Hygen 200

User’s manual
Hydrogen
generator
HyGen200
HyGen400
HyGen600
Summary
1. Introduction 3
2. Safety 4
3. Description of the generator 7
4. Demineralized water 13
5. Operator interface 14
6. Use 19
7. Installation 28
8. First start up 38
9. Uninstalling and transport 45
10. Maintenance 50
11. Fault list 69
12. Warranty 75
13. Declaration of conformity 76
14. Notes 77
2
Hydrogen generator HyGen
1. Introduction
This document is aimed at the user of a hydrogen generator model in the Hy-
Gen series and provides all the information regarding installation use and main-
tenance.
This manual is an integral part of the generator and as such is to be safeguarded
and must always accompany the appliance.
Make sure it is always consistent with any updates implemented in the genera-
tor.
Please contact Claind directly in order to use and reproduce this documentation.
Claind is always at the disposal of users to provide clarification on the appropri-
ate use of the information.
The intended use of the generator is to produce (as an alternative to cylinders)

ultra-pure hydrogen gas for analytical laboratory applications.
The generators in the Hygen series are listed below.
Code Description
422.01.0110 HyGen200 115/230V 50/60HZ
422.01.0210 HyGen400 115/230V 50/60HZ
422.01.0310 HyGen600 115/230V 50/60HZ
The margin of the text contains the following symbols, indicating:

m compulsory safety rules to be observed
c electrical hazard
e recommendations and important information
This manual describes only the operations that customers can perform, all other
operations (eg. maintenance of the circulation pump) must be performed by a
Claind specialized technician, otherwise Claind shall not be held liable for any
damage caused to property, animals or people.
It is assumed that the manual user is experienced in the use of pneumatic com-
ponents, and in particular is aware of all safety aspects linked to the use of hy-
drogen.
You are urged to pay particular attention to the safety warnings (par. 2.2 Warn-
ings) before performing any work on the generator
3
Safety
2. Safety
e The unit must be installed and used in observance of the instructions in this boo-
klet Furthermore, use of the generator must be limited to that described in
Chapter 1 Introduction. Failure to observe the foregoing will render the guaran-
tee null and void and release CLAIND from all liability for direct or indirect da-
mage or physical injury.
e The user is responsible for asking local authorities if there are local safety regu-
lations that are stricter than what is described in this manual.
The generator has been built following the acknowledged safety rules, however,
incorrect use can be a source of danger to the life and safety of the user or
others or of damage to property.
e Any non-compliance with the safety instructions or warnings can cause fatal
injuries.
Use the generator only in perfect technical condition, respecting the safety war-
nings. In the event of any trouble call the Claind service centre immediately (Par.
2.5 Technical Assistance)
2.1. Improper Use
e Improper use of the generator will void warranty. Claind shall not be held liable
for any damage caused to property, animals or people due to improper use of
the generator.
1. Never direct the gas issuing from the generator at people or animals.
2. If the generator is not to be used for a long time, unplug it from the mains.
3. Prohibit children and unauthorized personnel from using the generator.
4
2.2. Warnings
m Hydrogen forms FLAMMABLE MIXTURES WITH AIR when its percent-

age is greater than 4%. Therefore do not accumulate the gas: if nec-
essary, comply with the applicable current standards
m Place the generator FAR FROM SOURCES OF HEAT, SOURCES OF IGNI-
TION AND FLAMES
m The generator must work with its protective container: this ensures
proper air circulation and avoids the formation of pockets of gas.
m Place the generator in an environment PROTECTED AGAINST RAIN
AND WIND
c NEVER DISASSEMBLE the generator when it is connected to the elec-
tric mains: there a RISK OF DEATH from electric shock
e For any issues that cannot be resolved by following the procedures given in par.
11. troubleshooting, call solely CLAIND Technical Assistance. Repairs and in-
spections must be carried out exclusively by QUALIFIED PERSONNEL
2.3. Safety rules

Failure to follow the safety rules can cause unpredictable danger, so it is strongly
recommended to pay special attention to the following:
• Smoking and naked flames are strictly forbidden;
• do not deposit any flammable materials near the generator;
• ensure appropriate and sufficient lighting to read the warnings and carry out the
work safely;
• set up appropriate extinguishers;
• observe the required environmental conditions (par. 3.2.7. Environmental requi-
rements);
5
Safety
2.4. Safety devices

MAXIMUM PRESSURE: The maximum operating pressure that can be set is 8
bar.
There is a double pressure control:
• one is a pressure sensor, via the control system, which shuts down the generator
when pressure values exceed 0.5 bar (set value);
• a pressure switch, independent of the control system, limits the pressure to 11
bar.
HYDROGEN-AIR MIXTURE: The formation of a potentially hazardous hydro-

gen-air mixture inside the generator is prevented by a forced ventilation system.
If the ventilation system fails to operate, a dedicated sensor makes the genera-
tor stop.
Any significant gas leaks are also indicated by the line pressure control system.
2.5. Technical Assistance

Before performing any type of operation you must contact CLAIND technical as-
sistance at the following:
Tel. ++39 0344 56603
Fax ++39 0344 56627
e-mail: service@claind.it
6
3. Description of the generator
3.1. Equipment supplied

Unless otherwise agreed upon, the supply of a generator in the HyGen series
includes:
• No. 1 HyGen model hydrogen generator;
• No. 1 user manual CD.
• No. 1 cable for the electric mains;
• No. 1 Ethernet cable;
• No. 1 quick coupling elbow;
• No. 1 copper pipe fitting with outside diameter 1/8”;
• No. 2 fixing pins;
• No. 4 self-tapping screws;
• No. 2 flexible tabs;
• No. 1 anchoring plate;
• No. 1 Allen wrench size 8;
• No. 2 Resin bed;
• 5 m plastic pipe outside diameter 4mm;
• 2 m PVC pipe outside diameter 9mm.
7
Description of the generator
3.2. Technical specifications
3.2.1. Hydrogen
Capacity
HyGen 200 up to 0.200 Nl/min
Pressure (*) settable from 2 to 8 bar
(*) by default it is set to 4 bar
3.2.2. Demineralized water requirements

Consumption
HyGen 200 up to 0.4 fl oz/h
Temperature from 5°C to 35°C
Quality
required resistivity 1 MΩ cm @25°C ASTM Type II
3.2.3. Electrical requirements

Supply voltage 110-240 Vac; 50-60 Hz
Maximum power consumption
HyGen 200 110 W
HyGen 400 180 W
HyGen 600 250 W
3.2.4. Pneumatic connections

Hydrogen output 1/8" BSPT male for copper pipe
automatic coupling for plastic pipe
Air vent
diameter 4 mm
8
3.2.5. Electrical connections

Power supply Cable with Schuko plug
CAN bus IN, CAN bus OUT Ethernet cable with RJ45 connector
3.2.6. Dimensions
Width 38 cm
Depth 53 cm
Height (with support base) 47 cm
Weight (generator only) 25 kg
Weight (including support base) 27 kg
Protection rating IP20
3.2.7. Environmental requirements

indoor room, classified non-hazard-
Installation site*
ous
Minimum ventilation 4 Nm3/h
Maximum inclination ± 1°
Relative humidity up to 90%, no condensation
Use temperature from 5°C to 35°C
Storage and transport temperature from 5°C to 40°C
* = the air must be clean and free of harmful substances (eg. dust, fibres, sand)
3.2.8. Noise
Noise level at 1 metre < 50 dB(A)
9
3.3. Generator components
3.3.1. Front view

A. CPU: Generator interface via touch-screen display.
B. FRONT PANEL, removable for maintenance operations;
C. TANK LED (BACKLIGHTING): highlights the level of water contained in the
reserve tank;
D. STATUS LED (INDICATOR LIGHT): indicates the operating condition of the
generator;
E. BASE for setting it on a bench.
10
3.3.2. Rear view

A. H2 DELIVERY: coupling for connecting the hydrogen line;
B. H2 VENT for venting at ambient pressure;
C. DRAIN: quick coupling for 4mm pipe connecting the condensate drain line;
D. CAN BUS OUT: connection to any other generator with an Ethernet cable
(Breeze stack manual);
E. NETWORK ADDRESS: setting generator No. in network (Breeze stack manual);
F. CAN BUS IN: connector for connecting to the CPU;
G. DRAIN: fitting for connecting the drain line should any water come out from
the tanks;
H. CONNECTOR for the power cord; includes housing for the main FUSE;
I. ON-OFF SWITCH;
J. IDENTIFICATION LABEL: states the model, serial number (SN) and electrical
specifications.
A
B
C
H F
J I
G
11
3.3.3. Internal view

A. DRYER: pipe containing zeolite for drying the gas;
B. DEMINERALIZED WATER RESERVE TANK: tank that, when full, guarantees
continuous independent operation of the generator for 3 days. The tank is
backlit for better viewing of the water level;
C. DEMINERALIZED WATER DRAIN: automatic fitting for the drain pipe.
12
4. Demineralized water
e The range of the resistivity value displayed by the CPU is the following:
0.5 - 1.5 MΩ cm @25°C.
m The use of inadequately demineralized water irreversibly ruins the
hydrogen generation cell.
e CAUTION! Failure to comply with the instructions contained in this manual will
void the warranty.
The generator is equipped with a system that detects whether the water used
does not meet the required specifications, in which case a warning signal will be
emitted (Par. 11.3. List of Warnings)
4.1. Production of demineralized water

The water for the hydrogen generator must be adequately demineralized. It is
compulsory to use a professional demineralizer that can filter water to values
1 MΩ cm @25°C.
In order to ensure good demineralization, we recommend carefully following the
demineralizer maintenance sheet.
Avoid storing demineralized water for any longer than one month.
4.2. Bottles of demineralized water

A. The quality of the water bought in bottles or containers must comply with the
specifications contained in par.3.2.2.
e In particular, the resistivity must be 1 MΩ cm @25°C.
B. look at the expiry date;
C. do not use the water contained in containers that have been open for more
than a month: the risk that the water has lost its characteristics is very high. It
is strongly recommended to buy small containers;
D. check before use that the resistivity of the water meets the recommendation,
using a resistivity meter of which you know the uncertainty of measurement
(0.1 MΩ cm @25°C);
E. remember to close the bottle carefully after use.
13
Operator interface
5. Operator interface
TOUCH-SCREEN
The CPU screen enables the user to interact with the generator, i.e. give specific
commands or display and set parameters.
The table shows the function of the various buttons on the screen
Key Function
CPU access to the CPU menu
PREVIOUS goes back to the previous page
NEXT goes to the next page
ALARM access to the list of errors
WARNING access to the list of warnings
RESET resets errors and warnings
goes to the description of the maintenance

MAINTENANCE
request
MENU access to the different menus
ESC exits the menu
START starts the production of gas
STOP stops the production of gas
14
Key Function
INCREASE increases the value
DECREASE decreases the value
ADD adds a digit
DELETE deletes the last digit
PREVIOUS goes back to the previous page
NEXT goes to the next page
OK confirms the modified value
e Do not touch the touch-screen with sharp objects
15
Operator interface
5.1. Menu
The following diagram shows the menus accessible to the operator:
16
5.2. Abbreviations
When using the generator, the CPU will display abbreviations with the following
meanings:
Abbr
eviati Definition Meaning
on
H2 Hydrogen Gas produced
LCD Liquid Crystal Display CPU display
HMI Human Machine Interface Interface between the generator and user
Type of connection between the CPU and
ETH Ethernet
generator
IP Internet Protocol Generator identification number
CAN Controller Area Network Type of connection
System by which the generator pressure
DP Depressurization
reaches atmospheric pressure
Operation that takes time before being
WIP Work In Progress
resolved
RB Resin Bed Water purification system
Rtank Reserve tank 3-litre reserve tank
UPW Ultra Pure Water Demineralized water >1 MΩ
Seq. Sequence Sequence
"Revs per minute" Unit of measurement of
rpm Revolutions Per Minute
pump motor speed
h high Top
l Low Bottom
State of the generator in which hydrogen is
Prd Production
generated
P Pressure
tmt Timeout Time elapsed
E.B. Electronic Box Box containing the generator's electronics
C.G. Current generator Current generator in the electronic box
CK Check Check
17
Operator interface
5.3. Indicator lights (LEDs)
5.3.1. Front panel LED

In addition to the information on the CPU screen, a LED indicator light on the
front panel (par. 3.3.1. Front view) indicates the operating condition of the gen-
erator. In particular:
The LED is amber in the READY TO START condition (waiting for a production
start-up command);
the LED is green in the gas production condition;
the LED blinks red in the error condition (par. 11. Troubleshooting);
the LED is steady red when there is no connection with the CPU.
5.3.2. Tank LED

The reserve tank has the task of storing the demineralized water necessary to
keep the generator running for a period of at least 3 days. The level of the liquid
inside this tank can be seen through the vertical window on the front of the ge-
nerator, a green backlighting LED enables distinguishing the level in the tank and
provides information on its status:
The LED is on steady when the tank has sufficient water to allow the generator
to operate;
the LED blinks when the water reaches the minimum level in the tank and you
need to fill it (par. 4. Demineralized water and par. 11. Troubleshooting);
the LED is off when the resistivity sensor is not connected.
18
6. Use
6.1. Generator start-up

To switch on the generator, put the start button on the rear of the generator on
position I: the CPU screen will light up.
After a brief appearance of the page with the LOGO, the “GENERATORS LIST”
page is displayed;
touch the text for the required generator;

the "READY TO START" page will appear.
6.2. Hydrogen production

To start production, press the "START" operation button;
19
Use
if coming from start-up, the generator initially carries out a preparation cycle
(SET-UP) lasting about 30 seconds;
on completing set-up, the generator begins to produce hydrogen, showing the

following page.
e WARNING: Some parts of the generator contain air at the first start-up. For this
reason, the line should be vented with the hydrogen produced (for at least 20
minutes) before using it for the application.
6.3. Stopping the generator

At any time during production the generator can be stopped by pressing the
"STOP" button;
20
the generator will stop production immediately showing the following page;
when the "Shutting Down" phase is over (after approximately 5 seconds), the
"READY TO START" page will appear.
6.4. Generator shutdown

After stopping production (par. 6.3. Stopping the generator), put the main
switch on the rear of the generator on position “O”.
e Avoid shutting down the generator directly, without first stopping it as described
in par. 6.3. Stopping the generator
21
Use
6.5. Generator depressurization

The generator is not provided with a depressurization system that is accessible
by the customer. To proceed depressurize the hydrogen line.
e The guided procedures suggested by the CPU only depressurize the interior of
the generator and not the outlet (which remains under pressure). To be able to
completely depressurize the generator Claind recommends using a flow shutoff
valve and a discharge valve on the generator outlet.
6.6. Draining generator water

To drain the generator of demineralized water remove the front panel and empty
the internal tank and the reserve tank.
6.6.1. Internal tank draining

To empty the internal tank circuit and the demineralized water circuit, a quick
coupler and a piece of PVC pipe (A) (next page) are provided.
Connect the quick coupler with the pipe (A) to the automatic joint (B) in the ge-
nerator.
e Before draining, get a tank or a container to collect the drained water and place
it under the generator with the other end of the PVC pipe to let it drain comple-
tely.
22
After draining, disconnect the coupler.
B
A
TIME REQUIRED: approximately 1 minute
6.6.2. Reserve tank draining

To drain the reserve tank, carry out the following operations:
• Disconnect the tank both electrically and pneumatically by removing the jack and
the quick coupling (C);
e During the step described above, warnings will appear which will then disappear
after reconnecting the tank.
• physically remove the tank and empty it after removing the plug (D);
• screw the plug (D) back in, put the tank back into place, reconnect it by inserting
the jack and the quick coupling (C) and fit the front panel back on.
23
6.7. Parameter display
6.7.1. Hydrogen pressure display

The real time pressure and its unit of measurement can be viewed on the main
page at all times.
6.8. Parameter settings
e Modifying the parameters affects plant operation. Make sure you are fully aware
of the effects of any changes before modifying the parameters
6.8.1. Hydrogen delivery pressure settings

To set the operating pressure to the required value, proceed as follows.
Touch the pressure value;
24
the following page appears;
touch the pressure set-point value.

To modify the value, use the "INCREASE" or "DECREASE" buttons;
To acquire the value, touch the “OK” button.
6.8.2. Setting display contrast

To make it easier to read the CPU screen, touch the "CPU" button;
25
touch “LCD CONTRAST”;
set the desired value.

To exit the menu, tap the “ESC” button.
6.8.3. Selecting units of measurement

The CPU lets you choose from different units of measure for pressure and
temperature.
To make your selection, touch the "CPU" button;
26
touch "MEASURE UNIT" and select the desired unit of measurement for pres-
sure;
or go to the next page by touching the "NEXT" button.
Select the desired unit of measurement for temperature
To exit the menu, tap the ESC button
27
Installation
7. Installation
7.1. Installation area requirements
7.1.1. Environment
The area where the generator is installed must meet the requirements listed un-
der par 3.2.7. Environmental requirements.
m In particular, make sure that there is adequate ventilation. Do not in-
stall the generator in a closed cabin without sufficient ventilation.
7.1.2. Supporting surface

The surface where you plan to install the generator must be level (maximum in-
clination ± 1°)
7.2. Installation procedure
7.2.1. Step 1: remove the packing

• Open the packaging from the top;
• remove the box containing the accessories;
• lift the generator by grasping its side handles (two people are needed for this
operation) and set it momentarily on a flat surface;
• remove the support base, located in the packing under the generator, and place
it on the bench where you plan to install the generator.
e It is recommended to store the packaging to ensure adequate protection when
moved in the future.
7.2.2. Step 2: position the generator

• Position the generator on its support base or above another generator of the
BREZZA series (two people are needed for this operation).
m Ensure a clearance of at least 20 cm at the rear of the generator. There
must be no potential sources of ignition in this clearance at the rear of
the generator, such as: flames, electrical contacts, hot surfaces, mo-
ving parts that can generate sparks, etc.
To not decrease ventilation efficiency, also ensure a clearance of at le-
ast 20 cm at the front of the generator.
m If positioned stacked on other BREZZA series generators, the HyGen
hydrogen generator must be at the top (Brezza stack manual).
28
e For the proper installation of a column of BREZZA series generators, please see
the Brezza Stack” user's manual.
If the generator is used as a standalone unit it must be placed on the special

base, proceeding as listed in the instructions below:
1. attach the rubber feet on the base and place it in the installation area;
2. place the generator on the base making sure that the installation area complies
with the dimensions given in Par 7.1 Requirements of the installation area;
3. secure the generator to the base (at the rear) with the screws and the bracket
supplied;
29
Installation
4. remove the front panel;
5. and insert the pins into the holes;

6. have the generator protrude by at least 20 cm at the front, so as to be able to
lock the pins "A" with the clips "B".
A
B
30
7.2.3. Step 3: connect the cell

• Locate the tank for demineralized water "C" inside the generator, at top right,
and disconnect it by means of the quick connector "D" and the jack "E" located
on the front of the tank itself;
D
E
• remove the tank;

• locate the cell "F" inside the generator on the right;
31
Installation
• press the outer part of the quick connector "G" and extract the pipe "1";
1
• insert the pipe "1" into the quick connector at the inlet of the internal tank "H"
and connect the fitting "I" with the pipe 2.
7.2.4. Step 4: fill the reserve tank with demineralized water

• unscrew the cap of the tank previously removed;
• clean the tank by pouring in demineralized water, shaking it and emptying it, re-
peat the process at least 2 times;
• fill the tank with demineralized water of the quality required in par. 4. Demine-
ralized water;
• if necessary, use a flask to fill the tank following the instructions given below:
1. always use the same flask exclusively for this operation;
2. wash the flask thoroughly with demineralized water, fill it partially, shake it and
empty it, do this at least 2 times;
32
3. remember to wash the internal tank thoroughly;

4. after washing immediately fill the internal tank of the generator;
5. on completing this process, keep the flask closed for future use;
• leave the tank open for the shortest possible time so as to decrease the possibi-
lity of polluting the water;
e Do not use cloths or paper towels to clean the tank: they can release fibres and
particles that are harmful to the generator.
• screw on the cap of the internal tank;

• reposition the tank
e Connect only jack "E", do not connect the quick connector "D"!
The connector "D" will be connected during the "first start-up" procedure
e If the required type of water is not used, the performance of the generator may
no longer be ensured and it may lead to permanent damage to the generator
e The maximum resistivity value displayed by the CPU is 1.5 mΩ cm @25°C
7.2.5. Step 5: connect the hydrogen line

• locate the coupling "J" H2 DELIVERY at the rear of the generator;
• remove the cap "K";
e Keep the cap along with the connection kit as it will be needed in the event of
uninstalling the generator
• connect the line.
J
K
e The hydrogen line must be able to withstand a pressure of at least 10.2 bar
7.2.6. Step 6: connect the electric mains

• Check that the mains specifications correspond to the data on the generator da-
taplate;
• ensure that the "POWER" button "L" is set to OFF;
33
Installation
• make the electrical connection using the cable supplied with the generator to the
socket "M";
M
L
c make sure that the off button on the rear of the generator is easily ac-
cessible
c For reasons of safety, the following instructions must be strictly ob-
served.
The electrical installation must comply with current standards, in particular re-
garding the protection line.
c Recommendations for correct installation:
• do not use extension cords, adapters or multiple sockets; if necessary, replace
the cable supplied with a longer one. If the supplied cable cannot be used, it is
the Customer's responsibility to obtain a suitable cable for the local configuration
of the electrical socket outlet;
• always connect the protection wire;
• the mains socket must be located in an easily accessible position;
• comply with the "IEC" power standards.
e If a failure in gas supply (due to a power failure, activation of an electrical safety
device, or generator fault), even temporary, is not admissible, a pneumatic panel
should be envisaged, to enable provisional activation of a reserve gas source (to-
tally or partially automatic).
7.2.7. Step 7: connect the vent hose

The drain outlet is a vent for the pure oxygen where condensation may also be
present.
• Locale the drain outlet "N" at the rear of the generator;
34
• connect the drain line with the supplied polyamide pipe of outside diameter 4
mm;
• make sure that the drain line discharges into a container.

m the drain line must never be obstructed, subjected to pressure or to
the risk of freezing
7.2.8. Step 8: connect the water leak collection pipe

Should water leak from the tanks, the generator is equipped with a system for
collecting and expelling it.
To allow this, perform the following operations:
• Locate the coupling “O” at the rear of the generator;
• connect the water leak collection line with the fitting "P" and the polyamide pipe
of outside diameter 4 mm supplied;
35
Installation
• make sure that the water leak collection line drains into a container (you can use
the same container used for drain collection.
7.2.9. Step 9: connect the CPU

• Position the CPU where it will be used, e.g. above the generator, using the sup-
port;
• connect the Ethernet cable on the back of the CPU (top connector) and on the
back of the generator (CAN BUS IN connector)
e Please refer to the "Brezza Stack" user manual to make the correct generator
settings.
36
7.3. Packaging disposal

All packaging materials used are compatible with the environment and may be
stored without risk, or disposed of and recycled in accordance with local legisla-
tion governing classified waste collection.
However, when possible, it is recommended to store the packaging to ensure
adequate protection when moved in the future.
37
First start up
8. First start up
m Before you perform the steps written below, correctly perform the
operations described in the Installation subsection!
e Carry out all the points described in the following paragraph step by step to ena-
ble correctly starting up the generator.
e If the following procedure is not performed correctly, the functionality of the ge-
nerator may be compromised, in this case the warranty is invalidated and Claind
shall not be held liable for any damage caused to properly, animals or people.
• Switch on the generator by setting the start button, located on the back of the
generator, on the symbol "I";
• after a brief appearance of the page with the logo, the error screen is displayed;
• touch the screen to view a list of warnings including the warning W-07;
38
• select the active warning;
• tap on the "EDIT TIME NOW" field and set the current time and day, confirm by
tapping "OK" and then "SET", the latter box will turn black, and exit with "ESC";
• the following screen appears automatically with another warning active;
39
First start up
• select the warning box, the number W14 will be displayed which tells you to re-
place the resin bed (the generator is supplied with the resin bed included).
• tap on the warning box and start the process of replacing the resin bed;
• a warning screen will appear for the time needed to complete the process;
40
• proceed and the first step asks you to drain the water from the generator, as it
is supplied already drained the first step is skipped by tapping the ">>" button
without carrying out any operations;
• the second step asks you to connect the fitting (A) to the reserve tank filled be-
forehand (par. 7.2.4. Step 4: fill the reserve tank with demineralized water).
After making the connection, tap the “>>” button to go to the next step;
41
First start up
• the third step asks you to replace the Resin bed;
in this case we put the one supplied in the generator as shown in the following
images, taking care with the position of the arrow (upwards) on the body of the
Resin bed;
After carrying out the operation described above, move on to step 4;

• The fourth step asks you to perform quality control on the water contained in
the reserve tank, then tap the "Water test" button;
42
• the following will appear;
• If the quality of the water is adequate, the following screens will automatically
be shown;
• in the screen shown above you have the option to choose whether to fill the in-
ternal tank and start production or fill the internal tank and stop the generator
in "ready to start" mode.
43
First start up
Until the internal tank is completely filled the generator will show the following
screen (approximately 3 minutes);
• if the quality of the water is not adequate, the following screens will automati-
cally be shown;
• the CPU prompts the procedure again from step 1;

• change the water in the reserve tank and perform the steps described above
again;
• when the demineralized water reaches the required values (see par. 4 Demine-
ralized water);
• the first start-up procedure is concluded.
44
9. Uninstalling and transport
9.1. Uninstalling
• Stop the generator (see par. 6.3. Stop the generator);
• switch off the generator (see par. 6.4. Generator shutdown);
• close the valves downline of the generator (if there are any);
• depressurize the hydrogen line (see par. 6.5. Generator depressurization);
• disconnect the electric power cable;
• disconnect the Ethernet cable connected to the CPU;
• disconnect the pneumatic connections;
e Fit the cap provided on the hydrogen dispensing coupling to avoid wear of the
desiccant
• remove the Resin bed by disengaging the snap-on couplings locking it;
e Caution: Water is present in the Resin bed; before dismantling it put a paper
towel underneath to avoid wetting the generator.
m Spent Resin bed material is special waste, dispose of it as such in ac-
cordance with current regulations, do not dump it in the environment!
If you do not plan on using the generator for more than a month, carry out also
the following steps:
• drain the water from the generator (see par. 6.6. Draining generator water);
• close the cell circuit (see par. 9.4. Disconnecting the cell);
• remove the Dryer by unscrewing it anticlockwise, empty it and reassemble it.
e Do not perform the guided procedure to replace the desiccant.
m Spent desiccant is special waste, dispose of it as such in accordance
with current regulations, do not dump it in the environment!
• put the the front panel back on.
45
Uninstalling and transport
9.2. Transport
If conserved, use the original packaging; otherwise, use a pallet of adequate di-
mensions to hold the generator, affixing instructions in visible locations, such as:
THIS WAY UP, FRAGILE
e Take the necessary precautions so that the generator is never exposed to tem-
peratures lower than 5°C during transport and storage: risk of the demineralized
water freezing inside the electrolytic cell, with consequent permanent damage
to the generator.
9.3. Storage
Before storing the generator make sure that the uninstall operations have been
carried out correctly.
After lengthy storage (less than 6 months) it is recommended, if the aforemen-
tioned operations have not been carried out, to ensure proper functioning of the
generator, to perform the following steps:
1. drain the water from the generator (see par. 6.6. Draining generator water);
2. fill the external tank (see par. 4. Demineralized water);
Now you can start the generator.
e Do NOT store the Resin bed when wet! It CANNOT be reused!
e Replace the Resin Bed by carrying out the guided procedure
If the storage time exceeds six months, carry out all the operations described in
par. 8. Initial start-up.
46
9.4. Disconnecting the cell

• Remove the front panel and locate the deionized water tank "A" inside the ge-
nerator, at the top right;
• disconnect the tank with the quick coupler "C" and the jack "B" located on the
front of the tank;
C
B
e During the step described above, warnings will appear (if the generator is
switched on) which will then disappear after reconnecting the tank.
• remove the tank;
47
Uninstalling and transport
• locate the cell "D" inside the generator on the right;
• press the outer part of the compression fitting "F" and extract the pipe "1";
1
e The water remaining in the pipe and in the circulation pump will come out of the
pipe; use paper towels to dry it up.
48
• repeat the same steps described above to disconnect the pipe "2" from the fitting
"G" at the tank inlet;
• insert the pipe "2" in the quick coupler at the inlet of the cell "F";
49
Maintenance
10. Maintenance
The maintenance operations required on hydrogen generators of the HyGen se-
ries are minimum.
The subsections par. 10.4. Maintenance schedule and par. 10.5. Consumables
list these operations and their frequency.
e Use only Claind spare parts and consumables, otherwise warranty is void
10.1. Maintenance counters display

Touch the MENU button
then touch MAINTENANCE:
The following maintenance counters are displayed:
• WORKING TIME indicates the total hours of operation of the generator

• PRODUCED H2 indicates the total volume (in litres) of hydrogen produced by the
generator
50
To view the other counters, touch the NEXT button
the following counters are displayed:
• PUMP LIFETIME indicates the estimated remaining lifetime (in hours) of the cir-
culation pump.
• DESICCANT AUTONOMY indicates the estimated remaining duration (as a per-
centage) of the desiccant (par. 10.6. Changing desiccant)
e When a counter reaches zero, a warning appears to recommend performing the
relevant maintenance.
51
Maintenance
Touch the NEXT button until you reach the screen that lets you activate the guid-
ed procedures to: change the date and time, replace the Resin bed and change
the desiccant.
10.2. Maintenance icon

The following icon shows that the generator needs to be subjected to scheduled
maintenance;
clicking on it takes you to the maintenance list;
selecting active maintenance, when replacing the Resin bed and the desiccant,
automatically opens the guided procedure (par. 10.6. Changing desiccant and
par. 9.7. Resin bed replacement).
For pump maintenance, please contact technical assistance (par. 2.5. Technical
Assistance).
52
10.3. Maintenance schedule
e If a correct maintenance schedule is not followed, the performance of the gene-

rator may no longer be ensured and it may lead to permanent damage to the
generator.
e Maintenance must be performed solely by a SPECIALIZED TECHNICIAN
e Failure to carry out maintenance will void the warranty.
The following table indicates the frequency of the recommended maintenance

operations, expressed in "hours of operation" of the circulation pump (CP01).
Use of components in the maintenance schedule

Code Description 9000 h 18000 h
Set of parts for the water filling
R0531005 1
pump
Water circulation pump with feet
R700.M4.1140 1
and cable with connectors
R059309C Pressure switch connection 1/8" 1
Maintenance kit to use -> 422.93.0030 422.93.0046
The generator is equipped with a counter that, on reaching the set hours of ope-
ration, alerts the operator that it is necessary to perform scheduled maintenan-
ce.
10.4. Consumables
No
Component Code Replacement frequency
.
set of 2 consumable refills for the
1 422.93.0001 "Dryer lifetime" counter
Hydro and Hygen series
1 Set of 2 pieces of Resin bed 422.93.0034 Every 6 months
The consumable components must be replaced by the customer, as they are

easy to replace, with frequent replacement and without risk.
e Code 422.93.0034 contains 2 pieces of "Resin bed", just one piece should be re-
placed every six months, as a result this kit covers a period of one year.
53
Maintenance
e The replacement of consumables is guided by simple procedures prompted by

the CPU. To replace them correctly, scrupulously carry out all the recommended
steps.
10.5. Changing desiccant

Replace the desiccant by following the guided procedure, do not replace it with
the generator switched off.
The procedure lets you replace it safely and ensures cleanliness of the line
without introducing any contaminants.
e Failure to replace the desiccant causes a drop in the purity of the outgoing
hydrogen, increasing its moisture content
ALERT
The desiccant is to be replaced when the counter (%) reaches "0".
In that case the generator will signal the need to change it via the following pa-
ge:
clicking on it will show the main page with the maintenance and warning icon:
54
tapping on the warning icon will display the following screen with Warning W03
active;
selecting the active warning will show a page explaining why it appeared;
now, clicking on "START SEQ NOW" will start the guided sequence for changing
the desiccant.
e CAUTION! The procedure for replacing the desiccant, once begun, must be com-
pleted.
MATERIAL NECESSARY
No. Component Code

set of 2 consumable refills for the Hydro and Hygen
1 422.93.0001
series
TIME NECESSARY
Changing the desiccant takes 35 minutes of downtime, comprising:
15 minutes with the operator present to perform manual operations;
20 minutes of generator operation discharging hydrogen into the environment
to purify the dryer. This operation is designed not to pollute the line.
m Always wear protective goggles, gloves and mask. Prevent the desic-
cant from coming into contact with moist skin and eyes
55
Maintenance
e Before starting to replace the desiccant you are strongly advised to read the De-
siccant Safety Information Sheet in the Manual on CD.
OPERATIONS
e To avoid exposing the desiccant to humidity in the ambient air, open the rechar-
ge cartridge only at the time of transfer and close the dryer hose as soon as re-
charging is complete.
• Start the guided sequence for replacing Desiccant by tapping on “START SEQ
NOW”.
the generator requires hydrogen production to be stopped, so stop it by fol-
lowing the procedure described in par. 6.3. Stopping the generator;
Return to the "START SEQ NOW" screen and follow the instructions given in par.
10.2. Maintenance icon and begin performing the guided sequence;
• a warning screen will appear indicating the time needed to complete the pro-
cess;
56
• go to the first step that requires depressurizing the generator;
• tap on "START DP" to confirm depressurization;
• after approximately 30 seconds the depressurization completed warning will ap-

pear;
57
Maintenance
• the next step, Step 2, requires you to actually replace the Desiccant;
• remove the front panel;
• locate the Dryer (A) and remove the hose by turning it anticlockwise;
• remove the cap (B), empty the Dryer and fill it with new desiccant using the ac-
cessories provided;
• To let the desiccant settle correctly in the pipe, strike it lightly with a rubber mal-
let.
58
m Always wear protective goggles, gloves and mask. Prevent the desic-
cant from coming into contact with moist skin and eyes
Dispose of it in accordance with current legislation.
e before fitting the cap back on, clean the thread at the top of the dryer with a
cloth or paper towel so as to ensure the tightness of the cap.
• fit the plug, the dryer and place the front panel back on the box.
You can now continue with the guided procedure prompted by the CPU.
Clicking on the arrow displays the following screen which corresponds to
step 3;
• choose the option by selecting one of the two choices offered, the following scre-
en will appear;
59
Maintenance
• at the end of the wait time to enable cleaning the dryer, the generator will start
producing and reach the set-point pressure or, depending on the choice made
previously, it will stop.
The counter is automatically updated on 100%.
The procedure for replacing the Desiccant has concluded.
60
10.6. Resin bed replacement
e DO NOT reuse the Resin bed: once used it must be disposed of.
e The Resin bed must be replaced every six months, even if the generator has not
worked.
e Failure to replace the Resin bed every 6 months can irreversibly ruin the gene-
rator and voids the warranty.
ALERT
The Resin bed must be replaced every six months.
The generator contains a counter that alerts the customer when it needs to be
replaced.
The generator will signal the need to change the Resin bed via the following pa-
ge:
clicking on it will show the main page with the maintenance and warning icon:
61
Maintenance
• select the warning box, the number W14 will be displayed which tells you to re-
place the resin bed;
• now, by selecting the active alert you can start the procedure for replacing the
resin bed;
MATERIAL NECESSARY
No. Component Code

1 Set of 2 pieces of Resin bed 422.93.0034
e Code 422.93.0034 contains 2 pieces of "Resin bed", just one piece should be re-
placed every six months, as a result this kit covers a period of one year.
TIME NECESSARY
Replacing the resin bed requires 15 minutes of downtime during which it is nec-
essary for an operator to be present to carry out the operations.
e Before starting to replace the Resin bed you are strongly advised to read the De-
siccant Safety Information Sheet in the Manual on CD.
e The Resin bed contains a resin that causes irritation if it comes into contact with
the skin. In the event of any contact with it, follow the instructions given on the
Safety Information Sheet
OPERATIONS
62

• Start the guided sequence for replacing the Resin bed by tapping on “START SEQ
NOW”.
the generator requires hydrogen production to be stopped, so stop it by fol-
lowing the procedure described in par. 7.6. Stopping the generator;
Return to the "START SEQ NOW" screen and follow the instructions given in par.
10.2. Maintenance icon and begin performing the guided sequence;
• a warning screen will appear for the time needed to complete the process;
• the first step prompts you to drain the water from the generator;
63
Maintenance
• now remove the front panel;
• drain the water off from the generator as directed in par. 6.6. Draining generator
water;
e Fill the tank with demineralized water that meets the criteria listed in par. 4. De-
mineralized water.
• after carrying out the operations described above, move on to step 2;
• the second step prompts you to pneumatically and electrically (E) connect the
previously filled tank;
64
After making the connection, touch the “>>” button to go to the third step;
• this step asks you to replace the Resin bed;
• locate the Resin bed (A), disconnect the two quick couplings (B) by pressing on
the clips (C) and extract it from the ring collar (D);
B
C
A
D
C
B
• Replace it with the new Resin bed, taking care over the position of the arrow
(upwards) on the body, and reconnect the pneumatic connections;
e The new Resin bed is isolated from the external environment by diaphragms on
the caps; to use it you have to break them by firmly pressing on the quick cou-
plings on it.
e Check that the expiry date printed on the Resin bed is at least six months after
today's date.
65
Maintenance
• the fourth step asks you to perform quality control on the water contained in the
reserve tank, then tap the "Water test" button;
• the following will appear;
• if the quality of the water is adequate, the following screens will automatically
be shown;
66
• in the screen shown above you have the option to choose whether to fill the in-
ternal tank and start production or fill the internal tank and stop the generator.
Until the internal tank is completely filled, approximately 3 minutes, the genera-
tor shows the following screen;
• if the quality of the water is not adequate, the following screens will automati-
cally be shown;
• the CPU prompts the procedure again from step 1;

• change the water in the reserve tank and perform the steps described above
again;
• when the demineralized water reaches the required values (see par. 4 Demine-
ralized water) the procedure for replacing the Resin bed has concluded.
67
Maintenance
10.7. List of maintenance operations carried out

The following table lets the operator write down both routine and major main-
tenance work performed on the generator.
DATE
TECHNICIAN
OPERATION MAINTENANCE
HOURS TYPE
WORK PERFORMED
68
11. Fault list
11.1. Alarms
The generator informs you about malfunctioning or the need for servicing in two
different ways: warnings and errors.
11.1.1. WARNING
e If multiple generators are connected to a single CPU, go back to the main gene-
rator selection page to see which one is presenting the warning.
It indicates a condition that may require operator intervention, but gas produc-
tion is not interrupted.
In the WARNING condition:
• an audible warning is emitted;
• the following page is displayed
69
Fault list
11.1.2. ERROR
This indicates a condition that requires halting gas production. The generator
stops production and depressurizes the gas generation module.
In the ERROR condition:
• an audible warning is emitted;
• the LED on the front panel blinks red
• the following page is displayed
11.2. Resetting and identifying alarms

To silence the audible warning, touch the alarm page (amber WARNING page or
red ERROR page)
11.2.1. WARNING
To view the warning message, touch the WARNING symbol;
the active warning is the one highlighted with a black background; after identi-
fying the warning, follow the instructions in the next chapter or the prompted
procedure.
70
11.2.2. ERROR
To view the error message, touch the ERROR symbol;
to find the active error, scroll through the pages using the NEXT button
The active error is the one highlighted with a black background. After identifying
the error, follow the instructions in the next chapter.
To reset an alarm (either a warning or an error alarm) touch the RESET button
71
Fault list
11.3. List of Warnings

Warnings indicate situations which may require the work of a Claind specialized
technician or, if they are easy to resolve, a guided procedure is prompted by the
CPU.
The warnings with their cause and resolution are listed below.
Warni
Description Cause Resolution
ng
The memory has lost the set
Contact technical assistance
W-00 Data loss parameters and is using the
(par. 2.5. Technical Assistance)
default values
1) Fill the reserve tank with
Filling sequence
W-01 Active water reserve demineralized water
timeout
(par. 4. Demineralized water)
Circulation tank
W-02 Circulation tank running low demineralized water
empty
Carry out the guided sequence
W-03 Desiccant exhausted expected desiccant lifetime over prompted by the CPU
(par. 10.6. Changing desiccant)
Pump lifetime elap- Contact technical assistance
W-04 expected pump lifetime over
sed (par. 2.5. Technical Assistance)
Demineralized water with low
W-05 Poor water resistivity Replace water in reserve tank
resistivity
W-06 Reserve tank empty Reserve tank empty demineralized water
W-07 Clock data loss Extended power failure Record time
Temperature sensor Failure of the electronic box Contact technical assistance
W-08
fault temperature sensor (par. 2.5. Technical Assistance)
Temperature sensor Failure of the current generator Contact technical assistance
W-09
fault temperature sensor (par. 2.5. Technical Assistance)
W-10 Reserved - -
W-11 Reserved - -
W-12 Reserved - -
Resistivity sensor The resistivity sensor is not Contact technical assistance
W-13
fault responding (par. 2.5. Technical Assistance)
Carry out the guided sequence
The Resin bed has exhausted its
W-14 Resin bed exhausted prompted by the CPU (par. 10.7.
period of operation
Resin bed replacement)
Depressurization Generator depressurization has Contact technical assistance
W-15
timeout failed (par. 2.5. Technical Assistance)
72
11.4. Error List

Errors indicate situations of malfunctioning which require the work of a Claind
specialized technician to resolve the issue.
The errors with their cause and resolution are listed below.
Error Cause Resolution

assign an identification
the generator is not identi-
E-00 type error number to the generator
fied
(see the Stack user manual)
voltage to the electrolyzer
E-01 cell voltage high contact technical assistance
higher than the maximum
voltage to the electrolyzer
E-02 cell voltage low contact technical assistance
lower than the minimum
check the quality of the
deionized water; drain the
deionized water quality
E-03 poor water resistivity water from the generator
below the requirements
and refill with deionized
water of greater resistivity
water level below the mini-
E-04 water tank level empty fill the water filler tank
mum value
E-05 Hydrogen high pres- pressure higher than the check the pressure in the
sure set-point line
E-06 Reserved - -
pressure set-point not rea- check for leaks along the
E-07 product leak detected
ched line
E-08 Reserved - -
E-09 Reserved - -
E-10 Reserved - -
E-11 Reserved - -
E-12 Reserved - -
check whether the fan on
E-13 fan error fan failure the back is obstructed; con-
tact technical assistance
the circulation pump is not
E-14 pump error contact technical assistance
powered
E-15 Reserved - -
no communication between
E-16 microprocessor fault the control board and the contact technical assistance
microprocessor
E-17 invalid level sensor
level sensor failure contact technical assistance
state
E-18 Reserved - -
E-19 Reserved - -
73
Fault list
Error Cause Resolution

E-20 cell thermal switch fai- electrolyzer thermal switch
contact technical assistance
lure disconnected
E-21 Reserved - -
E-22 electronic box tempe- electronic box temperature
rature high higher than the maximum
the generator module fails check that the vent line is
E-23 vent error
to depressurize not obstructed
E-24 safety circuit malfunc- invalid condition of the
tioning safety sensors
E-25 Reserved - -
E-26 Reserved - -
E-27 Reserved - -
current to the electrolyzer
E-28 max current contact technical assistance
higher than the maximum
check the connection
E-29 CAN communication the CPU is not communica-
between the generator and
fault ting with the generator
CPU
74
12. Warranty
Warranty terms are as follows:
For the duration of the warranty, see the General Terms of Sale applied by
CLAIND
The guarantee includes the cost of materials and labour.
The guarantee is EX CLAIND WORKS and therefore does not include any callout
costs for technicians to visit the client’s premises.
The guarantee covers exclusively COSTS DERIVING FROM MANUFACTURING
DEFECTS and does not include:
1. Use of non-genuine spare parts and consumables
2. Damage caused by negligence or improper use of the equipment.
3. Damage caused by inadequate electric power supply.
4. Damage caused by natural catastrophes (e.g. Fire).
5. Damage caused by transport.
6. Damage caused by demineralized water with inadequate properties.
The guarantee is rendered null and void in the event of intervention by unautho-
rized personnel on the equipment.
75
Declaration of conformity
13. Declaration of conformity

MO10MCC Emiss. 26/10/2012
',&+,$5$=,21(',&21)250,7$¶
(DECLARATION OF CONFORMITY)
Con la presente dichiariamo, sotto la nostra esclusiva responsabilità,

che le seguenti apparecchiature:
(By this letter we declare, under our responsibility, that the following apparatus:)
Codice Versione Descrizione

(part number) (version) (Description)
422.01.0110 4.2 HyGen200
422.01.0210 4.2 HyGen400
422.01.0310 4.2 HyGen600
alla quale questa dichiarazione si riferisce, è conforme con quanto

stabilito dalle seguenti disposizioni, in particolare:
(to which this declaration regards, is fully in conformity with the following rules:)
2014/30/UE EMC Direttiva compatibilità elettromagnetica

(Electromagnetic compatibility directive)
2014/35/UE Direttiva bassa tensione

(Low voltage directive)
ATEX
Direttiva europea concernente gli apparecchi destinati ad essere utilizzati in
2014/34/UE atmosfera potenzialmente esplosiva. Gruppo II categoria 3.
(European directive concerning equipment to be used in potentially explosive atmosphere.
Group II category 3).
PED 'LUHWWLYDHXURSHDDWWUH]]DWXUDLQSUHVVLRQHHVRQHUDWRSHUO¶DSSOLFD]LRQH
2014/68/UE GHOO¶DUWLFROR4, paragrafo 3.
(Pressure equipment directive exempt according to the art.4, paragraph 3)
3
TS = 60°C PS = 10,2 bar V = 0,8 dm
RestUL]LRQHGHOO¶XVRGLGHWHUPLQDWHVRVWDQ]HSHULFRORVHQHOOH
2011/65/UE apparecchiature elettriche ed elettroniche (RoHs)
(The restriction of the use of certain hazardous substances in electrical and electronic
equipment)
Tremezzina, 28/02/2018
Firma del legale rappresentante

(Signature of legal representative)
Via Regina 24, 22016 Tremezzina
Loc. Lenno (CO) Italy
Giovanni Cogotzi Tel. ++39-0344-56603
Fax. ++39-0344-56627
e-mail: info@claind.it
www.claind.it
76
14. Notes
77
Notes
78
Claind srl
Via Regina, 24
22016 Tremezzina Loc. Lenno (CO) - Italy
Tel +39 0344 56603
Fax +39 0344 56627
e-mail service@claind.it
UM HyGen (HGC) en L.fm

Hygen 200

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User’s manual

3. Description of the generator 7

9. Uninstalling and transport 45

11. Fault list 69

13. Declaration of conformity 76

The intended use of the generator is to produce (as an alternative to cylinders)

The generators in the Hygen series are listed below.

The margin of the text contains the following symbols, indicating:

2.1. Improper Use

m Hydrogen forms FLAMMABLE MIXTURES WITH AIR when its percent-

2.3. Safety rules

2.4. Safety devices

HYDROGEN-AIR MIXTURE: The formation of a potentially hazardous hydro-

2.5. Technical Assistance

3. Description of the generator

3.1. Equipment supplied

3.2. Technical specifications

(*) by default it is set to 4 bar

3.2.2. Demineralized water requirements

3.2.3. Electrical requirements

3.2.4. Pneumatic connections

3.2.5. Electrical connections

3.2.7. Environmental requirements

3.3. Generator components

3.3.1. Front view

3.3.2. Rear view

3.3.3. Internal view

4.1. Production of demineralized water

4.2. Bottles of demineralized water

CPU access to the CPU menu

PREVIOUS goes back to the previous page

NEXT goes to the next page

ALARM access to the list of errors

WARNING access to the list of warnings

RESET resets errors and warnings

goes to the description of the maintenance

MENU access to the different menus

ESC exits the menu

START starts the production of gas

STOP stops the production of gas

INCREASE increases the value

DECREASE decreases the value

ADD adds a digit

DELETE deletes the last digit

PREVIOUS goes back to the previous page

NEXT goes to the next page

OK confirms the modified value

e Do not touch the touch-screen with sharp objects

5.3. Indicator lights (LEDs)

5.3.1. Front panel LED

5.3.2. Tank LED

6.1. Generator start-up

touch the text for the required generator;

6.2. Hydrogen production

on completing set-up, the generator begins to produce hydrogen, showing the

6.3. Stopping the generator

6.4. Generator shutdown

6.5. Generator depressurization

6.6. Draining generator water

6.6.1. Internal tank draining

After draining, disconnect the coupler.

TIME REQUIRED: approximately 1 minute

6.6.2. Reserve tank draining