4.3 Hydrogen vent to atmosphere

The hydrogen vent stack collects all hydrogen vent piping of the HySTAT and its options. Every connec-
tion line to the vent stack is such that moisture drains towards it.
The exhaust of the hydrogen vent line should be installed at a distance of 5 meters or more from the
exhaust of the oxygen vent line. Refer to local codes and standards and the explosion protection docu-
ment for specific instructions.
The length-to-diameter ratio of the vent stack must be limited to 100 to 1. For example a 2-inch sch. 10
(50.8 mm) diameter stack should not be longer than 200 inches (5080 mm). If this is practically not pos-
sible please refer to the local codes and standards, or contact Hydrogenics Europe NV.
Extend the stack straight upward at least 1 meter above surrounding structures (or in accordance with
local codes and standards).

Page 46 Section 3
Locate the hydrogen vent outlet away from any source of ignition and in a position
where winds and downdrafts will not carry the escaping gas into a ventilation intake,
work area, or other location where it could be a hazard.
3.4.4 Oxygen vent to atmosphere
If the produced oxygen is not used, it is sent directly to the oxygen vent stack.
The oxygen vent stack collects all oxygen vent piping of the HySTAT and its options. Every connection
line to the vent stack is such that moisture drains towards it.
The top (outlet) of the oxygen vent stack may be installed to blow out directly in the atmosphere. In this
case the outlet of the oxygen vent stack must be installed at least at 5 meters distance from the outlet of
the hydrogen vent stack. Refer to local codes and standards and the explosion protection document for
specific instructions. Position the outlet of the oxygen vent stack at least 1 meter lower than the outlet of
the hydrogen vent stack.
Extend the stack straight upward at least 1 meter above surrounding structures (or in accordance with
local codes and standards).
Locate the oxygen vent outlet away from any source of ignition and in a position
where winds and downdrafts will not carry the escaping gas into a ventilation
intake, work area, or other location where it could be a hazard.

Section 3 Page 47
A: Minimum 1 meter B: Minimum 5 meter
Figure 10 – Arrangement of vent lines above building roof
3.4.5 Feed water connection

Connect the feed water supply line with the appropriate connector to the designated connection at either
the reversed osmosis system or the conductivity transmitter panel. Refer to your set of mechanical and
interconnection drawings for details.
3.4.6 Water locks
5
1
4
3
Figure 11 – Water lock
1 Incoming connection from vent line 4 Connection to drain

2 U-curve (actual water lock) 5 Free opening
3 Plug (optional level switch)
Functionality
The condensate that collects in the vent lines, flows into the water locks (1) by gravity. Once the water
lock is full, the collected condensate flows out through the drain connection (4). This way condensate
can be drained to the sewer, while the gas flowing through the vent line is prevented from passing the
water lock and entering the process part or the drain system. In standard units, no automatic refill instal-
lation is present. Hence instead of a level switch, a plug is fitted on the middle connection of the water
lock (3). Always make sure the plug is fitted and tightened, otherwise the condensate will flow out the
opening instead of to the drain.
Installation
Installation of the water locks basically involves installing the connection to the drain.

Page 48 Section 3
Make sure the water lock to drain connection (4), is routed downward only from the
drain connection point (5). Disregarding this may cause condensate to flow out of
the free opening (5) instead of to the drain. For the same reason, make sure the plug
(3) is fitted and tightened.
Make sure that the free opening (5) remains free at all times. Disregarding this may
cause hydrogen or oxygen gas to flow to the drain system, creating an undetectable
explosive mixture inside.
3.4.7 Drain connections

All drain connections can be routed to a nearby gully trap using a fixed or flexible tube.
The water lock to drain connections can not be routed upward from the connection
point on (downward only). Disregarding this may cause water from the water locks
to be spilled, instead of being sent to the drain. Moreover, gas may escape inside
the process part.

Section 3 Page 49
3.5 Electrical connections

3.5.1 General
Make sure local codes & standards are met prior to installing and/or operating electrical
systems in or around the HySTAT.
Electrical installations in hazardous areas should be maintained to the highest standards. Make sure a
detailed inspection is carried out at regular intervals, and keep records of these inspections for later ref-
erence. Modifications should only be carried out by competent persons and should be recorded in detail.
Refer to ‘Section 1: Safety’ for more information on hazardous area regulations.
3.5.2 Cables
Refer to your contract and contact Hydrogenics Europe NV in case of doubt.
Refer to the electrical drawings supplied with the HySTAT. All supplied cables are labeled at both ends
according to the electrical drawings. Always make sure to pay great attention to terminal- and wire num-
bers. Install and connect all cables as specified in the electrical drawings.
Main cables
The main feeder cables are not supplied with the HySTAT. Refer to the electrical drawings and your con-
tract to find out what the specific electrical power requirements are. The type and section of cable to be
used depends on the nominal current rating and the conditions in which it is installed. Carefully abide by
local codes & standards.
Cell stack cables

Cut the DC cell stack power cables to the appropriate length, fit them with crimp-on terminals, and con-
nect them on both ends, i.e. inside the power rack to the copper DC bars, and to the cell stack end
flanges, using the threaded holes and appropriate bolts.
Check the polarity of the DC power cables. The positive and negative side of the
cell stack has to be connected with the correct cables. If these connections are
incorrect, the produced hydrogen and oxygen will go through the wrong piping.
This can result in dangerous situations.
3.5.3 Earthing and bonding

All system parts are to be effectively grounded and bonded, so that each conductive part is at the same
electrical potential, and as such the risk of stray currents and static electricity is minimized.
There are three types of power supply earthing systems (see standard IEC 60364-3):
A Connecting the HySTAT to a 'TN' network is allowed. The section of the protective conductor
(PE) must be determined based on local codes and standards.

Page 50 Section 3
A Connecting the HySTAT to a 'TT' network is allowed if a proper ground fault relay is selected
based on the measured earthing resistance and the allowable contact voltage following local
codes and standards.
A Connecting the HySTAT to an ' IT ' network is not allowed.
Pay special attention to the earthing and bonding of the vent lines and other
flanged connections: each flange is to be bridged with an earthing wire, properly
connected to the pipe on both sides of the flange, as such providing electrical
continuity for the entire piping route. Abide by local codes and standards.
3.5.4 Cable trays
Make sure that power cables and signal cables are separated along their route. It is
highly recommended to use separate cable trays. Use continuous metal tray
dividers if this is not possible. Disregarding this may cause the HySTAT to
malfunction.
Eex-i cables (with blue insulation) need to be separated from other cables (including
Eex-e cables) along their route. The minimum distance to be kept in between inside
the cable tray is 50mm.
3.5.5 Lightning protection

If a risk assessment would conclude that lightning-, and surge and overvoltage protection measures are
necessary, Hydrogenics Europe NV advises to abide by IEC 62305: ‘Protection against lightning’.
3.6 ATEX enclosure ventilation system
In case your HySTAT system is equipped with an ATEX enclosure, the ventilation system for
it needs to be designed during the building design phase.
Each skid that has an enclosure is also equipped with an exhaust fan to provide the necessary ventila-
tion. A duct system is to be designed so that the exhaust air from each skid (process and, if applicable,
HPS) can be guided to the outside of the building. Take the following design guidelines into account.

Section 3 Page 51
3.6.1 Design flow & pressure

Take the following flow and pressure values into account when designing the exhaust duct system. Make
sure that at the given flows, the calculated pressure drop in the duct system does not exceed the values
below.
Maximum pressure drop

Skid type Design flow
at design flow
HySTAT-S Process 1000 m³/h 200 Pa
HySTAT-D Process 1000 m³/h 200 Pa
HySTAT-Q Process 2000 m³/h 200 Pa
HySTAT-D/Q HPS 1000 m³/h 200 Pa
Refer to chapter 3.3.5: Heating and ventilation for HVAC design guidelines.
3.6.2 Layout
Contact Hydrogenics Europe NV for more information regarding the of the exhaust duct
system for your HySTAT installation.

Page 52 Section 3
3.7 Electrolyte
3.7.1 General
While handling electrolyte, the required safety precautions must be respected at all
times. Read ‘Section 1: Safety’, and refer to ‘Appendix F: Material Safety Data Sheets
(MSDS)’.
3.7.2 Specifications
Refer to ‘Appendix D: HySTAT Specifications utilities’ for more information on the electrolyte to be used.
3.7.3 Filling
Refer to the ‘HySTAT Section 5: Maintenance and troubleshooting’ section for the complete KOH filling
procedure.
3.8 Utilities
Refer to ‘Appendix D: HySTAT Specifications utilities’ for all detailed utility specifications.
3.8.1 Purge installation

The inert gas purge installation is not supplied by Hydrogenics Europe NV. Refer to ‘Appendix D: HyS-
TAT Specifications utilities’ for inert gas installation requirements.
3.8.2 Cooling water

Refer to ‘Appendix D: HySTAT Specifications utilities’ for details on cooling water purity and cooling sys-
tem voluminous content.
3.8.3 Closed loop cooling water
A closed loop cooling system is necessary only when a cooling water circuit is not available
on site.
Make sure that the closed loop cooling water is of the right purity, and of the correct ethylene glycol con-
centration. Add the cooling water through one of the system’s filling valves; refer to the P&ID. It is possi-
ble to calculate the necessary amount of pure ethylene glycol (starting from the cooling system
voluminous content) and to add this amount to the system first, adding clean water afterwards until the
system is filled. Refer to ‘Appendix D: HySTAT Specifications utilities’ for details on cooling water purity,
ethylene glycol concentrations and the cooling system’s voluminous content.
The default closed loop system pressure is 2barg. Note that the system has automatic degas valves.

Section 3 Page 53
3.8.4 Other
Refer to the manufacturer’s instructions supplied with your HySTAT for installation instructions for the
following equipment (if applicable):
A Chiller
A Reverse osmosis system
A Instrument air compressor
3.8.5 Optional components

The conditions in which the HySTAT will be operated, may require certain optional components to be
installed in order to prevent the HySTAT from malfunctioning. Read the following carefully, and verify
that your HySTAT is equipped according to site conditions. If it is not, cease installation and contact
Hydrogenics Europe NV as soon as possible.
Demineralized water
If no demineralized water can be supplied to the HySTAT, a reverse osmosis system must be installed in
order to purify the feed water to the HySTAT. If the feed water to the reverse osmosis system cannot be
brought within the required specifications (refer to ‘Appendix D: HySTAT Specifications utilities’); a pre-
treatment for the reverse osmosis system is necessary.
Specific hydrogen use

If the pressure in the user line downstream from the HySTAT often drops below 8 barg, a back pressure
regulator in the user line is recommended to keep the HySTAT system pressure constant.
The user line pressure regulator option can keep the pressure in the user line at a constant level, lower
than the standard HySTAT output pressure.
Oxygen in atmosphere transmitter

The OTA or oxygen in atmosphere transmitter measures the level of oxygen in the atmospheric air. An
alarm is generated when the oxygen level drops below or rises above the safety limits.
3.8.6 Adjustable setpoints

The following optional transmitter’s alarm setpoints can be adjusted to your application’s needs. Contact
Hydrogenics Europe NV for more information on adjusting them:
Hydrogen dewpoint transmitter
Oxygen in hydrogen (OTH) transmitter
Oxygen dewpoint transmitter

Page 54 Section 3

HYSTAT MANUAL
SECTION 4: OPERATION
Page 56 Section 4
HySTAT MANUAL OPERATION
Section 4: OPERATION
4.1 Introduction to the HySTAT system

4.1.1 Product code
The HySTAT product code is explained as follows:
HySTAT™ Hydrogen STATion (TradeMark)
10/15/30/60 System hydrogen production capacity in Nm³/h
/25 Added for 25bar units
4.1.2 Process description

The HySTAT uses the electrolysis principle for generation of hydrogen. In an electrolyser cell, electricity
causes dissociation of water into hydrogen and oxygen molecules. An electric current is passed between
two electrodes separated by a conductive electrolyte or ‘ion transport medium’, producing hydrogen at
the negative electrode (cathode) and oxygen at the positive electrode (anode). As water is H2O, twice
the volume of hydrogen is produced over oxygen. The chemical reaction is as follows:
2H2O (l) → 2H2 (g) + O2 (g)
4.1.3 Process flow

The hydrogen and oxygen bubbles formed inside the cell stack’s individual cells, are carried along with
the electrolyte to the tops of the cells, and collected in two separate channels in the cell stack. The gases
flow through the cell stack outlets into the gas-liquid separators, where the gas is separated from the
liquid electrolyte.
From the gas-liquid separator, the hydrogen passes the rinser in which the gas is rinsed with clean
incoming demineralized water, to reduce the amount of residual electrolyte in the gas stream.
Next the hydrogen flows through the coalescent filter, where it is cooled and the present water droplets
are removed. From this filter the gas flows either to atmosphere, to the deoxo dryer system or to the user
line.
The entire system is regulated by means of actuated valves. Closing of certain valves in the H2 or the O2
lines allows the system to build up pressure. The nominal pressure at which the hydrogen is produced is
between 4 and 10 barg. The final pressure in the user line depends on the configuration of the HySTAT.
4.1.4 System overview

The HySTAT consists of two sub systems: the process part, which produces the hydrogen, and the EPS
part (Electrolyzer Power Supply), which consists of the power supply and the PLC system
(Programmable Logic Controller). The PLC is the microprocessor-based controller of the HySTAT.

Section 4 Page 57
OPERATION HySTAT MANUAL
2 7
8
4
10
6 12 11
Figure 1 – Process part of a HySTAT-Q (Frontside View)
1 Frame (or ‘skid’) 7 Coalescing filter

2 User line connection 8 Break tank
3 Vent line connection 9 Demin water pump
4 Gas separator 10 Electrolyte cooler (heat exchanger)
5 Water lock 11 Cell stack
6 Electrolyte valve 12 Drip tray

Page 58 Section 4
1 4
7 6
Figure 2 – Process part of a HySTAT-Q (Backside View)
1 Rinser vessel 5 Instrument air/ purge gas panel

2 Solenoid valves 6 Flexible hoses in closed loop cooling system
3 GGS junction box 7 Threaded holes for DC cables connection
4 HTO panel
4.1.5 Main components
Electrolyte
The HySTAT uses KOH (potassium hydroxide) in a 30% w/v aqueous solution. Refer to ‘Appendix D:
Specifications utilities’ for more information.

Section 4 Page 59
Cell stack
Figure 3 – Cell stack
The cell stack consists of a series of circular cells. Each cell is composed of two different structural rings,
i.e. the hydrogen ring and the oxygen ring. These structural rings form the two chambers of each cell,
where the electrolysis process takes place. These cells are connected hydraulically in parallel, yet in
series electrically.
The hydrogen and oxygen are formed respectively at the cathode and anode of each cell, and prevented
from recombining by the inorganic membrane that separates these two.
The cell stack is split into two equal halves with a metal flange in between. A positive and negative
voltage is applied respectively at each end, while the central flange is earthed.
Gas-liquid separators
Figure 4 – Gas-liquid separators
The gas-liquid separators are designed to treat the produced hydrogen and oxygen separately. Because
of the electro-chemical reaction and the necessity of constant flow, the gas-liquid separators are about 2/

Page 60 Section 4
3 filled with electrolyte. Both the hydrogen gas and the oxygen gas are less dense than the electrolyte,
so these gases flow up via the gas collectors into the gas-liquid separators.
The gas-liquid separators are connected underneath. Thus a pressure difference between the hydrogen
and the oxygen side causes a level difference. The levels are monitored continuously to avoid that
hydrogen or oxygen will enter respectively the oxygen or hydrogen gas separator, which would create an
explosive atmosphere inside. If the transmitters read a value that is not within the setpoints, the control
system will take appropriate action to restore the level to its original value. If such action has no effect,
the HySTAT will shut down and an alarm will be raised.
Two level switches in each of the gas separators create a safety backup for this level measurement
system.
Electrolyte heat exchangers
Figure 5 – Electrolyte heat exchanger
The electrolyte flowing from the gas separators back to the cell stack, passes the electrolyte heat
exchangers for cooling. The electrolyte heat exchangers vary in type, size and capacity according to the
HySTAT type.
Demin water pump
Figure 6 – Demin water pump
The demin water pump pumps fresh demineralized water into the system. It sucks from the break tank
and pumps into the rinser, thus pressurizing the demin water from atmospheric pressure in the breaktank
to system pressure in the rinser. Whenever the sum of the 2 levels in the gas-liquid separators is below a
certain value, the pump will be activated to top up the levels.

Section 4 Page 61
Rinser
Figure 7 – Rinser - cutaway view
The rinser is a small vessel above and connected to the gas-liquid separator for hydrogen. Inside the
rinser, remaining KOH is rinsed or washed from the produced hydrogen. The gas flow passes a special
packing and a water seal, under high pressure, making the gas rinsing process very efficient. The
regular supply of clean water from the demin water pump increases the efficiency even more.
Coalescing filters
Figure 8 – Coalescing filter
The coalescing filter is a jacketed vessel, installed under an inclination, to serve two purposes: first is to
remove remaining water droplets from the gas stream; the collected water drains back into the rinser.
The second purpose is gas cooling: within the insulated jacket, chilled cooling water tubing runs along
the coalescing filter, cooling the gas inside.

Page 62 Section 4
Break tank
Figure 9 – Break tank
The break tank is a buffer vessel for demineralized water. It also functions as a separator between the
hazardous area and the general-purpose area: in case of a valve failure in the system, hydrogen will
always be vented to the hydrogen vent line through the break tank.
Water locks vent lines
Figure 10 – Water lock
The function of the water locks on the vent lines is to collect the water from the HySTAT, while
preventing the gases from escaping. Water flowing to the water locks comes from condensation in the
vent lines, from the fill-up system, the break tank exhaust, the deoxo dryer, and the coalescing filters.
The water level in the water locks is to be checked regularly, and refilled manually when necessary. For
more information refer to Section 3: Installation.

Section 4 Page 63
EPS
Figure 11 – EPS power rack
The Elecltrolyser Power Supply or EPS converts the three-phase AC supply voltage to a controlled DC
voltage for the cell stacks.
By controlling the DC voltage, the cell stack current (the hydrogen production) is adjusted as needed.
The short response time of the control enables real-time matching of the generated gas volume to the
demand.
The front door of the EPS rack holds volt- and ampmeters for immediate reference of HySTAT activity.

Page 64 Section 4
Control panel
Figure 12 – Control panel with HMI
The Control Panel or CP contains all control equipment for the HySTAT and it’s options. The PLC
(Programmable Logic Controller) controls the HySTAT. The HMI monitors the alarms and logs all data.
The front door of the control panel holds all components of the human-machine interface or HMI: the
display terminal, the key switch, the buzzer, and the emergency pushbutton.
The Safety PLC has a safety program that continuously monitors the safety systems and takes
appropriate action if certain inputs are triggered.
For remote assistance and troubleshooting, the HySTAT control panel is equipped with a router/modem,
allowing Hydrogenics Europe NV service engineers to log on to the installation remotely. In order to
make use of this feature, an analog telephone line or ethernet line (ADSL or LAN) at the customer site is
required. The modem also allows the optional remote access viewer and optional data collector to run
from a remote pc station that is not part of the local area network.
Optional components
The following components may or may not be included in your HySTAT system. Refer to your system's
P&ID’s for the exact setup of your HySTAT.

Section 4 Page 65
Deoxo dryer
Figure 13 – Deoxo dryer
The HySTAT deoxo dryer improves the standard H2 purity. The deoxo dryer is installed at the outlet of
the HySTAT installation, and will further remove impurities from the H2 gas stream. It is heat-activated,
and regenerated with H2.
The first stage removes the O2 from the H2 gas stream (deoxo stage); the second stage removes the
moisture from the H2 gas stream (dryer stage).
The first stage (deoxo) involves a chemical reaction in a catalytic conversion reactor column. In this
noble metal catalyst column, the O2 in the gas stream reacts with H2 to form H2O (+ heat). The H2O
formed in this reaction is added to the H2O that is already present in the gas stream.
The normal operating temperature of the catalyst column is 60 to 80°C; this prevents condensation in the
bed.
In the second stage of the deoxo dryer process, H2O is removed through molecular sieve adsorption.
The porous crystalline nature of the molecular sieves allows it to selectively adsorb H2O impurities.
Dehydro dryer
The dehydro oxygen dryer is identical in operation to the deoxo hydrogen dryer; except that the main gas
is oxygen instead of hydrogen.
Frit sparger
The frit sparger reduces the nitrogen content in the hydrogen stream. This nitrogen mostly comes from
the feed water: the lower its temperature, the higher the nitrogen concentration.
The frit sparger is located inside the break tank, and purges the feed water with hydrogen from the
generator. The total flow through the frit sparger is less than 1% of the total capacity of the HySTAT.

Page 66 Section 4
Reverse osmosis system
Figure 14 – Reverse osmosis system
The reverse osmosis system purifies the incoming water supply if the specifications are not met. Refer to
‘Appendix D: Specifications utilities’ utilities for more information.

Section 4 Page 67
Closed loop cooling
Figure 15 – Closed loop cooling pump unit
The closed loop cooling system consists of a pump unit, the electrolyte heat exchangers and a water-to-
air heat exchanger (dry cooler). The pump unit circulates the coolant, a mixture of water and glycol,
through the system. The dry cooler transfers the cooling water heat to the environmental air.
The closed loop cooling is controlled by the PLC.

Page 68 Section 4
Chiller
Figure 16 – Chiller
The chiller cools the coolant in the gas cooling circuit. The chiller itself is cooled with water from the
closed loop cooling system.
The first purpose of cooling the gas is to minimize the water content in the H2 stream after the deoxo
vessel. Thus the stay-on time of the dryer bed can be maximized, and the total H2 losses during
regeneration of the dryer vessels minimized. The second purpose is to minimize the KOH content in the
H2 stream. This increases the lifetime of valves and deoxo catalyst.

Section 4 Page 69
Ventilation and Heating (Containerized)
1 2 3 4 5 6 7 8 9
10
11
1
Figure 17 – Ventilation and heating equipment
1 Air inlet grid 7 Ex heaters

2 Inlet filters (optional) 8 Ex Fan 1
3 Recuperation heater (optional) 9 Ex Fan 2
4 Heater 1 10 Power rack fans
5 Heater 2 11 Power rack inlet grids + optional inlet filters
6 Transfer grid
Electrical fan heaters (4 and 5) are installed in the general purpose room. For standard -20°C installa-
tions, these heaters also heat the process room via the ventilation system. For -40°C installations, extra
Ex-heaters (7) are installed in the process room to compensate the higher heat losses.

Page 70 Section 4
Figure 18 – Ventilation flow overview
The flow is as indicated in the figure above.
The ventilation interlocks are:
A air flow switch that is located near the transfer grid (6)
A current switches to verify the status of Ex fan 1 and 2 (8 and 9)
The differential pressure switch that is located near inlet filters (2) is an indicator for replacing the Inlet fil-
ters.
The power rack and container ventilation are seperated systems.
Keep container doors and power rack doors closed under normal operation.
Coalescing filters
The additional coalescing filters further reduce the residual moisture and KOH in the gas stream, and
can be applied when no deoxo dryer is installed.
Mass flow meter

The mass flow meter measures the exact mass of hydrogen that flows into the user line, and can be
used for exact quantification of the hydrogen produced to the user line.
Remote access viewer and data collector Software

With the remote access viewer and data collector software, the unit can be supervised on a remote
Microsoft® Windows® pc. Basic remote control actions such as start, stop and depressurize can be
performed.

Section 4 Page 71
4.2 HySTAT Electrolyzer operation

4.2.1 General
This chapter is a basic guide to HySTAT electrolyzer operation. If any problems are experienced during
basic operation of your HySTAT, please refer to the ‘HySTAT Maintenance and troubleshooting’ section.
Options and utilities included in your HySTAT installation are set up to require no additional operational
instructions from the operator. Therefore, they are not mentioned in this section.
For all options included in your unit, the installation and setup guidelines are discussed in the ‘HySTAT
Installation’ section, and the maintenance instructions in the ‘HySTAT Maintenance and troubleshooting’
section. Particular safety issues concerning the options included, are discussed in the ‘HySTAT Safety’
section. For more information, always refer to the specific vendor documentation.
4.2.2 HySTAT human-machine interface

The HySTAT HMI or Human-Machine Interface enables the user to operate the HySTAT by
communicating with the PLC. The HMI is mounted on the front of the control panel and consists of a key
switch, an alarm buzzer, a display terminal and an emergency pushbutton.
The HySTAT works fully automatically and is controlled by the PLC. All that is required is user input to
start, stop, depressurize or emergency-stop the unit. The key switch and the emergency pushbutton(s)
enable the user to command these actions. In case of alarm, the user is notified by the buzzer.
The display terminal enables the user to consult process parameters, and can be used to change
setpoints, and read events and alarms. For a detailed description of the display terminal and its
operation basics, refer to ‘Appendix A: HMI display terminal’.
4.2.3 HySTAT basic operation principles

The HySTAT operation is based on three operating principles:
A Start conditions
A Operation phases
A Level control
These three operating principles are explained in the next three paragraphs.
4.2.4 HySTAT start conditions
General
Start conditions are system parameters, which must be within certain limits before the HySTAT can start
(or progress to the next operational phase).
If a start condition fails when the unit is running, it becomes a stop condition and the control system will
take appropriate action.
Basic start conditions

Upon first startup of the HySTAT, the PLC performs a set of self-diagnostic checks, including emergency
pushbutton positions, fuse conditions and power supply status. These start conditions are the basic start
conditions for nitrogen purge.
Common hydrogen production basic start conditions

Upon first startup of the HySTAT, the PLC performs a set of self-diagnostic checks, including chiller,
closed loop cooling and ventilation status. These start conditions are the basic start conditions for
hydrogen production.

Page 72 Section 4
Nitrogen purge start conditions

Together with the basic start conditions, for the system to perform a nitrogen purge, the nitrogen purge
start conditions need to be met. These mostly involve checks of the electrolyte levels in the gas-liquid
separators.
Hydrogen purge & production start conditions

Together with the basic start conditions and common hydrogen production basic start conditions, for the
system to perform a hydrogen purge or production, the hydrogen purge and production start conditions
need to be met. Hydrogen purge is performed after nitrogen purge, and before hydrogen production. As
hydrogen needs to be produced to perform hydrogen purge, the hydrogen purge start conditions are the
same as the hydrogen production start conditions.
The hydrogen purge & production start conditions imply individual cell stack start conditions, detailed
checks of the cooling and ventilation systems, checks of various flow- and level switches and all checks
necessary to provide the safety level needed for hydrogen production.
If a deoxo dryer is present, it has its own set of start conditions: the dryer start conditions.
Refer to ‘Appendix C: Start conditions’ for a complete list of start conditions and their explanation.
4.2.5 HySTAT operational phases
General
The three HySTAT operational phases are nitrogen purge, hydrogen purge and hydrogen production.
Both the nitrogen and hydrogen purge phases are preparation phases, hydrogen production is the
HySTAT standard production mode. Nitrogen and hydrogen purge are necessary to be able to start
hydrogen production in a safe way, and with the right quality of gas to the user line.
The flow diagram below is a graphical representation of the HySTAT operational phases, and the
sequence in which they can occur. Each of the phases can be activated only when its start conditions
(see further) are fulfilled. After a production session, the HySTAT enters the 'standby'-position, from
which either a production session can be started via a start signal, or the depressurization phase can be
initiated.
A production session is ended by a stop signal, which comes either from the user, local or remote, or
automatically: pressure in the user line, a fault or failing start conditions.

Section 4 Page 73
Figure 19 – HySTAT operational phases flow diagram
Nitrogen purge
The nitrogen purge phase is necessary to avoid the presence of explosive mixtures in the gas-liquid
separators or other gas-treatment parts like the rinser, the coalescing filter, and all interconnecting
tubing. During the nitrogen purge phase all existing gases in the HySTAT are replaced with inert
nitrogen. The nitrogen purge is a semi-automatic process controlled by the PLC, and can be started
when all the nitrogen purge start conditions are fulfilled.
Nitrogen purge must be performed:
A at first startup;
A before maintenance;
A after maintenance or repair (when the internal parts of the electrolyzer have been exposed to
air);
A when the electrolyzer has been depressurized for a long time (when air may have entered the
system).
The first stage of the nitrogen purge is a depressurization cycle. As soon as the system pressure is low
enough (approximately 1 barg) to allow injection of nitrogen, the actual nitrogen purge starts. The
depressurization cycle is skipped when the HySTAT is at atmospheric pressure.
The result of the nitrogen purge phase is verified by the control system. The outcome is either 'OK' or
‘NOT OK’.

Page 74 Section 4
Hydrogen purge
The purpose of the hydrogen purge cycle is to remove the nitrogen from the hydrogen gas system and to
replace it with hydrogen. Hydrogen purge is controlled by the PLC and can only be activated after a
successful nitrogen purge. It can only be started when the start conditions for hydrogen production and
at least one of the cell stack start conditions are fulfilled.
Apart from some operational parameters, hydrogen purge is functionally identical to hydrogen
production, however the produced gas is vented to atmosphere instead of released to the user line.
The purge is successful when the necessary amount of hydrogen is produced. Hydrogen purge is
stopped when one of the hydrogen production start conditions is no longer fulfilled or when the operator
interrupts the phase. If this happens before the necessary amount has been produced, the hydrogen
purge is considered to have failed and has to be restarted.
Hydrogen production
The production of hydrogen is controlled by the PLC. To start hydrogen production, the hydrogen
production start conditions and the start conditions of at least one cell stack have to be fulfilled.
The operating pressure, and – to a certain extent – the production rate, can be set on the HMI display
terminal.
Bleeder Status
In order to minimize the number of start/stops the "bleeder status" is implemented. This bleeder mode
will keep the current level trough the cell stack at the minimum level (175A). If the consumption is lower
then the "bleeder" production level the pressure in the system will increase until the pressure is reached
at which the solenoid valve to atmosphere is opened (MV H-A). This point is also referred to as the
"bleed point".
The bleed point is depending on the pressure set point and the pressure high alarm. This means also
that if one of both is changed the bleed point is changed also.
The difference between consumption and production will determine the frequency of bleeding (opening
of MV H-A).
Depressurization
Depressurization reduces the pressure inside the HySTAT to a safe level. This is done automatically.
There are two ways to depressurize the unit:
A Standby depressurization: Automatically, by pressing the button on the HMI display terminal, or
when the 24V supply drops below a minimum level. Pressure is decreased to approx. 0,15
barg. An inert gas purge is required afterwards, before restarting the unit.
A Emergency depressurization: Automatically, after a generator failure. Pressure is decreased to

approx. 0,50 barg. No inert gas purge is required afterwards.
The following alarms evoke emergency depressurization:
A HTA: Hydrogen in Atmosphere detection
A OTA: Oxygen (High level) in Atmosphere detection
A Process ventilation fan 1 or 2 not running
A Air flow stopped: Air flow switch not ok
A EMS: Emergency Stop Button pressed
A Smoke or Fire alarm

Section 4 Page 75
A LTH L, LTO L: Electrolyte level gas separator low

A LS Drip Tray: Drip tray leak detection
A UPS: UPS low voltage
For more information refer to chapter 4.4: Critical alarms.
4.2.6 Level control, pressure control and current control

The entire electrolyzer operation depends on three control systems: level control, pressure control and
current control.
Level control
The HySTAT control system is based on keeping the electrolyte levels in the gas separators within limits:
the valves to the user line or to the vent line are controlled such that electrolyte levels are maintained.
Too large an electrolyte level unbalance in the gas separators will immediately cause one or more start
conditions to fail and stop the unit.
Pressure control and current control

The pressure inside the system is the basis for the current control system: when the current through the
cell stack is increased, more gas is produced and the pressure inside the system rises. As soon as the
pressure reaches its high set point, the current is decreased again. Thus a constant hydrogen pressure
to the user line is maintained.
4.2.7 Starting the HySTAT
Pre-start system checks

Prior to starting the HySTAT, check all valve positions.
Always refer to your installation’s P&ID’s and make sure all valve positions
correspond to what is indicated on the P&ID.
Make sure to check the water locks and (re)fill them if necessary. Disregarding
this may cause oxygen and/or hydrogen to enter the process part, respectively
resulting in an OTA (oxygen in atmosphere) or HTA (hydrogen in atmosphere)
alarm, shutting down the unit.
Nitrogen purge
For specific nitrogen purge instructions for the deoxo dryer, refer to the deoxo dryer
section.

Page 76 Section 4
Figure 20 – Nitrogen panel (manual and automatic)
1 PI N 5 MV N2 (Nitrogen to HySTAT)
2 HV N 6 MV N3 (Nitrogen to vent)
3 BV N1 (Nitrogen supply) 7 MV N1 (Nitrogen supply)
4 BV N3 (Nitrogen to vent)
1. Make sure the HySTAT is in the ‘Standby for N2 purge’ status.
2. Open the nitrogen supply. Check the nitrogen pressure on the nitrogen pressure gauge PI N
mounted on the nitrogen panel. This pressure has to be between 4 and 6 barg. If not, adjust the
nitrogen pressure until it reaches this value.
The nitrogen pressure should not be greater than the rating of the fitted safety
relief valves.
3. Close BV N3 and then open BV N1.
4. Open the hand valve HV N.
5. Turn the key switch from 0 to 1.
6. The generator status changes to ‘N2 purging’; one counter indicates the remaining time for valve
MV H-A to be opened, and the other counter indicates the remaining time allowed. The counter
values are visualized on the HMI display terminal.
7. When nitrogen purge is finished the generator status changes to ‘Standby for H2 purge’.
8. Close the hand valve HV N. Close BV N1 and then open BV N3.
9. Turn the key switch back to position 0. Nitrogen purge is completed.

Section 4 Page 77
If your HySTAT is equipped with ‘Automatic N2 purge’, N2 purge is started from the HMI
display terminal and no further operator action is required.
If your HySTAT is equipped with ‘Automatic N2 initialisation’, three phases are

completed: depressurisation, N2-Purge and again depressurisation. The HySTAT unit
will wait in this position.
Hydrogen purge
1. Make sure the HySTAT is in the ‘Standby for H2 purge’ status.
2. Enable one or two (maximum two) cell stacks through the HMI display terminal.
3. Turn the key switch from 0 to 1.
4. The generator status changes to ‘H2 purging’; a counter indicates the remaining liters to be pro-
duced.
5. When hydrogen purge is finished the generator status changes to ‘Standby for H2 production’.
6. Turn the key switch back to position 0. Hydrogen purge is completed.
Hydrogen Production
For specific production instructions for the deoxo dryer, refer to the deoxo dryer section.
1. Make sure the HySTAT is in the ‘Standby for H2 production’ status.
2. Enable one or more cell stacks (depending on the production required) on the HMI display termi-
nal.
3. Turn the key switch from 0 to 1. Hydrogen (and oxygen) production starts.
4.2.8 Stopping the HySTAT

Turn the key switch from 1 to 0. If in hydrogen production mode, the generator status changes back to
‘Standby for H2-production’.
4.2.9 Depressurizing the HySTAT

Depressurization reduces the pressure inside the HySTAT (in the gas separator and the deoxo dryer) to
a safe level. This is done automatically.
There are two ways to depressurize the unit:
A Standby depressurization: Automatically, by pressing the button on the HMI display terminal
(for the gas liquid seperator and for the deoxo drier), or when the 24V supply drops below a
minimum level. Pressure is decreased to approx. 0,15 barg. An inert gas purge is required
afterwards, before restarting the unit.
A Emergency depressurization: Automatically, after a generator failure. Pressure is decreased to

approx. 0,50 barg. No inert gas purge is required afterwards.

Page 78 Section 4
The following alarms evoke emergency depressurization:
A HTA: Hydrogen in Atmosphere detection

A EMS: Emergency Stop Button pressed
A LTH L, LTO L: Electrolyte level gas separator low
A LS Drip Tray: Drip tray leak detection
A UPS: UPS low voltage
After an emergency depressurization, the pressure inside the HySTAT is still

around 50kPa, and the HySTAT is still in the ‘hydrogen production’ phase.

Section 4 Page 79
4.3 Deoxo dryer operation

4.3.1 Deoxo dryer operational phases
The dryer stage of the deoxo dryer operates in different phases. An overview of these dryer phases is
shown below.
Dryer B Dryer A
Phase A HEAT DRY
Phase B COOL DRY
Phase C PRESSURIZE DRY
Phase D DRY HEAT
Phase E DRY COOL
Phase F DRY PRESSURIZE
While one dryer bed is in operation (drying stage), the other is regenerating. During regeneration, the
bed is first depressurized to around 50kPa. Then the bed is heated (heating phase), afterwards it is
allowed to cool down (cooling phase), and finally it is pressurized. During the heating and cooling
phases, a flow of regeneration gas, which is dry gas that comes from the active bed, flows through the
bed that is regenerating. The dry gas transports the moist that is freed from the molecular sieve during
the heating phase, to the vent line, thus ‘drying’ the bed. After pressurization, the bed is standby to take
over (standby).
Both the ‘heat’ and the ‘cool’ phases of the dryers are performed at atmospheric
pressure.
The volume of hydrogen that has passed through the bed determines which valves are opened and
which are closed (further referred to as the ‘valve sequence’). Typical phase time values (at full capacity)
are:
Drying phase: > 12 hours
Heating phase: ~ 5 hours
Cooling phase: > 6.5 hours

Pressurization phase: ~ 0.5 hours
Standby: ~ 0.5 hours
Drying phase times are adjusted according production rate; regeneration phase times
are not.

Page 80 Section 4
4.3.2 Nitrogen purge of the deoxo dryer
Nitrogen purge of the deoxo dryer is required:
A before initial startup;

A before maintenance;
A after maintenance;
A whenever the system pressure has dropped below 0,20 barg.
The HMI does not inform the operator of the need for nitrogen purge. It is the
operator’s own responsibility to perform a nitrogen purge of the deoxo dryer
when needed, based on the indications on the dryer pressure gauges (PI_Deo;
PI_Da; PI_Db)
1. Make sure the nitrogen purge of the dryer is performed after the nitrogen purge of the electrolyzer.
2. Turn the key switch to position 0.
3. Isolate the deoxo dryer from the electrolyzer and the user line by closing valves BV H and BV H-U.
4. Open the nitrogen supply. Check the nitrogen pressure on the nitrogen pressure gauge PI N. The
pressure should be controlled between 1 barg and 2 barg.
5. Close BV N_Deo-A and then open BV N_Deo.
6. Open the hand valve HV N_Deo fully.
7. Open hand valve RHV RG_H on the regeneration flow meter of the dryer.
8. Open the hand valve HV H-D fully.
9. Start the nitrogen purge from the HMI display terminal; a counter indicates the remaining time.
The purge time counter will only count down if the flow switch on the regeneration flow
meter is activated (i.e. if the flow is equal to or greater than required).
10. Regulate the nitrogen flow with the hand valve RHV RG-H to 100% of full scale of the regeneration
gas flow indicator.
11. Dryer beds A and B are purged in series.
12. The HMI display terminal displays a message when the dryer purge is finished.
13. Close the hand valve HV N_Deo.
14. Close the hand valve RHV RG_H on the regeneration flow meter of the dryer, and then open one
turn (360°).
15. Close the hand valve HV H-D and then open it 3 to 4 full turns.
The regeneration flow and pressure will have to be re-adjusted using the valve RHV
RG_H once the dryer is in production (regeneration phase) again. The correct flow rate
should be indicated on the flow indicator during first startup of the unit.

Section 4 Page 81
16. Close BV N_Deo and then open BV N_Deo-A.
17. Nitrogen purge of the deoxo dryer is finished. The HySTAT is ready for hydrogen production.
If your deoxo dryer is equiped with ‘Automatic N2 purge’, the following valves are
replaced:
A BV N_Deo is replaced by MV N_D1

A HV N_Deo is replaced by MV N_D2
A BV N_Deo-A is replaced by MV N_D3
After nitrogen purge of the deoxo dryer, the system pressure is between 1 barg
and 2 barg. If the deoxo dryer is purged for maintenance reasons, it needs to be
depressurized afterwards. Follow the procedure ‘4.3.3 Depressurization of the
deoxo dryer’ below.
4.3.3 Depressurization of the deoxo dryer

1. Turn the key switch to position 0.
2. Isolate the deoxo dryer from the electrolyzer and the user line by closing valves BV H and BV H-U.
3. Ensure the nitrogen supply to the dryer is closed by closing BV N_Deo and HV N_Deo, and
opening BV N_Deo-A. (In case of automatic block & bleed, isolate the nitrogen supply from the
source).
4. Open hand valve RHV RG_H on the regeneration flow meter of the dryer.
5. Open hand valve HV H-D fully.
6. Start nitrogen purge on the HMI display terminal.
7. Dryer beds A and B are depressurized in series.
8. If the pressure is not atmospheric at the end of this sequence, repeat it.
After a dryer purge cycle the regeneration flow and pressure will have to be reset
once the system is put back into normal operation.
4.3.4 Deoxo dryer into production

1. Make sure the hand valve HV N_Deo is closed.
2. Start hydrogen production as described above. Note that the dryer start conditions need to be ful-
filled.
3. Adjust the flow rate with the hand valve RHV RG_H as specified. (the correct flow rate should be
indicated on the flow indicator during first startup of the unit).
4. Close the hand valve HV H-D and then open it 3 to 4 full turns.

Page 82 Section 4
4.4 Critical alarms

The big difference between critical alarms generated by failing safety inputs and failing start conditions is
the action related to this failure:
A failing safety input: the safety program of the PLC de-energizes a part of the unit or the com-
plete unit through safety relays
A failing start condition: the process program of the PLC will put the unit into standby or depres-
surization or the ventilation is put to full flow
You can see that some alarms are used in both types. The actions for the different critical alarms are
mentioned below:
1. EMS (emergency pushbutton), fire and smoke alarm
A Each main contactor is switched off so that all systems are shut down. That is including the ven-
tilation system, so that the process room ventilation stops.
A The unit (= the gas generator system or GGS and the hydrogen purification system or HPS) is
depressurized to a pressure of approx. 0,50 barg.
2. Flooding detection device alarm
A Each main contactor is switched off so that all systems are shut down. That is including the ven-
tilation system, so that the process room ventilation stops.
A The magnetic valve ‘Water header inlet’ MV1 F_BT-H closes
3. HTA Alarm
A The contactor to the thyristor in the power racks and for the drier is switched off so that these
systems are shut down.
A The unit is depressurized to a pressure of approx. 0,50 barg.
A The ventilation is pushed to full flow for as long as the HTA alarm remains active.
4. Power rack alarm: door switch or temperature switch cell stack alarm
A The contactor to the thyristor in the power rack is switched off so that this system is shut down.
A The unit is put into ‘standby’ mode.
5. HTO alarm or level switches of the drip trays (electrolyte leak) in alarm
6. Level switches in hydrogen and oxygen site of the gas liquid seperator (low or high level)
A The contactor and protector to the thyristor in the power rack is switched off so that this system
is shut down.
A The unit is depressurized to a pressure of approx. 0,50 barg.
7. Air flow switch (General purpose room to process room) alarm
When the flow switch contact raises an alarm and the alarm is not reset within half an hour:
A The contactor to the thyristor in the power rack is switched off so that this system is
shut down.

Section 4 Page 83
A The GGS is depressurized to a pressure of approx. 0,50 barg.
8. Current switch fan alarm
A The GGS is depressurized to a pressure of approx. 0,50 barg.
9. OTA alarm (optional, high or low level)
A The OTA or oxygen concentration measurement in atmosphere (process room) has an ana-
logue output. If the analogue output rises above 22% O2 in air, the PLC will stop the HySTAT,
depressurize it, and push the ventilation to full flow as long as the unit is under pressure. If the
value drops below 20% O2 in air, the HySTAT is not stopped, but an alarm is raised and a
warning light and acoustic signal on the outside of the process part entrance door are activated,
indicating the risk of hypoxia inside the process part.
When an emergency pushbutton is pushed, this alarm has more priority then the other
alarms.
In case of a HTA or OTA alarm, the ventilation is pushed to full flow. Sub-zero air
can be blown into the process part for a certain time. This time-span however is
not considered to be long enough to cause frost damage.
10. Temperature switch drier alarm
A The contactor for the drier is switched off so that this system is shut down.

Page 84 Section 4

HYSTAT MANUAL
SECTION 5: MAINTENANCE AND TROUBLE-

SHOOTING
Page 86 Section 5
HySTAT MANUAL MAINTENANCE AND TROUBLESHOOTING
Section 5: MAINTENANCE AND

TROUBLESHOOTING
5.1 Introduction
This maintenance section assists an engineer in the maintenance and troubleshooting of the HySTAT
system.
It is strongly recommended that all operations described in this manual are carried out by a qualified
service engineer.
For further information also refer to your HySTAT's technical file for manufacturers’ manuals and
instructions.
The following information is delivered on a CD-Rom or DVD:
A Station Manual
A Manuals of auxilliary equipment
A P&ID’s
A Mechanical Drawings
A Electrical diagrams
A Parts List
A MSDS (Material Safety Data Sheets)

A Code Compliance Documents
A Technical documentation HS numbers
For direct information from Hydrogenics Europe NV please contact the service department
at:
service-eu@Hydrogenics.com
(+32) 14 462 110 (Monday till Friday between 8am and 5pm CET)

Section 51 Page 87
MAINTENANCE AND TROUBLESHOOTING HySTAT MANUAL
5.2 Generator status

For each maintenance procedure described in this manual, the status the HySTAT should be in is given
as well.
There are 3 main states for the generator: Run, Standby and Stop. These are further sub defined for
maintenance purposes.
5.2.1 Status for maintenance procedures
Only the generator status itself is described, not how the status is reached. Refer
to Section 4: Operation for instructions on how to reach each generator status.
Run
The generator can be in operation (nitrogen purge, hydrogen purge or hydrogen production). Be aware
that the cell stacks of the system can be energized as well as the rest of the electrical system.
Operations performed whilst the generator is running are normally limited to visual inspections (see
further) or tests of the sensors and switches in the system.
Equipment used in the process area whilst the generator is in Run must be
suitable for use in an Ex-environment. Refer to the explosion protection
document and local codes and standards.
Standby
The generator is not in operation (nitrogen purge, hydrogen purge or hydrogen production), the key
switch is in position 0 and the key is removed.
The Standby status does not imply that the HySTAT is depressurized. Therefore
equipment used in the process area whilst the HySTAT is in Standby must be
suitable for use in an Ex-environment. Refer to the explosion protection
document and local codes and standards.
Stop – purged
The generator is not in operation (nitrogen purge, hydrogen purge or hydrogen production), it has been
depressurized and purged with an inert gas and then depressurized once more. The key switch is in
position 0 and the key is removed.
Stop – cell stacks isolated

Equal to the ‘Stop – purged’ status, but the main fuses supplying power to the SCR, transformer and
diode bridge for each cell stack are switched off as well.
Stop – cold
Equal to the ‘Stop – cell stacks isolated’ status, but the system is allowed to cool to ambient temperature.
Depressurizing the system whilst hot can result in an under pressure in the gas
separator later as the gases cool.

Page 88 Section 5
Stop – open
Equal to the ‘Stop – cold’ status, but any remaining pressure in the gas separators has been safely
vented. The valves to atmosphere (refer to P&ID) are open, so that the gas separators are at
atmospheric pressure and can be further opened safely.

Section 51 Page 89
5.3 Inspection of the HySTAT system

Regular inspections must be carried out to the HySTAT system. For safety purposes, Hydrogenics
Europe NV makes certain definitions with respect to the HySTAT system to assist in the set up and to
ensure the safety of inspections.
In order to further safe guard the HySTAT system it is also recommended that a periodic visual
inspection of the system be carried out. Thus an early detection of possible faults in the system can be
guaranteed. It also provides the operator with practical experience of the generator operating conditions.
The following list is recommended as a minimum of checks. Other checks relevant to the actual situation
of the HySTAT may need to be added. These visual checks should be extended to include any of the
options present. Some checks are noted below, but always refer to the manufacturers' detailed
documentation for further information.
5.3.1 Definitions of inspections

There are 3 types of inspection:
Visual inspection – an inspection, which identifies, without the use of access equipment or tools,
those defects, which are apparent to the eye. The use of the display for viewing data is not classed
as the use of tools.
Close inspection – an inspection encompassing those aspects covered by a Visual inspection

and, in addition, identifies those defects which will be apparent only by the use of access equip-
ment, e.g. steps, and tools. Close inspections do not normally require the enclosure to be opened
or the equipment to be de-energized.
Detailed inspection – an inspection encompassing those aspects covered by a Close inspection

and, in addition, identifies those defects which will be apparent only after the opening of the enclo-
sure, and/or by the use of access equipment, test equipment and tools. Detailed inspections nor-
mally require the enclosure to be opened and the equipment to be de-energized. This inspection
should only be performed by an operator with an appropriate maintenance training.
Visual Inspections of the system can be made whilst the system is in any status. For Close and
Detailed inspections the system status is defined as per the specific inspection.

Page 90 Section 5
5.3.2 Overview of inspections – HySTAT
Refer to the HySTAT Safety section for safety instructions, prior to performing
inspections. Always wear the appropriate personal protective equipment before
entering the HySTAT.
Pressure gauges & transmitters

A visual inspection of the various pressure gauges and their comparison to the transmitter readings on
the HMI display terminal is a good safety check. This can be performed at any time and is a good
practice for an operator to perform regularly.
If as a result of the visual inspection there is any discrepancy, then gauges and/or transmitters should be
tested against a calibrated reference during maintenance.
Cell stack drip tray

Beneath each cell stack is a tray for catching any KOH that may leak from the system. A visual
inspection of this and the pipework above and below the cell stack may catch leaks before they become
a problem. A check should be made not only for liquid but also for the white crystalline staining that is left
behind when KOH has dried.
If as a result of the visual inspection there is a suspicion of leak then a detailed inspection must be made,
with the system in the ‘Stop – cold’ status. This is classed as a “detailed inspection” because the
protective covers on the cell stack have to be removed.
Do not attempt to access beneath a cell stack unless the system is at least in
‘Stop – cell stacks isolated’.
General pipework
A visual inspection of the pipework is also recommended for safety purposes. As well as the electrolyte
loop, as mentioned above, the gas piping should also be checked. If there is a suspicion of a leak a close
inspection can be made with a leak detection fluid or spray such as Snoop®.
Water system
The integrity of the demineralized water supply to the system should also be checked regularly as leaks
in the piping or break tanks can affect the purity of the supply as well as allow the growth of algae. A
visual inspection for leaks in the piping and tanks and for the presence of algae should be made as well
as the integrity of the overflow of the tanks.
Vent lines
Visual inspection of the ventlines mainly involves manually checking the temperature of the lines. A
ventline that is warmer than ambient temperature may indicate problems with gas cooling. A check
should also be made of the external section of the vent lines, to ensure no damage has been caused or
no obstruction has occured.
If there is a suspicion of a leak, a close inspection can be made with a leak detection fluid or spray such
as Snoop®.

Section 51 Page 91
Water locks
Visual inspection of the water locks implies ensuring the presence of water inside, and checking the
overflow opening for possible obstructions. If the water level is found to be too low, water is to be added
manually.
HTO – Hydrogen Transmitter in Oxygen

A visual inspection of the HTO and its associated pipework should be made in the same way as the other
piping. However a special check should be made to ensure there is the correct flow to the HTO and
against the presence of water vapor and condensation. The condensation pot in the system should
remove the unwanted water but this needs to be checked to prevent the drying agent from being used
up. The drying agent will change color when it is saturated with moisture; when this is noticed the drying
agent needs to be replaced.

Page 92 Section 5
5.3.3 Overview of inspections – Dryer systems

The drying systems (deoxo dryer and/or dehydro dryer), if present, should have the following visual
inspections made whenever possible.
Pressure gauges & transmitters

A visual inspection of the various pressure gauges and their comparison to the readings on the HMI is a
good safety check, if pressure transmitters are fitted to the dryer. In the case of no pressure transmitters
then a comparison of the pressure in the dryer to the pressure in the HySTAT during operation, is a good
safety check. A comparison can also be made between the deoxo pressure gauge and the gauge on the
dryer bed in use and so at the same pressure. This can be performed at any time and is a good practice
for an operator to perform as regularly as possible.
If as a result of the visual inspection there is any discrepancy, during maintenance, gauges can be tested
against a calibrated reference.
Regeneration flow
The flow of gas to the regenerating bed of the dryer should be checked during the appropriate phases of
the dryers operation. The values required should be marked on the flow meters in advance or during
commissioning. Adjustments can be made using the regulating valve on the flow meter. Refer to the
dryer P&ID.
Regeneration pressure
The pressure of the regenerating bed of the dryer should be checked during the appropriate phases of
the dryers operation. Pressure in the regenerating bed should be just above atmospheric pressure.
Adjustments can be made by adjusting the hand valves to drain on the system. Refer to the dryer P&ID.
Instrument air pressure

In some drying systems the valves fitted are pneumatically operated, requiring a supply of instrument air.
The pressure of this supply should be checked and maintained at about 6 barg.

Section 51 Page 93
5.3.4 Overview of inspections – Auxiliaries
The auxiliary equipment described may not be applied to your HySTAT. If so, disregard
the inspection instructions.
Always refer to the manufacturers’ detailed instructions supplied with the HySTAT
equipment.
Closed loop cooling

A System pressure should be maintained at the recommended value.
A A visual inspection of the pipework for any leaks.
A Entrapped air should be checked for using the specially fitted bleed points and as an audible
check for noise in the piping.
A Air flow through the dry cooler should be checked ensuring that no dirt is blocking the flow.
Detailed inspection: glycol concentration should be checked when possible and always after a leak is
discovered in the system. Actual concentration may vary, refer to Appendix D: Specifications utilities for
more details.
Chiller
A Pressure in the system should be checked and maintained at the recommended value.
A A visual inspection of the pipework for any leaks.
A Entrapped air should be checked by using the specially fitted bleed points and as an audible
check.

A Leak tightness should be checked with a visual inspection for leaks.
A Supply water pressure should be checked.
A Pressures and flows compared to values supplied with the system at commissioning.
A CT value should be within range.
A Check the remaining filter bed time, as marked on the bottle.
Outdoor housing
A Check all ventilation grids for dirt.
A Check the fan filters for clogging.
A Check the heating system (room heaters) during winter time.
A Check the blades of the ventilation grids.

Page 94 Section 5
5.4 Scheduled maintenance – HySTAT

In order to ensure a continuous and reliable supply of hydrogen, a preventive maintenance scheme must
be followed. The general warranty of the HySTAT is subject to the user following this scheme as
described further in this manual.
The re-certification of certain detectors or pressure vessels related to the HySTAT are not described, but
must be performed by authorized and qualified personnel. The time period between these certifications
is dependent to local codes and standards and must be performed accordingly.
Only qualified personnel are allowed to perform maintenance to the HySTAT. If

no personnel are qualified to perform maintenance to the HySTAT, only the
HySTAT supplier is allowed to perform maintenance.
5.4.1 Maintenance schedule
The maintenance schedule below is valid for the HySTAT and the deoxo dryer. For all
peripheral equipment, if present, refer to the manufacturers’ technical documentation for
maintenance instructions and intervals.
The safety signals are highlighted in yellow and in the description an ‘(S)’ is
added. Hydrogenics Europe NV advises to check the safety signals as
mentioned in the schedule below.
HySTAT - General and outdoor housing
Interval Description Hours Paragraph

2-weekly Perform visual inspections ¼ 5.3.2
Monthly Check and clean the power- and control cabinets ¼ 5.4.2
6 monthly Check leak tightness ½ 5.4.9
6 monthly Clean the container housing internally and externally 3 5.4.3
6 monthly Check the functionality of the door switch of the power rack (S) ½ 5.4.29
6 monthly Check the functionality of the flooding detection device (S) ½ 5.4.30
6 monthly Check the functionality of the air flow switch (S) ½ 5.4.31
6 monthly Check the functionality of the current switch for fan (S) ½ 5.4.32
Yearly Check the 24 volt UPS batteries ¼ 5.4.4
2 Yearly Replace the UPS batteries ½ 5.4.4
2 Yearly Replace the thyristor cooling fans 2 5.4.6
HySTAT - Process

Variable Check the torque on the cell stack(s): at commissioning, after the 2 5.4.8
first, third and sixth month; every six months from then
6 monthly Check the electrolyzer valves – Hydrogen to User, Hydrogen to 4 5.4.20
Atmosphere, Oxygen to User, Oxygen to Atmosphere

Section 51 Page 95
HySTAT - Process

6 monthly Check the concentration of the electrolyte 1 5.4.10
6 monthly Check the fixing of the power cables 1 5.4.5
6 monthly Check the functionality of the level switches (S) 2 5.4.14
Yearly Check the functionality of the temperature switches 2 5.4.13
Yearly Replace the level transmitter floats 1 5.4.16
Yearly Replace the level switch floats 1 5.4.15
2 Yearly Inspect and clean break tank 4 5.4.22
3 Yearly Replace or recalibrate the (safety) relief valves 1 5.4.18
3 Yearly (local Inspect the pressure vessels Variable 5.4.19
regulations
apply)
Predictive Replace the solenoid and pneumatic valves 1 5.4.21
<
Dryer systems

6 monthly Replace the coalescing filter after DEOXO (DP H) 1 5.5.2
6 monthly Check instrument air supply ¼ 5.5.3
Yearly Replace the coarse particle filter element (FU) 1 5.5.5
Yearly Check the functionality of the temperature switches 2 5.4.13
Yearly Check the functionality of the level switches 2 5.4.14
3 Yearly Replace or recalibrate the (safety) relief valves 1 5.4.18
3 Yearly (local Inspect the pressure vessels Variable 5.4.19
regulations
apply)
2-5 Yearly Replace the catalyst in the deoxo dryer 8 5.5.8
7-10 Yearly Replace the molecular sieve in the dryer vessels. 8 5.5.9
Predictive Replace the solenoid valves 1 5.5.6
Predictive Replace the pneumatic valves 1 5.5.7
Gas sensors

3 monthly Calibrate OTH sensor 1 5.4.27
6 monthly Test of the HTA detector (S) 2 5.4.25
6 monthly Calibrate the HTA detector (S)
6 monthly Test of the OTA detector 2 5.4.26
6 monthly Calibrate the OTA detector
6 monthly Calibrate the HTO analyzer (S) 1 5.4.23
6 monthly Clean the HTO panel 2 5.4.24
Yearly Replace the sensor in OTA detector 2 5.4.26
Yearly Replace the sensor in OTH detector 2 5.4.27
Yearly Calibration of the dewpoint transmitter 1 5.4.28

Page 96 Section 5
Gas sensors

18 monthly Replace the sensor in HTA detector (S) 2 5.4.25
Chiller

weekly Check degas points for leaks? Adjust if necessary ¼ Vendor
manual
weekly Check if temperature is at the setpoint ¼ “
weekly Check if pressures are OK ¼ Vendor
manual
weekly Check the water level(s) in the tank(s) 1 “
weekly Check the filters (if fitted) 1 “
monthly Clean the condensor 1 “
monthly Clean the housing of the chiller internally and externally 3 “
6 monthly Check leak tightness ½ “
Yearly Replace filters (if fitted) 3 “
Yearly Flush circuits to remove sludge 4 “
Yearly Refill the circuit with the appropriate coolant. Refer to Appendix 2 “
D: Specifications utilities.
Closed loop cooling system

weekly Check system pressures ¼ Vendor
manual
weekly Check pumps for overheating ¼ “
weekly Check valves (3-way) for operation ¼ “
weekly Check the filters (if fitted) ¼ “
weekly Check degas points for leaks. Adjust if necessary. ¼ “
monthly Clean the dry cooler 2 “
monthly Clean pumps and housing internally and externally 4 “
yearly Replace filters (if fitted) 2 “
yearly Flush circuits to remove sludge 4 “
yearly Refill the cooling circuit 2 “
Always refer to the specific vendor documentation for more information on

servicing the chiller and/or the closed loop cooling equipment.
Always contact Hydrogenics Europe NV if a spare or wear part is required. The

use of original parts supports the lifetime of the HySTAT in the best possible
way.

Section 51 Page 97
5.4.2 Power- and control cabinet maintenance
Condition of the HySTAT

A Standby or Stop
Necessary tools
A Vacuum cleaner
A Screwdriver
A Brush
Safety aspects
A See ‘HySTAT Safety’ section.
The fans may continue to run for several minutes once the generator is stopped (key
switch to 0). Wait until the fans have stopped before opening a door or removing any
covers.
Consumables
A Filter cloth (when necessary)
Cleaning/ replacement of the door fan filter
Figure 1 – Removing filter covers
A Take the screwdriver and loosen the front panel of the filters
A Take out the filter elements
A Rinse the filters with pressurized air or a vacuum cleaner. Make sure the air flow during clean-
ing is in the opposite direction of the airflow during operation, so the dust can come off.
A If necessary replace the filter with a new one
A Put the filter back in its original place
A Replace the fan cover

Page 98 Section 5
If the filters are very contaminated with dust, they can be cleaned with a soap solution.
Never use sharp objects or water jets to clean the filters.
Removal of dust and dirt from the electrical cabinets
Make sure the electrical cabinet is switched off, and that the cabinet is
electrically isolated. Consult the electrical drawing set and make sure that any
voltage fed from an external source is switched off as well.
Dust and dirt cause poor cabinet cooling, and may cause fire. If dust and dirt are moist, they can alter the
insulation resistance of electrical components, causing severe damage.
If there is any accumulation of dust or dirt, clean the electrical cabinet with a brush or a vacuum cleaner.
Do not use compressed air, for dust may be blown into the electrical
components this way.
Conductors and connections

Inspect all conductors and connections visually to ensure that they are clean and solid. Loose or dirty
connections increase electrical resistance, which can cause overheating. Examine the contact stress of
connections. Tighten any loose connections. If there is any sign of overheating, replace the connection.
Overheating is visible through discoloration or flaking off of the insulation and/or metal parts.
Look for dampness or signs of previous moistness. Condensation or dampness coming from the outside
of the electrical cabinet should be avoided at all times; take appropriate measures if necessary. Check
all components and replace any component that has been damaged by moisture or penetrating damp.
Oxidized parts must be replaced.
If a short-circuit has occured, the abnormally high currents may have damaged components and
conductors due to mechanical stress, thermal damage, metal deposits, smoke etc. Check whether the
components and insulators have tears or cracks. Contact Hydrogenics Europe NV before starting to
clean or repair the electrical cabinet.
Always replace defect components with identical ones.

Section 51 Page 99
5.4.3 Cleaning the outdoor housing

Cleaning the outdoor housing (container or building surrounding the HySTAT) prevents the build up of
dirt, dust and vegetation, which are potential ignition sources for, or fuels in case of an explosion or a fire.

A Stop – open
Necessary tools
A Broom
A Cloth
A Sponge
A Bucket
A Other cleaning tools
Safety aspects
Do not use water near electrical equipment. Use a damp cloth instead. ALWAYS
double check the presence of voltage when cleaning or servicing electrical
equipment.
Consumables
A Water
A Soap
Procedure
1. Clear all rubbish, dirt and vegetation from around the container
2. Sweep outside and inside
3. Clean all ventilation grids
4. Wipe all parts thoroughly with a damp cloth to remove dust
5. Clean all filters (replace if necessary)
Periodically clean all axial fans. This will increase their lifetime.

Page 100 Section 5
5.4.4 Checking and replacing the 24V UPS batteries
Figure 2 – 24 volt UPS batteries inside the control panel

A Stop – open
Necessary tools
A Set of spanners
A Battery Amp-hour tester
A Multimeter
Safety aspects
A Refer to the electrical drawing set.
Consumables
A Cleaning paper
Procedure
1. Switch off the 24V transformer that charges the batteries.
2. Confirm the charge on the batteries with a multimeter and Amp-hour tester.
3. Replace the batteries if needed: carefully remove the old batteries and replace with new ones.
4. Switch on 24V transformer.
Make sure the old batteries are disposed of properly, according to local codes and standards.

Section 51 Page 101
5.4.5 Checking the fixing of the power cables
1 4 3 2 3 4
Figure 3 – Power connections to the cell stack and EPS main connections
1 Cell stack end flange DC cable connections 3 Main protector for cell stack circuit
2 Main fuse 4 Main contactor for cell stack circuit

A Stop – cold
Necessary tools
A A set of metric Allen keys
A Set of electrical screwdrivers
A A multimeter
Safety aspects
A Make sure the main fuse supplying power to the SCR, transformer and diode bridge for each
cell stack, inside the EPS enclosure, is “OFF”.
A Be aware of the fact that only switching of the main switch in the process enclosure will not nec-
essarily shut down the 240 V circuit. (Refer to electrical drawings).
A Check if there is no remaining voltage on the cell stack (use a multimeter).
Consumables
A None
Procedure
A Remove the plastic covers on the cell stack
A Tighten up the hexagon socket head cap screws with the Allen key on both end flanges and the
earth connection on the mid flange.
A Replace the plastic covers on the cell stack.
A Open door to EPS power rack.
A Switch off main power supply
A Check electrical connections of the following items:

Page 102 Section 5
Incoming/outgoing power to main fuse

Incoming/outgoing power to net filter
Incoming/outgoing power to cell stack fuse
Incoming/outgoing power to main contactor
Incoming/outgoing power to SCR
Incoming/outgoing power to transformer
Incoming/outgoing power to diode bridge
Incoming/outgoing power to distribution busbar
A Switch on main power supply
A Close door to EPS power cabinet.
A Reset alarms.
Before checking any power connection, first check the connection with a
multimeter to ensure there is no voltage.
The cell stack may hold some residual voltage. Check for residual voltage before
commencing work. If there is a residual voltage the end flanges can be grounded
before commencing work.
Figure 4 – Inside the EPS power cabinet

Section 51 Page 103
5.4.6 Replacing the thyristor cooling fans
Figure 5 – Thyristor stack with cooling fan

A Stop – cold
Necessary tools
A Set of Electrical screwdrivers
Safety aspects
Consumables
A None
Procedure
1. Stop and isolate all cell stacks
2. Confirm no voltage is present with a certified meter on SCR and fans
3. Unplug power from fans
4. Unscrew fans
Mind the air flow direction arrow on the fan. The new fan has to be placed with the flow in
the correct direction
5. Screw in new fans

Page 104 Section 5
6. Plug in new fans
7. Switch on power
8. Check if fan runs

Section 51 Page 105
5.4.7 Replacing the complete thyristor stack
1 2 3 4 5
Figure 6 – Thyristor stack
1 Thermal paste 4 Heat sink

2 Busbar 5 Twisted pair gate leads
3 Cable conductors

A Stop – cold
Necessary tools
A Set of Electrical screwdrivers
A Set of spanners
A New thyristor module
A New pair of gate leads
A Thermal paste
Safety aspects
Consumables
A New thyristor module
Procedure
1. Stop and isolate all cell stacks
2. Confirm no voltage is present with a certified meter on SCR and fans
3. Disconnect conductors from the thyristor module

Page 106 Section 5
4. Remove busbar from thyristor module
5. Disconnect thyristor gate leads
6. Unscrew 4 screws of thyristor module
7. Remove thyristor module from heat sink
8. Take new thyristor module
9. Apply thermal conductivity paste between the heat sink and the thyristor module. Layer thickness
approximately 0.5mm evenly spread.
10. Mount new thyristor module onto heat sink with the 4 screws (torque 5Nm)
11. Connect thyristor gate leads as per the electical drawings
12. Mount the busbar to the thyristor module (torque 9Nm)
13. Connect conductors to the thyristor module
14. Switch ON power
15. Check if functionality is OK

Section 51 Page 107
5.4.8 Checking the torque on the cell stack
Figure 7 – Checking the torque on the cell stack

A Stop – cold
Necessary tools
A Torque wrench – range 0-320 Nm
A 36mm spanner and a socket of minimum 12 cm length
Safety aspects
A Ensure the HySTAT system is stopped and depressurized, and has cooled sufficiently.
The cell stack may hold residual voltage. It is recommended that the engineer
check for residual voltage before commencing work. If it is found there is a
residual voltage the end flanges can be grounded before commencing work.
Consumables
A None
Procedure
1. After ensuring the HySTAT is depressurized and has cooled sufficiently, remove the cell stack
cover.
2. Remove sides of enclosure to allow access to both ends of the cell stack.
Care must be taken with the connections of the HySTAT that pass through the panels,
which need to be removed.

Page 108 Section 5
3. Mark the ends of the cell stack as per Figure 9 – Cell stack tightening sequence.
4. Remove the lock nuts at one end. (See below)
Figure 8 – Cell stack lock nuts
5. Proceed around the tension rods, in order as per the cell stack tightening sequence, applying a
torque of 300 Nm. It is easier if a second person prevents the turning of the rods with a spanner at
the opposite end.
6. Repeat the sequence a second time
7. Refit and re-tighten all the lock nuts, and reassemble the enclosure.
Figure 9 – Cell stack tightening sequence

Section 51 Page 109
5.4.9 Checking leak tightness

A leak tightness check has to be performed on all piping. This includes the piping for hydrogen, oxygen,
inert gas, cooling water and demineralized water. Check also the pipes to the user for possible leakage.
Figure 10 – Checking for gas leaks with soap solution

A Stand-by
Necessary tools
A There are no specific tools needed for this procedure.
Safety aspects
Consumables
A Leak detection liquid
A Cleaning paper
Procedure
It is important to keep the HySTAT pressurized during these checks.
1. Open the process enclosure, if necessary.
2. Check every connection of the gas loops for leakage by using a soap solution in water. E.g. use
Snoop® (use cleaning paper to remove the excess liquid).
3. Check the electrolyte loop visually for any leakage; look also for traces of KOH in the drip tray.
Whenever a leak of KOH is detected, perform an electrolyte concentration check.
4. Check the cooling circuit visually for any leakage.
5. When a leak is detected, depressurize the HySTAT and call a service technician.
6. Check all external couplings to the users and/ or the vent lines.

Page 110 Section 5
7. Close the doors of the process enclosure, if necessary.
While the leak tightness check is performed on a pressurized system, a

connection should never be tightened when it is under pressure.

Section 51 Page 111
5.4.10 Checking the concentration of the electrolyte
3 1
Figure 11 – KOH sampling equipment & electrolyte sample valve
1 Compression fitting plug (for example 3 Measurement recipient

Swagelok® plug) 4 Densimeter
2 Sample valve
A concentration and a leak check are recommended in the following situations:
A After the first KOH filling when the HySTAT is installed. This is only needed in case the KOH
solution needs to be mixed on site or there is uncertainty on the concentration.
A After detection of a KOH leak
A After adjustment of the electrolyte concentration (one or two days afterwards)

A Stop – cold
Necessary tools
A Set of metric spanners, an adjustable spanner
A A measurement recipient (part of the delivery see ‘Figure 11 – KOH sampling equipment & elec-
trolyte sample valve’)
A A densimeter (part of the delivery see ‘Figure 11 – KOH sampling equipment & electrolyte sam-
ple valve’)
A A long enough piece of PFA or other KOH resistant tubing (supplied with your unit)
Safety aspects
A Read carefully the safety aspects related to KOH listed in the ‘HySTAT Safety’ section.
Consumables
A Cleaning paper
Procedure for checking the concentration

The description refers to ‘Figure 11 – KOH sampling equipment & electrolyte sample valve’ above

Page 112 Section 5
1. Unscrew the compression fitting plug (for example Swagelok® plug), with one spanner while hold-
ing the valve with the other spanner
2. Fix the PFA tubing with to the valve using one spanner while holding the valve with the other span-
ner.
3. Position the recipient vertically on the floor and put the PFA tube in the recipient.
4. Gently open the valve a few turns until the KOH starts to flow slowly.
5. When the recipient is filled to the level of 400 ml, close the valve.
6. Gently unscrew the flexible PFA tube and use the cleaning paper to clean up the droplets of KOH
coming out of the tube and the valve.
7. Tighten the plug again using the two spanners.
8. Put the densimeter in the liquid and read the value.
If the density is below 1.25 or higher than 1.35 the electrolyte concentration has to be adjusted.
The electrolyte can have a temperature up to 85°C when the HySTAT has recently
been shut down. Let it cool down sufficiently.
If there is a discoloration of the KOH or the presence of particles is discovered,

retain a sample and please contact Hydrogenics Europe NV.
Never use a pump to suck up the KOH from the sample valve to a container. This
can cause permanent damage to the internal components of the cell stack and
will result in major repairs.
The HMI display terminal can be used to visualize the electrolyte levels. For more
information see ‘Appendix A: HMI display terminal’. The electrolyte level should
always be between 140mm and 180mm.

Section 51 Page 113
Density of KOH at different temperatures
KOH % 15°C 21°C 30°C 40°C 50°C 60°C 70°C 80°C 90°C
10 1.092 1.090 1.087 1.082 1.078 1.074 1.068 1.061 1.058
11 1.102 1.100 1.096 1.092 1.187 1.083 1.077 1.070 1.067
12 1.111 1.109 1.105 1.100 1.096 1.092 1.085 1.079 1.075
13 1.121 1.119 1.115 1.110 1.105 1.102 1.095 1.089 1.085
14 1.131 1.128 1.125 1.120 1.115 1.111 1.104 1.098 1.094
15 1.141 1.138 1.135 1.129 1.125 1.10 1.114 1.107 1.104
16 1.150 1.147 1.144 1.139 1.134 1.129 1.123 1.116 1.113
17 1.160 1.157 1.154 1.149 1.144 1.139 1.133 1.126 1.123
18 1.170 1.168 1.164 1.159 1.153 1.149 1.143 1.136 1.133
19 1.180 1.178 1.174 1.169 1.162 1.159 1.153 1.146 1.143
20 1.189 1.187 1.184 1.179 1.172 1.168 1.162 1.155 1.152
21 1.200 1.197 1.194 1.189 1.181 1.178 1.172 1.165 1.162
22 1.209 1.206 1.203 1.197 1.192 1.181 1.178 1.175 1.171
23 1.220 1.217 1.214 1.207 1.202 1.191 1.188 1.185 1.182
24 1.230 1.227 1.223 1.218 1.212 1.201 1.197 1.194 1.192
25 1.240 1.237 1.234 1.228 1.221 1.212 1.208 1.204 1.201
26 1.250 1.247 1.243 1.237 1.323 1.222 1.218 1.214 1.210
27 1.261 1.258 1.254 1.248 1.242 1.232 1.228 1.225 1.221
28 1.271 1.268 1.264 1.258 1.253 1.241 1.238 1.235 1.231
29 1.282 1.279 1.276 1.270 1.264 1.252 1.249 1.245 1.242
30 1.292 1.289 1.286 1.280 1.274 1.263 1.260 1.254 1.252
31 1.302 1.300 1.297 1.210 1.284 1.273 1.270 1.265 1.263
32 1.313 1.310 1.307 1.301 1.294 1.283 1.280 1.276 1.273
33 1.324 1.320 1.317 1.311 1.305 1.294 1.290 1.287 1.284
34 1.334 1.330 1.327 1.321 1.315 1.304 1.300 1.297 1.294
35 1.345 1.342 1.333 1.332 1.326 1.316 1.313 1.308 1.305
36 1.356 1.354 1.349 1.343 1.337 1.327 1.325 1.319 1.316
37 1.367 1.365 1.361 1.354 1.349 1.338 1.335 1.330 1.327
38 1.378 1.376 1.371 1.365 1.359 1.348 1.345 1.341 1.338
39 1.390 1.387 1.382 1.376 1.370 1.360 1.355 1.352 1.349
40 1.400 1.397 1.392 1.387 1.380 1.371 1.365 1.363 1.359

Page 114 Section 5
5.4.11 Removing the electrolyte

A Stop – cold
Necessary tools
A KOH recipients
Safety aspects
Consumables
A Cleaning paper
Procedure for KOH removal

The following is a procedure for removing KOH from the system in the event of maintenance.
Follow the appropriate safety rules when handling KOH. Consult the KOH MSDS
sheet in Appendix D, and the ‘HySTAT Safety’ section for more details. Make sure
to wear suitable personal protective equipment.
1. Before commencing the unit should be stopped and allowed to cool to ambient temperature.
2. Prepare suitable containers to place the KOH into.
3. Depressurize the HySTAT (see ‘HySTAT Operation’ section).
4. Nitrogen purge the HySTAT (see ‘HySTAT Operation’ section).
5. Close the valve HV N after the nitrogen purge (see photo below).
6. The unit will now be full of nitrogen at about 1.5 bar pressure in the gas separator.
Verify that the PLC battery is in good condition before executing the next step!
Disregarding this may cause the PLC program memory to be erased.
7. Switch off the power to the PLC (see electrical drawings).
8. Connect flexible 12mm PFA tubing to the valves HV E-D1 and HV E-D2 located under the cell
stacks (see photos below).
9. Place the loose end of the PFA tubing in the container for the KOH and fix in position to prevent
movement.

Section 51 Page 115
Figure 12 – Hand valves electrolyte to drip tray
Valves
HV E-D1
HV E-D2
Figure 13 – Hand valves electrolyte to drip tray (close-up)
10. Slowly open the hand valves HV E-D1 & HV E-D2 to allow the KOH to flow into the prepared con-
tainers.
11. Regulate the nitrogen supply to about 1 bar.
12. As the KOH is pushed out of the system the pressure will start to drop. The pressure can be
increased by opening the valve HV N to allow nitrogen into the system. The pressure should be
maintained at about 0.5 to 1.0 bar.
13. When nitrogen begins to flow through the PFA tubing the valves HV E-D1 & HV E-D2 can be
closed slowly to reduce the flow and allow all the KOH to be removed.
14. Close valve HV N.
15. Once all the pressure is released from the system the valves HV E-D1 & HV E-D2 can be closed
and the PFA tubing disconnected.
16. The power to the PLC can be switched on again (see electrical drawings).
In case KOH needs to be disposed, always abide by local law.

Page 116 Section 5
5.4.12 Filling with electrolyte

A Stop – cold
Necessary tools
A KOH recipients
A KOH pump
A KOH filling adapter (supplied with your unit)
Safety aspects
Consumables
A Cleaning paper
Follow the appropriate safety rules when handling KOH. Consult the KOH MSDS
sheet in Appendix D, and the ‘HySTAT Safety’ section for more details. Make sure
to wear suitable personal protective equipment.
The required quantity of KOH solution for your HySTAT depends on its capacity. Refer to ‘Appendix D.1:
Electrolyte’ for more information.
1. Check the unit for remaining liquids, and drain if necessary. Refer to the procedure for KOH
removal for draining instructions.
2. Nitrogen purge the unit.
3. Depressurize the unit.
4. Prepare a KOH container and place it near the gas separator.
5. Prepare the chemically resistant pump for the KOH.
6. Open both hand valves HV H-A & HV O-A (fitted with the orange valve covers).
Hand valves HV H-A and HV O-A must be opened TOGETHER so that any
remaining pressure is released from BOTH gas separators SIMULTANEOUSLY.
Disregarding this may cause a level unbalance inside the gas separators.
Always have a second person checking the electrolyte levels on the HMI display
terminal.

Section 51 Page 117
Figure 14 – Hand valves H-A and O-A
1 Valve HV O-A 2 Valve HV H-A
7. Disconnect the grounding connection from the level transmitter of the oxygen gas separator.
8. Loosen the compression fitting (for example Swagelok®) connection of the level transmitter. This
allows the transmitter to rotate while removing it.
1
2
Figure 15 – Unscrewing the level transmitter

Page 118 Section 5
1 Remove earthing connection 4 The threaded adaptor can then be unscrewed

2 Loosen the compression fitting connection (for from the gas separator while the transmitter
example Swagelok® connection) shown here does not rotate. The transmitter can then be
removed without disconnecting the cable.
3 Loosen the compression fitting nut (for example
Swagelok® nut)
9. With the threaded adaptor fully unscrewed, carefully remove it together with the level transmitter
from the gas separator, and place to one side.
10. Remove the oxygen gas separator level switch as follows: undo the small screws that hold the
level switch head onto its float section.
Figure 16 – Removing the oxygen level switch head
11. Unscrew the level switch float section from the gas separator, and place it aside carefully.
12. Repeat steps 9 to 10 for the level switch on the hydrogen gas separator.
13. Take the electrolyte filling adapter and screw it tightly into the oxygen level switch’s threaded hole.
Figure 17 – The electrolyte filling adapter screwed in place

Section 51 Page 119
Make sure that, with the electrolyte filling adapter screwed in place, there is ONE
free opening (from either level switch or transmitter) on EACH of the two gas
separators. Disregarding this may cause KOH to be spilled and people to be
injured.
14. Prepare the KOH pump and make sure the outlet hose diameter matches the electrolyte filling
adapter’s diameter.
15. Connect the KOH pump outlet hose to the KOH filling adapter. Fix the hose to the adapter with a
hose clamp.
Make sure the KOH pump’s outlet hose is connected firmly to both the pump and
the KOH filling adapter. Disregarding this may cause the hose to come loose
during the filling procedure, causing KOH to be spilled and people to be injured.
16. Start the pump so the KOH is pumped into the gas separator. Frequently check the level on the
HMI display terminal to ensure the unit is not overfilled. The level of the hydrogen gas separator
can be monitored, and since both separators are connected this will correspond to the approximate
level in the oxygen gas separator.
17. Stop the KOH pump as soon as the level reaches 165mm.
18. Let the KOH settle for 10 to 15 minutes and recheck the levels.
19. If the level is stable and remains so, the unit is filled. If not, more KOH must be pumped in and the
levels left to settle again until the level is correct.
20. Once the unit is filled, disconnect and remove the KOH pump carefully. Make sure not to spill.
21. Unscrew the KOH filling adapter and remove it carefully.
22. Refit the oxygen and hydrogen gas separator level switches.
23. Refit the oxygen gas separator level transmitter.

Page 120 Section 5
5.4.13 Checking the functionality of the temperature switches

The correct functionality of the temperature switches of the system is an important part of the overall
safety of the system. As such it is important to perform regular checks of the switches during
maintenance schedules.
Figure 18 – Temperature switches from cell stacks

A Stop – open
Necessary tools
A Large adjustable spanner
A Set of screwdrivers
A Heat bath or hot air gun
A Thermometer
Safety aspects
A Read the safety aspects related to KOH in the ‘HySTAT Safety’ section.
Consumables
A Cleaning paper
Procedure
1. Remove the temperature sensor from the pipework whilst still connected to the junction box. (For
the cell stack temperature switch, the pipework is above the cell stack, see picture above. For the
Dryer temperature switches, the sensor is inserted into a pipe in the top of the vessel).
2. Verify the set point of the temperature switch.
3. Place the sensor probe in a heated water bath or heat gently with hot air gun.
4. Increase the temperature of the water bath/ hot air until the Temperature switch is activated and an
alarm produced.
5. Record the temperature at which the switch is activated and check against the manufacturers stan-
dards.
6. If possible allow the bath to cool until the switch is deactivated and record this temperature for
comparison against the manufacturers standards.

Section 51 Page 121
7. Replace the sensor back in the pipework.
If a hot water bath is not available then a hot air gun can be used to warm the sensor.
The temperature can be verified with the HMI display terminal or an independent
measurement such as a thermometer.

Page 122 Section 5
5.4.14 Checking the functionality of the level switches

The correct functionality of the level switches of the system is an important part of the overall safety of
the system. As such it is important to perform regular checks of the switches during maintenance
schedules.
Figure 19 – Level switches from the drip tray (left) and level switches of the gas separator (right)

A Stop – open
Necessary tools
Safety aspects
Consumables
A Cleaning paper
Procedure
Level switch drip tray
The level switch of the cell stacks drip tray is easily accessible and can be activated manually. Lifting the
float section of the switch will activate it and create an alarm. This can be viewed using the HMI display
terminal. When the switch is lifted the signal shown on the HMI display terminal will go from 'true'-status
to 'false'. It will only return to 'true' after the switch is reset and the alarms of the system reset.
Replace the level switch drip tray when it’s contaminated with KOH.

Section 51 Page 123
Level switch gas separator
See chapter 5.4.15: ‘Replacing the level switch floats’ for procedures on removing and testing level
switches.
LS HG H OK M: True or FalseHigh switch hydrogen gas separator
LS HG L OK M: True or FalseLow switch hydrogen gas separator
LS OG H OK M: True or False High switch oxygen gas separator
LS OG L OK M: True or FalseLow switch oxygen gas separator
In a normal situation the lower level switch float is in its highest position and should read ‘true’ on the
HMI display terminal. The upper float in its lowest position should also read ‘true’.
The opposite positions should read ‘false’.
If the above positions give incorrect messages on the HMI display terminal then the float is probably
upside down, it needs to be turned around and the test repeated.
Level switch normal operating positions.
Figure 20 – Level switch normal operating positions

Page 124 Section 5
5.4.15 Replacing the level switch floats
Figure 21 – Level switch

A Stop – open
Necessary tools
Safety aspects
Consumables
A Cleaning paper
A Level switch floats – 2 per switch
Procedure
1. Undo the small screws that holds the level switch head onto the float section.
Figure 22 – Removing the level switch head
2. Then unscrew the level switch float section from the gas separator, and remove it.

Section 51 Page 125
At this point an entire replacement switch can be fitted and the old switch retro-fitted as
time allows.
3. Clean level switch with warm water and remove any KOH from shaft
4. With the level switch removed, mark the position of the retaining clips with a marker.
Figure 23 – Marking level switch retaining clip positions
5. With the positions of the retaining clips clearly marked, the clips and floats can be removed.

Page 126 Section 5
Figure 24 – Removing level switch retaining clips and floats
The top retaining clip can be left in place as it is not necessary to remove it to change the
float.
6. The new top float can be fitted and its lower retaining clip fitted. The level switch head then needs
to be fitted to the switch and the direction of the float checked.
7. With the top float in place the signal should be checked on the HMI display terminal.
8. With the top float checked, fit the bottom float and check on the MHI display terminal.
9. Ensure all the clips are tightened sufficiently.
10. Refit the level switch into the gas separator, replacing seals as necessary.
11. Fit the level switch head. Take note of the arrangement of slots on the connector, as the head will
fit in only one position.
Figure 25 – Level switch connector arrangement

Section 51 Page 127
5.4.16 Replacing the level transmitter floats
Figure 26 – Float type level transmitter

A Stop – open
Necessary tools
Safety aspects
Consumables
A Cleaning paper
A Level switch floats – 1 per transmitter.
Procedure
1. First unscrew the top from the head of the level transmitter.
2. Take notes or a picture of the wiring arrangement of the inside of the level transmitter.
3. Remove the wiring from the level transmitter; isolate it with electrical isolation tape and place to
one side.
As the level transmitter is connected in an intrinsically safe circuit there is no need to turn
off the power when removing the wiring.

Page 128 Section 5
Figure 27 – Opening the level transmitter head
4. Unscrew the level transmitter and remove from the gas separator.
5. Clean the transmitter thoroughly with paper.
6. At the bottom of the stem of the transmitter is a retaining clip that prevents the float from being
removed. Remove the clip and float from the stem.
Figure 28 – Removing the level transmitter retaining clip and float
7. Replace the old float with a new one ensuring that the float is the correct way up.
8. Refit the retaining clip and tighten.
9. With the transmitter not fitted, reconnect the wiring.
10. Move the transmitter float up and down the stem and verify the position against the display termi-
nal.
11. Remove the wiring from the sensor.
12. Refit the level transmitter to the gas separator replacing any o-rings as necessary. Rewire the
transmitter and confirm the level on the HMI display terminal.

Section 51 Page 129
5.4.17 Checking the level transmitter
Figure 29 – Float type level transmitter

A Stop – open
Necessary tools
Safety aspects
Consumables
A Cleaning paper
A Level switch floats – 1 per transmitter.
Procedure
1. First unscrew the top from the head of the level transmitter.
2. Take notes or a picture of the wiring arrangement of the inside of the level transmitter.
3. Remove the wiring from the level transmitter; isolate it with electrical isolation tape and place to
one side.
As the level transmitter is connected in an intrinsically safe circuit there is no need to turn
off the power when removing the wiring.

Page 130 Section 5
Figure 30 – Opening the level transmitter head
4. Unscrew the level transmitter and remove from the gas separator.
5. Clean the transmitter thoroughly with paper.
6. Reconnect the wiring in the level transmitter outside the gas seperator.
7. Check the bottem, middle and top level of the level transmitter. The bottem should read approxi-
mately 30mm , the middle 150mm and the top 300mm on the electrolyzer screen of the HMI.
8. Disconnect the wiring in the level transmitter.
9. Refit the level transmitter to the gas separator replacing any o-rings as necessary. Rewire the
transmitter and confirm the level on the HMI display terminal.

Section 51 Page 131
5.4.18 Replacing or recalibrating the safety relief valves
Figure 31 – Safety relief valve

A Stop – open
Necessary tools
A Two adjustable spanners or a set of metric spanners
Safety aspects
A See the ‘HySTAT Safety’ section.
Consumables
A None
Procedure
Depending on local codes and standards, safety relief valves need to be recalibrated on a regular basis.
Hydrogenics Europe NV recommends to recalibrate the valves every 3 years.
Be sure that the certificates of the relief valves are valid and check if the sealing is still in place.
It is good practice to have a second set of safety relief valves, to minimize shutdown time.
Recalibration may take several days.

Page 132 Section 5
5.4.19 Inspecting pressure vessels

The pressure vessels of the system include the gas separator, the rinser, demistor, deoxo, drier and heat
exchanger vessels. In-service inspection is subject to National legislation. Explicit reference to in-service
inspection is done in EN 13445-5.
Figure 32 – Pressure vessels of the HySTAT: dryer vessels and gas separator

A Stop – open
Necessary tools
A Dependant on testing procedure
Safety aspects
Consumables
A None
Procedure
Apart from the legal requirements, Hydrogenics Europe NV recommends following inspection intervals.
1. Gas seperator
The gas liquid separator vessel is critical equipment which need periodic inspection to assess their
continued fitness for further service. Corrosion will be the most critical life-limiting factor for this vessel.
Hydrogenics Europe NV recommends a maintenance interval of every 6 years, minimum every 10 years,
implying the following:
1.1. Thorough external visual inspection with special attention for the weld areas.
1.2. NDE of the vessel wall by either one of the following techniques at the location of all
weld areas and areas where possible stress is located (e.g. pipe caps, welded nozzles):
A Ultrasonic scanning technique
A Eddy current test

Section 51 Page 133
Furthermore Hydrogenics recommends to carry out a simple visual external inspection of the vessel
every 2 months. When possible and practical, it is advised that this external inspection is combined with
a visual internal inspection by camera every 3 years, especially at the top of the pipe caps of the O2-gas
separator.
2. Rinser, Demister, Deoxo, Drier and Heat Exchanger Vessels
Hydrogenics recommends a maintenance interval of minimum every 10 years, implying the following:
2.1. Thorough external visual inspection with special attention for the weld areas.
2.2. NDE of the vessel wall by either one of the following techniques:
A Ultrasonic wall thickness measurements on major components and wall thick-

ness evaluation.
A Re-hydrotest of the isolated vessel on the initial hydrotest pressure.
Furthermore we recommend to carry out a simple visual external inspection of the vessel every 2
months.

Page 134 Section 5
5.4.20 Checking and cleaning the electrolyzer solenoid valves

The valves Hydrogen to User, Hydrogen to Atmosphere, Oxygen to User and Oxygen to Atmosphere
should be checked every six months for wear and damage from KOH contamination.
Figure 33 – Valves of the HySTAT

A Stop – open
Necessary tools
A Depending on the type of valve and the connection, a set of metric spanners are necessary and
a set of metric Allen keys.
Safety aspects
A Please read the safety aspects related to hydrogen, oxygen and KOH listed in the ‘HySTAT
Safety’ section.
Consumables
A Valve internal replacement kits.

Section 51 Page 135
Procedure
Always replace the entire valve, and not the solenoid or valve body separately.
Internal spare parts from valve maintenance kits may be used, but solenoid and
valve body should stay together at all times. Contact Hydrogenics Europe NV for
spare and wear parts.
Valves can be cleaned with hot water. Washed valves can be dried with air or nitrogen.
Do not use soap to clean a valve.
Valves used in an oxygen line need oxygen-cleaning before they are (re-)
installed.
See following sections on valve replacement for details.

Page 136 Section 5
5.4.21 Replacing solenoid & pneumatic valves

The counters of the different solenoid & pneumatic valves are incorporated in the PLC and the current
status can be checked on the HMI display terminal. If the number of switches a valve made exceeds
80% of the maximum expected number, the HMI will warn the operator. The valves that will be the first to
reach the maximum amount of switching are the MV O-A valves. For the valve counters see ‘Appendix
A: HMI display terminal’. Some valves will need to be changed before the maximum number of switches
due to wear or KOH contamination.
Figure 34 – Valves of the HySTAT

A Stop – open
Necessary tools
A Depending on the type of valve and the connection, a set of metric spanners are necessary and
a set of metric Allen keys.
Safety aspects
A Read the safety aspects related to hydrogen, oxygen and KOH in the ‘HySTAT Safety’ section.
Consumables
A None
Procedure
Always replace the entire valve, and not the solenoid (or pneumatic actuator) or
valve body separately. Internal spare parts from valve maintenance kits may be
used, but solenoid or pneumatic actuator and valve body should stay together at
all times. Contact Hydrogenics Europe NV for spare and wear parts.
The following procedures use valves XB262C080E, XB262C086E and XB262C007E.

These valves are identical except for the orifice size of the body of the valve.

Section 51 Page 137
A. Replacing entire valve
1. Remove solenoid retaining clip and place carefully to one side.
Figure 35 – Removing the solenoid retaining clip
2. Remove solenoid and place safely to one side (still connected). Remove solenoid spring and put
safely to one side.
Figure 36 – Solenoid valve overview
1 Solenoid 4 Valve body

2 Solenoid retaining clip & spring 5 Compression fitting connections (for example
3 Valve stem Swagelok® connections)
3. Loosen compression fitting connections (for example Swagelok® connections) at inlet and outlet of
valve.
4. Remove piping from one side of valve, to allow removal of the valve.
5. Remove valve.
6. Place new valve in position (with compression fitting connectors for example Swagelok® connec-
tors fitted)
7. Replace pipework.
8. Replace solenoid spring, solenoid and finally retaining clip.
9. Tighten all connections.

Page 138 Section 5
B. Using valve replacement kits
When replacing internal valve parts from replacement kits, make sure the
solenoid or pneumatic actuator is reassembled to the same valve body it was
removed from. Never exchange or interchange solenoids, pneumatic actuators
or valve bodies.
1. Remove solenoid retaining clip and place carefully to one side.
2. Remove solenoid and place safely to one side (still connected).
3. The valve can then be opened, whilst in position, if there is enough room.
4. To open the valve, use a spanner to unscrew the stem from the body of the valve.
Figure 37 – Solenoid valve - opened (1)
5. Remove the stem from the body being careful to catch the internal working parts.
6. Remove the o-ring from the body of the valve.
7. The valve is now broken down into its component parts. (see picture following page)

Section 51 Page 139
2
1
1 Plunger & spring 4 Body

2 Stem 5 Valve replacement kit
3 O-ring
8. The internal parts then can be replaced if worn or damaged, using a 'Valve Replacement Kit'.
9. The stem of the valve (also a spare part) can also be replaced as necessary.
10. The valve can then be re-assembled.
11. Add some oxygen grease to the O-ring.
On the following page can be seen the different valves of the HySTAT and the valve replacement kits
that are available for them.

Page 140 Section 5
Valves of the HySTAT

XB262C080E, XB262C086E and XB262C007E
These valves are the most commonly used valves of the system. The difference between the valves is
the orifice size. (These are the valves used in the two procedures above)
Figure 41 – Valves XB262C080E, XB262C086E and XB262C007E

Section 51 Page 141
XB327A002E – This valve is a 3-way valve with one of the exits permanently blocked. This valve is
normally closed (opens when the valve is energized).
Figure 42 – Valve XB327A002E
1 Stem 4 O-rings
2 Spring 5 Body
3 Plunger 6 Valve replacement kit

Page 142 Section 5
XB262A130E & XB262A134E
These two valves are based on the standard XB262 body but differ in function. These valves unlike the
others of the system are normally open (closed when the valve is energized). The difference between
the two valves is the orifice size. The normally open valves can be recognized by the egg shaped washer
on top of the coil.
3
1
1
3 5
4 4
Figure 43 – Valves XB262A130E & XB262A134E
1 Plunger 4 Body
2 Stem 5 Exploded view of plunger
3 O-rings

Section 51 Page 143
XB202A012E
Whilst most valves of the system are digital in operation (open or closed), this valve is analogue in
operation (variable opening). It is based on the XB262 body but with different internal parts.
Figure 44 – Valve XB202A012E
1 Stem 4 O-rings
2 Spring 5 Body
3 Plunger 6 Valve replacement kit
The valve also differs slightly as there are two white plastic guide rings that are fitted around the plunger.

Page 144 Section 5
Figure 45 – Plastic guide rings around plunger
1 Ring fitted in grooves around plunger

Section 51 Page 145
Pneumatic Valves
There are several pneumatic valves fitted in the system. These are the following.
1
3
Figure 46 – Pneumatic valve
1 Air supply inlet 3 Pneumatic Actuator

2 Description and flow direction notes 4 Valve body
Valve Direction
The valves of the HySTAT, in most cases have a flow direction depending on the valve and the pressure.
Below is shown a cut away view of a typical solenoid valve showing the internal working parts.
Figure 47 – Valve direction
If the flow comes from under the plunger, as shown above, then an increase in pressure (higher than the
differential pressure mentioned on the solenoid) will force the valve open. This means that the direction
of flow can make a difference to the operation of the valve.
For most valves of the system the flow direction is clearly marked with a small sticker. (See below.)
Also on the body of the valve is stamped a number over the inlets and outlets of the valve.

Page 146 Section 5
Figure 48 – Valve flow direction indication
1 Flow direction sticker
However in case of a missing direction sticker, the following list will help:
XB262C080E, XB262C086E, XB262C007E Flow 1 to 2
XB327AOO2E Flow any direction
XB210CO88E Flow IN to OUT
XB202A012E Flow 2 to 1
XB262A130E & XB262A134E Flow 1 to 2

Section 51 Page 147
5.4.22 Cleaning the break tank
Figure 49 – Break tanks

A Stop – open
Necessary tools
A Set of spanners
A Anti-bacterial cleaning agent
A Cleaning equipment
Safety aspects
Consumables
A Cleaning paper
A Cleaning solution
Procedure
1. Close feed water supply to break tank or disable reverse osmosis system.
2. Drain break tank and disconnect all pipework.
3. If possible remove break tank for cleaning. If not cleaning will be performed in place.
4. Prepare cleaning solution.
5. Using solution, clean break tank thoroughly.
6. Rinse the break tank several times to remove cleaning solution with demineralized water.
7. Refit and/or reconnect the break tank.
8. Open feed water supply or enable the reverse osmosis system.
The presence of chlorine in the water supply is damaging to the system. If chlorine is
used during cleaning ensure that the break tank and surrounding pipework are
thoroughly rinsed.

Page 148 Section 5
5.4.23 The HTO analyzer

It is essential for the overall safety of the complete system that the Hydrogen Transmitter in Oxygen
(Ados GTR 196) functions properly. According to the manufacturers’ recommendations for this
equipment, its operation has to be checked every six months. If necessary the HTO has to be
recalibrated. The checking and the calibration have to be done by qualified personnel using the
appropriate calibration gasses.

A Stand-by or Stop
Necessary tools
A Suitable regulators and connecting hoses
Safety aspects
A Read the safety aspects related to oxygen in the Material Safety Data Sheets and the HySTAT
Safety section.
Consumables
A Zero calibration gas: Composition 100% by volume (high purity) oxygen
A Span calibration gas: Composition 1% (or 2%) by volume hydrogen (high purity) in oxygen
Procedures
The re-calibration can be done without stopping production. However if the signal
exceeds the thresholds (high or low) during the re-calibration of the HTO, the HySTAT
will be stopped.

Section 51 Page 149
The HTO panel
7
1
Figure 50 – The HTO panel
1 Magnetic inlet valve – MV O-HTO 5 Inline filter – F O-HTO

2 3-way valve for sampling and calibration gas 6 Ados Hydrogen Transmitter in Oxygen – HTO
connection 7 Flow indicator + flow switch - FI O-HTO + FS O-
3 Flow regulating valve – HV O-HTO HTO
4 Receptacle – D O-HTO 8 Pressure control valve with pressure indicator

Page 150 Section 5
Calibrating the HTO analyzer
To access the Ados GTR 196 calibration controls, remove the manufacturer’s label on
the front.
Figure 51 – Ados GTR 196 HTO analyzer: front controls
1 ZERO point potentiometer 3 Voltage test sockets

2 SPAN potentiometer
ZERO GAS CALIBRATION:
1. Make sure the Ados HTO has been switched ON for at least two hours before continuing.
2. Connect a regulated supply of the zero calibration gas to the 3-way valve (Figure 3-2).
3. Adjust the pressure to 0.7 bar approximately.
4. Adjust the flow to 0.7 l/min approximately using the flow regulating valve (Figure 3-3).
5. Use a voltmeter to measure the voltage between the (+) and the (-) of the voltage test sockets (Fig-
ure 4-3).
6. Let the Ados HTO stabilize until the voltage on the voltmeter no longer changes.
7. Adjust the zero point potentiometer so that the voltmeter reads 204mV (this corresponds to a 4mA
output signal - the internal resistor value equals 51 Ohms).
SPAN GAS CALIBRATION:
1. Connect a regulated supply of the span calibration gas to the 3-way valve (Figure 3-2).
2. Adjust the pressure to 0.7 bar approximately.
3. Adjust the flow to 0.7 l/min approximately using the flow regulating valve (Figure 3-3).

Section 51 Page 151
4. Use a voltmeter to measure the voltage between the (+) and the (-) of the voltage test sockets (Fig-
ure 4-3).
5. Let the Ados HTO stabilize until the voltage on the voltmeter no longer changes.
6. Find the exact percentage by volume hydrogen in oxygen of the calibration gas that is used. Use
the following formula to determine the voltage the voltmeter should read when the calibration gas is
applied to the sensor (in the example, a value of 1 % by volume is used):
(((1 / 2) * 0,016) + 0,004) * 51 = 0,612 V or 612mV.
7. Adjust the span potentiometer so that the voltmeter reads the calculated value.
8. Refit the manufacturer’s label in its original position.

Page 152 Section 5
Automatic check of the HTO analyzer calibration
5
1
6
2
7
3
4
9
Figure 52 – The HTO panel with automatic check of the HTO calibration
1 Non return valve - NRV CG-HTO 6 Flow indicator + flow switch - FI O-HTO + FS
2 Magnetic calibration valve - MV CG-HTO O-HTO
3 Magnetic inlet valve – MV O-HTO 7 Receptacle – D O-HTO
4 3-way valve for sampling and calibration gas 8 Inline filter – F O-HTO
connection 9 Flow regulating valve – HV O-HTO
5 Ados Hydrogen Transmitter in Oxygen – HTO
The calibration gas needs to be connected to NRV CG-HTO. The pressure should be around 3-5 barg.
On the HMI the connected calibration gas needs to be specified in %. Standard a span calibration gas
with composition 1% (or 2%) by volume hydrogen (high purity) in oxygen is used. Every two weeks a
check will be performed to check if the HTO is still within limits:
A If measured value < 75% of calibration gas value: a pre-alarm will be generated
A If measured value > 125% of calibration gas value: a pre-alarm will be generated
A If measured value < 50% of calibration gas value: the unit will be put into standby
This calibration check is used for checking if the calibration of the HTO is done correctly and regularly.
The purpose of this automatic calibration check is only for checking the limits of
the HTO. The customer still has the responsability to calibrate and clean the HTO
analyzer.
For bypassing the HTO calibration check contact Hydrogenics Europe NV.

Section 51 Page 153
5.4.24 Cleaning the HTO panel

It is essential for the overall safety of the complete system that the HTO functions properly. At this time
the panel should be stripped down and the valves and pipework washed with warm water to remove
traces of KOH.

A Stop – open
Necessary tools
A Cleaning water (warm)
A Hand tools for disassembly
Safety aspects
See ‘HySTAT Safety’ section for precautions regarding oxygen and KOH.
Consumables
A Clean water
A Oxygen cleaning fluid
Procedures
The panel should be stripped down and cleaned with warm water and then cleaned with oxygen cleaning
fluid before reassembly.

Page 154 Section 5
5.4.25 The HTA analyzer

The correct operation of the Hydrogen Transmitter in Atmosphere (Zellweger Apex) is essential for the
overall safety of the complete system. A registered company should perform calibration, according to the
information supplied by the manufacturer of this equipment.
Figure 53 – Zellweger HTA
1 Body 3 Cell
2 Sensor

A Stop – purged
Necessary tools
The company performing the calibration may supply these.
A Pressure regulator for gas cylinder
A Flexible tubing from regulator to sensor
A APEX sensor flow housing (see below)
Figure 54 – Apex sensor flow housing
Safety aspects

Section 51 Page 155
Consumables
A Calibration gas 1: 1.8% Hydrogen in Air or Nitrogen.

A Calibration gas 2: Nitrogen or Clean Air
Procedure
The following are recommendations made by Hydrogenics Europe NV. Actual frequency
of testing and recalibration will depend on local regulations. If there are any questions
please contact the Hydrogenics Europe NV service department.
For more information refer to the technical documentation.
A Every 6 months the HTA should be tested using Calibration gas 1. The gas should be applied to
the sensing head, which will result in an alarm.
A Every 6 months, Hydrogenics Europe NV or Zellweger or a registered agency recognized by
Zellweger, should perform a recalibration of the sensor.
A Every 18 months the sensing cell (‘cartridge’) of the HTA should be replaced. For the specific
procedures refer to the APEX technical manual supplied.
The Apex menu controls can be seen in the picture below.
Figure 55 – Apex menu controls

Page 156 Section 5
1. Testing the sensor
1.1. Remove the sensor cap and fit the flow housing.
Figure 56 – Remove the sensor cap and fit the flow housing
1.2. Fit the tubing from the calibration gas pressure regulator to one of the flow housing noz-
zles.
1.3. Open the calibration gas 1: 1.8% H2 in Air/N2 and regulate the flow to about 1 litre/
minute.
1.4. Read the front display to confirm the correct reading (1.8% or 45% LEL).
1.5. Confirm the alarm is activated and the correct action of the unit (stop and depressurize).
1.6. If the reading is not correct or the alarm is not activated then the sensor will need calibra-
tion or replacement.

Section 51 Page 157
2. Calibrating the sensor
2.1. Remove the sensor cartride cap and fit the flow housing.
Figure 57 – Remove the sensor cap and fit the flow housing
2.2. Fit the tubing from the calibration gas pressure regulator to one of the flow housing noz-
zles.
2.3. Press 'ESC' to enter the Main menu of the display.
Figure 58 – Entering main menu
2.4. Using the 'UP' and 'DOWN' keys, navigate to the 'Calibration menu'.
2.5. Press OK
2.6. At the prompt, enter the password: OK, UP, DOWN, DOWN.
Figure 59 – Entering the password
2.7. The Calibration menu will be displayed (see below).
Figure 60 – Entering calibration menu
2.8. Using the 'UP' and 'DOWN' keys, navigate to the 'Gas Calibrate' menu.
2.9. Press OK
2.10. The Zero calibration menu will be displayed -'Zero Gas then OK'.

Page 158 Section 5
2.11. Connect Calibration Gas 2: Nitrogen or Clean Air.

2.12. Open the calibration gas and regulate the flow to about 1 litre/minute.
2.13. Allow the reading to stabilize for a minute or two.
2.14. Press OK.

2.15. The sensor will perform a zero calibration during which the message 'Calibrating' will be
displayed.
2.16. If the calibration is successful the message will display 'Success! Ok:Continue'.
2.17. Press OK.
2.18. The Span calibration window will be displayed - 'Calibrate OK/ESC'.
2.19. Press OK to continue (pressing ESC will exit).
2.20. The 'Span Concentration' of the sensor will be shown on the display.
2.21. Adjust the reading using the 'UP' and 'DOWN' keys until the Concentration shown is the
same as the calibration gas.
2.22. Press OK - the screen shows 'Apply Gas then OK'.
2.23. Connect Calibration Gas 2: 1.8% Hydrogen in Air or Nitrogen.
2.24. Open the calibration gas and regulate the flow to about 1 litre/minute.
2.25. Allow the reading to stabilize for a minute or two.
2.26. Press OK. (pressing ESC will exit the Span calibration).
2.27. The sensor will perform a span calibration during which the message 'Calibrating' will be
displayed.
2.28. If the calibration is successful the message will be displayed - 'Calibrate OK/ESC'.
2.29. Press OK.
2.30. The Calibration Menu will be shown once more.
2.31. Press 'ESC' to exit the calibration menu.
2.32. The 'Main Menu' will be shown.
2.33. Press ECS to exit the' Main menu'

2.34. Remove the flow housing.
2.35. Replace the sensor cap and filter.

Section 51 Page 159
3. Changing the sensor cartridge
3.1. Press 'ESC' to enter the 'Main Menu' (see below).
Figure 61 – Entering main menu
3.2. Using the 'UP' and 'DOWN' keys navigate to the Configuration menu.
3.3. Press 'OK'.
3.4. At the prompt, enter the password: OK, UP, DOWN, DOWN.
Figure 62 – Entering the password
3.5. The Configuration Menu will be shown (see below).
Figure 63 – Entering calibration menu
3.6. Using the 'UP' and 'DOWN' keys navigate to 'Change Cartridge'.
3.7. Press OK.
3.8. The following screen will be displayed.
Figure 64 – Change cartridge menu
3.9. Remove the old cartridge and replace with a new one. Check the fitting direction below.

Page 160 Section 5
Figure 65 – Removing the cartridge
3.10. The screen will change when the cartridge is removed. This is displayed as the sensor
checks the new cartridge.
Figure 66 – Change cartridge in progress
3.11. Once the check is complete the following will be displayed.
Figure 67 – Change cartridge settings
3.12. Press OK.
Figure 68 – Change cartridge OK
3.13. Press OK.
3.14. This return to the configuration menu.
3.15. Press ESC to leave the configuration menu
3.16. Press ESC to leave the Main menu.

Section 51 Page 161
5.4.26 The OTA analyzer

The correct operation of the Oxygen Transmitter in Atmosphere (Zellweger Apex) is essential for the
overall safety of the complete system. If possible a registered company should perform calibration,
according to the information supplied by the manufacturer of this equipment.
Figure 69 – Zellweger APEX OTA
1 Body 3 Cell
2 Sensor

A Stop – purged
Necessary tools
A Regulator
A Flow adapter
Safety aspects
Consumables
A Calibration gas 2

Page 162 Section 5
Procedure
The following are recommendations made by Hydrogenics Europe NV. Actual frequency
of testing and recalibration will depend on local regulations. If there are any questions
please contact the Hydrogenics Europe NV service department.
Zellweger APEX OTA
For more information refer to the technical documentation.
A Every 6 months the OTA should be tested using Calibration gas 2. The gas should be applied to
the sensing head, which will result in an alarm.
A Every 12 months, Zellweger or a registered agency recognized by Zellweger if possible, should

perform a recalibration of the sensor.
Every 24 months the sensing cell (‘cartridge’) of the OTA should be replaced. For the specific
procedures refer to the APEX technical manual supplied.

Section 51 Page 163
5.4.27 The OTH Analyzer

The Oxygen Transmitter in Hydrogen (Panametrics O2X1) is optional. If a deoxo dryer is present, the
OTH is installed after the deoxo dryer; if not, it is installed directly after the generator. For each setup a
different sensor cell is used since the hydrogen purities do not correspond:
A After generator: 10 000ppm (1%) oxygen sensor cell

A After deoxo dryer: 10ppm oxygen sensor cell
Consequently the calibration procedure differs for both setups, and instructions have to be followed
carefully in order not to damage the sensor.
General considerations
A The measuring element of the oxygen cell is a galvanic fuel cell. Exposure to air (the content of
oxygen in air is ~ 21%Vol = 210 000ppm O2) will completely degenerate the fuel cell within a
few hours. Each precaution during operation or transport aims at avoiding exposure to air.
Moreover, air calibration of a 10ppm sensor is strictly prohibited, since it will most likely damage
the fuel cell and warranty will expire.
A During operation, a continuous hydrogen flow of 0.5 l/min over the cell is regulated by a needle
valve and indicated by a flow indicator upstream. If there is no hydrogen production, a flow of
nitrogen will automatically flush the cell and prevent this to come in contact with atmospheric
oxygen (air). Furthermore, if no hydrogen production is to be expected for a longer period of
time, the measurement cell should be switched off; nitrogen purge however should not.
A The procedure described below is for installation of a new sensor. For sensor calibration, follow
through steps 12 to the end. Also refer to the sensor manual.
Figure 70 – Analyzer Panel with Oxygen Transmitter in Hydrogen

Page 164 Section 5
Figure 71 – OTH Analyzer command buttons

A Stop
Necessary tools
A Pressure regulator and piping (6mm compression fitting for example Swagelok®)
A Multi-meter for measuring milli-amp signal
A Basic tool kit
Safety aspects
Consumables
A Calibration Gas 5 for a 10ppm sensor
A Calibration Gas 4 for a 1% sensor
Refer to Appendix D: Specifications utilities for calibration gas specifications.
Procedure
The following procedure is taken from the Panametrics manual for the O2X1 and is for installation of a
new sensor. For calibration perform steps as necessary.
1. Disconnect the power from the O2X1.
2. Loosen the knurled slip nut and remove the O2X1 body from the sensor manifold. If a previous
oxygen sensor is already fitted, remove it now.

Section 51 Page 165
3. Wire a multi-meter in series with the positive power lead of the O2X1, in order to read the milli-amp
signal. This should be done close to the sensor in order to read the signal while adjusting the sen-
sor. Refer to the Electrical Drawings for connection details or contact Hydrogenics Europe NV.
4. Apply power to the O2X1. The sensor initialises in about 15 seconds and then all three LEDs light
up momentarily.
5. Trim the 4-20 mA signal.
Enter the Main menu

5.1. Enter the Main menu by pressing the ‘-’ key and holding for 3 seconds until the LED 3 is
on.
5.2. Press the 'MODE SET' key and the LED 3 turns off and LED 2 turns on.
5.3. Press the ‘-’ key and LED 2 turns off and LED 1 starts blinking. This indicates you have
entered the Main menu and are in the Range Select section of the menu.
5.4. Press the 'MODE SET' key and the LED 1 turns off and LED 2 starts blinking. This
indicates you are in the Output Trim section of the menu.
5.5. Note if the sensor is not touched for 60 seconds then the sensor will exit the Main menu
without saving any changes.
Trimming the Output Low (4 mA)

5.6. Press the ‘-’ key and all LEDs switch off. The O2X1 is now producing an analogue output
at the low range (approx 4 mA)
5.7. Checking the signal with the multi-meter, adjust the milli-amp output to 4.00 ± 0.01 mA,
by pressing ‘+’ key to increase and ‘-’ to decrease.
5.8. When the signal is correct, press ‘MODE SET’ to exit and the LED 2 will start to blink.
Trimming the Output High (20 mA)

5.9. Press the ‘+’ key and all LEDs switch off. The O2X1 is now producing an analogue
output at the high range (approx 20 mA)
5.10. Checking the signal with the multi-meter, adjust the milli-amp output to 20.00 ± 0.01 mA,
by pressing ‘+’ key to increase and ‘-’ to decrease.
5.11. When the signal is correct, press ‘MODE SET’ to exit and the LED 2 will start to blink.
Saving the changes
5.12. Press the ‘MODE SET’ and ‘-’ keys and hold down until all three LEDs start blinking.
Then release the keys, once the results are saved all three LEDs will switch off.
6. Fitting the new sensor
6.1. Open the airtight package and remove the oxygen sensor. In order to maintain the oxy-
gen sensors energy level do not remove the red grounding tabs until ready to proceed to
the next step.
6.2. Orientate the sensor so that its gold plated electrodes are facing the spring loaded
contact pins in the sensor base.
6.3. Firmly press the sensor in to the sensor base.

Page 166 Section 5
Calibration procedure for the 10 000ppm (1%) sensor (after generator)
1. Change the sensor to the 0-10 000ppm range
Enter the Main menu

on.
1.2. Press the 'MODE SET' key and the LED 3 turns off and LED 2 turns on.
Set the Sensor range
1.5. With the LED 1 blinking, press the key ‘+’ to display the current measurement range.
See table for status.
1.6. To change to the required range press the keys ‘+’ or ‘-’ to scroll through the available
options.
1.7. When the correct range is selected (0-10 000 ppm = LED 1 off, LED 2 & 3 on) then press
the key ‘MODE SET’ to exit.
1.8. You are now back in the Main menu, LED 1 blinking.
LED Range Codes
LED 1 LED 2 LED 3 RANGE

OFF ON ON 0-10 ppm
ON OFF OFF 0-100 ppm
OFF ON OFF 0-1000 ppm
OFF OFF ON 0-10000 ppm
ON ON OFF 0-10 %
ON ON ON 0-25 %
Saving the changes

2. Perform Air calibration
Enter the Main menu
on.
2.2. Press the ‘MODE SET’ key and the LED 3 turns off and LED 2 turns on.
2.4. Press the ‘MODE SET’ key and the LED 1 turns off and LED 2 starts blinking. This
2.5. Press the ‘MODE SET’ key and the LED 2 turns off and LED 1 turns on and LED 3 starts
blinking. This indicates you are in the Span Gas Calibration section of the menu.

Section 51 Page 167
2.6. Press the ‘MODE SET’ key and the LED 1 turns off and LED 2 turns on and LED 3
remains blinking. This indicates you are in the Air Calibration section of the menu.
Air Calibration
2.8. Expose the sensor to air for about 2 minutes – the sensor body and cell should not be
fitted to the sensor manifold and as such are exposed to air.
2.9. For the first Air Calibration, press the key ‘-’ and LED 2 & 3 will light up for about 5
seconds whilst the reference value is stored in the memory.
2.10. If the sensor fails to calibrate or there is a problem, then the LEDs will start to flash,
alternately LED 2 on, then LED 1 & 3 on, then LED 2 on etc. If this is the case then
attempt to repeat the calibration and if it fails once more the sensor needs to be
replaced.
2.11. The sensor will then return to the Main menu, LED 2 on and LED 3 blinking.
Saving the changes

Page 168 Section 5
Calibration procedure for the 10ppm sensor (after deoxo dryer)
Air calibration as described above is to be performed on a 10 000ppm sensor

only. If it is performed on a 10ppm sensor, the sensor is very likely to get
damaged, and warranty will expire.
1. Fit the sensor to the manifold and apply Calibration Gas 5 (low ppm)
1.1. Fit the sensor body and sensor into the manifold using the knurled nut on the body.
1.2. Rotate the sensor to the required position.

1.3. Tighten the knurled nut by hand to hold the body in position.
1.4. Apply a flow of Calibration Gas 5 (low ppm).
2. Change the sensor to the 0-10 ppm range
Enter the Main menu
on.
Set the Sensor range
2.5. With the LED 1 blinking, press the key ‘+’ to display the current measurement range.
See table for status.
2.6. To change to the required range press the keys ‘+’ or ‘-’ to scroll through the available
options.
2.7. When the correct range is selected (0-10 ppm = LED 1 off and LED 2 & 3 are on) then
press the key ‘MODE SET’ to exit.
2.8. You are now back in the Main menu, LED 1 blinking.
LED Range Codes
LED 1 LED 2 LED 3 RANGE

OFF ON ON 0-10 ppm
ON OFF OFF 0-100 ppm
OFF ON OFF 0-1000 ppm
OFF OFF ON 0-10000 ppm
ON ON OFF 0-10 %
ON ON ON 0-25 %
Saving the changes
3. Perform span gas calibration (10 ppm range)

Section 51 Page 169
Enter the Main menu

on.
3.4. Press the ‘MODE SET’ key and the LED 1 turns off and LED 2 starts blinking. This
3.5. Press the ‘MODE SET’ key and the LED 2 turns off and LED 1 turns on and LED 3 starts
blinking. This indicates you are in the Span Gas Calibration section of the menu.
Span gas calibration
3.7. Ensure that the sensor has been exposed to Calibration Gas 5 (low ppm) for about 2
minutes – the sensor body and cell should still be fitted to the sensor manifold. Allow the
reading stabilise.
3.8. For the first Span Gas Calibration, press the key ‘-’ and all the LEDs will switch off.
3.9. Check the milli-amp signal on the multi-meter. The signal should correspond to the
following formula
span gas ppm
Output (mA) = 4.0 + (16.0 x )
full range ppm
E.g. for 8 ppm calibration gas in the 10 ppm range:
Output (mA) = 4.0 + (16.0 x 8/10) = 16.8 mA
3.10. If the signal is not correct it can be adjusted using the ‘+’ & ‘-’ keys.
3.11. When the signal is stabile at the correct value, press the 'MODE SET' key. If the sensor
is calibrated ok it will return to the Main menu, LED 1 on and LED 3 blinking.
3.12. If the sensor fails to calibrate or there is a problem, then the LEDs will start to flash,
alternately LED 2 on, then LED 1 & 3 on, then LED 2 on etc. If this is the case then
attempt to repeat the calibration and if it fails once more the sensor needs to be
replaced.
Saving the changes
The procedure should be repeated 24 hrs later, from step 7 until the end.

Page 170 Section 5
5.4.28 Replacing the dewpoint transmitter
Figure 72 – Analyzer panel with dewpoint transmitter

A Stop – cold
Necessary tools
Safety aspects
Consumables
A None
Procedure
It is not possible to calibrate the dewpoint transmitter in place, it will have to be sent to a registered agent
for recalibration.
Remove the power from the transmitter and isolate the gas supply to the analyzer panel. Remove the
wiring and pipe work from the transmitter and take out the complete unit.

Section 51 Page 171
5.4.29 Check functionality of door switch power rack
Figure 73 – Checking functionality of door switch power rack

A Run
Necessary tools
A N/A
Safety aspects
Consumables
A N/A
Procedure
1. Open power rack door for ±10 centimeters.
Don’t touch any components inside the enclosure!
2. Desired response:
2.1. DC current drops immediately to 0 A
2.2. Main contactors in the power rack open after approximately 5 s.
3. Repeat his sequence untill all power rack door switches have been tested.

Page 172 Section 5
5.4.30 Check functionality of flooding detection device
Figure 74 – Checking functionality of flooding detection device

A Run
Necessary tools
A N/A
Safety aspects
Consumables
A N/A
Procedure
1. Simulate flooding by activating the detection device (level switch LS EPS 1.1 or conductivity
probe).
2.1. Magnetic valve ‘Water header inlet’ MV1 F_BT-H closes
2.2. DC current drops immediately to 0 A for all Cell Stacks.

2.3. Main contactors in the power rack and controll panel open after approximately 5 s.
3. Repeat his sequence untill all level switches have been tested.

Section 51 Page 173
5.4.31 Check functionality of air flow switch
Figure 75 – Checking functionality of air flow switch

A Run
Necessary tools
A N/A
Safety aspects
Consumables
A N/A
Procedure
1. Check that all container doors are closed and that flow switch status is ‘ok’. This can be seen as a
green dot on the HMI screen for the utilities OH.
2. Open process room door for ± 45°
3.1. Flow switch status ‘Nok’. This can be seen as a red dot on the HMI screen for the utilities
OH.
3.2. After 30 minutes:
A the DC current drops to 0A for all Cell Stacks.

A Main contactors in the power rack open after approximately 5 s.
A Unit is depressurized automatically

Page 174 Section 5
5.4.32 Check functionality of current switch for process fan
1
2
Figure 76 – Checking functionality of current switch for process fan
1 Breakers of fans 2 Current switches of fan

A Run
Necessary tools
A N/A
Safety aspects
Consumables
A N/A
Procedure
1. Check that all container doors are closed.
2. Switch breaker to the OFF position of the operation fan.
3.1. the DC current drops to 0A for all Cell Stacks
3.2. Main contactors in the power rack open after approximately 5 s.

3.3. Unit is depressurized automatically

Section 51 Page 175
5.4.33 Changing taps of transformer in power rack
Figure 77 – Changing taps of transformer in power rack
1 Primary taps of transformer 2 Secundary taps of transformer
The power transformers in the power rack is equipped with 3 primary taps and 3 secundary taps. This
allows the AC/DC converter to work in its optimal point independent from grid voltage or cell voltage.
Primary taps: 0 (nominal), -5% and -10%
Secundary taps: 0 (nominal), -7% and +14%

A Stop - cold
Necessary tools
A A multimeter
Safety aspects
A Make sure the main fuse supplying power to the SCR, transformer and diode bridge for each
cell stack, inside the EPS enclosure, is “OFF”.
A Be aware of the fact that only switching of the main switch in the process enclosure will not nec-
essarily shut down the 240 V circuit. (Refer to electrical drawings).
A Check if there is no remaining voltage on the transformer (use a multimeter).
Consumables
A None

Page 176 Section 5
Procedure
Allways shut down the unit and disconnect from the electrical supply before
changing the taps.
Before checking any power connection, first check the connection with a
multimeter to ensure there is no voltage.
For choosing the most optimal working point for the transformer the graphic shown below should be
used. On the X-axis the grid voltage and on the Y-axis the cell voltage is shown. In the legend different
settings of the primary (P) and secundary (S) taps of the tranformer are listed.
1
2
Figure 78 – Settings graph for optimal point of transformer
1 Axis for 3x400 VAC installation 2 Axis for 3x480 VAC installation
For a tap setting example:
A grid voltage = 380 VAC
A cell voltage = 1,9 V/cell
The next steps need to be followed to determin the most suitable tap settings:
1. Draw a vertical line at the grid voltage and a horizontal line at the cell voltage. Find the intersection
of these two lines (green dot)
2. Find all intersections between the drawn vertical line and all sloped lines (red circles).
3. Now pick the first red circle starting from the green dot going upwards. The sloped line that inter-
sects here is the optimal tap setting.

Section 51 Page 177
For this example the result is:
A primary taps: -10%

A secundary taps: 0 (nominal)
Figure 79 – Settings graph for example 380 VAC and 1,9 V/cell
1 Use axis for 3x400 VAC installation 3 Intersection with optimal tap setting
2 Draw vertical and horizontal line
Before turning back on the main power, check that the taps and other electrical
connections are torqued sufficiently.

Page 178 Section 5
5.5 Scheduled maintenance – Deoxo dryer

The deoxo dryer is designed to run completely automatically and almost maintenance free. Users of the
deoxo dryer are however recommended to follow a preventive maintenance schedule in order to ensure
a continuous and reliable supply of hydrogen.
It is recommended to perform a regular analysis of the gas after the dryer to ensure quality. Insufficient
gas quality may be the result of a failure of the dryer system; please contact Hydrogenics Europe NV if
this is the case.
Perform a general check up every 6 months and replace parts according to the maintenance schedule
found in chapter ’5.4.1: Maintenance schedule’.
Only qualified personnel are allowed to perform maintenance to the HySTAT. If

no such personnel is available, only the HySTAT supplier is allowed to perform
maintenance.

Section 51 Page 179
5.5.1 Purging the deoxo dryer

During many maintenance operations or in the event of 'hot work' within the hazardous area then the
deoxo dryer needs to be purged with an inert gas to ensure the system is safe.
It is recommended that an engineer, before performing maintenance to the deoxo dryer, performs an
inert gas purge of the deoxo dryer, followed by a deoxo dryer depressurization to ensure a safe
environment. Refer to ‘4.2: HySTAT Electrolyzer operation‘ for operating instructions.
After any purge cycle the regeneration flow and pressure will have to be reset
once the system is put back into normal operation.

Page 180 Section 5
5.5.2 Replacement of the coalescing filter after deoxo vessel
Figure 80 – In-line filters after deoxo dryer
Condition of the deoxo dryer

A Stop
Necessary tools
A Adjustable spanner
Safety aspects
A See ‘HySTAT Safety’ section
Consumables
A Filter cartridge
Procedure
See technical information on Balston Compressed Air and Gas In-Line Filters.

Section 51 Page 181
5.5.3 Check instrument air supply
Figure 81 – Instrument air pressure indicator

A Run
Necessary tools
A None
Safety aspects
Consumables
A None
Procedure
Read instrument air pressure on gauge PI IA. Pressure should be between 5 and 7 barg.

Page 182 Section 5
5.5.4 Check/Replace filter on instrument air supply
Figure 82 – Instrument air filter

A Stop
Necessary tools
A None
Safety aspects
Consumables
A New filter element
Procedure
See technical documentation Balston Compressed Air and compression fitting filters (for example
Swagelok® filters).

Section 51 Page 183
5.5.5 Replacement of the coarse particle filter element
Figure 83 – Filter element replacement

A Stop
Necessary tools
A Adjustable spanner
Safety aspects
Consumables
A Filter cartridge
Procedure
See technical documentation Balston Compressed Air and compression fitting filters (for example
Swagelok® filters).

Page 184 Section 5
5.5.6 Replacement of the solenoid valves
Figure 84 – Solenoid valve replacement

A Stop
Necessary tools
A Two adjustable spanners
Safety aspects
Consumables
A None
Procedure
See chapter ‘5.4.21: Replacing solenoid & pneumatic valves’ in this manual for details of valves and their
replacement.

Section 51 Page 185
5.5.7 Replacement of the pneumatic valves
Figure 85 – Pneumatic valve

A Stop
Necessary tools
A Two adjustable spanners
Safety aspects
Consumables
A None
Procedure
See chapter ‘5.4.21: Replacing solenoid & pneumatic valves’ in this manual for details of valves and their
replacement.

Page 186 Section 5
5.5.8 Exchange catalyst in deoxo dryer
Figure 86 – Deoxo dryer

A Stop – open
Necessary tools
A Heavy lifting equipment (chain block or forklift)
Safety aspects
A Risk of injury through eye contact! If the catalyst gets into contact with the eyes, flush them thor-
oughly with clean water and seek medical attention in all cases.
A Risk of injury through swallowing! Seek medical attention in all cases.
A While handling the catalyst, a dust mask must be worn.
Consumables
A Cleaning paper
Procedure
Every five years or depending on an analysis of the produced hydrogen, then the entire contents of the
catalyst vessel (deoxo) should be changed.
For references to filling and emptying the system, contact Hydrogenics Europe NV.

Section 51 Page 187
5.5.9 Exchange molecular sieve in deoxo/dehydro dryer
Figure 87 – Typical lifetime molecular sieve and H2 losses for dryer with dew point -60°C and -75°C
If the cooling water is supplied from an external network (no closed loop cooling system),
the deoxo dryer molsive exchange interval is highly dependent on the temperature of the
cooling water. Refer to the graph above to determine the correct exchange interval.

A Stop – open
Necessary tools
A Heavy lifting equipment (chain block or forklift)
Safety aspects
A Risk of injury through eye contact! If the molecular sieve gets into contact with the eyes, flush
them thoroughly with clean water and seek medical attention in all cases.
A Risk of injury through swallowing! Seek medical attention in all cases.

A While handling the molecular sieve, a dust mask must be worn.
Consumables
A Cleaning paper

Page 188 Section 5
Procedure
Every ten years, or according the graph shown above, the entire contents of the two drying vessels
(dryer A and dryer B) should be changed.
For references to filling and emptying the system contact Hydrogenics Europe NV for further information.

Section 51 Page 189
5.6 Troubleshooting
Troubleshooting of the HySTAT is assisted by the system itself. The PLC automatically records various
events concerning the operation of the system such as change of set points, changes of the phase of
operation, alarms, shutdowns, etc. These events are a very powerful tool in the troubleshooting of the
system as they provide information leading up to the problem as well as during the problem itself. For
this reason the first part of troubleshooting is the interpretation of the events listing of the system. The
events deal with not only the HySTAT but also the deoxo dryer and all other options.
The second part of this section deals with certain problems not covered by the events listing or where the
events may not be accessible. This is dealt with in tabular form.
The operator performing the troubleshooting must be familiar with all sections of
the HySTAT manual, including the appendices. Only qualified personnel are
allowed to perform maintenance or repairs.

Page 190 Section 5
5.6.1 The events table
General
Events can be consulted on the HMI display terminal.
This troubleshooting guide is based on the events that can occur with the generator and its options. In
the event of the generator stopping then the events list should be consulted and the table shown (see
further) referred to. Make a note of the event and its code for reference to the table.
HMI display terminal events listing
For detailed operating instructions for the HMI display terminal, refer to ‘Appendix A: HMI
display terminal’.
The events screen gives an overview of all relevant events that have been logged. Each event can
contain the following information:
A chronological order of the event
A date or time of the event; the operator can alternate between both
A event code
A event description (comment)
A event unit (if applicable)

Section 51 Page 191
5.6.2 Investigating start conditions

The flowchart below shows the way in which start conditions should be investigated. A detailed list of
start conditions and their explanation can be found in ‘Appendix C: Start conditions’.
Figure 88 – Start conditions investigation flowchart

Page 192 Section 5
5.6.3 Troubleshooting
Events and troubleshooting concerning the deoxo dryer and oxygen drying systems are covered in the
same table as those of the HySTAT.
Whenever you are working on the unit always take care with operating conditions such as the power
connection and pressure (please refer to the precautions in the ‘HySTAT Safety’ section).
Troubleshooting HySTAT
No Failure mode Potential cause of failure Corrective action

1 Display does not light up Main cable defective Check fuses in local distribution
when HySTAT connected A fuse is open panel and verify mains circuit
to the mains supply. Plug and/or unit cable defective Check plug and cable and replace if
Control unit defective necessary
Call service technician
2 The HySTAT does not Start up conditions are not fulfilled Refer to section HySTAT Operation
start Key switch is switched to “0” and Appendix C: Start conditions
Switch key to “I”
3 Level difference between A solenoid valve in the highest- Call the service technician
LTH and LTO more than level circuit is leaking.
20 mm during normal A solenoid valve in the lowest level
operation circuit is closed or there is a restric-
tion.
The PLC indicates an incorrect sig-
nal.
4 H Warning on LTH and Too much electrolyte in the system Check that the electrolyte level is
LTO at the same time not too high or too low in standby
(140mm). If necessary drain elec-
trolyte through the KOH sampling
valve HV E-S.
5 L warning on LTH and Too little electrolyte in the system or Check water supply
LTO at the same time demin water fill-up system does not Fill electrolyte
work properly.
6 Warning LTH L or warning The oxygen valve is defective or Call service technician
LTO L Level transmitter defective
7 Alarm PT H Hydrogen pressure is too high due Call service technician.
to defect in pressure regulating sys- Change maximum current setting
tem on the HMI display terminal. See
Warning PT L Maximum current setting is too low Appendix A: HMI.
Gas consumption is too high Reduce the demand.
8 Alarm TTE H Electrolyte temperature is too high Check electrolyte cooler
due to defective cooling Check water supply
Water pressure too low Check water supply
Temperature of cooling water too Call service technician
high
Cooling solenoid valve defective
9 Alarm TTE BW Hydrogen temperature is too low Call service technician
due to:
• Defective transmitter, defective
sensor or open connections
• Ambient temperature below zero
10 Alarm on low current Pressure in the customer system Check for blocked pipes
was too high Increase flow or create extra con-
Requested flow is too low sumption
11 Warning UT CSx H Cell stack voltage too high Call service technician

Section 51 Page 193
Troubleshooting deoxo dryer
No. Failure mode Potential cause of failure Corrective action

1 Production stops - To identify the correct alarm see HMI
Buzzer on or HySTAT SCADA.
The temperature of one of the dryer Check heating unit, solid-state relay.
vessels has risen above the upper
alarm set point
The temperature of the deoxo has Check heating unit, solid-state relay.
risen above the upper alarm set point
The temperature of one of the dryer Check flow of regeneration gas, check
vessels during the cooling step is still heating unit, solid state relay
above the set point after a predefined
time interval
The temperature of one of the dryer Check heating unit, solid-state relay.
vessels during the heating step is still
below the set point after a predefined
time interval
The temperature of the deoxo during Check heating unit, solid-state relay.
the heating step is still below the set
point after a predefined time interval
The temperature of one of the vessels Check heating unit, solid-state relay.
(deoxo and dryer) has risen above the
set points of the thermostats
2 Pressure or flow of Filter after the dryer FU is blocked Replace the filter element (use recom-
the purified gas too mended filter element)
low The loading of the coalescing filter ele- Replace filter element (use recom-
ment of the DP H is too high mended filter element)
Flow regeneration gas too high Check flow indicator RHV RG
One of the pneumatic activated valves See 3
(XV…) isn't opening
3 One of the pneu- Compressed air supply not correct: Adjust pressure with air pressure regu-
matic activated see PI IA lator (APR)
valves (XV…) isn't Pressure should be 5 to 7 barg
opening One of the pneumatic valves is dam- Replace pneumatic valve
aged
One of the solenoid valves that oper- Replace solenoid head of relevant
ates the pneumatic valves is damaged solenoid valve
4 Gas purity drops Reaction in catalyst column not OK See 5
Adsorption in column not OK See 6
Contamination due to leaks Check leak tightness. Correct if neces-
sary
5 Reaction in catalyst Temperature during reaction too low Check set point and heating elements
column not OK (set point at 60°C)
Catalyst packing is not OK (activity The complete vessel should be
loss) exchanged. The activity loss is a slow
process (many years). If the operating
temperature is increased, the activity
will be slightly better. This allows you
to make the necessary arrangements
to exchange the vessel without any
downtime.

Page 194 Section 5
No. Failure mode Potential cause of failure Corrective action

6 Adsorption in col- Volume of regeneration gas too low See 7
umn not OK Check flow indicator RHV RG
Temperature during regeneration too
low
Temperature during adsorption too See 8
high
Moisture content in the gas entering See 9
the adsorption column is too high
7 Flow regeneration Needle valve RHV RG not correctly set Adjust flow (reading on Flow indicator)
gas too low One of the pneumatically activated See 3
valves (XV…) isn't opening
8 Temperature during Insufficient cooling See 10
adsorption too high Heating occurs if not desired Check heating unit – solid state relay
9 Moisture content in Coalescing filter (DP H) is damaged Replace filter element (use recom-
the gas entering the mended filter element)
adsorption column Level switch drain pot DP H is not Order and replace level switch
is too high functioning In the mean time the deoxo dryer can
still be operated. Empty the drain pot
DP H weekly
Outside temperature is above design Reduce maximum capacity and
condition change timers regeneration steps
Very important for closed loop cooling
systems
Incorrect time sequences Contact Hydrogenics Europe NV to
change time sequences
Adsorption packing is not OK (activity Complete vessel(s) should be
loss) exchanged
The activity loss is a slow process
(many years). If the regeneration pro-
cess is adjusted and/or the capacity of
the HySTAT limited, the deoxo dryer
will be able to obtain the required
purity. This allows you to make the
necessary arrangements to exchange
the vessel with a minimum downtime.
Contact Hydrogenics Europe NV to
change the regeneration process.
10 Insufficient cooling Cooling water temperature is too high Action depends on the cooling water
supply
This failure mode will be seen at the
HySTAT (electrolyte cooling) first
Flow cooling water insufficient See 11
11 Volume of cooling Cooling water circuit blocked Clean circuit
water insufficient

Section 51 Page 195
Level control failure

Automatic safety measures due to a failure of the level control requires special attention. Whenever a
problem with the level control in one of the gas separators is detected, a special routine is activated. The
following problems can occur:
Detected problem Automatic safety routine

No measurement: no signal from level transmit- All valves will be closed.
ters and level switches
LTO BW AND LTH BW: Broken wire of the both Depressurization based on the level switches
level transmitters (standby)
LTH BW: only Level Transmitter Hydrogen Broken Depressurization based on the oxygen level
Wire transmitter (standby)
LTO BW: only Level Transmitter Oxygen Broken Depressurization based on the hydrogen level
Wire transmitter (standby)
All LS failed: no signal from the Level Switches Depressurization based on the level transmitters
(standby)
LS HG Failed: No signal from Level Switch Hydro- Depressurization based on the level transmitters
gen (standby)
LS OG Failed: No signal from Level Switch Oxy- Depressurization based on the level transmitters
gen (standby)
LS HG H: High position Level Switch Hydrogen Depressurization based on the oxygen level
activated transmitter (standby)
LS HG L: Low position Level Switch Hydrogen Depressurization based on the oxygen level
activated transmitter (standby)
LS OG H: High position Level Switch Oxygen acti- Depressurization based on the oxygen level
vated transmitter (standby)
LS OG L: Low position Level Switch Oxygen acti- Depressurization based on the oxygen level
vated transmitter (standby)

Page 196 Section 5

HySTAT MANUAL
Appendix A: HMI display terminal

Page 2 Appendix A:
HySTAT MANUAL HMI DISPLAY TERMINAL
Appendix A: HMI DISPLAY TERMINAL
A.1 Getting Started

A.1.1 General
The Exter T70®, Exter T100® or Exter T150® HMI display terminal installed in your HySTAT, displays all
information required to operate the HySTAT, and can be used as an input device to enter set points and
other data. This appendix shows the most common screens, and how they are accessed and operated.
Due to product development, some screen layouts on your HySTAT HMI display terminal
may differ from those represented in this manual. Feel free to contact Hydrogenics Europe
NV when in doubt.
The Exter Txx® HMI display terminal is a touchscreen, which allows the operator to interact with it intu-
itively. The functions displayed on the screen can be activated by lightly pressing the screen.
Using an object with a small and soft tip may help to access small command buttons.
Each HySTAT can be divided in several sub-assemblies: the electrolyzer, utilities (like closed loop cool-
ing, reverse osmosis system, chiller, ...), the deoxo drier and the dehydro drier. These sub-assemblies
and tools for controlling and debugging the HySTAT are the main components of the HMI. The following
groups can be found:
A GGS: information and actions for controlling the Electrolyzer
A UTIL: information and actions for the Utilities (closed loop cooling, reverse osmosis system,
chiller, outer housing cooling and ventilation, ...)
A HPS: information and actions for the deoxo drier
A OPS: information and actions for the dehydro drier
A Info and Debug: general information and tools for debugging and overviewing the complete unit

Appendix A: Page 3
HMI DISPLAY TERMINAL HySTAT MANUAL
A.1.2 Using the display terminal

Once the screen is started up, the Main screen pops up:
Figure 1 – Main screen
In this screen you can see the project number of the installation and the contact information of Hydrogen-
ics Europe NV.
Pressing the Go to Process key will open the Electrolyzer screen, as shown in Figure 6 – GGS1 screen.
A.1.3 Screen headers

In the Exter different headers can be distinguished according the different sub-assemblies in the unit:
A Screen header for GGS
A Screen header for UTIL
A Screen header for HPS
A Screen header for OPS

A Screen header for Debugging tools
Screen header for GGS1
Figure 2 – GGS1 screen header
The header as shown in Figure 2 – GGS1 screen header, is visible at the top. Next to a number of com-
mand buttons, it contains the following information labels:

Page 4 Appendix A:
A day, date and time
A HySTAT status (N2 purge, H2 production, etc.)
A actual password level (PW 0 to PW 7)
A keyswitch position (green/red, i.e. on/off)
A additional status information (during production: actual production rate

and produced volume of hydrogen; during purge phases: time left in sec-
onds; etc.)
A buzzer status (green/red, i.e. off/on)
The command buttons in the header, when pressed, invoke the action indicated as follows:
Info Show Info screen

GGS1 Show GGS1 screen
UTIL Show UTIL screen
HPS Show HPS screen
Previous Show previous screen
Reset Reset alarms
Screen header for UTIL
Figure 3 – UTIL screen header
The header as shown in Figure 3 – UTIL screen header, is visible at the top. Next to a number of com-
A additional status information off the CT panel or ROS installation


HPS Show HPS screen
Reset Reset alarms

Appendix A: Page 5
Screen header for HPS
Figure 4 – HPS screen header
The header as shown in Figure 4 – HPS screen header, is visible at the top. Next to a number of com-
A additional status information about the HPS
A heating of the HPS enabled or disabled

HPS Show HPS screen
Reset Reset alarms
Screen header for OPS

This is comparable to the HPS header.
Screen header for Info and debugging tools
Figure 5 – Info and debugging screen header
The header as shown in Figure 5 – Info and debugging screen header, is visible at the top. Next to a
number of command buttons, it contains the following information labels:


Page 6 Appendix A:
HPS Show HPS screen

Reset Reset alarms
STCD Show STCD screen
Events Show Event screen
Alarms Show Alarms screen
Debug Show Debug screen

Appendix A: Page 7
A.2 Electrolyzer screens

A.2.1 GGS1 screen
Figure 6 – GGS1 screen
Path: Main - Go to Process
The GGS1 screen shows all available information from the electrolyzer process. The main screen ele-
ments are the cell stacks, and the 2 gas-liquid separators. Specific colors are used for the different
media:
A blue lines for oxygen
A red lines for hydrogen
A green lines for inert gas

A light blue lines for demin water
Valve states are to be interpreted as follows:
A a colored valve symbol means the valve is open
A a white valve symbol means the valve is closed
The green ( ) or red ( ) dots indicate the states of the switches in the system (flow switches, level
switches, temperature switches etc.). A green dot means the switch status is OK, a red dot means its
status is NOK. Alarm states from analog measurements, such as the TTCS, ITCS, etc, are also indicated
by a green or a red dot, as well as the demin water pump status: a green dot indicates the pump is run-
ning, a red dot means it is not.

Page 8 Appendix A:
The information given above about line colors, valve states, switch states etc. is valid
throughout this manual.
The command buttons at the bottom of the screen, when pressed, invoke the actions indicated as fol-
lows:
Tr. Proc. Show Process trends screen

PWR Show Power systems screen
En/Dis CS Show Enable/disable cell stacks screen
CS Det. Show Cell stack details screen
Data Show Production counters screen
Actions Show Actions screen
STCD Show N2P Start conditions of GGS1
A.2.2 Trending Process screen
Figure 7 – Trending Process screen
Path: Main - Go to Process - Tr. Process
The Trending Process screen shows real-time trends of the different analog channels in the HySTAT
process. The actual values of each channel are written in the colored boxes on the right hand side of the
screen (the colors of the boxes correspond to the colors used in the trending screen). Other trending
screens can be accessed by pressing the command buttons at the bottom of the screen.
The visible time frame can be set between 0,05 hours and 24 hours. The actually used time frame is indi-
cated in the grey label at the right hand bottom side of the screen (1 hour in the screen printed above).

Appendix A: Page 9
A.2.3 Power screen
Figure 8 – Power screen (PA1)
Path: Main - Go to Process - PWR
The Power screens show a simple schematic of the electrical power circuit and all of its available param-
eters in the concerned power cabinet. The used abbreviations are explained hereafter:
CS1 (or 2) Cell stack 1(or 2)

EAM Enable angle mode
FQ Frequency drive
Main cont. Main contactor
R Up (Down) Ramp up (down)
SP Set point
Thyr. Stack Thyristor stack
TS Temperature switch
TS DIO Temperature switch diode bridge
TT Temperature transmitter
The command buttons at the bottom of the screen, when pressed, invoke the actions indicated as fol-
lows:
PWR 2 Show Power screen PA2

Tr PWR1&2 Show Power rack temperature transmitters screen

Page 10 Appendix A:
A.2.4 Enable/Disable cell stacks screen
Figure 9 – Enable/disable cell stacks screen
Path: Main - Go to Process - En/Dis CS
The status of the hardware enabling is displayed for reference. The software enabling and disabling of
the purge and production of the cell stacks can be done through the HMI display terminal with the purge
enabled/disabled and prod. enabled/disabled button on the screen. See ‘Chapter 4.2.7: Starting the HyS-
TAT’ for more information about the operation.
Pressing a green or red command button will respectively software disable or software enable the cell
stack in question. The command buttons at the bottom of the screen can be used to either software
enable (En All) or software disable (Dis All) all of the cell stacks at once.

Appendix A: Page 11
A.2.5 Cell stack details screen
Figure 10 – Cell stack details screen
Path: Main - Go to Process - CS Det.
The Cell stack details screen displays all relevant information for each cell stack separately.

Page 12 Appendix A:
A.2.6 Production counters screen
Figure 11 – Production counters screen
Path: Main - Go to Process - Data
The Production counters screen displays all relevant production data for each cell stack separately, plus
the total production, for the course of the past month. Pressing the Next command button at the bottom
of the screen will scroll the table further down (backwards in history).

Appendix A: Page 13
A.2.7 Electrolyzer actions screen
Figure 12 – Electrolyzer actions screen
Path: Main - Go to Process - Actions
This screen allows for the operator or engineer to invoke certain actions to the electrolyzer. The avaible
actions are accessible to higher login levels only:
Depress. Depressurize the HySTAT

Skip Seq. Skip the current sequence (Hydrogenics Service only)
Auto St. Automatic start the HySTAT after purge (Hydrogenics Service only)
Start BT Fill. Start break tank filling
Setpoint Pressure Change the pressure setpoint
Setpoint Temperature Change the temperature setpoint
Setpoint Current Change the current (amps) setpoint

Page 14 Appendix A:
A.2.8 Electrolyzer start conditions screens
Figure 13 – Electrolyzer start conditions screen
Path: Main - Go to Process - STCD
The Start conditions screens, of which the N2 Purge start conditions screen is shown above, contain a
list of all appliccable start conditions for the selected action or piece of equipment. The words TRUE and
FALSE are used to indicate whether the listed start condition is true or false.
The command buttons at the bottom of the screen can be pressed to open the subsequent start condi-
tions screens:
N2P Show Nitrogen purge STCD screen

H2P Show Hydrogen purge STCD screen
CS1/2/3/4 Show Cell stack 1/2/3/4 STCD screen

Appendix A: Page 15
A.3 Utility screens

A.3.1 Closed loop cooling screen
Figure 14 – Closed loop cooling screen
Path: Main - Go to Process - UTIL
The Closed loop cooling screen shows all available information: temperature- and pressure values, ana-
lyzer values, switch states, valve states, etc off the chiller, the electrolyte cooling system and the closed
loop cooling system.
Command buttons at the bottom of the screen:
ROS Show Reverse osmosis system screen

OH Show Outdoor housing screen
STCD Show Util basic startconditions screen
TR CLC PT Show Trend closed loop cooling pressure transmitters screen
TR CLC TT Show Trend closed loop cooling temperature transmitters screen

Page 16 Appendix A:
A.3.2 RO System screen
Figure 15 – RO System screen
Path: Main - Go to Process - UTIL - ROS
A RO system status
A RO system enabled (green) / disabled (red)
A Break tank filling enabled (green) / disabled (red)
A Conductivity transmitter value
A Anti-scalant level switch and dosing pump indication
A Break tank level switch states (High/Low/Low low)
Command buttons at the bottom of the screen (note that some actions are accessible to higher login lev-
els only):
CLC Show Closed loop cooling screen

OH Show Outdoor housing screen
Start BT Fil. Start filling of break tank
Fill Calc. Show Fillup calculations screen
TR CLC/RO Show Trending screen for RO system and Closed loop cooling

Appendix A: Page 17
A.3.3 Fill calculation screen
Figure 16 – Fill calculation screen
Path: Main - Go to Process - UTIL - ROS - Fill Calc.
The Fill calculation screen is used for controlling and regulating the filling of the break tank. Some
parameters for filling the break tank can be adjusted here. In normal operation filling is enabled at
standby. With the three command buttons under the filling command button, some events can be logged.

Page 18 Appendix A:
A.3.4 Outdoor housing screen
Figure 17 – Outdoor housing screen
Path: Main - Go to Process - UTIL - OH
The Outdoor housing screen shows all relevant information available for the HySTAT’s outdoor housing,
in a graphical layout:
A temperature transmitter values
A temperature switch status indications

A flow switch status indication
A differential pressure switch status indication
A ventilation setpoints (fan speed indication in %)

A emergency pushbutton status indications
A room air analyzers: HTA (hydrogen in atmosphere) and OTA (oxygen in atmosphere)
Command buttons at the bottom of the screen (note that some actions are accessible to higher login lev-
els only):
CLC Show Closed loop cooling screen

ROS Show Reverse osmosis system screen
TR Heat Show Trending screen for heating of outdoor housing
TR Vent Show Trending screen for ventilation of outdoor housing

Appendix A: Page 19
A.4 Deoxo drier screens

A.4.1 HPS screen
Figure 18 – HPS screen
Path: Main - Go to Process - HPS
A Indication of actual HPS status
A Indication of remaining H2 production capacity until dryer bed swap
A Pressure transmitter values
A Temperature switch states (dryer Da, dryer Db, deoxo vessel Dxo)
A Flow switch status
A Analyzer panel transmitter values (if applicable)
A Booster pump (if applicable)

Page 20 Appendix A:
Command buttons at the bottom of the screen:

:
TR HPS Show Trend HPS screen

TR HPS AP Show Trend HPS Analyzer panel screen (if applicable)
TR HPS PT Show Trend HPS Pressure transmitter user line screen (if applicable)
N2 Purge Show HPS N2 Purge screen
STCD Show HPS STCD screen
Booster ON/ Put booster pump ON or OFF (if applicable)
OFF

Appendix A: Page 21
A.4.2 HPS Nitrogen purge screen
Figure 19 – HPS N2 purge screen
Path: Main - Go to Process - HPS - N2P
Follow the instructions on the screen to perform a nitrogen purge of the HPS.

Page 22 Appendix A:
A.5 Information screens

A.5.1 Info overview screen
Figure 20 – Info overview screen
Path: Main - Go to Process - Info
The Info screen displays command buttons that, when pressed, open another screen as follows:
Main Show Main screen

Password Show Login screen
Clock & Language Show Clock & Language screen
The Info screen also shows information about the status off the different sub-assemblies like the utilities
(UTIL), the electrolyzer (GGS1) and the deoxo drier (HPS).

Appendix A: Page 23
A.5.2 Clock & Language screen
Figure 21 – Clock & Language screen
Path: Main - Go to Process - Info - Clock & language screen
The Clock & language screen displays both the HMI display terminal’s time and the PLC’s time. By
pressing the Set time command button, these settings can be changed, and the PLC’s time and date set-
tings can be matched to those in the display terminal.

Page 24 Appendix A:
A.5.3 Start conditions overview screen
Figure 22 – Start conditions overview screen
Path: Main - Go to Process - Info - STCD
The Start conditions overview screen shows a tree view of the start conditions for the different process
equipment, in a hierarchical order. Each command button can be pressed to open the subsequent start
conditions screen. A green command button means the start conditions are fulfilled, a red command but-
ton means they are not.
In each process you can see a button, like for example ‘UTIL: OK’. This means that there are no delayed
start condtions. If some start conditions are delayed you can see ‘UTIL: Warning’. This means that after
the delay time is passed that specific start condtion goes from ‘TRUE’ to ‘FALSE’ status. By pushing this
button, the subsequent delayed start condition screen will be opened.

Appendix A: Page 25
A.5.4 Basic start conditions screens
Figure 23 – Basic start conditions screen
Path: Main - Go to Process - Info - STCD - Basic STCD: True or False
The Basic start conditions screen contains a list of all appliccable start conditions for the selected action
or piece of equipment. The words ‘TRUE’ and ‘FALSE’ are used to indicate whether the listed start con-
dition is true or false
The command buttons at the bottom of the screen can be pressed to open the subsequent start condi-
tions screen:
Bas H2P Show Basic hydrogen production STCD screen

Page 26 Appendix A:
A.5.5 Basic delayed start conditions screens
Figure 24 – Basic delayed start conditions screen
Path: Main - Go to Process - Info - STCD - Basic: OK or Warning
The Basic delayed start conditions screen contains a list of delayed start conditions for the selected
action or piece of equipment. The words ‘TRUE’ and ‘FALSE’ in the column state start condtion are used
to indicate whether the listed start condition is true or false
If there is a warning the time delay specified in the last column will decrease. When the start condition is
‘TRUE’ again, this time will be preset to the original delay time. The status ‘WARNING’ will be gone when
the button ‘Reset’ is pressed.

Appendix A: Page 27
A.5.6 Events screen
Figure 25 – Events screen
Path: Main - Go to Process - Info - Events
The Events screen shows a list of events, starting with the most recent. The event number, the date and
time of its occurrence, its event code, its event description and, if appliccable, its analog value, are dis-
played. The command buttons at the bottom of the screen can be used to navigate in the event history,
up by either a single line, half a page or a full page, and down by the same means.

Page 28 Appendix A:
A.5.7 Analog alarms overview screen
Figure 26 – Analog alarms overview screen
Path: Main - Go to Process - Info - Alarms
The Analog alarms overview screen shows the alarm data of all analog measurements in the HySTAT
system. The alarm data for each measurement consists of the following alarm states:
A HH (High High alarm)
A H (High alarm)
A L (Low alarm)
A LL (Low Low alarm)
A BW (Broken Wire alarm)

For each of those alarm types mentioned above, a memory state (indicated by the added letter M) is
shown in the appropriate column as well. The number 1 indicates the alarm state is OK, the number 0
indicates the alarm state is NOK (and that there is an alarm). If the number 0 is written in the memory (M)
column, this indicates there has been an alarm for that channel (even though it may have been restored).

Appendix A: Page 29
A.5.8 Analog basic alarms screen
Figure 27 – Analog basic alarms screen
Path: Main - Go to Process - Info - Alarms - UTIL
The Analog basic alarms screen shows the alarm data of all analog measurements in the HySTAT sys-
tem. The alarm data for each measurement consists of the following alarm states:
A HH (High High alarm)
A H (High alarm)
A L (Low alarm)
A LL (Low Low alarm)
A BW (Broken Wire alarm)

For each of those alarm types mentioned above, a memory state (indicated by the added letter M) is
shown in the appropriate column as well. The number 1 indicates the alarm state is OK, the number 0
indicates the alarm state is NOK (and that there is an alarm). If the number 0 is written in the memory (M)
column, this indicates there has been an alarm for that channel (even though it may have been restored).

Page 30 Appendix A:
A.6 Debugging screens

A.6.1 Debug overview screen
Figure 28 – Debug overview screen
Path: Main - Go to Process - Info - Debug
The Debug overview screen displays command buttons that open others screens. Command buttons
that can be used by the operator for debugging, are the following:
Counters Show Counters actuators screen

Actuators
Diagnostics Show Diagnostics screen
Production Limits Show Production Limits screen
Profisafe Show Profisafe screen
The other command buttons are used by a service engineer of Hydrogenics Europe NV for changing
specific parameters of the unit. These cannot be accessed by the operator. This is because important
settings may not be changed without complete and full knowledge of the PLC program.

Appendix A: Page 31
A.6.2 Diagnostics screen
Figure 29 – Diagnostics screen
Path: Main - Go to Process - Info - Debug - Diagnostics
The Diagnostics screen displays general information off the Exter. To leave this screen, just tap the
screen and the previous screen will reappear.

Page 32 Appendix A:
A.6.3 Counters actuators screen
Figure 30 – Counters actuators screen of UTIL
Path: Main - Go to Process - Info - Debug - Counters Actuators (of UTIL)
The Counters actuators screen displays the number off switches for actuators in the unit.

Appendix A: Page 33
A.6.4 Production limitations screen
Figure 31 – Production limits screen of GGS1
Path: Main - Go to Process - Info - Debug - Production limits (of GGS1)
The Production limits screen displays if the production limitations are OK. The command buttons F9 untill
F12 can be used to see detailed information about the calculations behind these product limitations.

Page 34 Appendix A:
A.6.5 Profisafe overview screen
Figure 32 – Profisafe overview screen
Path: Main - Go to Process - Info - Debug - Profisafe
The Profisafe Overview screen displays if the different safety levels are OK.
The Profisafe Overview screen shows command buttons that, when pressed, open another screen as
follows:
Overview Show Profisafe overview screen

UTx Show Profisafe utility screen
GGS1 Show Profisafe electrolyzer 1 screen
HPS Show Profisafe deoxo drier screen

Appendix A: Page 35
A.6.6 Profisafe UTx screen
Figure 33 – Profisafe UTx screen
Path: Main - Go to Process - Info - Debug - Profisafe - UTx
The Profisafe UTx screen displays the safety inputs and safety outputs that belong to the utilities. The
safety inpts and outputs are shown on the screen. When the status led is green, the complete safety sys-
tem is OK. If one of the safety inputs or safety outputs is NOK this is indicated by a red color/line.
The Profisafe UTx screen shows command buttons that, when pressed, open another screen as follows:


Page 36 Appendix A:
A.6.7 Profisafe GGS1 screen
Figure 34 – Profisafe GGS1 screen
Path: Main - Go to Process - Info - Debug - Profisafe - GGS1
The Profisafe GGS1 screen displays the safety inputs and safety outputs that belong to the electrolyzer
1. The safety inpts and outputs are shown on the screen. When the status led is green, the complete
safety system is OK. If one of the safety inputs or safety outputs is NOK this is indicated by a red color/
line.
The Profisafe GGS1 screen shows command buttons that, when pressed, open another screen as fol-
lows:


Appendix A: Page 37
A.6.8 Profisafe HPS screen
Figure 35 – Profisafe HPS screen
Path: Main - Go to Process - Info - Debug - Profisafe - HPS
The Profisafe HPS screen displays the safety inputs and safety outputs that belong to the deoxo drier.
The safety inpts and outputs are shown on the screen. When the status led is green, the complete safety
system is OK. If one of the safety inputs or safety outputs is NOK this is indicated by a red color/line.
The Profisafe HPS screen shows command buttons that, when pressed, open another screen as follows:


Page 38 Appendix A:

HySTAT MANUAL
Appendix B: Tag reference

Page 40 Appendix B:
HySTAT MANUAL TAG REFERENCE
Appendix B: TAG REFERENCE
B.1 General
A The table below contains an overview of all tags used for HySTAT components. The tags are
listed alphabetically per HySTAT sub-system.
A Depending your HySTAT configuration, one or more components listed below may not be
present in your system.
B.2 HySTAT process

HySTAT process
Tag Explanation
BT1_H Break Tank 1 Feed Water for Hydrogen
BT1_O Break Tank 1 Feed Water for Oxygen
BT2_H Break Tank 2 Feed Water for Hydrogen
BV BT_H-D Ball Valve Break Tank 1(&2) Hydrogen to Drain
BV BT_O-D Ball Valve Break Tank 1(&2) Oxygen to Drain
BV H-OTH Ball Valve Hydrogen to Oxygen Transmitter n Hydrogen
BV N1 Ball Valve 1 Nitrogen Inlet
BV N3 Ball Valve 3 Nitrogen to Atmosphere
BV O-HTO Ball Valve Oxygen to Hydrogen Transmitter in Oxygen
BV P_F-H-In Ball Valve Pump Inlet Feed Water Hydrogen
BV P_F-H-Out Ball Valve Pump Outlet Feed Water Hydrogen
BV P_F-O-In Ball Valve Pump Inlet Feed Water Oxygen
BV P_F-O-Out Ball Valve Pump Outlet Feed Water Oxygen
C_CS1&2_H Cooler Cell Stack 1&2 Hydrogen line
C_CS1&2_O Cooler Cell Stack 1&2 Oxygen line
C_CS3&4_H Cooler Cell Stack 3&4 Hydrogen line
C_CS3&4_O Cooler Cell Stack 3&4 Hydrogen line
C_H Cooler (gas) Hydrogen
C_O Cooler (gas) Oxygen
CF_H Coalescent Filter Hydrogen
CF_O Coalescent Filter Oxygen
CS 1 Cell Stack 1
CS 2 Cell Stack 2
CS 3 Cell Stack 3
CS 4 Cell Stack 4
CV EC Check Valve Electrolyte Cooling
CV F-H Check Valve Feed Water Hydrogen
CV F-O Check Valve Feed Water Oxygen
CV GC Check Valve Gas Cooling

Appendix B: Page 41
TAG REFERENCE HySTAT MANUAL
HySTAT process
Tag Explanation
D O-HTO Dryer Oxygen to Hydrogen Transmitter in Oxygen
DPS Differential Pressure Switch Ventilation
DT1 Drip Tray 1
DT2 Drip Tray 2
F H-OTH Filter Hydrogen to Oxygen Transmitter in Hydrogen
F O-HTO Filter Oxygen to Hydrogen Transmitter in Oxygen
F_F-H Filter Feed Water Hydrogen
F_F-O Filter Feed Water Oxygen
FD 1 Fire Detection Sensor (1)
FI O-HTO Flow Indicator Oxygen to Hydrogen Transmitter in Oxygen
FS O-HTO Flow Switch Oxygen to Hydrogen Transmitter in Oxygen
GS_H Gas Separator Hydrogen
GS_O Gas Separator Oxygen
HTA 1 Hydrogen Transmitter 1 in Atmosphere
HTO Hydrogen Transmitter in Oxygen
HV E-D1 Hand Valve Electrolyte to Drain 1
HV E-D2 Hand Valve Electrolyte to Drain 2
HV H-A Hand Valve Hydrogen to Atmosphere
HV H-OTH Hand Valve Hydrogen to Oxygen Transmitter in Hydrogen
HV N Hand Valve Nitrogen
HV N-OTH Hand Valve Nitrogen to Oxygen Transmitter in Hydrogen
HV O-A Hand Valve Oxygen to Atmosphere
HV O-HTO Hand Valve Oxygen to Hydrogen Transmitter in Oxygen
ITCS 1 Current Cell Stack 1
LI BT_H Level Indicator Break Tank 1(&2) Hydrogen
LI BT_O Level Indicator Break Tank 1(&2) Oxygen
LS BT_H-H Level Switch Break Tank Hydrogen High
LS BT_H-L Level Switch Break Tank Hydrogen Low
LS BT_H-LL Level Switch Break Tank Hydrogen Low-Low
LS BT_O-H Level Switch Break Tank Oxygen High
LS BT_O-L Level Switch Break Tank Oxygen Low
LS BT_O-LL Level Switch Break Tank Oxygen Low-Low
LS DT1.1 Level Switch Drip Tray 1.1
LS H H&L Level Switch Hydrogen High & Low (notation on P&ID for switch with 2
alarms)

Page 42 Appendix B:
HySTAT process
Tag Explanation
LS O H&L Level Switch Oxygen High & Low (notation on P&ID for switch with 2
alarms)
LS WL H-L Level Switch Water lock Hydrogen Low
LS WL O-L Level Switch Water lock Oxygen Low
LT_H Level Transmitter Hydrogen
LT_O Level Transmitter Oxygen
MV BT_H-D Magnetic Valve Break Tank Hydrogen to Drain / Filling Water lock H2
MV BT_O-D Magnetic Valve Break Tank Oxygen to Drain / Filling Water lock O2
MV F-H Magnetic Valve Feed Water Hydrogen
MV F-O Magnetic Valve Feed Water Oxygen
MV H-OTH Magnetic Valve Hydrogen to Oxygen Transmitter in Hydrogen
MV N1 Magnetic Valve 1 Nitrogen
MV N-OTH Magnetic Valve Nitrogen to Oxygen Transmitter in Hydrogen
MV O-HTO Magnetic Valve Oxygen to Hydrogen Transmitter in Oxygen
MV1 H-A Magnetic Valve 1 Hydrogen to Atmosphere
MV1 H-U Magnetic Pilot Valve 1 Hydrogen to User
MV1 O-U Magnetic Pilot Valve 1 Oxygen to User
MV1a H-U Magnetic Valve 1 Hydrogen to User (a)
MV1a O-A Magnetic Valve 1 Oxygen to Atmosphere (a)
MV1a O-U Magnetic Valve 1 Oxygen to User (a)
MV1b H-U Magnetic Valve 1 Hydrogen to User (b)
MV1b O-A Magnetic Valve 1 Oxygen to Atmosphere (b)
MV1b O-U Magnetic Valve 1 Oxygen to User (b)
MV1c O-A Magnetic Valve 1 Oxygen to Atmosphere (c)
MV1d O-A Magnetic Valve 1 Oxygen to Atmosphere (d)
NRV F-H Non Return Valve Feed Water Hydrogen
NRV F-O Non Return Valve Feed Water Oxygen
NRV1 H-U Non Return Valve 1 Hydrogen to User
NRV1 N Non Return Valve 1 Nitrogen Main Line
NRV1 O-U Non Return Valve 1 Oxygen to User
NRV2 N Non Return Valve 2 Nitrogen Electrolyzer
NRV3 N Non Return Valve 3 Nitrogen Electrolyzer
OTA 1 Oxygen Transmitter 1 in Atmosphere
OTH Oxygen Transmitter in Hydrogen
P_F-H Pump Dosing Feed Water Hydrogen
P_F-O Pump Dosing Feed Water Oxygen
PCV H-OTH Pressure Control Valve Hydrogen to Oxygen Transmitter in Hydrogen
PCV O-HTO Pressure Control Valve Oxygen to Hydrogen Transmitter in Oxygen
PD F-H Pulsation damper Feed Water Hydrogen
PI EC Pressure Indicator Electrolyte Cooling

Appendix B: Page 43
HySTAT process
Tag Explanation
PI F-H Pressure Indicator Feed Water Hydrogen
PI F-O Pressure Indicator Feed Water Oxygen
PI GC Pressure Indicator Gas Cooling
PI GS Pressure Indicator Gas Separator
PI N Pressure Indicator Nitrogen Main line
PI N_B&B Pressure Indicator Nitrogen Block and Bleed
PI O-HTO Pressure Indicator Oxygen to Hydrogen Transmitter in Oxygen
PI PD F-H Pressure Indicator Pulsation damper Feed Water Hydrogen
PS H P_F-H Pressure Switch Pump Feed Water Hydrogen High
PS H P_F-O Pressure Switch Pump Feed Water Oxygen High
PT GS Pressure Transmitter Gas Seperator
PT F-H Pressure Transmitter Feed Water Hydrogen
PT H-U Pressure Transmitter Hydrogen to User
RC_H Rinser (Scrubber) Hydrogen
RC_O Rinser (Scrubber) Oxygen
RHV CW GC Regulation Hand Valve Cooling Water Gas Cooling
SV EC Safety Valve Electrolyte Cooling
SV GC Safety Valve Gas Cooling
SV F-H Safety Valve Feed Water Hydrogen
SV F-O Safety Valve Feed Water Oxygen
SV H Safety Valve Hydrogen
SV N Safety Valve Nitrogen
SV O Safety Valve Oxygen
TSE CS1 Temperature Switch Electrolyte Cell Stack 1
TT EPS Temperature Transmitter EPS Room
TT Process Temperature Transmitter Process Room
TTE CS1 Temperature Transmitter Electrolyte Cell Stack 1
UTCS 1_A Voltage Cell Stack 1 - first half (A)
UTCS 1_B Voltage Cell Stack 1 - second half (B)

Page 44 Appendix B:
HySTAT process
Tag Explanation
XV H-U Pneumatic Isolator valve Hydrogen to User
XV O-U Pneumatic Isolator valve Oxygen to User
B.3 Deoxo dryer

Deoxo dryer
Tag Explanation
AD_H Automatic Drain Hydrogen Condensate in HPS
BPR H-U Back Pressure Regulator Hydrogen to Atmosphere
BV H Ball Valve Hydrogen Inlet
BV H-U Ball Valve Hydrogen to User
BV N_Deo Ball Valve Nitrogen Deoxo
BV N_Deo-A Ball Valve Nitrogen Deoxo to Atmosphere
C Deo Cooler Deoxo Hydrogen
CV GC_Deo Check Valve Cooling Water Deoxo
DP_H Drainpot Hydrogen
F Da_H-RG Filter Drier A Hydrogen to Regeneration
F Db_H-RG Filter Drier B Hydrogen to Regeneration
F DP_H Filter Drain Pot Hydrogen
F H-U Filter Hydrogen to User
FI RG_H Flow Indicator Regeneration Gas Hydrogen
FS RG_H Flow Switch Regeneration Gas Hydrogen Dryer
H Da_H Heating Dryer A Hydrogen
H Db_H Heating Dryer B Hydrogen
H Deo Heating Deoxo
HTA 2 Hydrogen Transmitter 2 in Atmosphere
HV DP_H Hand Valve Drain Pot Hydrogen
HV H-D Hand Valve Hydrogen to Drain
HV N_Deo Hand Valve Nitrogen Deoxo
HV S1_H Hand Valve Sample Valve 1 Hydrogen
HV S2_H Hand Valve Sample Valve 2 Hydrogen
HV2 H-A Hand Valve 2 Hydrogen to Atmosphere
HV3 H-A Hand Valve 3 Hydrogen to Atmosphere (Blow off logic)
LS DP_H H&L Level Switch Drain Pot Hydrogen High & Low
MS_H Moisture Seperator Hydrogen
MV AD_H-A Magnetic Valve Automatic Drain Hydrogen to Atmosphere
MV Da_H-A Magnetic Valve Dryer A Hydrogen to Atmosphere
MV Da_H-U Magnetic Valve Dryer A Hydrogen to User
MV Db_H-A Magnetic Valve Dryer B Hydrogen to Atmosphere
MV Db_H-U Magnetic Valve Dryer B Hydrogen to User
MV DP_H-A Magnetic Valve Drain Pot Hydrogen to Atmosphere

Appendix B: Page 45
Deoxo dryer
Tag Explanation
MV H-Da_H Magnetic Valve Hydrogen to Dryer A Hydrogen
MV H-Db_H Magnetic Valve Hydrogen to Dryer B Hydrogen
MV N_D1 Magnetic Valve Nitrogen 1 to Dryer
MV R-Da_H Magnetic Valve Regeneration gas to Dryer a Hydrogen
MV R-Db_H Magnetic Valve Regeneration gas to Dryer b Hydrogen
MV RG_H Magnetic Valve Regeneration Gas Hydrogen
MV Spare Magnetic Valve Spare
MV2 H-A Magnetic Valve 2 Hydrogen to Atmosphere
MV2 H-U Magnetic Valve 2 Hydrogen Dryer to User
NRV RG_H Non Return Valve Regeneration Gas Hydrogen
NRV1 N Non Return Valve Nitrogen HPS
NRV2 H-U Non Return Valve 2 Hydrogen to User
OF RG_H Orifice Regeneration Gas Hydrogen
PCV N-Deo Pressure Control Valve Nitrogen to Deoxo Dryer
PI Da_H Pressure Indicator Dryer A Hydrogen
PI Db_H Pressure Indicator Dryer B Hydrogen
PI Deo Pressure Indicator Deoxo
PS Da_H Pressure Switch Dryer A
PS Db_H Pressure Switch Dryer B
PS Deo Pressure Switch Deoxo
PT Da_H Pressure Transmitter Dryer a Hydrogen
PT Db_H Pressure Transmitter Dryer b Hydrogen
PT Deo Pressure Transmitter Deoxo
PT H-U Pressure Transmitter Hydrogen to User
RHV CW_Deo Regulating Hand Valve Cooling Water Deoxo
RHV RG_H Regulating Hand Valve Regeneration Gas Hydrogen
SV Da_H Safety Valve Dryer A Hydrogen
SV Db_H Safety Valve Dryer B Hydrogen
SV Deo Safety Valve Deoxo
TS Da_H Temperature Switch Dryer A Hydrogen
TS Db_H Temperature Switch Dryer B Hydrogen
TS Deo Temperature Switch Deoxo
TT Da_H Temperature Transmitter Dryer A Hydrogen
TT Db_H Temperature Transmitter Dryer B Hydrogen
TT Deo Temperature Transmitter Deoxo
XV Da_H-A Pneumatic Valve Dryer A Hydrogen to Atmosphere
XV Da_H-U Pneumatic Valve Dryer A Hydrogen to User
XV Db_H-A Pneumatic Valve Dryer B Hydrogen to Atmosphere
XV Db_H-U Pneumatic Valve Dryer B Hydrogen to User

Page 46 Appendix B:
Deoxo dryer
Tag Explanation
XV H-Da_H Pneumatic Valve Hydrogen to Dryer A Hydrogen
XV H-Db_H Pneumatic Valve Hydrogen to Dryer B Hydrogen
XV R-Da_H Pneumatic Valve Regeneration gas to Dryer A Hydrogen
XV R-Db_H Pneumatic Valve Regeneration gas to Dryer B Hydrogen
XV2 H-U Pneumatic Isolator Valve Hydrogen to User
XV3 H-A Pneumatic Valve 3 Hyrogen to Atmosphere (Blow off logic)
B.4 Deoxo dryer: Full Flow Zero Loss (optional)

Deoxo Dryer: Full Flow Zero Loss (optional)
Tag Explanation
C Drier Cooler Drier A&B Hydrogen
DP_H Deoxo Drainpot Deoxo Hydrogen
DP_H Drier Drainpot Drier Hydrogen
F DP_H Deoxo Filter Drainpot Deoxo Hydrogen
F DP_H Drier Filter Drainpot Drier Hydrogen
H RG_H Preheater Regneration Gas Hydrogen
HV DP_H Deoxo Hand Valve Drain Deoxo Hydrogen
HV DP_H Drier Hand Valve Drain Drier Hydrogen
LS DP_H Deoxo Level Switch Drainpot Deoxo Hydrogen High & Low
LS DP_H Drier Level Switch Drainpot Drier Hydrogen High & Low
MS_H-Deo Moisture Seperator Deoxo Hydrogen
MS_H-Drier Moisture Seperator Drier Hydrogen
MV DP_H-A Deo Magnetic Valve Drainpot Deoxo Hydrogen to Atmosphere
MV DP_H-A Drier Magnetic Valve Drainpot Drier Hydrogen to Atmosphere
RHV CW_Drier Regulating Hand Valve Cooling Water Drier
SV GC_Drier Safety Valve Cooling Water Drier
TS H-RG Temperature Switch Preheater Hydrogen Vessel Surface
TS RG_H Temperature Switch Preheater Hydrogen Gas Stream
TT Da-In Temperature Transmitter Drier A Gas Stream Hydrogen In
TT Da-Out Temperature Transmitter Drier A Gas Stream Hydrogen Out
TT Db-In Temperature Transmitter Drier B Gas Stream Hydrogen In
TT Db-Out Temperature Transmitter Drier B Gas Stream Hydrogen Out
TT RG_H Temperature Transmitter Regeneration Gas Hydrogen
XV1 - XV12 Pneumatic Valve Hydrogen Gas stream

Appendix B: Page 47
B.5 Deoxo dryer: Booster pump (optional)

Deoxo Dryer: Booster pump (optional)
Tag Explanation
AD BOP_H Automatic Drain Booster Pump Hydrogen Condensate
BOP_H Booster Pump Hydrogen
BV BOP_H-In Ball Valve Booster Pump Hydrogen In
BV BOP_H-Out Ball Valve Booster Pump Hydrogen Out
BV IA BOP_H Ball Valve Instrument Air to Booster Pump Hydrogen
C BOP_H Cooler Booster Pump Hydrogen
MS BOP_H Moisture Seperator Booster Pump Hydrogen
MV IA BOP_H Magnetic Valve Instrument Air to Booster Pump Hydrogen
NRV BOP_H Non Return Valve Booster Pump Hydrogen
PT BOP_H Pressure Transmitter Booster Pump Hydrogen
RHV CW BOP_H Regulation Hand Valve Cooling Water Booster Pump Hydrogen
TS BOP_H Temperature Switch Booster Pump Hydrogen
XV BOP_H Pneumatic Valve Bypass Booster Pump Hydrogen
XV IA BOP_H Pneumatic Valve Instrument Air to Booster Pump Hydrogen
B.6 Dehydro dryer

Dehydro dryer
Tag Explanation
BPR O-U Back Pressure Regulator Oxygen to Atmosphere
BV N_Deh Ball Valve Nitrogen Dehydro
BV N_Deh-A Ball Valve Nitrogen Dehydro to Atmosphere
BV O Ball Valve Oxygen Inlet
BV O-U Ball Valve Oxygen to User
C Deh Cooler Dehydro Oxygen
CV GC_Deh Check Valve Cooling Water Dehydro
DP_O Drainpot Oxygen
F DP_O Filter Drain Pot Oxygen
F O-U Filter Oxygen to User
FI RG_O Flow Indicator Regeneration Gas Oxygen
FS RG_O Flow Switch Regeneration Gas Oxygen Dryer
H Da_O Heating Dryer A Oxygen
H Db_O Heating Dryer B Oxygen
H Deh Heating Dehydro
HV DP_O Hand Valve Drain Pot Oxygen
HV N_Deh Hand Valve Nitrogen Dehydro
HV O-D Hand Valve Oxygen to Drain
HV S1_H Hand Valve Sample Valve 1 Oxygen
HV S2_H Hand Valve Sample Valve 2 Oxygen

Page 48 Appendix B:
Dehydro dryer
Tag Explanation
HV2 O-A Hand Valve 2 Oxygen to Atmosphere
LS DP_O H&L Level Switch Drain Pot Oxygen High & Low
MS_O Moisture Seperator Oxygen
MV Da_O-A Magnetic Valve Dryer A Oxygen to Atmosphere
MV Da_O-U Magnetic Valve Dryer A Oxygen to User
MV Db_O-A Magnetic Valve Dryer B Oxygen to Atmosphere
MV Db_O-U Magnetic Valve Dryer B Oxygen to User
MV DP_O-A Magnetic Valve Drain Pot Oxygen to Atmosphere
MV O-Da_O Magnetic Valve Oxygen to Dryer A Oxygen
MV O-Db_O Magnetic Valve Oxygen to Dryer B Oxygen
MV R-Da_O Magnetic Valve Regeration gas to Dryer a Oxygen
MV R-Db_O Magnetic Valve Regeration gas to Dryer b Oxygen
MV Spare Magnetic Valve Spare
MV2 O-A Magnetic Valve 2 Oxygen to Atmosphere
MV2 O-U Magnetic Valve 2 Oxygen Dryer to User
NRV RG_O Non Return Valve Regeneration Gas Oxygen
NRV2 O-U Non Return Valve 2 Oxygen to User
PCV N-Deh Pressure Control Valve Nitrogen to Dehydro Dryer
PI Da_O Pressure Indicator Dryer A Oxygen
PI Db_O Pressure Indicator Dryer B Oxygen
PI Deh Pressure Indicator Deoxo
PS Da_O Pressure Switch Dryer A
PS Db_O Pressure Switch Dryer B
PS Deh Pressure Switch Dehydro
PT Da_O Pressure Transmitter Dryer a Oxygen
PT Db_O Pressure Transmitter Dryer b Oxygen
PT Deh Pressure Transmitter Dehydro
PT O-U Pressure Transmitter Oxygen to User
RHV CW_Deh Regulating Hand Valve Cooling Water Deoxo
RHV RG_O Regulating Hand Valve Regeneration Gas Oxygen
SV Da_O Safety Valve Dryer A Oxygen
SV Db_O Safety Valve Dryer B Oxygen
SV Deh Safety Valve Dehydro
TS Da_O Temperature Switch Dryer A Oxygen
TS Db_O Temperature Switch Dryer B Oxygen
TS Deh Temperature Switch Deoxo
TT Da_O Temperature Transmitter Dryer A Oxygen
TT Db_O Temperature Transmitter Dryer B Oxygen

Appendix B: Page 49
Dehydro dryer
Tag Explanation
TT Deh Temperature Transmitter Dehydro
XV Da_O-A Pneumatic Valve Dryer A Oxygen to Atmosphere
XV Da_O-U Pneumatic Valve Dryer A Oxygen to User
XV Db_O-A Pneumatic Valve Dryer B Oxygen to Atmosphere
XV Db_O-U Pneumatic Valve Dryer B Oxygen to User
XV O-Da_O Pneumatic Valve Oxygen to Dryer A Oxygen
XV O-Db_O Pneumatic Valve Oxygen to Dryer B Oxygen
XV R-Da_O Pneumatic Valve Regeneration gas to Dryer A Oxygen
XV R-Db_O Pneumatic Valve Regeneration gas to Dryer B Oxygen
XV2 O-U Pneumatic Isolator Valve Oxygen to User
B.7 Analyzer panel deoxo dryer

Analyzer panel deoxo dryer
Tag Explanation
BV S3_H Ball Valve Sample Valve 3 Hydrogen
BV H-DPT_H Ball Valve Hydrogen to Dew Point Transmitter Hydrogen
BV N-DPT_H Ball Valve Nitrogen to Dew Point Transmitter Hydrogen
DPT_H-U Dew Point Transmitter Hydrogen to User
F DPT_H Filter Dew Point Transmitter Hydrogen
FI DPT_H Flow Indicator Dew Point Transmitter Hydrogen
MV H-DPT_H Magnetic Valve Hydrogen to Dew Point Transmitter Hydrogen
MV N-DPT_H Magnetic Valve Nitrogen to Dew Point Transmitter Hydrogen
NRV N-DPT_H Non Return Valve Nitrogen to Dew Point Transmitter Hydrogen
OTH U Oxygen Transmitter in Hydrogen to User
PCV H-DPT_H Pressure Control Valve Hydrogen to Dewpoint Transmitter Hydrogen
PCV N-DPT_H Pressure Control Valve Nitrogen to Dewpoint Transmitter Hydrogen
PI H-DPT_H Pressure Indicator Valve Hydrogen to Dewpoint Transmitter Hydrogen
PI N-DPT_H Pressure Indicator Nitrogen to Dewpoint Transmitter Hydrogen
RHV H-DPT_H Regulating Hand Valve Hydrogen to Dew Point Transmitter Hydrogen
B.8 Analyzer panel dehydro dryer

Analyzer panel dehydro dryer
Tag Explanation
BV S3_O Ball Valve Sample Valve 3 Oxygen
BV N-DPT_O Ball Valve Nitrogen to Dew Point Transmitter Oxygen
BV O-DPT_O Ball Valve Oxygen to Dew Point Transmitter Oxygen
DPT_O-U Dew Point Transmitter Oxygen to User
F DPT_O Filter Dew Point Transmitter Oxygen

Page 50 Appendix B:
Analyzer panel dehydro dryer
Tag Explanation
FI DPT_O Flow Indicator Dew Point Transmitter Oxygen
HTO U Hydrogen Transmitter in Oxygen to User
MV N-DPT_O Magnetic Valve Nitrogen to Dew Point Transmitter Oxygen
MV O-DPT_O Magnetic Valve Oxygen to Dew Point Transmitter Oxygen
NRV N-DPT_O Non Return Valve Nitrogen to Dew Point Transmitter Oxygen
PCV H-DPT_O Pressure Control Valve Oxygen to Dewpoint Transmitter Oxygen
PCV N-DPT_O Pressure Control Valve Nitrogen to Dewpoint Transmitter Oxygen
PI H-DPT_O Pressure Indicator Valve Oxygen to Dewpoint Transmitter Oxygen
PI N-DPT_O Pressure Indicator Nitrogen to Dewpoint Transmitter Oxygen
RHV O-DPT_O Regulating Hand Valve Oxygen to Dew Point Transmitter Oxygen
B.9 Instrument air panel

Instrument air panel
Tag Explanation
BV IA Ball Valve Instrument Air
PCV IA Pressure Controle Valve Instrument Air
PI IA Pressure Indicator Instrument Air to Process
PS/PI-IA Pressure Indicator with Switch Instrument Air
B.10 Conductivity measurement panel

Conductivity measurement panel
Tag Explanation
BV F-BT_H Ball Valve Feed Water to Break Tank Hydrogen
CT Conductivity Transmitter
HV MB-BP Hand Valve Mixed Bed Bypass
HV MB In Hand valve Mixed Bed In
HV MB Out Hand Valve Mixed Bed Out
MB1 Mixed Bed 1
MB2 Mixed Bed 2
MV F_BT-H Magnetic Valve Feed water to Break Tank Hydrogen
MV F-D Magnetic Valve Feed Water to Drain
PS/PI-FW Pressure Indicator with Switch Feed Water
TV RO1 Test Valve Mixed Bed 1
TV RO2 Test Valve Mixed Bed 2

Appendix B: Page 51
B.11 Frit sparger

Frit sparger
Tag Explanation
BV FS1_H Ball Valve Hydrogen to Fritsparger 1
BV FS2_H Ball Valve Hydrogen to Fritsparger 2
FI FS1_H Flow Indicator Hydrogen to Fritsparger 1
FI FS2_H Flow Indicator Hydrogen to Fritsparger 2
FS1_H Frit Sparger 1
FS2_H Frit Sparger 2
MV FS_H Magnet Ventil Hydrogen to Frit Sparger
NRV FS_H Non Return Valve Hydrogen to Frit Sparger
RHV FS1_H Regulating Hand Valve Hydrogen to Frit Sparger 1
RHV FS2_H Regulating Hand Valve Hydrogen to Frit Sparger 2
B.12 Chiller
Chiller
Tag Explanation
AV1 Ch Air Vent 1 Chiller
BV Ch-In Ball Valve Chiller In
BV Ch-Out Ball Valve Chiller Out
BV FP_Ch Ball Valve Filling Port Chiller
BV GC_Deo-In Ball Valve Gas Cooling from Deoxo Dryer
BV GC_Deo-Out Ball Valve Gas Cooling to Deoxo Dryer
BV GC-In Ball Valve Gas Cooling In
BV GC-Out Ball Valve Gas Cooling Out
BV HC_GC-In Ball Valve Gas Cooling to Hydrogen Compressor
BV HC_GC-Out Ball Valve Gas Cooling from Hydrogen Compressor
F F_Ch Filter Filling Port Chiller
PI Ch Pressure Indicator Chiller
PT Ch Pressure Transmitter Chiller
TT Ch Temperature Transmitter Chiller
B.13 Closed loop cooling

Closed loop cooling
Tag Explanation
AV CLC-Ch Air Vent Closed Loop Cooling of Chiller
AV DC Air Vent Cooling Water Dry Cooler
AV EC Air Vent Electrolyte Cooling
AV HX_Ch Air Vent chilled Heat Exchanger

Page 52 Appendix B:
Closed loop cooling
Tag Explanation
BV CLC_Ch-In Ball Valve Closed Loop Cooling Chiller Inlet
BV CLC_Ch-Out Ball Valve Closed Loop Cooling Chiller Outlet
BV CLC_EC-In Ball Valve Closed Loop Cooling to Electrolyte Cooling
BV CLC_EC-Out Ball Valve Closed Loop Cooling from Electrolyte Cooling
BV DC-In Bal Valve Dry Cooler Inlet
BV DC-Out Ball Valve Dry Cooler Outlet
BV EV Ball Valve Expansion Vessel
BV F_CW-Ch Ball Valve Cooling Water Filter to Chiller
BV F_HX-Ch Ball Valve Filter chilled Heat Exchanger
BV HX_Ch-In Ball Valve chilled Heat Exchanger Chiller Inlet
BV HX_Ch-Out Ball Valve chilled Heat Exchanger Chiller Outlet
BV HX_CLC-In Ball Valve Heat Exchanger Closed Loop Cooling Inlet
BV HX_CLC-Out Ball Valve Heat Exchanger Closed Loop Cooling Outlet
BV P_CLC-In Ball Valve Pump Closed Loop Cooling Inlet
BV P_CLC-Out Ball Valve Pump Closed Loop Cooling Outlet
BV P_EC-In Ball Valve Pump Electrolyte Cooling Inlet
BV P_EC-Out Ball Valve Pump Electrolyte Cooling Outlet
CV HX_Ch Check Valve chilled Heat Exchanger
DP CLC-Ch Drain Port Closed Loop Cooling Chiller
DP DC Drain Port Dry Cooler
EV CLC Expansion Vessel Closed Loop Cooling
F CW-Ch Filter Cooling Water to Chiller
F_CLC Filter Closed Loop Cooling
FP CLC Filling Port Closed Loop Cooling
HX_CLC Heat Exchanger Closed Loop Cooling
NRV P_EC Non Return Valve Pump Electrolyte Cooling
P_CLC Pump Closed Loop Cooling
P_EC Pump Electrolyte Cooling
PI CLC Pressure Indicator Closed Loop Cooling
PT CLC Pressure Transmitter Closed Loop Cooling
RHV BP-DC Regulating Hand Valve Bypass Dry Cooler Loop
RHV DT_Ch Regulating Hand Valve Distribution Chiller Outlet
RHV DT_PR-In Regulating Hand Valve Distribution to Process
RHV DT_PR-In Regulating Hand Valve Distribution from Process
RHV EC-Out Regulating Hand Valve Electrolyte Cooling Outlet
RHV1 BP-HX Regulating Hand Valve 1 Bypass chilled Heat Exchanger
RHV2 BP-HX Regulating Hand Valve 2 Bypass chilled Heat Exchanger
RV BP-CLC Regulating Valve Bypass Closed Loop Cooling
RV BP-DC Regulating Valve Bypass Dry Cooler Loop
RV BP-HX Regulating Valve Bypass chilled Heat Exchanger
TI CLC Temperature Indicator Closed Loop Cooling

Appendix B: Page 53
Closed loop cooling
Tag Explanation
TI CLC-In Temperature Indicator Closed Loop Cooling Inlet
TI CLC-Out Temperature Indicator Closed Loop Cooling Outlet
TT CLC Temperature Transmitter Closed Loop Cooling
TT HX Temperature Transmitter chilled Heat Exchanger
TT HX-In Temperature Transmitter Heat Exchanger Inlet
B.14 Cooling water from customer

Cooling water from customer
Tag Explanation
BV CW-In Ball Valve Cooling Water Inlet
BV CW-Out Ball Valve Cooling Water Outlet
BV EV Ball Valve Expansion Vessel
BV F_CW-BP Ball Valve Filter Cooling Water Bypass
BV F_CW-In Ball Valve Filter Cooling Water Inlet
DPR EC-Out Differential Pressure Regulator Electrolyte Cooling Outlet
EV CLC Expansion Vessel Closed Loop Cooling
F_CW Filter Cooling Water
F_EC Filter Electrolyte Cooling
PI CW-In Pressure Indicator Cooling Water Inlet
PI CW-Out Pressure Indicator Cooling Water Outlet
RHV BP-EC Regulation Hand Valve Bypass Electrolyte Cooling
RHV EC-In Regulation Hand Valve Electrolyte Cooling Inlet
RHV EC-Out Regulation Hand Valve Electrolyte Cooling Outlet
RV BP-EC Regulation Valve Bypass Electrolyte Cooling
RV EC Regulation Valve Electrolyte Cooling
SV CLC Safety Valve Closed Loop Cooling
TI EC-In Temperature Indicator Electrolyte Cooling Inlet
TI EC-Out Temperature Indicator Electrolyte Cooling Outlet
B.15 Total gas counter

Total gas counter
Tag Explanation
BV BP_MFM-H Ball Valve Mass Flow Meter Hydrogen Bypass
BV1 MFM-H Ball Valve 1 Hydrogen to Mass Flow Meter
BV2 MFM-H Ball Valve 2 Hydrogen from Mass Flow Meter
F_MFM-H Filter Hydrogen to Mass Flow Meter
MFM H-U Mass Flow Meter Hydrogen to User

Page 54 Appendix B:
B.16 Reverse osmosis system

Tag Explanation
ACB Active Coal Bed
ACF2 Partical Filter 2 (Active Coal)
BV DP Ball Valve Drain Port Reverse Osmosis
BV RO In Ball Valve Reverse Osmosis Inlet
CT 1 Conductivity Transmitter 1
CT 2 Conductivity Transmitter 2 Inlet RO
DP AS Dosing Pump Anti-Scalent
DP SB Dosing Pump Bisulfide
DP SH Dosing Pump Biocide
FB Filter Bed
FI F_MB Flow Indicator Filter to Mixed Bed
FI R Flow Indicator Regeneration
FI ROB-D Flow Indicator Reverse Osmosis Bed to Drain
HV MB In Hand valve Mixed Bed In
HV MB Out Hand Valve Mixed Bed Out
HV MB_BP Hand Valve Mixed Bed Bypass
HV W_RO Hand Valve Water to Reverse Osmosis
LS AS L Level Switch Anti-Scalent Low
LS Biocide L Level Switch Biocide Low ROS
LS Bisulfide L Level Switch Bisulfide Low ROS
LS Chloor L Level Switch Chloor Low ROS
LS PH L Level Switch PH Low ROS
MB 1 Mixed Bed 1
MB 2 Mixed Bed 2
MV C-D Magnetic Valve Concentrate to Drain
MV F_ROS-D Magnetic Valve Feed Water ROS to Drain
MV P_RO Magnetic Valve Pump to ROS
MV_MB a Magnetic Valve a Mixed Bed
MV_MB b Magnetic Valve b Mixed Bed
NRV C-D Non Return Valve Concentrate to Drain
NRV F_MB Non Return Valve Feed Water to Mixed Bed
NRV P_RO Non Return Valve Pump to Reverse Osmosis
NRV R Non Return Valve Regeneration
P RO Pump Reverse Osmosis
PF1 Practical Filter 1 (Depth Filter)
PF2 Practical Filter 2 (Active Coal)
PF3 Practical Filter 3 (Depth Filter)
PI P_RO In Pressure Indicator Pump to Reverse Osmosis In
PI P_RO Out Pressure Indicator Pump to Reverse Osmosis Out
PI W_RO Pressure Indicator Water to Reverse Osmosis

Appendix B: Page 55
Tag Explanation
PS FW Pressure Switch Feed Water to Reverse Osmosis
PS P_RO L Pressure Switch Pump Reverse Osmosis Low
RHV P_RO Regulating Hand Valve Pump to Reverse Osmosis
RHV R Regulating Hand Valve Regeneration
RHV W_RO Regulating Hand Valve Water to Reverse Osmosis
ROB 1 Reverse Osmosis Bed 1
ROB 2 Reverse Osmosis Bed 2
RV ROB-D Regulating Valve Reverse Osmosis Bed to Drain
TV RO 1 Test Valve Reverse Osmosis 1
TV RO 2 Test Valve Reverse Osmosis 2
B.17 Hydrogen Cylinder Filling Station

Total gas counter
Tag Explanation
BV CS_H-U Ball Valve Cylinder Station Hydrogen to User
HV CS_H-A Hand Valve Cylinder Station Hydrogen to Atmosphere
HV CS_H-PI Hand Valve Pressure Indicator Cylinder Station Hydrogen
HV CS H-PT Hand Valve Pressure Transmitter Cylinder Station Hydrogen
HV CS_H-U Hand Valve Cylinder Station Hydrogen to User
HV CS_N Hand Valve Cylinder Station Nitrogen In
Hva CS_H - HVx Hand Valve for Filling Cylinder a to x Cylinder Station Hydrogen
CS_H
NRV CS_H Non Return Valve Cylinder Station Hydrogen from Compressor
NRV CS_N Non Return Valve Cylinder Station Nitrogen In
PCV CS_H Pressure Controll Valve Cylinder Station Hydrogen
PI CS_H Pressure Indicator Cylinder Station Hydrogen
PT CS_H Pressure Transmitter Cylinder Station Hydrogen
SV CS_H Safety Valve Cylinder Station Hydrogen
B.18 Vacuum Pump for Hydrogen Cylinder

Total gas counter
Tag Explanation
BV VP_H Ball Valve Vacuum Pump for Hydrogen Cylinders
HV VP_H-PI Hand Valve Pressure Indicator Vacuum Hydrogen Cylinders
NRV VP_H Non Return Valve Vacuum Pump for Hydrogen Cylinders
PI VP_H Pressure Indicator Vacuum Hydrogen Cylinders

Page 56 Appendix B:

HYSTAT MANUAL
APPENDIX C: START CONDITIONS

Page 58 Appendix C:
HySTAT MANUAL START CONDITIONS
Appendix C: START CONDITIONS
C.1 General Remarks

A In the following tables, a number of “spare” functions are listed. This document is meant to be
complete and therefore a direct reflection of what is implemented in the automation program.
The spare functions are always secured in a true status so there is no influence from these on
the functionality of the logics.
A In the overview tables further in this document most conditions have the suffix “M”. This suffix
stands for Memorized and indicates that the start condition remains false, even when the actual
functional status becomes True in the mean time. A “Reset Alarms” is necessary to get the start
condition in the True status.
A Delayed start condition! For certain start conditions a time delay is implemented. Thus a fail-
ing function stops the electrolyzer only after a set time delay. For instance when a valve opens,
the flow switch in its loop has to detect flow. If this is not the case, a pre-alarm will be activated
and only after a preset time the start condition will fail and consequently stop the electrolyzer.
When a start condition fails, the buzzer will be activated and a specific event will be shown.
C.2 Basic start conditions

Code Explanation
EMS_A_OK_MEM Emergency stop A not pressed
EMS_B_OK_MEM Emergency stop B not pressed
EMS_C_OK_MEM Emergency stop C not pressed
EMS_D_OK_MEM Emergency stop D not pressed
EMS_E_OK_MEM Emergency stop E not pressed
EMS_F_OK_MEM Emergency stop F not pressed
EMS_G_OK_MEM Emergency stop G not pressed
EMS_H_OK_MEM Emergency stop H not pressed
EMS_I_OK_MEM Emergency stop I not pressed
EMS_J_OK_MEM Emergency stop J not pressed
EMS_K_OK_MEM Emergency stop K not pressed
EMS_L_OK_MEM Emergency stop L not pressed
EMS_M_OK_MEM Emergency stop M not pressed
EMS_N_OK_MEM Emergency stop N not pressed
EMS_O_OK_MEM Emergency stop O not pressed
EMS_P_OK_MEM Emergency stop P not pressed
HWSS_RELEASE_OK_MEM Hard wired safety system OK
SMOKE_AND_FIRE_ALARM Smoke and fire alarm OK
OTA_PR_DETHEAD_OK_MEM Oxygen transmitter in process room detection head OK
OTA_PROC_ROOM_H_OK_MEM Oxygen transmitter in process room high alarm OK
OTA_PROC_ROOM_L_OK_MEM Oxygen transmitter in process room low alarm OK
OTA_HIGH_OK_MEM Oxygen transmitter high alarm OK
OTA_LOW_OK_MEM Oxygen transmitter low alarm OK

Appendix C: Page 59
START CONDITIONS HySTAT MANUAL
Code Explanation
OTA_2_DETHEAD_OK_MEM Oxygen transmitter 2 in process room detection head OK
OTA_2_ROOM_H_OK_MEM Oxygen transmitter 2 in process room high alarm OK
OTA_2_ROOM_L_OK_MEM Oxygen transmitter 2 in process room low alarm OK
OTA_2_HIGH_OK_MEM Oxygen transmitter 2 high alarm OK
OTA_2_LOW_OK_MEM Oxygen transmitter 2 low alarm OK
HTA_PR1_DETHEAD_OK_MEM Hydrogen detecion 1 in process room detection head OK
HTA_PROC1_ROOM_OK_MEM Hydrogen detection 1 in process room OK
HTA_Dr_DETHEAD_OK_MEM Hydrogen detecion in dryer detection head OK
HTA_Drier_ROOM_OK_MEM Hydrogen detection in dryer room OK
FUSES_MV_OK_MEM Fuses magnetic valves OK
POWERSUPPLY_OK_MEM 24 Volt power supply OK
UPS_HIGH_OK_MEM UPS 24 volt high alarm OK
UPS_LOW_OK_MEM UPS 24 volt low alarm OK
FUSE_RIO_CP_OK_MEM Fuse RIO control panel OK
FUSE_RIO_Utill_A_OK_MEM Fuse RIO Utility A OK
FUSE_RIO_Utill_B_OK_MEM Fuse RIO Utility B OK
PS_INST_AIR_OK_MEM Pressure switch instrument air OK
PS_N2_LL_OK_MEM Pressure switch nitrogen low alarm OK
BSC_FREE_45 Not used Spare Condition 45
There are also some delayed start conditions in the table above:
A OTA_PR_DETHEAD_OK_MEM with warning signal in HMI
A OTA_2_DETHEAD_OK_MEM with warning signal in HMI

A HTA_PR1_DETHEAD_OK_MEM with warning signal in HMI
A HTA_Dr_DETHEAD_OK_MEM with warning signal in HMI
A PS_INST_AIR_OK_MEM with warning signal in HMI
A PS_N2_LL_OK_MEM with warning signal in HMI
C.3 Common hydrogen production basic start conditions

Code Explanation
CHILLER_OK_MEM Chiller OK

Page 60 Appendix C:
Code Explanation
PT_CLC_HH_OK_MEM Pressure closed loop cooling high high alarm OK
PT_CLC_LL_OK_MEM Pressure closed loop cooling low low alarm OK
PT_CLC_BW_OK_MEM Pressure closed loop cooling broken wire alarm OK
PT_Chiller_HH_OK_MEM Pressure chiller high high alarm OK
PT_Chiller_LL_OK_MEM Pressure chiller low low alarm OK
PT_Chiller_BW_OK_MEM Pressure chiller broken wire alarm OK
LS_H2_WL_OK_MEM Level switch waterlock hydrogen OK
LS_O2_WL_OK_MEM Level switch waterlock oxygen OK
FAN_PROCESS_OUT_OK_MEM Fan process room to outside OK
FAN_EPS_PROCESS_OK_MEM Fan EPS room to process room OK
Main_Sw_VentGr_OK_MEM Main switch ventilation group OK
VENT_GRP_PROCESS_OK_MEM Ventilation group process room OK
AIRFLOW_TOFRM_PRC_OK_MEM Airflow to/from process room OK
TT_EPS_HH_OK_MEM Temperature EPS room high high alarm OK
TT_CP_HH_OK_MEM Temperature control panel high high alarm OK
TT_UTIL_HH_OK_MEM Temperature utility room high high alarm OK
DR_SW_PROCESS_ROOM Door switch process room OK
CLOSED_LOOP_OK_MEM Closed loop cooling OK
PS_CW_OK_MEM Pressure switch cool water OK
CLC_PUMP_Common_1_OK_MEM Closed loop cooling common header 1 OK
CLC_PUMP_Common_2_OK_MEM Closed loop cooling common header 2 OK
CLC_FANS_GRP_1_OK_MEM Closed loop cooling fans ventilation group 1 OK
CLC_FANS_GRP_2_OK_MEM Closed loop cooling fans ventilation group 2 OK
CLC_PUMP_GC_OK_MEM Closed loop cooling pump gas cooling OK
CLC_PUMP_ChilComp_OK_MEM Closed loop cooling pump chiller/compressor OK
MainSw_Util_P_OK_MEM Main switch utility panel OK
AIRFLOW_RATE_OK_MEM Air flow rate from general purpose to process room OK
NR_Vent_Fan_1_LS_OK_MEM Next release ventilation fan 1 low speed OK
NR_Vent_Fan_1_HS_OK_MEM Next release ventilation fan 1 high speed OK
NR_Vent_Fan_2_LS_OK_MEM Next release ventilation fan 2 low speed OK
NR_Vent_Fan_2_HS_OK_MEM Next release ventilation fan 2 high speed OK
PHASE_CP_Panel_OK_MEM Phase control control panel OK
COM_H2P_SC_FREE_33 Not used Spare Condition 33

Appendix C: Page 61
Code Explanation
A CHILLER_OK_MEM with warning signal in HMI
A PT_CLC_LL_OK_MEM
A PT_Chiller_LL_OK_MEM
A LS_H2_WL_OK_MEM with warning signal in HMI
A LS_O2_WL_OK_MEM with warning signal in HMI
A FAN_PROCESS_OUT_OK_MEM
A FAN_EPS_PROCESS_OK_MEM
A VENT_GRP_PROCESS_OK_MEM
A AIRFLOW_TOFRM_PRC_OK_MEM
A DR_SW_PROCESS_ROOM
A CLC_PUMP_Common_1_OK_MEM
A CLC_PUMP_Common_2_OK_MEM
A CLC_PUMP_GC_OK_MEM
A CLC_PUMP_ChilComp_OK_MEM
C.4 Nitrogen purge start conditions

Code Explanation
BASIC_STC Basic start conditions OK
LS_HG_H_OK_MEM Electrolyte level switch high H2 separator OK
LS_HG_L_OK_MEM Electrolyte level switch low H2 separator OK
LS_OG_H_OK_MEM Electrolyte level switch high O2 separator OK
LS_OG_L_OK_MEM Electrolyte level switch low O2 separator OK
PT_HH_OK_MEM Pressure transmitter gas separator high high alarm OK
PT_BW_OK_MEM Pressure transmitter gas separator broken wire alarm OK
LTH_HH_OK_MEM Electrolyte level H2 gas separator high high alarm OK
LTH_LL_OK_MEM Electrolyte level H2 gas separator low low alarm OK
LTH_BW_OK_MEM Electrolyte level H2 gas separator broken wire alarm OK
LTO_LL_OK_MEM Electrolyte level O2 gas separator low low alarm OK
LTO_HH_OK_MEM Electrolyte level O2 gas separator high high alarm OK
LTO_BW_OK_MEM Electrolyte level O2 gas separator broken wire alarm OK
N2P_NOT_Failed Nitrogen purge has been completed successfully
Maj_Faults_Lvls_Not_act Major faults on levels graphcet NOT active

Page 62 Appendix C:
Code Explanation
FUSE_RIO_Proc_A_OK_MEM Fuse RIO process part A OK
FUSE_RIO_Proc_B_OK_MEM Fuse RIO process part B OK
N2P_FREE17 Not used Spare Condition 17
C.5 Hydrogen deoxo dryer start conditions

Hydrogen deoxo dryer start conditions
Code Explanation
H2Dryer_Purge_Active N2 purge not active. When the nitrogen purge of the deoxo
dryer is active, the equipment is unavailable for normal opera-
tion, so electrolyzer hydrogen production is disabled. Thus no
hydrogen can enter the deoxo dryer.
N2_Purge_SUCCESFULL N2 purge of the drier succesfull

Appendix C: Page 63
Code Explanation
H2TSDxo_Pre_HH_OK_MEM H2 temperature switch high deoxo preheater OK
H2TSDxo_HH_OK_MEM H2 temperature switch high deoxo OK
H2TSDa_HH_OK_MEM H2 temperature switch high dryer A OK
H2TSDb_HH_OK_MEM H2 temperature switch high dryer B OK
TTDxo_Pre_HH_OK_MEM H2 temperature transmitter deoxo preheater high high alarm
OK
TTDxo_Pre_LL_OK_MEM H2 temperature transmitter deoxo preheater low low alarm
OK
TTDxo_Pre_BW_OK_MEM H2 temperature transmitter deoxo preheater broken wire
alarm OK
TTDxo_HH_OK_MEM H2 temperature transmitter deoxo high high alarm OK
TTDxo_LL_OK_MEM H2 temperature transmitter deoxo low low alarm OK
TTDxo_BW_OK_MEM H2 temperature transmitter deoxo broken wire alarm OK
TTDa_HH_OK_MEM H2 temperature transmitter dryer high high alarm OK
TTDa_LL_OK_MEM H2 temperature transmitter dryer A low low alarm OK
TTDa_BW_OK_MEM H2 temperature transmitter dryer A broken wire alarm OK
TTDb_HH_OK_MEM H2 temperature transmitter dryer B high high alarm OK
TTDb_LL_OK_MEM H2 temperature transmitter dryer B low low alarm OK
TTDb_BW_OK_MEM H2 temperature transmitter dryer B broken wire alarm OK
H2FlSw_Reg_Gas_OK_MEM Flow switch regeneration gas OK
PTDeo_HH_OK_MEM H2 pressure transmitter deoxo high high alarm OK
PTDeo_LL_OK_MEM H2 pressure transmitter deoxo low low alarm OK
PTDeo_BW_OK_MEM H2 pressure transmitter deoxo broken wire alarm OK
PTDa_HH_OK_MEM H2 pressure transmitter dryer A high high alarm OK
PTDa_LL_OK_MEM H2 pressure transmitter dryer A low low alarm OK
PTDa_BW_OK_MEM H2 pressure transmitter dryer A broken wire alarm OK
PTDb_HH_OK_MEM H2 pressure transmitter dryer B high high alarm OK
PTDb_LL_OK_MEM H2 pressure transmitter dryer B low low alarm OK
PTDb_BW_OK_MEM H2 pressure transmitter dryer B broken wire alarm OK
PTBOP_H_HH_OK_MEM H2 pressure transmitter booster pump high high alarm OK
PTBOP_H_LL_OK_MEM H2 pressure transmitter booster pump low low alarm OK
PTBOP_H_BW_OK_MEM H2 pressure transmitter booster pump broken wire alarm OK
PTU_HH_OK_MEM H2 pressure transmitter user line high high alarm OK
PTU_LL_OK_MEM H2 pressure transmitter user line low low alarm OK
PTU_BW_OK_MEM H2 pressure transmitter user line broken wire alarm OK
DPT_HH_OK H2 dewpoint transmitter high high alarm OK
DPT_BW_OK_M H2 dew point transmitter broken wire alarm OK
OTH_DEOXO_HH_OK_M Oxygen in hydrogen high high alarm OK
OTH_DEOXO_BW_OK_M Oxygen in hydrogen broken wire alarm OK
FlSw_H2_DPT_OTH_OK_MEM Flow switch H2 to dewpoint/OTH transmitter OK
DrainPot_Fault Drainpot fault OK
DrainPot2_Fault Drainpot 2 fault OK
DrHt_H_FB_OK_MEM Feedback signal enable H2 dryer heating OK
FUSE_RIO_H2_Drier_OK_MEM Fuse remote IO H2 dryer heating OK
HPS_MF_BF_OK_MEM Main fuse feedback OK

Page 64 Appendix C:
Code Explanation
HPS_Dxo_P_Heat_FB_OK_MEM Deoxo pre heating feedback OK
HPS_Dxo_Heat_FB_OK_MEM Deoxo heating feedback OK
HPS_DrA_Heat_FB_OK_MEM Drier A heating feedback OK
HPS_DrB_Heat_FB_OK_MEM Drier B heating feedback OK
H2Dr_FREE49 H2_Dr-STCD : 49
A H2FlSw_Reg_Gas_OK_MEM with warning signal in HMI

A DPT_HH_OK with warning signal in HMI
A OTH_DEOXO_HH_OK_M with warning signal in HMI
A FlSw_H2_DPT_OTH_OK_MEM with warning signal in HMI
A DrainPot_Fault with warning signal in HMI
A DrainPot2_Fault with warning signal in HMI
A HPS_MF_BF_OK_MEM
A HPS_Dxo_P_Heat_FB_OK_MEM
A HPS_Dxo_Heat_FB_OK_MEM
A HPS_DrA_Heat_FB_OK_MEM
A HPS_DrB_Heat_FB_OK_MEM
C.6 Oxygen dehydro dryer start conditions

Oxygen dehydro dryer start conditions
Code Explanation
O2Dryer_Purge_Active N2 purge not active. When the nitrogen purge of the dehydro
dryer is active, the equipment is unavailable for normal opera-
tion, so electrolyzer oxygen production is disabled. Thus no
oxygen can enter the dehydro dryer.

Appendix C: Page 65
Code Explanation
N2_Purge_SUCCESFULL N2 purge of the drier succesfull
O2TSDxo_Pre_HH_OK_MEM O2 temperature switch high dehydro preheater OK
O2TSDxo_HH_OK_MEM O2 temperature switch high dehydro OK
O2TSDa_HH_OK_MEM O2 temperature switch high dryer A OK
O2TSDb_HH_OK_MEM O2 temperature switch high dryer B OK
TTDho_Pre_HH_OK_MEM O2 temperature transmitter dehydro preheater high high
alarm OK
TTDho_Pre_LL_OK_MEM O2 temperature transmitter dehydro preheater low low alarm
OK
TTDho_Pre_BW_OK_MEM O2 temperature transmitter dehydro preheater broken wire
alarm OK
TTDho_HH_OK_MEM O2 temperature transmitter dehydro high high alarm OK
TTDho_LL_OK_MEM O2 temperature transmitter dehydro low low alarm OK
TTDho_BW_OK_MEM O2 temperature transmitter dehydro broken wire alarm OK
TTDa_HH_OK_MEM O2 temperature transmitter dryer high high alarm OK
TTDa_LL_OK_MEM O2 temperature transmitter dryer A low low alarm OK
TTDa_BW_OK_MEM O2 temperature transmitter dryer A broken wire alarm OK
TTDb_HH_OK_MEM O2 temperature transmitter dryer B high high alarm OK
TTDb_LL_OK_MEM O2 temperature transmitter dryer B low low alarm OK
TTDb_BW_OK_MEM O2 temperature transmitter dryer B broken wire alarm OK
O2FlSw_Reg_Gas_OK_MEM Flow switch regeneration gas OK
PTDho_HH_OK_MEM O2 pressure transmitter dehydro high high alarm OK
PTDho_LL_OK_MEM O2 pressure transmitter dehydro low low alarm OK
PTDho_BW_OK_MEM O2 pressure transmitter dehydro broken wire alarm OK
PTDa_HH_OK_MEM O2 pressure transmitter dryer A high high alarm OK
PTDa_LL_OK_MEM O2 pressure transmitter dryer A low low alarm OK
PTDa_BW_OK_MEM O2 pressure transmitter dryer A broken wire alarm OK
PTDb_HH_OK_MEM O2 pressure transmitter dryer B high high alarm OK
PTDb_LL_OK_MEM O2 pressure transmitter dryer B low low alarm OK
PTDb_BW_OK_MEM O2 pressure transmitter dryer B broken wire alarm OK
PTBOP_O_HH_OK_MEM O2 pressure transmitter booster pump high high alarm OK
PTBOP_O_LL_OK_MEM O2 pressure transmitter booster pump low low alarm OK
PTBOP_O_BW_OK_MEM O2 pressure transmitter booster pump broken wire alarm OK
PTU_HH_OK_MEM O2 pressure transmitter user line high high alarm OK
PTU_LL_OK_MEM O2 pressure transmitter user line low low alarm OK
PTU_BW_OK_MEM O2 pressure transmitter user line broken wire alarm OK
DPT_HH_OK O2 dewpoint transmitter high high alarm OK
DPT_BW_OK_M O2 dew point transmitter broken wire alarm OK
HTO_DEHYDRO_HH_OK_M Hydrogen in oxygen high high alarm OK
HTO_DEHYDRO_BW_OK_M Hydrogen in oxygen broken wire alarm OK
FlSw_O2_DPT_HTO_OK_MEM Flow switch O2 to dewpoint/HTO transmitter OK
DrainPot_Fault Drainpot fault OK
DrainPot2_Fault Drainpot 2 fault OK
DrHt_O_FB_OK_MEM Feedback signal enable O2 dryer heating OK
FUSE_RIO_O2_Drier_OK_MEM Fuse remote IO O2 dryer heating OK

Page 66 Appendix C:
Code Explanation
OPS_MF_BF_OK_MEM Main fuse feedback OK
OPS_Dho_P_Heat_FB_OK_MEM Dehydro pre heating feedback OK
OPS_Dho_Heat_FB_OK_MEM Dehydro heating feedback OK
OPS_DrA_Heat_FB_OK_MEM Drier A heating feedback OK
OPS_DrB_Heat_FB_OK_MEM Drier B heating feedback OK
O2Dr_FREE49 O2_Dr-STCD : 49
OTA_OPS_DETHEAD_OK_MEM Oxygen to atmosphere detection head OK
OTA_OPS_HSw_OK_MEM Oxygen to atmosphere high switch OK
OTA_OPS_LSw_OK_MEM Oxygen to atmosphere low switch OK
OTA_OPS_HIGH_OK_MEM Oxygen to atmosphere measurment high OK
OTA_OPS_LOW_OK_MEM Oxyten to atmosphere measurement low OK
CHILLER_OPS_OK_MEM Chiller OK
PT_Chiller_OPS_HH_OK_MEM Pressure transmitter chiller high high alarm OK
PT_Chiller_OPS_LL_OK_MEM Pressure transmitter chiller low low alarm OK
PT_Chiller_OPS_BW_OK_MEM Pressure transmitter chiller broken wire alarm OK
TT_Chiller_OPS_HH_OK_MEM Temperature transmitter chiller high high alarm OK
TT_Chiller_OPS_LL_OK_MEM Temperature transmitter chiller low low alarm OK
TT_Chiller_OPS_BW_OK_MEM Temperature transmitter chiller broken wire alarm OK
A O2FlSw_Reg_Gas_OK_MEM with warning signal in HMI

A DPT_HH_OK with warning signal in HMI
A OTH_DEHYDRO_HH_OK_M with warning signal in HMI
A FlSw_O2_DPT_OTH_OK_MEM with warning signal in HMI
A DrainPot_Fault with warning signal in HMI

Appendix C: Page 67
A DrainPot2_Fault with warning signal in HMI

A OPS_MF_BF_OK_MEM
A OPS_Dho_P_Heat_FB_OK_MEM
A OPS_Dho_Heat_FB_OK_MEM
A OPS_DrA_Heat_FB_OK_MEM
A OPS_DrB_Heat_FB_OK_MEM
A CHILLER_OPS_OK_MEM
A PT_Chiller_OPS_LL_OK_MEM
C.7 Hydrogen production start conditions

Hydrogen production start conditions
Code Explanation
COMMON_H2PROD_STC Common hydrogen production start conditions OK
N2P_STC Nitrogen purge start conditions OK
H2_DRIER_STC Hydrogen drier start conditions OK
O2_DRIER_STC Oxygen drier start conditions OK
ZL_DRIER_STC Zero loss drier start conditions OK
FS_HTO_OK_MEM Flow switch HTO > minimum OK
HWSS_HTO_H_OK_MEM Hard wired H2 in O2 high alarm OK
HWSS_HTO_L_OK_MEM Hard wired H2 in O2 low alarm OK
HTO_HH_OK_MEM H2 in O2 high high alarm OK
HTO_LL_OK_MEM H2 in O2 low low alarm OK
LS_DT1_1_OK_MEM Level switch drip tray 1_1 OK
LS_BT_H_LL_OK_MEM Level switch break tank hydrogen low low alarm OK
LS_BT_O_LL_OK_MEM Level switch break tank oxygen low low alarm OK
FS_OTH_OK_MEM Flow switch OTH > minimum OK
HWSS_OTH_H_OK_MEM Hard wired O2 in H2 high alarm OK
HWSS_OTH_L_OK_MEM Hard wired O2 in H2 low alarm OK
OTH_HH_OK_MEM O2 in H2 high high alarm OK
OTH_LL_OK_MEM O2 in H2 low low alarm OK
TT_PROC_HH_OK_MEM Temperature process room high high alarm OK
CLC_PUMP_EC_A_OK_MEM Closed loop cooling pump electrolye A OK
CLC_PUMP_EC_B_OK_MEM Closed loop cooling pump electrolyte B OK
H2P_FREE24 Not used Spare Condition 24

Page 68 Appendix C:
Hydrogen production start conditions
Code Explanation
A FS_HTO_OK_MEM with warning signal in HMI
A HWSS_HTO_L_OK_MEM
A HTO_LL_OK_MEM
A FS_OTH_OK_MEM with warning signal in HMI
A HWSS_OTH_L_OK_MEM
A OTH_LL_OK_MEMI
C.8 Cell stack 1 start conditions

Cell stack 1 start conditions
Code Explanation
H2PROD_STC Hydrogen production start conditions OK
C_EPS_CS1_OK_MEM Contactor EPS cell stack 1 Ok
MAIN_PROT_CS1_OK_MEM Main protector cell stack 1 OK
PHASE_CS1_OK_MEM Phase controll cell stack 1 OK
EPS_DOOR_SW_CS1_OK_MEM EPS door switch cell stack 1 OK
TTHS_Th_CS1_HH_OK_MEM Temperature heatsink thyristor cell stack 1 high high alarm
OK
TTHS_Th_CS1_LL_OK_MEM Temperature heatsink thyristor cell stack 1 low low alarm OK
TTHS_Di_CS1_HH_OK_MEM Temperature heatsink diode cell stack 1 high high alarm OK
TTHS_Di_CS1_LL_OK_MEM Temperature heatsink diode cell stack 1 low low alarm OK
TTPWR1_HH_OK_MEM Temperature power rack 1 high high alarm OK
TTPWR1_LL_OK_MEM Temperature power rack 1 low low alarm OK
TSCS1_HH_OK_MEM Temperature switch cell stack 1 high high alarm OK

Appendix C: Page 69
Code Explanation
TTCS1_HH_OK_MEM Temperature cell stack 1 high high alarm OK
TTCS1_LL_OK_MEM Temperature cell stack 1 low low alarm OK
ITCS1_HH_OK_MEM Current cell stack 1 high high alarm OK
ITCS1_LL_OK_MEM Current cell stack 1 low low alarm OK
UTCS1a_HH_OK_MEM Voltage cell stack 1a high high alarm OK
UTCS1a_LL_OK_MEM Voltage cell stack 1a low low alarm OK
UTCS1b_HH_OK_MEM Voltage cell stack 1b high high alarm OK
UTCS1b_LL_OK_MEM Voltage cell stack 1b low low alarm OK
UTCS1a_SmallrThen_UTCS1b Votage cell stack 1a smaller then voltage cell stack 1b
UTCS1a_BiggerThen_UTCS1b Votage cell stack 1a bigger then voltage cell stack 1b
C_PROT_CS1_FANS_OK_MEM Contactor/Protector fans cell stack 1 OK
FB_FRQ_CS1_FAN_OUTS_OK_M Feedback frequency drive fan EPS to outside cell stack 1 OK
Fuse_RIO_CS1_OK_MEM Fuse RIO cell stack 1 OK
EPS_CS1_TSW_TH_OK_MEM EPS Temperature switch thyristor cell stack 1 OK
EPS_CS1_TSW_DI_OK_MEM EPS Temperature switch diode cell stack 1 OK
CS1_FREE27 Not used Spare Condition 27
A C_EPS_CS1_OK_MEM
A UTCS1a_SmallrThen_UTCS1b
A UTCS1a_BiggerThen_UTCS1b
A C_PROT_CS1_FANS_OK_MEM
A FB_FRQ_CS1_FAN_OUTS_OK_M

Page 70 Appendix C:

Code Explanation
OK

Appendix C: Page 71
Code Explanation
A C_EPS_CS2_OK_MEM

Code Explanation
TTHS_Th_CS3_HH_OK_MEM Temperature heatsink thyristor cell stack 3 high high alarm OK
C_PROT_CS3_FANS_OK_MEM Contactor/Protector fans cell stack 3OK

Page 72 Appendix C:
Code Explanation
FB_FRQ_CS3_FAN_OUTS_OK_M Feedback frequency drive fan EPS to outside cell stack 3OK
A C_EPS_CS3_OK_MEM

Code Explanation

Appendix C: Page 73
Code Explanation
OK

Page 74 Appendix C:
A C_EPS_CS4_OK_MEM

HYSTAT MANUAL
APPENDIX D: SPECIFICATIONS UTILITIES

Page 76 Appendix D:
HySTAT MANUAL SPECIFICATIONS UTILITIES
Appendix D: SPECIFICATIONS UTILITIES
D.1 Electrolyte
The electrolyte to be used in the HySTAT is KOH (Potassium Hydroxide) in a 30% w/v aqueous solution.
Hydrogenics Europe NV strongly recommends the use of a prepared solution rather than preparing it on
site. On the market, typically 30% w/v and 50% w/v KOH solutions can be found. The minimum quality of
the KOH pellets used to prepare the solution, and the quality of the KOH solution itself, is indicated in the
tables below.
Required KOH purity
Potassium Hydroxide 30%

KOH
MW 56.11
Total alkalinity: 29% - 32%
Maximum % impurity:
Potassium carbonate K2CO3 0.6
Sodium Na 0.5
Maximum mg/kg (ppm) impurity

Chloride Cl 25 Copper Cu 1
Silica SiO2 15 Iron Fe 3
Sulphates SO4 10 Mercury Hg 0.05
Aluminium Al 5 Manganese Mn 0.1
Barium Ba 5 Nickel Ni 1
Calcium+Magnesium Ca+Mg 10 Lead Pb 0.5
Cadmium Cd 1 Zinc Zn 0.5
Cobalt Co 1 Other heavy metals 1
Chromium Cr 5
Required electrolyte quantity
HySTAT ELECTROLYTE QUANTITY
HySTAT MODEL CAPACITY

HySTAT-10 (10 barg) 300 l
Refer to the KOH MSDS for additional information.

Appendix D: Page 77
SPECIFICATIONS UTILITIES HySTAT MANUAL
D.2 Demineralized water

The quality of the demineralized water supply will ultimately effect the lifetime of the unit. The specifica-
tion should be as listed below.
Demineralized water purity
Purified water
H20
MW 18.02
BP 100°C
Properties
Appearance clear and colorless
Electrical Conductivity 5,0 µS/cm (20°C) max
Langelier Index 0,15 to -0,15
pH 5,0 to 7,0
Evaporation Residue 1,0 ppm
Maximum Impurity
Calcium Ca 0,1 ppm
Calcium Carbonate CaCO3 1 ppm
Chloride Cl 0,5 ppm
Chromium Cr 0,05 ppm
Copper Cu 0,05 ppm
Iron Fe 0,03 ppm
Lead Pb 0,05 ppm
Nitrate NO3 0,2 ppm
Silicon Si 0,05 ppm
Sodium Na 0,1 ppm
Sulphates SO4 1,0 ppm
Zinc Zn 0,05 ppm
Every HySTAT is equipped with a conductivity transmitter to check the quality of the water. The conduc-
tivity measurement is a reliable method to verify the quality of the water, but it doesn't give an absolute
guarantee that the quality of the water complies with the specification in table 3. Consequently Hydro-
genics Europe NV recommends to periodically sending a sample to a specialized lab for further analysis.
D.3 Supply water to reverse osmosis system

In the case a reverse osmosis system is fitted, the water supplied to the RO system should also be of a
certain standard. If the quality is as listed below the standard RO system which already includes an anti-
scaling pre-treatment is likely to be sufficient. In order to design the RO system properly, the concentra-
tion of all the listed elements should preferably be known in advance and evaluated. If one expects that
the quality of the water is not stable, one should mention the min and max concentration. Hydrogenics
Europe NV also recommends to periodically verify the quality of the water going to the RO system as the
quality of the water is critical for the lifetime of the generator.

Page 78 Appendix D:
Water to reverse osmosis system purity
Element Unit Maximum concentration

Microbiological contamination count/ml 0 (Not allowed)
Langelier index 2,5
Free chlorine mg/l 0,02
Total suspended solids mg/l 0,05
Total dissolved solids mg/l 500
CO32- mg/l 0,5
Turbidity NTU < 0,5
+
Na mg/l 200
+
K mg/l 50
Ba2+ mg/l 0,05
Ca2+ mg/l 50
2+
Mg mg/l 30
-
Cl mg/l 150
SO42- mg/l 150
3-
HCO mg/l 100
2+
Fe mg/l 0,03
Fe(tot) mg/l 0,5
Al(tot) mg/l 0,05
Conductivity µS/cm 1000
SiO2 mg/l 0,5
2+
Mn mg/l 0,05
pH 7,0 - 8,5
Temp °C 10 - 30
Pressure barg 2-4
D.4 Cooling water

If the supplied cooling water is not within the specifications below, the heat
exchangers in the system may fail, which can lead to severe KOH- and/or gas
leaks.
In order to protect the cooling water circuit, the used water must have physical and chemical properties
so that it is not aggressive. If this water contains products outside any of the limits listed in the table
below, it can damage the materials and parts used in the HySTAT cooling system.
Please review whether corrosion inhibitors are required for your application (e.g. if you intend to operate
the cooling water system with an open loop system).
Note also that demineralized water with a conductivity < 50 microS/cm can be harmful for some of the
materials used.

Appendix D: Page 79
D.4.1 Cooling water purity

Cooling water
PH at 25°C 7 - 8.0
Conductivity: 50 - 800 µS/cm
Total hardness: < 150 ppm
M-alkalinity: < 100 ppm CaCO3
Chlorine ion: < 200 ppm Cl-
Sulphuric acid ion: < 200 ppm SO42-
Sulphuric acid: < 0.05 ppm H2S
Total iron: < 0.2 ppm Fe
Silica: < 50 ppm SiO2
Sulphur ion: <0 ppm S2-
Ammonium ion: <2 ppm NH4+
Particulates: < 150 microns
Pressure: 2 - 3.5 bar
Temperature: 35 °C See performance data
D.4.2 Ethylene glycol – water solution

A The water used to prepare the glycol-water solution has to be extremely soft. If the available tap
water is too hard, distilled or demineralized water should be used. Too hard water will form
scale on the inside of the cooling system walls, significantly impeding heat transfer.
A The coolant mixture should not be contaminated with other products.
A If not replaced, the coolant mixture freeze point should be checked at least twice a year using a
refractometer, and adjusted if necessary by adding pure glycol.
A The glycol concentration of the mixture depends on the minimum environmental temperature.
Refer to the table below:
FREEZING POINT OF ETHYLENE GLYCOL BASED WATER SOLUTIONS

EG-solution 0 10 20 30 40 50 60
(% by volume)
Temperature °C 0 -3 -8 -16 -25 -37 -55
Temperature °F 32 23 14 2 -13 -36 -70
D.4.3 Cooling system capacity
The table below indicates the contents in litres of the HySTAT closed loop cooling
system. Please note that these values are indicative, and that actual content may vary
slightly.
HySTAT COOLING SYSTEM CAPACITY
HySTAT MODEL CAPACITY

HySTAT-15 84l + 20l (Chiller - see D.4.4:Chiller coolant)

Page 80 Appendix D:
D.4.4 Chiller coolant

In most cases the chiller cooling circuit is filled with cooling water as described above. However, the ven-
dor chiller manual contains a set of specifications with which the chiller coolant must comply. These
specifications may be more strict than the cooling water purity specifications given in ‘D.4.1: Cooling
water purity’. If the available cooling water proves to be out of the specifications as stated in the vendor
chiller manual, it is advised to use refrifluid. Refrifluid is a liquid specially designed for the treatment and
conservation of the internal surface of tanks and piping in the chiller system. It provides both bacterial
and chemical corrosion protection.
If in doubt about the required chiller coolant, contact Hydrogenics Europe NV for more
information.
D.5 Nitrogen gas

The nitrogen gas that is used to purge the installation must be free of oil and particles. For nitrogen gas
purge of the HySTAT, a nitrogen pressure of 6barg is advised. For pressure testing, a pressure of
10barg is required.
HySTAT INERT GAS PURGE QUANTITY
HySTAT MODEL HySTAT PURGE DEOXO DRYER PURGE

HySTAT-15 0,5 Nm³ 0,25 Nm³
HySTAT-30 1 Nm³ 0,5 Nm³
HySTAT-60 2 Nm³ 1 Nm³
D.6 instrument air

For HySTAT-30 and HySTAT-60 units including a deoxo dryer, instrument air is needed. The instrument
air must comply with the following specifications (according to ISO 8573 Class 3):
Maximum dirt particle Maximum dirt Pressure dew point, °C Maximum oil content
size, microns concentration, mg/m³ (ppm) at 7 barg (incl. vapor), mg/m³
5 5 -20 (128) 1
A Minimum pressure: 7 barg

A Maximum pressure: 10 barg
The maximum needed flow is approximately 1 m³ per hour.
D.7 Calibration gases

Calibration gas 1: Composition 1.8% by volume hydrogen in air
Calibration gas 2: Composition 100% by volume (high purity) oxygen
Calibration gas 3: Composition 1% by volume hydrogen (high purity) in oxygen
Calibration gas 4: Clean air
Calibration gas 5: Span gas of 6-8ppm oxygen in nitrogen

Appendix D: Page 81
D.8 Electrical power supply

D.8.1 Grid specifications
Standard supply voltage for CE units

A 400Vac +/-10%
A 3ph + PE
A 50Hz +/-3%
Standard supply voltage for North-American units

A 480Vac +/-10%
A 3ph + PE
A 60Hz +/-3%
During normal operation of the HySTAT, the supply voltage may not vary more
then +/-5% of the specified supply voltage. A steep drop in the power supply
must be avoided at all times.
D.8.2 Power specifications
Required power for HySTAT

Indoor/containerized
HySTAT-15 HySTAT-30 HySTAT-60
Required power Indoor, HySTAT S10: 100kVA 240kVA 480kVA
including deoxo dryer S15: 120kVA
option
Required power Containerized HySTAT S10: 140kVA 285kVA 2 x 240kVA
(EPS part) + deoxo dryer, chiller, S15: 160kVA
Required power RO, CLC. Standard 0 0 50kVA
(Control panel) environmental
conditions.

Page 82 Appendix D:

HYSTAT MANUAL
APPENDIX E: REMOTE ACCESS AND DATA-

LOGGING
Page 84 Appendix E:
HySTAT MANUAL REMOTE ACCESS AND DATA-LOGGING
Appendix E: REMOTE ACCESS AND DATA-

LOGGING
E.1 Getting started

Remote access and datalogging is possible on the HMI of Beijer Electronics. The Exter T70® is our stan-
dard HMI. The other HMI’s that are used by Hydrogenics are the Exter T100® and the Exter T150®. For
remote access and datalogging three programs have to be installed on the PC:
A Remote Access Viewer of Beijer Electronics: this program presents an image of the HMI on the
PC monitor.
A Beijer Electronics Data Collector (Optional): this program connects automatically to a number of
operator panels and collects trends and alarm data, and writes to a database.
A Beijer Electronics Data Viewer (Optional): this program reads the information from the database
and presents it in graphs and tables.
To log the data in the Exter Txx® an external memory card has to be inserted. Standard a Compact-
Flash® card of 4.0 GB is used. In bigger applications a USB-card is inserted into the Exter Txx®. This is
done because in bigger applications the internal memory has to be extended with an internal Compact-
Flash® card of 2.0 GB. The external card option is not available in this configuration.
Please note that changes may be applied to the actual version of your software, and that
some screens displayed in this manual may differ from your configuration. Depending
the setup of your HySTAT, some screens may not be accessible. Contact Hydrogenics
Europe NV in case of doubt.
E.2 Remote Access Viewer

E.2.1 Introduction
It is possible to access, reflect and control an HMI from a PC by using the VNC client program Remote
Access Viewer together with the built-in VNC server in the HMI. Remote Access Viewer is a free remote
control software derived from the software package TightVNC.
It is also possible to use a web browser as a viewer, see the section "Using a Web Browser as a Viewer"
Please note that this remote control software is different then SCADA (Supervision,
Control, And Data Acquisition) software. The SCADA software is a common process
control application that collects real-time data from sensors or controllers in remote
locations via a PLC and sends them to a central computer for management and control.
The remote controll software is an application that accesses, reflects and controls an
HMI from a PC. It doesn’t connect to the PLC.
VNC (Virtual Network Computing) is a client/server software package allowing remote network access to
graphical desktops. Basically, when using VNC, it is possible to access a PC or other PC-based equip-
ment, for example an operator terminal that is connected to the Internet from any other Internet-con-
nected PC anywhere.

Appendix E: Page 85
REMOTE ACCESS AND DATA-LOGGING HySTAT MANUAL
It can be very helpful to use the Remote Access function for the operator terminals when for example
performing remote customer support, remote control and troubleshooting.
Remote Access Viewer presents an image of the operator terminal on the PC monitor. The image in
Remote Access Viewer is updated at regular intervals or when requested. The Remote Access function
has the same function as the actual operator terminal.
Please note that Only one VNC client (for example Remote Access Viewer) can be
connected to the operator terminal simultaneously.
E.2.2 Installation
Remote Access Viewer is VNC client program used for remote access and control of an operator termi-
nal.
System requirements
To use Remote Access Viewer, a PC with at least 5 MB of available memory and Microsoft Windows
2000/XP Professional is required. Remote Access Viewer can be used on either a color or monochrome
screen. Microsoft Internet Explorer version 5.0 or later must be installed on the PC.
Activate Java console

In Microsoft Internet Explorer, it can be useful to activate the Java console function when troubleshoot-
ing. Select Tools/Internet Options in Internet Explorer, click Advanced and select the box for Activate
Java console. Restart the browser. Also check that the latest version of Microsoft Virtual Machine or Sun
Microsystems Java Virtual Machine is installed on the PC. Download the latest version, if necessary,
from the Java web page (www.java.com, search for Virtual Machine).
Installing
Double-click on the file RemoteAccessViewerSetup.exe on your PC or install Remote Access Viewer
from your software CD. Follow the instructions in the Remote Access Viewer Setup Wizard to install
Remote Access Viewer.
Clicking Start and selecting All Programs/Remote Access Viewer/Remote Access Viewer starts the pro-
gram.
Uninstalling
Remote Access Viewer can be uninstalled by using the Add/Remove Programs utility in the Control
Panel. The Remote Access Viewer installation does not copy any files into the system directory on your
PC. Make sure that Remote Access Viewer is not running before uninstalling.
E.2.3 Connecting to the Operator Terminal

Connection to the operator terminal (the VNC server) from the PC with the VNC client program Remote
Access Viewer is accomplished by entering the operator terminals' IP address (or host name). In the
installation the standard IP address of the HMI is 192.168.100.2
Start Remote Access Viewer by clicking Start and selecting All Programs/Remote Access Viewer/
Remote Access Viewer. Click Help to view the help file for the program.
VNC server
Enter the operator terminal's IP address or select an already used IP address in the drop-down list.

Page 86 Appendix E:
Figure 1 – Remote Access Viewer Connection
Select a connection profile that matches the speed of your network connection:
A Low-bandwidth connection: This connection profile is optimized for a low-bandwidth network

connection. Use this profile if you are using a 56Kbps modem to access the operator terminal.
A High-speed network: connection: This connection profile is optimized for a high-speed network
connection. Choose this profile if you are accessing an operator terminal in the same Ethernet
LAN (Local Area Network) as your PC or over a 10/100Mbit LAN.
Using the Low-bandwidth connection will enable JPEG compression at the lowest image
quality (8 bit colors), consuming a minimum of the bandwidth available.
Simply click Connect to attempt to connect to the operator terminal with the specified IP address
Figure 2 – Remote Access Viewer Authentication
Using Remote Access Viewer
Remote Access Viewer presents an image of the operator terminal on the PC monitor. The image in
Remote Access Viewer is updated at regular intervals or when requested. The Remote Access function
has the same function as the actual operator terminal.

Appendix E: Page 87
The Toolbar
Figure 3 – Toolbar
The icons in the Remote Access Viewer toolbar have the following functions:
Controlling the Operator Terminal

Clicking with the mouse on the function keys on the operator terminal image or with the PC keyboard
controls the operator terminal. On an operator terminal with a touch screen, you click directly on the
screen. Text strips for the operator terminals are not shown in Remote Access Viewer.
Security
Remote Access Viewer encrypts passwords sent over the network but the rest of the traffic is sent as is,
unencrypted. Using Remote Access Viewer over the Internet or other untrusted networks can be a secu-
rity risk.
The Internet is not the same thing as an Ethernet LAN (Local Area Network). It is
considered safe to use Remote Access Viewer in a stand-alone LAN.
E.2.4 Using a Web Browser as a Viewer

The built-in VNC server in the operator terminal also contains a small VNC applet. You can connect to
the operator terminal with a web browser that supports Java applets, e.g. Microsoft Internet Explorer.

Page 88 Appendix E:
The picture of the operator terminal frame is not displayed when a web browser is used as a viewer. Only
the contents of the operator terminal's display are shown.
Connecting to the Operator Terminal

The VNC server listens for HTTP (Hypertext Transfer Protocol) connections on TCP (Transmission Con-
trol Protocol) port 5800 (as set in operator terminal for the Remote Access function, see the section Set-
tings in the Operator Terminal).
Enter the operator terminal's IP address followed by : (colon) and the TCP port number 5800 in the web
browser's Address field, for example http://192.168.98.47:5800/ if the operator terminal's IP address is
192.168.98.47.
Figure 4 – Web Browser View
Controlling the Operator Terminal

An operator terminal with keypad is controlled by using the PC keyboard. The following keys on a PC
keyboard correspond to the keys on the operator terminal:
On an operator terminal with a touch screen, you click directly on the screen.
It is not recommended to connect to the operator terminal via a proxy

Appendix E: Page 89
E.3 Beijer Electronics Data Collector (Optional)

E.3.1 Introduction
In our application the Beijer Electronics Data Collector is used to save trend data logged in the operator
panels to a database in a PC. Since the number of records is limited only by the capacity of the data-
base, much more data can be stored compared to the operator panel. The connection can be made via
Ethernet, a modem (PPP) or a null modem PPP. The information from the database can be presented in
graphs and tables.
For the Beijer Electronics Data Collector a HASP key must be inserted into the USB or
parallel port, otherwise the program will run in demo mode for a limited trial period. This
Beijer Electronics Data Collector is optional.
Beijer Electronics Data Collector is a software that:
A Makes trend and alarm records logged in operator panels available in a database on a PC.
A Increases the number of trend records that can be stored.
Beijer Electronics Data Collector consists of two programs:
A Beijer Electronics Data Collector
A Beijer Electronics Viewer.
Beijer Electronics Viewer reads the information from the database and presents it in graphs and tables
Figure 5 – Overview possible configuration
E.3.2 System requirements

The software works with Microsoft Windows NT/2000/XP/VISTA. Dial-Up Networking must be installed
in Windows if RAS connections are to be used. Acrobat Reader must be installed to view the help file. A
USB/parallel port key is used to authorize Beijer Electronics Data Collector. Without the key, the program
will run in demo mode for 10 days.
Databases
The software has been tested with the following databases: Microsoft Access, MSDE and Microsoft SQL
Server but should work together with any database with ODBC. If the included Microsoft Access data-
base is used, it is recommended that the database file is placed on the same computer as Beijer Elec-

Page 90 Appendix E:
tronics Data Collector, and that the size of the database is kept under 100 Mbyte. Otherwise a more
powerful database should be used.
Connecting to Operator Panels

Beijer Electronics Data Collector has two ways of communicating with operator panels: Via Ethernet or
via PPP. The standard communication that is used by Hydrogenics Europe NV is ethernet. Here follows
four examples of communication between the PC and the HMI:
A Ethernet: The computer with Beijer Electronics Data Collector and any number of the operator
panels are connected to Ethernet. In this case the operator panels must have an Ethernet card
installed.
Figure 6 – Ethernet
A PPP via a Modem to a Remote Computer with a Modem: The computer with Beijer Electron-
ics Data Collector uses RAS and a modem to call up a remote computer. The remote computer
and any number of operator panels are connected to Ethernet. In this case the operator panels
must have an Ethernet card installed.
Figure 7 – PPP via a Modem to a Remote Computer with a Modem
A PPP via a Modem to an Operator Panel with a Modem: The computer with Beijer Electronics
Data Collector uses RAS and a modem to call up one operator panel. In this case the RS232
port on the operator panel will be occupied by the modem. If the modem is to be used by other
applications for monitoring of devices at a connected controller, the transparent mode protocol
cannot be used, instead a tunneled transparent mode protocol have to be used.
Figure 8 – PPP via a Modem to an Operator Panel with a Modem
A PPP via a Null Modem Cable: The computer with Beijer Electronics Data Collector uses RAS
and a null modem cable to connect to the RS232 port set up for PPP on one operator panel.
This case could be useful if the operator panel do not have a network or a modem. In this case

Appendix E: Page 91
the RS232 port on the operator panel will be occupied by the PPP. If the modem is to be used
by other applications for monitoring of devices at a connected controller, the transparent mode
protocol cannot be used, instead a tunneled transparent mode protocol have to be used. The
RS232 port may still be used for transfer of the operator panel project from the PC to the opera-
tor panel though.
Figure 9 – PPP via a Null Modem Cable
It is recommended to use the ethernet connection. The ethernet connection is made with
the router installed in the Control Panel. In the Control Panel no new connection has to
be made.
E.3.3 Installation
Beijer Electronics Data Collector is installed in the computer by double-clicking on Setup.exe, or by
selecting Run from the Start menu and typing e:\setup.exe (assuming that e: is the default drive for the
CD), and following the instructions.
Figure 10 – Installation Wizard
It is possible to install one of the two programs in case you want to run Beijer Electronics Data Collector
and Beijer Electronics Viewer on two different computers. This is possible only if both computers can
connect to the same database. You may want to use a database like Microsoft SQL Server in that case.

Page 92 Appendix E:
HASP
When Beijer Electronics Data Collector is started, the HASP key must be inserted into the USB or paral-
lel port, otherwise the program will run in demo mode for a limited trial period.
Multiple Data Collectors

It is possible to run more than one Beijer Electronics Data Collector in a computer. Multiple copies of the
Beijer Electronics Data Collector software must be installed in different folders so that they have their
own INI files for settings. Start the programs with the command line parameter -Multiple to allow multiple
copies of the program to run, e.g. C:\Program Files\Beijer Electronics AB\ BEDataCollector\BEDataCol-
lector.exe -Multiple.
Uninstalling the Software

To uninstall Beijer Electronics Data Collector, run Add/Remove Programs from the Control Panel.
E.3.4 Using Beijer Electronics Data Collector

Beijer Electronics Data Collector is a program that communicates with operator panels that are con-
nected with the host computer in an Ethernet network, or via modem (PPP). The program collects all
trends from one operator panel at the time and writes them to a database. Only new data will be added
to the database. To start Beijer Electronics Data Collector, double-click its icon on the Windows desktop
or select the program from the Start menu.
The Main Window

The main window has a menu and a status bar.
Figure 11 – Datacollector: The Main Window
The File Menu
Figure 12 – Datacollector: The File Menu
The File Menu has three options:

Appendix E: Page 93
A Settings: General configuration of Beijer Electronics Data Collector. Use this function to define
operator panels, database, and other settings.
A Show log: Use this function to show the log file with messages from the program.
A Exit: Use this function to exit the program.
The Tools Menu
Figure 13 – Datacollector: The Tools Menu
The Tools Menu has two options:
A Manual collection: This allows the user to collect data from the operator panels instantly.
A Transfer recipes: A tool for manual transfer of recipes from/to the operator panel. This option is
not usedl in our application.
The Status Bar
The Status Bar has three parts:
A In the left part: Beijer Electronics Data Collector displays different types of messages.
A In the middle part: displays the date and time for the next automatic collection of data from
operator panels.
A In the right part: the status bar displays current date and time in the computer.
Cancel Button and Error Messages
When the program collects data, a button with a stop sign will be displayed in the window. The button
can be used to cancel the collection. If there is an error message in the log file, a symbol and the text
Error(s) reported in logfile will be displayed. The symbol will be shown until the log file is viewed or the
program is shut down.

Page 94 Appendix E:
Figure 14 – Datacollector: Cancel Button and Error Messages
Minimizing the Application
If Beijer Electronics Data Collector is minimized, its icon will be displayed in the notification area in the
bottom right-hand corner on the screen. When in the notification area, the program can be restored to
normal size again by double-clicking the icon in the systray. Right-click the icon in the notification area to
display a small menu.
Figure 15 – Datacollector: Minimizing the Application
Select Open to restore the program to normal size. Select Exit to close the program.
The settings dialog has three tabs:
A Terminals tab
A Database tab
A General tab
Clicking a tab displays the settings for that tab.
The Terminal Tab

All information about an operator panel is defined on the Terminals tab. When all the information is
entered click the Save button. Clicking Cancel cancels all changes made (except new RAS connections
in Windows.) If changes are made and the Cancel button is clicked, a message will appear notifying
about unsaved changes.

Appendix E: Page 95
Figure 16 – Datacollector: The Terminal Tab
To view the settings for an operator panel, select that operator panel in the operator panel list. The
checkbox to the left of the operator panel name in the list is used to enable or disable the operator panel.
If an operator panel is disabled, no data for that operator panel will be collected. The following settings
can be made for the operator panel:
Operator Panel Settings
Option Description
Ethernet or PPP Select if the connection to the operator panel should be via Ethernet or via a modem (PPP).
IP Address/URL The IP address for the operator panel. If Ethernet and DHCP is used, it can also be a name
that identifies the operator panel.
Terminal (FTP) This name must be the same as an account name for an account with FTP access. Leave
User Name blank if accounts are not used.
Terminal (FTP) The password for the account. Leave blank if accounts are not used.
Password
Terminal (RAS) The name of a Windows RAS Connection. The field will only be visible if PPP is selected.
Connection
Terminal (RAS) The phone number to the modem connected to the operator panel. Or left empty if a null
Phone modem cable is used. The field will only be visible if PPP is selected.
Date Time For- These settings must be identical to the ones used in the operator panel, or the data cannot
mat be saved to the database.
FTP Delimiter This setting must be identical to the one used in the operator panel, or the data cannot be
saved to the database. Note that depending on delimiter, the files saved in the _Temp direc-
tory will have different file extensions and file formats.
CF/USB If enabled, also the trends saved to Compact Flash or USB memory via the operator panel
backup function will be collected and stored in the database.

Page 96 Appendix E:
Operator Panel Settings
Option Description
Max folders If CF/USB is enabled only so many folders specified for Max folders will be downloaded from
the operator panel. Set to 0 if no limit.
Clicking the Post processing button makes it possible to enter the path and file name of an application
that is to be run when data for the current operator panel are collected. This application will be started
with the parameters entered in the field called With parameters.
Figure 17 – Datacollector: Post Processing
A small green square on the Post processing button indicates that post processing is enabled for the cur-
rent operator panel. Note that the application will be started after every collection for that operator panel,
it is up to that application to stop running. E.g. if the program name is C:\Program Files\MyApp.exe and
the parameter is /Panel1, Beijer Electronics Data Collector will make this call "C:\Program
Files\MyApp.exe /Panel1". Post processing can either be enabled or disabled.
Clicking the Collection interval button makes it possible to configure a special collection interval for an
operator panel. Like post processing, this can be enabled or disabled. When enabled, data collection for
this operator panel will only occur according to interval specified here. However, if manual collection is
initiated, data for all/included operator panels will be collected disregarding collection interval.
Figure 18 – Datacollector: Collection Interval
First select the interval of the automatic collection. Days, Hours, Minutes or Manual can be selected. If
the interval is set to Manual, data for this operator panel will not be downloaded automatically on a time
interval. Then enter values for the fields Collect every and start date and time. Example: If the Collec-
tion interval is set to Days, the Collect every to 7, and start date and time is 2005-11-01 05:00:00, the
automatic collection will run once every week, starting at 2005-11 01 05:00:00. The program will update
the date and time value for next collection when the collection has been done. In the example the next
date and time will be set to 2005-11-08 05:00:00.

Appendix E: Page 97
Figure 19 – Datacollector: Retry Settings
If the connection to an operator terminal fails, the program will try to again later. Max number of retries
states how many such retries and Interval between retries how many minutes between each attempt. If
all attempts fails, data from this operator terminal will not be collected until its time for next automatic col-
lection.
Click the Ping terminal button to determine if it is possible to establish a connection to the selected oper-
ator panel.
The Database Tab

On the Database tab, settings concerning the database can be altered.
Figure 20 – Datacollector: The Database Tab
The Data connection can be of the following kinds:

Page 98 Appendix E:
Database Settings
Data
Description
Connection
Access Used for Microsoft Access databases only. A Microsoft Access database is included with the
installation.
DSN (ODBC) Can only be used if a DSN have been configured in Windows Control Panel. Beijer Elec-
tronics Data Collector should be able to use any database with a DSN, even though it has
only been tested with Microsoft Access, MSDE and Microsoft SQL Server.
File DSN Can only be used if a File DSN have been configured in Windows Control Panel.
(ODBC)
Connection A user-defined string to establish connection to the database.
string
The setting for provider is only used when database connection is set to Access. The default setting
Microsoft.Jet.OLDEB.4.0 could be used if using the default database.
The setting for Data source depends on the setting for Data connection:
Data source Settings
Data
Description
Connection
Microsoft Access The path and file name for the database file. Click the button to the right of the text field to
database (with browse for a file. The default database is a Microsoft Access database called betrend.mdb
the default pro- with the path: "installation path"\betrend.mdb.
vider)
DSN (ODBC) The name of a DSN as defined in the ODBC manager in Windows Control Panel. Click the
button to the right of the text field to browse for a DSN.
File DSN The path and filename of a file DSN as defined in the ODBC manager in Windows Control
(ODBC) Panel. Click the button to the right of the text field to browse for a file DSN.
If login information is requested by the database, then enter user name and password in the fields called
User and Password. To check the connection with the database, click the Test connection button.
There are two methods for database maintenance:
A Backup (for Microsoft Access only)

A Deletion of old records; both trend and alarm data will be affected.
The setting for the backup operation is a backup directory where the backup copy of the Microsoft
Access database should be stored. The database copy will have the current date as file name, e.g.
2005-10-31.mdb. Click the browse button next to the field for backup directory to select a directory.
Check Backup to enable the backup operation. The setting for the deletion operation is a numerical
value. E.g. if the value is set to 1 day, then records older than 1 day will be deleted. (If the deletion oper-
ation runs at 2005-02-23 14:30:00, records older than 2005-02-22 00:00:00 will be deleted). If a
Microsoft Access database is used, the database will be compacted when the deletion operation has fin-
ished. Check Delete records older than to enable the deletion function. It is possible to run the enabled
functions manually by clicking the Manual button. If a backup file with the file name already exists, a
warning will be displayed. The enabled functions can run automatically if Automatic is checked. The
settings for automatic maintenance are a value for interval in days and a start date and time. Example: If
the interval is set to 1 day and start date and time is set to 2005-11-01 23:00:00, automatic maintenance
will run once every day and the first time will be at 2005-11-01 23:00:00. The program will update the

Appendix E: Page 99
start date and time when the maintenance is finished. If automatic backup is executing and a file with
that name already exists, the file will be overwritten by the new file.
The General Tab

Additional settings are available on the General tab.
Figure 21 – Datacollector: The General Tab
The program automatically collects data from all enabled operator panels, with no collection interval of
their own enabled, with the interval set up on this tab. First select the interval of the automatic collection.
Days, Hours or Minutes can be selected.
Then enter values for the fields Collect every and start date and time. Example: If the Collection interval
is set to Days, the Collect every to 7, and start date and time is 2005-11-01 05:00:00, the automatic col-
lection will run once every week, starting at 2005-11-01 05:00:00. The program will update the date and
time value for next collection when the collection has been done. In the example the next date and time
will be set to 2005-11-08 05:00:00.
General Collection Interval and Settings
Parameter Description Default Setting

Number of dec- Number of decimals for the values when saved to the database. 4
imals
Remove Files If checked the SKV/TXT/CSV files that has been collected from the oper- Unchecked
ator panel will be deleted after the information is saved to the database.
The SKV/TXT/CSV files are stored in a folder called _temp located in the
folder where Beijer Electronics Data Collector was installed.

Page 100 Appendix E:
General Collection Interval and Settings
Parameter Description Default Setting

Convert If this is checked the function that stores the information in the database Checked
will be activated. If not, the SKV/TXT/CSV files will be downloaded, and
saved in the _temp directory but nothing will be stored in the database.
Download If this is checked the function that collects the SKV/TXT/CSV files will be Checked
activated. If not, no files will be downloaded, but values in already exist-
ing files in the _temp directory will be stored in the database.
Log File
Beijer Electronics Data Collector will save messages about events and problems in a log file.
Log File messages
Example of logged message Steps to take to solve the problem

2001-10-25 14:30:00: Error while downloading. Cannot Check the settings, the IP-address, user name or
connect to 172.20.101.46 using User and Password password could be wrong.
parameters.
2001-10-25 14:30:05: The file C:\Pro- Check the settings, the trend name probably does
gram\Beijer\BEDataCollector\_temp\TREND_operator not match the name in the operator panel.
terminal2_BAR' could not be found.
2001-10-25 14:30:06: The file C:\Pro- Check the settings, the alarm group name probably
gram\Beijer\BEDataCollector\_temp\ALARM_operator does not match the name in the operator panel.
terminal2_FUNTION' could not be found.
Figure 22 – Datacollector: The LogViewer File
Collecting Data
When all settings have been made it is possible to manually collect data from the operator panels. This
command also runs automatically if set up on the General tab and applies to operator panels without
individual collection interval enabled.
Manual collection makes it possible to collect data from all or specific operator panels instantly, disre-
garding their collection interval. When selecting Manual collection from the Tools menu, the following
window will be displayed.

Appendix E: Page 101
Figure 23 – Datacollector: Manual Collection Options
The user can select if all operator panels are to be collected or specify the operator panel(s) of interest.
By clicking Collect now, the window will close and the collection will start.
Compact Flash/USB Backup Folders

Depending of the system software in the operator panel there are two formats for the backup folders cre-
ated via the backup function (TBUP/TBS/TMB, for more information see the operator panel manual):
A Old Format:MMDDHHNN.SS - where MM is month, DD is day, HH is hour, NN is minute and

SS is second.
A New Format:YYMMDDHH.xxx - where YY is year, MM is month, DD is day, HH is hour and xxx

is a number between 000 and 999.
Different Backup Approaches
When Beijer Electronics Data Collector downloads from the backup, two different approaches are used:
one if all folders have the old format, one if at least one folder has the new format.
All Folders Have the Old Format
If all folders have the old format, a list of already downloaded folders will be kept on the PC. At the next
collection, only those folders that does not already exist in that list will be downloaded. This is because
there is no way of telling the order of folders just by looking at the folder name. The folders are then
ordered by looking into the trend file record dates. At the first collection when there is no list, no folders
will be downloaded. This means that the function will start working from the second collection and for-
ward. (To download all folders could possibly take several hours.)
At Least One Folder Has the New Format
If at least one folder has the new format, only the folders with the new format will be handled. It is possi-
ble to order the folders just by looking at the folder name. Only those folders with record dates newer
than the newest in the database will be downloaded.
If the value for Max folders is set too high at the first download, the download may take
several hours.
When the trend data is entered into the database, first the backup trends will be entered, and then the
data from current trend objects.

E.3.5 Database Tables

The default database installed with Beijer Electronics Data Collector is a Microsoft Access database with
the name Betrend.mdb. The database tables will be created automatically. When an operator panel is
removed from the Settings in Beijer Electronics Data Collector, the corresponding tables in the database
will not be removed.
If using another database than the provided MS access database betrend.mdb, an

empty database must be manually created. The login used to connect to this database
must have permissions to create tables within the database.
The following to tables in the database are important for us:
A Trend Table
A Trend Curve
Trend Table
There is one trend table for each trend and operator panel. This table contains information about each
curve in the trend object. The name of a trend table will be TREND_"PanelName"_"trend".
A trend table could for example be named TREND_Panel2_trend2, and have the following columns:
Trend Table
Column name Description Data Type

LogDt Date and time for the logged value DATETIME
Trendcurve1 The value from the first curve (the name set in File settings) FLOAT or CHAR(2) if ASCII is
selected
Trendcurve2 The value from the second curve (the name set in File set- FLOAT or CHAR(2) if ASCII is
tings) selected
And so on until a maximum of six trend curves (16-curves for data logger)
Trend Curve
If a curve name in a trend is edited, a new table is created with alias names for the trend curves. (The
original trend table column names will never be edited.) The name of this table will be
DEF_TREND_"PanelName"_"Trend". A table could for example be named
DEF_TREND_Panel2_trend2 and have the following columns:
Trend Curve
Column name Description Data Type

Index Index of the curve, 1,2 etc. INTEGER
Name The new name for the curve VARCHAR(20)

E.4 Beijer Electronics Viewer (Optional)

Beijer Electronics Viewer is used to view the alarms and trends that have been collected by Beijer Elec-
tronics Data Collector. Beijer Electronics Viewer can also view recipe files. To start Beijer Electronics
Viewer, select the program from the Start menu.
E.4.1 The Main Window

The main window has four menus: File, Show, Window and Help.
Figure 24 – Data Viewer: The Main Window
The File menu contains the commands Settings and Exit. The command Exit shuts down Beijer Elec-
tronics Viewer.
E.4.2 Settings
Beijer Electronics Viewer has its own settings for database. This is because Beijer Electronics Viewer
can be installed in another directory or on another PC than Beijer Electronics Data Collector. It is also
possible to view data from another database than selected in Beijer Electronics Data Collector, e.g. a
backup database.
Figure 25 – Data Viewer: Settings
Beijer Electronics Viewer can be run in two ways:

A Beijer Electronics Viewer is in the same directory as Beijer Electronics Data Collector. When
Beijer Electronics Viewer is started, it will get the current settings for the database from Beijer
Electronics Data Collector. The database settings can be changed in Beijer Electronics Viewer
but those changes will only last until Beijer Electronics Viewer is stopped.
A Beijer Electronics Viewer is in another directory or on another PC. Beijer Electronics Viewer
has its own settings for database. These settings can be saved and used again at next startup
of Beijer Electronics Viewer.
Changes made to database settings in Beijer Electronics Viewer will never affect the database settings
for Beijer Electronics Data Collector. For database connection settings, please see the section Data-
base Settings.
E.4.3 View Trend

To view a trend, select Trend in the Show menu.
Figure 26 – Data Viewer: Trend
The window can display trends from all the operator panels.
The following settings can be made:
Settings in Data Viewer
Setting Description
Start date. Start date and time for the interval. To change the date, either type the date in the
field or click the button to the right of the date to pick the wanted date from a cal-
endar.
End date. End date and time for the interval.
Show points Displays an X in the graph for all records in the trend.
Legend Information about each line in the trend will be displayed in the top right corner.

Settings in Data Viewer
Setting Description
Tooltip The X and Y value will be shown if the mouse pointer is placed over a point in the
trend area.
Min/Max Draw dotted lines for min and max values in the interval.
Decimals The number of decimals used on the y-axis.
Filter curves Makes it possible to show/hide any curve in the trend.
Terminal Select an operator panel to show trends for, or select All to show trends from all
operator panels.
Trend Choose between the different trends that are available for the selected operator
panel. The trend names have the format TREND_Panel1_TREND1, where
Panel1 is the operator panel name and TREND1 is the trend name.
Customized trend configu- Instead of showing curves from a selected panel and trend, it is also possible to
ration show curves defined by a configuration.
When all settings have been set, click the button Display to show the chart. If settings are changed, click
Display again. It is possible to zoom in on a trend by clicking the left mouse button, holding it down and
drawing a rectangle. This procedure can be repeated to get a more detailed view of the trend. Click Dis-
play to reset zoom. Use the Print button to print the graph.
An asterisk will be shown before a timestamp (see last timestamp in trend above) as an
indication of that the actual timestamp is not part of the selected interval. This means
that there might be data for the actual timestamp if the interval is expanded.
It is possible to add up to 16 different curves to a configuration. The curves can be from different trends
and even different panels.
Figure 27 – Data Viewer: Trend Configuration
Select panel name, trend name, and curve and then click Add to add that curve to the configuration.

To remove a curve, first select that curve in the list and then click the Remove button. In the File menu
there are functions for:
A Making a new configuration
A Open an existing configuration for editing

A Saving an edited configuration
A Saving a configuration with a new name
A Deleting a configuration
Configurations will be saved to a file with the same name as the configuration in a folder TrendConfig.
These files can be copied and reused on another computer. Since it is possible to select curves from dif-
ferent trends it is not always the case that the log interval is the same for all curves. If, for example, the
configuration has two curves and one curve is missing a value at a time, the latest known value will be
used for that curve. This means that it may seem as if the curve had a value when it in fact had not.
However, every curve must have at least one value in the selected interval, otherwise the graph can not
be shown.

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HySTAT Manual

Revision date: 25/01/2011

B-2260 Oevel, Belgium

Revision: 09 - Revision date: 25/01/2011

Chapter 1: Safety .............................................................................................................8

Chapter 2: Environmental information ............................................................................26

Revision: 09 - Revision date: 25/01/2011

Chapter 3: Installation (indoor units) ..............................................................................30

Chapter 4: Operation ......................................................................................................56

Revision: 09 - Revision date: 25/01/2011

4.2.1. General ....................................................................................................... 71

Chapter 5: Maintenance and troubleshooting ................................................................86

5.4.25. The HTA analyzer ................................................................................... 154

Appendix A: HMI display terminal .................... .........................................................2

Revision: 09 - Revision date: 25/01/2011

A.5.3.Start conditions overview screen .................................................................24

Appendix B: Tag reference ............................. .........................................................40

Appendix C: Start conditions .......................... .........................................................58

Revision: 09 - Revision date: 25/01/2011

Appendix D: Specifications utilities ................ .........................................................76

Appendix E: Remote access and data-logging ........................................................84

Revision: 09 - Revision date: 25/01/2011

1.1 Conventions used in this publication

Note sign. Notes call attention to information that is especially significant to

1.2 Registered trademarks

A HySTAT® www.hydrogenics.com (Hydrogen Station)

A Simatic NET® www.siemens.com

A Exter T100® www.beijerelectronics.com

A Exter T150® www.beijerelectronics.com

Revision: 09 - Revision date: 25/01/2011

1.3 The Hydrogenics Safety Philosophy

Every HySTAT is designed from an “integrated safety” perspective:

1st priority: elimination of actions likely to create a hazardous situation;

A IEC 61508: Functional safety of electrical/electronic/programmable electronic safety-related

Alltough Hydrogenics Europe NV has chosen widely accepted design criteria,

Revision: 09 - Revision date: 25/01/2011

1.4 Hydrogenics general safety guidelines

Always wear personal protective equipment: minimum recommendations are safety

Revision: 09 - Revision date: 25/01/2011

1.5 First aid equipment

A cambric bandage (5 cm x 5 m and 7 cm x 5 m)

A adhesive plaster (1,25 cm x 5 m)

A adhesive plaster (2,50 cm x 5 m)

A easy-application bandage (8 x 10 cm and 12 x 12 cm)

A hybin, hygienic solution (30 ml)

A medicated cotton-wool (25 gr)

A waterproof woundbandage (7 x 2 cm) - 12 pc

A isothermal blanket (1,6 x 2,2 m)

A packet of latex gloves (powder free) - 4 pc

A elastic squeezing bandage

A Diphoterine aerosol can (www.prevor.com)

1.5.2 Eye wash station

Hydrogenics Europe NV recommends an eye wash station containing Diphoterine® as active

1.5.3 Emergency shower

Revision: 09 - Revision date: 25/01/2011

1.6 Hydrogen properties

Hydrogen is non toxic, but does not support life.

Hydrogen flames tend to ascend rapidly with the gas in air.

Revision: 09 - Revision date: 25/01/2011

1.7 Oxygen properties

Revision: 09 - Revision date: 25/01/2011

1.8 Explosion hazard

When mixed with oxygen, hydrogen combusts or explodes when ignited.

LFL*: 4.0% *Lower Flammability Limit, considered as LEL

LFL: 4.0% Lower Flammability Limit, considered as LEL

UFL: 75.0% Upper Flammability Limit, considered as UEL