XM50000 HMXT Manual (30%KOH)

TM
TELEDYNE TITAN HMXT GENERATOR SERIES
Hydrogen/Oxygen Gas Systems
OPERATION AND MAINTENANCE MANUAL
HMXT HYDROGEN GAS SYSTEM
XM50000 Revision D
October 2012
HMXT Generator Operations and Maintenance Manual XM50000 Rev. D
"These commodities, technology or software were exported from the United

States in accordance with the export administration regulations. Diversion
contrary to U.S. Law is prohibited.
United states law prohibits disposition of these commodities, technology or

software to any end-user for any end-use related to the design, development,
production, stockpiling, or use of chemical, biological or nuclear weapons or
missiles, without the prior approval of the United States government."
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FOREWORD
Electrolysis of water is in principle a simple process. The equipment necessary

to assemble a system that supports the process effectively and efficiently results
in a configuration that is relatively complex. The technology that has evolved at
Teledyne Energy Systems Inc. (TESI) represents a continuous development
effort to improve systems that support the basic alkaline water electrolysis
process. The HMXT incorporates the latest developments to provide an efficient,
reliable and safe system for the production of hydrogen gas.
The purpose of this manual is to provide the operator with a basic description of
the system and sufficient information to install, operate, and maintain the
equipment. This information is intended for use by qualified personnel. Use of
the information by other than qualified personnel may negate the warranty
extended by Teledyne Energy Systems Inc. to the equipment Purchaser.
v
NOTICE
The manual contains Teledyne Energy Systems Inc. proprietary information which
may not be used for the benefit of others except by express permission.
Distribution and availability of this manual should be restricted to activities
concerned with operation and maintenance of the equipment described herein.
LIMITED WARRANTY
This equipment is covered by a limited warranty that establishes limitation of

obligations. See gas generator system warranty in appendix.
ALL FOREIGN CUSTOMERS AND REPRESENTATIVES
To avoid unnecessary charges and delays in U. S. Customs, any and all returned
components of the Teledyne Energy Systems equipment should be handled as
follows:
1. Notify Teledyne Energy Systems Inc. (Attention to Customer Service

Department) of the need and reason for returning the part. Identify the
part as to catalog and/or part number, name, the purchase order and
equipment serial number under which the part was originally purchased.
2. Supply Teledyne Energy Systems Inc. with Proforma Invoices and copies
of Bills of Lading indicating the part as "Returned U.S. Goods."
3. All shipments should be made to Teledyne Energy Systems Inc., 10707

Gilroy Road, Hunt Valley, Maryland 21031, U.S.A., by way of the Port of
Baltimore, Maryland (for sea) and Baltimore-Washington International
Airport (by air).
4. Failure to clear these returned components through U.S. Customs as

“Returned U.S. Goods" will result in payment of duty which will be to the
customer's account.
vii
TABLE OF CONTENTS
FOREWORD ........................................................................................................ v
1 System Safety ............................................................................................... 7

1.1 General Safety Guidelines .......................................................................... 7
1.2 Specific Hazards associated with the HMXT Hydrogen System .................. 7
1.2.1 Hydrogen..................................................................................................................... 7
1.2.2 Oxygen ........................................................................................................................ 8
1.2.3 Potassium Hydroxide (KOH)........................................................................................ 8
1.2.4 Compressed Nitrogen ................................................................................................. 8
1.2.5 Electrical Hazards ........................................................................................................ 9
1.2.6 High Temperature ....................................................................................................... 9
1.3 Safety Measures ......................................................................................... 9
1.3.1 Shields and Panels....................................................................................................... 9
1.3.2 Safety Devices ............................................................................................................. 9
1.3.3 Plant design ................................................................................................................. 9
1.3.4 Operator Training...................................................................................................... 10
1.3.5 Personal Protective Equipment ................................................................................ 10
2 System Description ..................................................................................... 11

2.1 Introduction.............................................................................................. 11
2.2 Electrolyte ................................................................................................ 13
2.3 Electrolysis Module .................................................................................. 14
2.4 Electrolyte Subsystem .............................................................................. 14
2.4.1 KOH Pump ................................................................................................................. 15
2.4.2 KOH Reservoirs ......................................................................................................... 15
2.4.3 Heat Exchangers........................................................................................................ 15
2.4.4 KOH Filters ................................................................................................................ 15
2.4.5 Flow Switches............................................................................................................ 16
2.4.6 KOH Temperature Sensors........................................................................................ 16
2.4.7 KOH Level .................................................................................................................. 16
2.5 Feed water Subsystem ............................................................................. 16
2.5.1 Feed water ................................................................................................................ 17
2.5.2 Feed water Quality Monitor ..................................................................................... 17
2.5.3 Feed water Pump ...................................................................................................... 17
2.5.4 Feed water Control ................................................................................................... 17
2.6 Gas Control and Conditioning Subsystem ................................................ 18
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Rev. D XM50000 HMXT Generator Operations and Maintenance Manual
2.6.1 Pressure Transducers ................................................................................................ 18

2.6.2 Production Rate ........................................................................................................ 18
2.6.3 Pre-pressurization ..................................................................................................... 19
2.6.4 Standby ..................................................................................................................... 19
2.6.5 Pressure Release ....................................................................................................... 19
2.6.6 Back Pressure Regulator ........................................................................................... 19
2.6.7 Differential Pressure Control System ....................................................................... 20
2.6.8 Relief Valves .............................................................................................................. 20
2.6.9 Vent Valve ................................................................................................................. 20
2.6.10 Condensers and Traps........................................................................................... 21
2.6.11 Nitrogen Purge ...................................................................................................... 21
2.7 Hydrogen Drying....................................................................................... 21
2.7.1 Dryers ........................................................................................................................ 21
2.7.2 Dryer Valves .............................................................................................................. 22
2.8 Cooling and Condenser Cooling Water Subsystems ................................. 22
2.8.1 Temperature Regulating Valve ................................................................................. 23
2.8.2 Condenser Cooling and Water Control ..................................................................... 23
2.9 Hydrogen System Safety........................................................................... 23
2.9.1 Hydrogen in Oxygen and Oxygen in Hydrogen Monitoring ...................................... 24
2.9.2 Hydrogen Detector ................................................................................................... 24
2.9.3 Shutdown Alarms ...................................................................................................... 24
2.10 Electrical Power and Process Control Subsystems ................................... 25
2.10.1 DC Power Supply ................................................................................................... 25
2.10.2 Programmable Controller ..................................................................................... 26
2.10.3 Process Control and Sequencing .......................................................................... 27
2.10.4 Dryer Sequencing .................................................................................................. 29
2.11 Data Display and Process Monitoring....................................................... 30
2.11.1 Touch Screen Display ............................................................................................ 30
3 Generator Installation ................................................................................ 31

3.1 System Classification ................................................................................ 31
3.2 Storage ..................................................................................................... 32
3.3 Generator Mounting ................................................................................ 32
3.4 Unpackaging ............................................................................................. 33
3.5 Facility Connections.................................................................................. 33
3.5.1 Feed Water ............................................................................................................... 35
3.5.2 Cooling Water ........................................................................................................... 35
3.5.3 Condenser Cooling Water ......................................................................................... 35
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3.5.4 Hydrogen and Oxygen Vents .................................................................................... 35

3.5.5 Product Gas Delivery................................................................................................. 36
3.5.6 Electrical Power ........................................................................................................ 36
3.5.7 Nitrogen Purge .......................................................................................................... 37
3.6 Power Supply Electrical Connections ....................................................... 37
3.7 Optional Connections ............................................................................... 37
3.7.1 External Alarm Connections ..................................................................................... 37
3.7.2 Instrument Connections ........................................................................................... 38
3.7.3 Plant Communication and Monitoring ..................................................................... 38
4 Generator Operation .................................................................................. 39

4.1 General ..................................................................................................... 39
4.2 Initial Startup ............................................................................................ 39
4.2.1 Uninterruptible Power Supply (UPS) ........................................................................ 39
4.2.2 Preliminary Procedures............................................................................................. 41
4.3 Start Mode ............................................................................................... 41
4.4 Run Mode ................................................................................................. 42
4.5 Standby Mode .......................................................................................... 42
4.6 Normal Operation .................................................................................... 42
4.7 Pressure Release ...................................................................................... 44
4.8 Shutdowns ................................................................................................ 44
4.9 Emergency Stop Switch ............................................................................ 46
5 Maintenance and Calibration Procedures ................................................... 47

5.1 General ..................................................................................................... 47
5.2 Electrolyte ................................................................................................ 48
5.2.1 Electrolyte Mixing ..................................................................................................... 51
5.2.2 Electrolyte Fill............................................................................................................ 52
5.2.3 Electrolyte Check ...................................................................................................... 52
5.2.4 Electrolyte Drain ....................................................................................................... 55
5.3 Module Inspection ................................................................................... 56
5.3.1 External Inspection ................................................................................................... 56
5.3.2 Internal Inspection .................................................................................................... 57
5.3.3 Re-torque Procedure ................................................................................................ 57
5.4 Cross Leak Check ...................................................................................... 60
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5.5 KOH Filter Replacement ........................................................................... 60

5.6 Feed water Filter Replacement ................................................................ 63
5.7 KOH Pump Inspection............................................................................... 64
5.8 Valve and Regulator Maintenance And Calibration ................................. 66
5.8.1 Solenoid Valves ......................................................................................................... 67
5.8.2 Back Pressure Regulators .......................................................................................... 70
5.8.3 Differential Pressure Regulator ................................................................................ 73
5.8.4 Check Valve and Relief Valve .................................................................................... 74
5.9 Hydrogen in Oxygen Monitor Maintenance and Calibration ................... 75
5.9.1 Flow Controller ......................................................................................................... 75
5.9.2 Filter Tank ................................................................................................................. 76
5.9.3 Temperature Sensor ................................................................................................. 76
5.10 Leak Check ................................................................................................ 77
5.10.1 Bubble Check ........................................................................................................ 77
5.10.2 System Pressure Test ............................................................................................ 77
5.11 Pressure Transducer Calibration Check .................................................... 79
5.12 KOH Flow Switch Check ............................................................................ 79
5.13 Feed water Pump Priming and Purging .................................................... 82
5.14 Feed water Monitor Check ....................................................................... 82
5.15 Dryer Maintenance................................................................................... 83
5.15.1 Orifice Maintenance ............................................................................................. 84
5.15.2 Check Valve Maintenance..................................................................................... 85
5.15.3 Molecular Sieve Change........................................................................................ 86
5.15.4 Gas Filter Replacement ......................................................................................... 87
5.16 Temperature Regulating Valve Check ...................................................... 87
5.17 Cooling Water Maintenance .................................................................... 88
6 Troubleshooting Guide ............................................................................... 89
7 Optional Instruments ................................................................................. 98

7.1 Instrument description ............................................................................. 98
7.1.1 Introduction .............................................................................................................. 98
7.1.2 Combustible Gas Detector ........................................................................................ 98
7.1.3 Hygrometer ............................................................................................................... 98
7.1.4 Trace Oxygen Analyzer.............................................................................................. 99
7.2 Installation ................................................................................................ 99
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7.2.1 Wiring ........................................................................................................................ 99

7.3 Operation ................................................................................................. 99
7.3.1 General ...................................................................................................................... 99
7.3.2 Instrument Operation ............................................................................................... 99
8 Appendix .................................................................................................. 101
5
LIST OF FIGURES
Figure 3-1 Recommended Hydrogen Delivery Valve Configuration ............................................. 36

Figure 5-1: Belleville washer stacking pattern (positive endplate) .............................................. 58
Figure 5-2: Tie rod torquing sequence (positive endplate) .......................................................... 58
Figure 5-3 KOH Filter ..................................................................................................................... 62
Figure 5-4 Feed water Filter .......................................................................................................... 63
Figure 5-5 KOH Pump .................................................................................................................... 66
Figure 5-6 Normally Closed Solenoid Valve .................................................................................. 68
Figure 5-7 Condenser Water Solenoid Valve ................................................................................ 69
Figure 5-8 Back Pressure Regulator .............................................................................................. 72
Figure 5-9 Relief Valve Assembly .................................................................................................. 75
Figure 5-10 Flow Controller .......................................................................................................... 76
Figure 5-11 Flow Switch ................................................................................................................ 81
Figure 5-12 Dryer Purge Control Assembly................................................................................... 84
Figure 5-13 Dryer Check Valve ...................................................................................................... 85
LIST OF TABLES
Table 3-1 HMXT Generator Input Requirements .......................................................................... 34

Table 4-1 Module Voltage............................................................................................................. 43
Table 4-2 System Shutdowns ........................................................................................................ 45
Table 5-1 Regular Maintenance Schedule .................................................................................... 47
Table 5-2 KOH chemical specification (solid form) ....................................................................... 49
Table 5-3 KOH chemical specification at 45% by weight .............................................................. 49
Table 5-4 Specific Gravity of KOH Solution at Various Temperatures .......................................... 51
Table 5-5 Electrolyte Quantities ................................................................................................... 52
Table 5-6 Mixing Ratios and Quantities for Producing 30% Solution ........................................... 54
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1 SYSTEM SAFETY
1.1 General Safety Guidelines
TESI has designed your equipment to eliminate as many hazards as possible

however some hazards exist. All users should familiarize themselves with these
hazards and know how to act to ensure safe operation. In chapter 1 of this
manual, hazards are identified and methods to operate the equipment safely are
explained. Some general guidelines and descriptions are provided here but a
material safety data sheet (MSDS) should be consulted for a comprehensive
explanation of all health risks and first aid measures related to specific materials.
Throughout this manual, specific hazards and safety measures will be
recognized by bold type and the following symbols:
An item critical to user safety or equipment
i Important information
1.2 Specific Hazards associated with the HMXT Hydrogen System
1.2.1 Hydrogen
Hydrogen is a colorless and odorless gas that is extremely flammable. With as

little as 4% hydrogen in oxygen, the mixture is flammable and the flame is nearly
invisible to the naked eye. Sources of ignition such as smoking or equipment
that may spark must be kept away from the generator and the generator must be
kept in a ventilated location to avoid any accumulation of hydrogen. A small
inventory of hydrogen is stored within the generator piping, but if the generator is
running, leaks at pipe or hose junctions could provide a continuous source.
Consult the piping and instrumentation diagram located in the appendix of this
manual for details on piping. A hydrogen detector is recommended to alert
personnel and to shut down the generator in the event of a leak. If burning
hydrogen ignites another material, the flame may be visible so it is best to
assume any visible fire is caused by burning hydrogen.
In the event of a fire, the flow of hydrogen must be

stopped by sealing the leak or shutting down the
generator. Attempting to extinguish a hydrogen fire while
the system is still leaking may result in an explosion.
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1.2.2 Oxygen
Oxygen is a colorless and odorless gas. Alone, oxygen is not flammable,

however it reacts very quickly in the presence of fuels such as hydrogen or oils.
Even small amounts of shipping oil mixed with oxygen and an ignition source can
be very dangerous so caution should be exercised. It is notable that some flame
resistant materials will be significantly less effective against fires where fuel is
mixed with pure oxygen instead of air.
1.2.3 Potassium Hydroxide (KOH)
KOH (Potassium Hydroxide) is a white or yellow solid that is typically mixed with
water in a 30% KOH solution to be used as an electrolyte in the generator
module. Hazards associated with this caustic chemical include burns and, if
ingested, organ failure. KOH should not be handled alone and should only be
handled with appropriate PPE. Required PPE include
 Safety goggles or a face shield
 Covered shoes
 Gloves resistant to KOH
 Clothing resistant to KOH
In addition to PPE, it is recommended to maintain a container of saturated boric

acid solution (3-5%) to neutralize any KOH that comes into contact with skin.
The HMXT Generator normal operating pressure is 147 psig

(10.2 kg/cm2). Pressure can compound the hazards above.
Do not work on the generator unless the generator is totally
depressurized and de-energized.
1.2.4 Compressed Nitrogen
Nitrogen is an inert, colorless, and odorless gas. While nitrogen is non-toxic, if it

displaces oxygen, asphyxiation can occur. Nitrogen is used as a purge gas for
the system. To avoid potential asphyxiation, the area around the generator
should be ventilated. Safety glasses are recommended to protect against high
pressure leaks.
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1.2.5 Electrical Hazards
480 VAC three phase power is supplied to the power supply unit of the HMXT
which then supplies DC power (up to 180 VDC depending on the machine) to the
generator module(s). Either power source is potentially fatal if contacted directly.
After power is shut off, residual voltage may exist and a zero energy state should
be verified with a voltage tester. When working with potentially energized
equipment, appropriate non-conductive gloves should be worn.
1.2.6 High Temperature
Hot surfaces on the generator can cause skin burns. The dryers can reach
160°C. Other surfaces are maintained below 75°C. When working around a unit
that may have been operating recently, check the temperature of surfaces and
wear appropriate clothing.
1.3 Safety Measures
1.3.1 Shields and Panels
Each standard HMXT generator is shipped with shields and panels to protect
personnel from hazards and guard the generator from potential external
disturbance.
Do not operate the generator with safety shields or panels

removed unless troubleshooting equipment.
NEVER energize the module with the polycarbonate

shields removed.
1.3.2 Safety Devices
See Table 4-2 System Shutdowns for a list of alarms which will cause the system
to be de-energized and/or shut down and depressurized.
1.3.3 Plant design
For your specific facility, a nearby alarm should be provided as well as warning
signs and a map of the proper escape route. Signs should indicate no smoking
within 15 feet (5 meters) of the generator.
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1.3.4 Operator Training
All system operators should review this manual and be trained either by TESI or
by a competent operator.
1.3.5 Personal Protective Equipment
PPE is always the last line of defense and is not a substitute for any of the above
safety measures. The following PPE should be available for use with the
hydrogen system:
Safety shoes
Safety glasses, goggles, and face shield
Gloves
Appropriate clothing for the task performed
This manual will identify specific PPE required to perform tasks within the task
description.
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2 SYSTEM DESCRIPTION
2.1 Introduction
The basic HMXT system configuration includes two pieces of equipment, the
hydrogen generator, and the power supply. The hydrogen generator contains all
the mechanical components and plumbing necessary for sustaining the
electrolysis process. The system control and instrumentation functions are
located within the generator. A control panel displays process conditions and
data necessary for efficient operation and monitoring of the system. The HMXT
generator has been designed for operation in a NEC class I, division 2, location.
The power supply contains the equipment for converting an AC power input to
DC power necessary for electrolysis. The power supply is intended for
installation in a separate unclassified area.
The inputs required to operate the system include high purity water and electrical
power for electrolysis, nitrogen for initial purging and cooling water for waste heat
removal. Using these inputs, the system will supply hydrogen at 147 psig (10.2
kg/cm2). The produced oxygen is either vented or used after going through
Teledyne’s optional O2 Purifier. The complete generator installation must
include provisions for supplying the feed water, nitrogen, cooling water, electrical
power, plumbing for gas delivery and separate hydrogen and oxygen vents.
The system is designed for automatic operation. When operation is initiated with
a depressurized system, an automatic start-up sequence brings the system into
operating parameters. The gas production rate responds directly to the user's
demand rate up to the maximum capacity of the generator. If gas delivery is not
required, the system will remain at pressure with minimum production where gas
is instantly available for delivery. All important operating parameters are
continually monitored. Should conditions within the system deviate beyond the
allowable range, system shutdown will occur. If switched off, the system will
purge and depressurize.
The system has been designed for a safe and reliable operation. However, it is
important that preventive maintenance be scheduled and performed to maintain
system reliability. Routine maintenance includes component inspection/
adjustment, electrolyte checks/changes, and controller/instrumentation
calibration. In the event of a component failure, the system displays alarm
information useful in determining the cause of a system shutdown.
The system description that follows uses letter coded references to individual
components. These references can be found as component labels on the piping
diagram, wiring diagram, and figures in the Appendix to this manual. It is
recommended that the reader refer to these diagrams as an aid in understanding
11
the HMXT system. The physical location of each of the components is illustrated
in the detailed views in Figures A1-A4 in the appendix (XM50019).
Major HMXT generator system components
Gas/liquid
separators Dryers
Touch
screen
display
E-stop
Electrolysis
Module(s)
KOH pumps
12
2.2 Electrolyte
Electrolysis of pure water is inefficient because water has a low ionization

constant and a relatively high electrical resistance. Alkaline water electrolysis
uses a strong aqueous alkaline solution to provide an abundance of hydroxyl
ions (OH-) and minimize the electrical resistance between electrodes. When a
voltage is applied and a DC current flows through to the electrodes, an individual
half-cell electrochemical reaction occurs at each electrode. At the anode
4OH-  O2 + 2H2O + 4E-
and at the cathode
4H2O + 4E-  2H2 + 4OH-
the overall reaction is
2H2O  2H2 + O2
The rate of the reaction is directly proportional to the amount of current that flows
between electrodes.
The HMXT system uses an electrolyte, commonly referred to as KOH, which is a

30 weight percent aqueous solution of potassium hydroxide. The Equivalent
Specific Gravity Is 1.288 At 20C (68F).
The electrolyte is a strong caustic requiring specific

material for plumbing and components throughout the
system. Adequate safety precautions should be observed
when handling KOH. The solution is harmful and a severe
irritant to skin and eyes.
13
2.3 Electrolysis Module
The heart of the HMXT system is the electrolysis module. This is where the
basic process of separating H2O into its elemental components occurs. The
HMXT electrolysis module seems deceivingly simple from the outside but the
process occurring inside is complex. The configuration requires close tolerances
and special equipment for disassembly/assembly.
The module consists of a series of individual electrolysis cells where hydrogen

and oxygen are produced on separate electrode surfaces. Each cell contains a
hydrogen electrode and flow screen, a membrane, and an oxygen electrode and
flow screen. A porous matrix material saturated with electrolyte separates the
electrodes in each cell. When wet, the matrix material provides a gas impervious
membrane, preventing the generated gases from recombining. The thin cells
within the module are electrically connected in series using bipolar plates. All the
cells are compressed between large endplates, using 8 tie rods evenly spaced
around the circumference of the endplates. This configuration usually referred to
as bipolar or filter-press construction, results in a compact and efficient
electrolysis module.
2.4 Electrolyte Subsystem
The electrolyte is continually circulated within a closed plumbing loop. The loop
includes reservoirs, filters, circulating pumps, heat exchangers, flow switches,
temperature sensors, and the module itself. Circulation of the electrolyte through
the loop allows for a continuous supply of water for each cell of the module while
removing the waste heat of the process.
14
The produced hydrogen and oxygen from each cell is carried away with the
electrolyte and separated in its respective reservoirs. The electrolyte is cooled in
the heat exchangers and solids are removed in the filters. The flow switches and
temperature sensors provide electrolyte flow and temperature monitoring. The
system will shut down as a result of either low electrolyte flow or high electrolyte
temperature.
2.4.1 KOH Pump
The electrolyte is circulated by means of magnetically coupled centrifugal pumps.

The centrifugal design allows for continuous and long-life operation. The use of
a magnetic coupling between the pump motor and pump impeller provides for
leak-free operation by eliminating rotating seals at the pump shaft. Except for
bearing surfaces, all wetted parts of the pump are stainless steel. The impeller
bearing is a carbon-thermoplastic compound that rotates on a ceramic shaft.
Periodic inspection of these bearing surfaces is recommended as part of the
preventive maintenance schedule. Nominal KOH flow rate is between 8 and 11
GPM (30 and 42 LPM) depending on electrolysis module size and electrolyte
filter condition.
2.4.2 KOH Reservoirs
The reservoirs are stainless steel pressure vessels providing storage volume for
KOH within the electrolyte plumbing loop. Tri-Clamp fittings are provided at both
the top and bottom of the reservoirs. The system is filled with electrolyte through
the top Tri-Clamp fitting, while the bottom fitting provides access to the electrolyte
filter in the reservoirs. The reservoirs are located upstream of the KOH pumps
supplying the necessary start-up conditions for the pumps. Produced gases and
electrolyte returning from the electrolysis module are separated within this
volume. The water consumed by electrolysis is also replaced by adding fresh
water to these reservoirs.
2.4.3 Heat Exchangers
The heat exchanger is a standard plate-type configuration of stainless steel

construction. The heat rejection rate is controlled to maintain a stable electrolyte
temperature into the electrolysis module by varying the cooling water flow rate.
The water flow rate to each heat exchanger is controlled by a proportional valve
(MV1).
2.4.4 KOH Filters
The electrolyte filters are located in the bottom of the KOH reservoirs. The filter
element consists of a stainless steel cartridge. The cartridge is capable of
removing all particles down to 100 microns in size. Keeping the electrolyte
subsystem free of particulate matter is especially important for the electrolysis
15
module where solids can deposit on charged surfaces and clog intricate flow
passages. Cleaning or replacing the cartridge at regular intervals is part of the
routine maintenance schedule.
i Keeping the electrolyte solution clean is important for the

electrolysis module and regular maintenance is required.
2.4.5 Flow Switches
Adequate electrolyte flow to the electrolysis module must be maintained in order

to prevent drying of the matrix material and to prevent overheating of the module.
The flow switches (FS1) and (FS2) are vane-operated devices that are actuated
by the flow of fluid through the device. When the flow drops below the minimum
that actuates the vane, a magnetic switch is activated and the system is shut
down due to low flow.
2.4.6 KOH Temperature Sensors
Three iron-Constantine thermocouples (TC1, TC2 and TC3) are used to sense
the electrolyte temperature within the flow loop. Thermocouple TC1 monitors the
KOH temperature leaving the electrolyte heat exchanger before entering the
module. This temperature is used in controlling the heat rejection rate by varying
the cooling water flow to the heat exchanger. The TC2 and TC3 thermocouples
monitor the KOH temperature leaving the electrolysis module to prevent
overheating. If this temperature exceeds a preset maximum, the system is shut
down.
2.4.7 KOH Level
Monitoring the liquid level in the Oxygen KOH reservoir controls the quantity of
electrolyte in the system. As the system consumes water the electrolyte level, as
monitored by a liquid level transmitter, will fall. The transmitter reads the actual
level and takes action at different set points. The low level set point controls feed
water addition to the reservoir. When the level transmitter reaches the low level
set point, the PLC sends a signal for addition of feed water. Feed water is added
by running the feed water pump until the level transmitter is satisfied. There is a
low level alarm set point. When the level transmitter indicates this level KOH
condition, the system is shut down to prevent pump cavitation. There is a high
level alarm set point. When the level transmitter indicates this high level KOH
condition, the system is shut down to prevent overflowing the reservoirs.
2.5 Feed water Subsystem
The feed water subsystem delivers the high purity water required for electrolysis
16
to the electrolyte in the KOH reservoir. The system includes a feed water quality
monitor, a high-pressure pump, and switches/valves for control.
2.5.1 Feed water
The HMXT system consumes approximately 3 GPH (11 LPH) of water at a

hydrogen production rate of 200 SLM. At other gas production rates, the feed
water consumption rate is directly proportional.
Feed water should conform to the American Society for Testing and Materials
(ASTM) specification D1193-99 for Type IV water. This water may be prepared
by distillation, ion exchange, reverse osmosis, or electrodialysis. The minimum
allowable electrical resistivity is 200k-cm at 25C (77F).
Using feed water of inferior quality may lead to the

formation of deposits in the electrolysis module which, if
extreme, can cause module failure.
2.5.2 Feed water Quality Monitor
A water resistivity sensor is used to monitor feed water quality. The flow probe is
located in a plastic tee just inside of the feed water inlet port. The probe has a 4
to 20 mA analog output which is proportional to the resistivity of the feed water.
The resistivity alarm set point is 200 k-cm. If the resistivity drops below the set
point, the system will shut down.
2.5.3 Feed water Pump
The feed water pump is a positive displacement rotary-vane type pump. Pump
capacity from near atmospheric conditions to the 147 psig (10.2 kg/cm2)
discharge is approximately 15 GPH (1.0 LPM). The pump does not require any
routine maintenance. The internal bearings, vanes, and liner are made from a
carbon graphite material. The remainder of the wetted parts is stainless steel.
The pump internals can be damaged if run dry for more

than 30 seconds.
2.5.4 Feed water Control
The level transmitter initiates automatic control of the feed water subsystem
components. When the liquid level drops below the low level set point, solenoid
valve SV1 is opened and feed water pump operation begins. Feed water will be
added for only a very short time interval. A button in the system control panel
17
can be used to manually run the feed water pump. Feed water valve SV1 will
open during manual feed water pump activation. Manual operation of the pump
is provided only for pump priming or purging of the feed water quality monitor
probe.
2.6 Gas Control and Conditioning Subsystem
The majority of the equipment located in the upper-half of the hydrogen

generator is associated with controlling and conditioning the products of the
process. The gas controls are set to produce hydrogen and oxygen at a nominal
system pressure of 147 psig (10.2 kg/cm2). Pressure controls and monitors are
included to maintain system pressure within normal operating range and shut the
system down if pressures diverge out of the normal range. In the event that the
demand for the supply of hydrogen is beyond system capacity, the backpressure
regulator will eliminate the possibility of a low pressure shut down.
Hydrogen and oxygen from the KOH reservoirs leave as gases saturated with
water vapor. Both gases flow through separate water cooled condensers and
moisture traps to remove much of the moisture. The condensate from the traps
returns directly to its respective KOH reservoirs.
2.6.1 Pressure Transducers
Pressure control is crucial to the automatic operation of the HMXT system.

Pressure transducers (PT1, PT2) continuously monitor both the hydrogen and
oxygen pressure. The 4 to 20 mA signals from the transducers are input directly
to the programmable controller to provide complete system pressure control.
Two separate pressure transducers (PT3, PT4) are used with the dryer process.
These pressure transducers monitor the hydrogen pressure at the exit of each
dryer assembly.
2.6.2 Production Rate
The HMXT generator uses a separate DC power supply to provide electrical

power for electrolysis. The power supply is matched to provide specific
requirements for the electrolysis module (three sizes available) used in the
generator. The programmable controller in the generator controls the DC current
output to the electrolysis module through a signal to the power supply control
board.
The programmable controller in the HMXT has been programmed to vary the
electrolysis production rate to constantly maintain the nominal system hydrogen
pressure. At hydrogen production demands of 30-100% of the maximum
capacity of the generator, the current to the electrolysis module is varied
proportionally so that the production rate matches the demand while maintaining
18
the nominal system pressure. At production demands greater than 100%, the
generator produces at the maximum rate and the system pressure is allowed to
drop to the set point of a back pressure regulator (BPR2). At production
demands of less than 30%, the generator will vent the excess hydrogen through
a back pressure regulator (BPR3) while maintaining system pressure. RV2
functions as a relief valve for the system. It is set to release system pressure above
180 psig (12.7 kg/cm2).
In addition to pressure control, the production rate may be limited by the

electrolyte temperature. When the electrolyte temperature is below the
acceptable operating temperature (55C), the maximum production rate is
limited. The limit is proportional to the difference between the measured
electrolyte temperature and the acceptable operating temperature.
2.6.3 Pre-pressurization
When the HMXT system initially starts without any residual hydrogen pressure, a
pre-pressurization period is required. The system is pressurized with nitrogen to
10 psig (0.7 kg/cm2). The system then depressurizes to 5 psig (0.35 kg/cm2) and
increases back to 10 psig (0.7 kg/cm2) multiple times before hydrogen production
initiates.
2.6.4 Standby
The HMXT has been designed to always remain at pressure during normal
operation, regardless of demand for hydrogen. The nominal internal hydrogen
system pressure has been factory set for 150 psig (10.4 kg/cm2). If there is
limited or no gas demand (the delivery line from the system is closed off), the
internal pressure of the system will begin to increase above the nominal
pressure. When the pressure reaches 160 psig (11.2 kg/cm2) the excess
hydrogen is vented. The system will run at its minimum production rate when gas
generation is unnecessary. When the internal pressure of the system drops to
the nominal system pressure, higher generation will begin again.
2.6.5 Pressure Release
A pressure release button is provided to allow the operator to depressurize the

system. Depressing this button shuts the system down and initiates a nitrogen
purge and controlled pressure release through vent valves. Pressure is also
released during several of the automatic shutdowns.
2.6.6 Back Pressure Regulator
There are three (3) back pressure regulators, which serve as the upper and lower
limit controls for the system pressure.
19
Back pressure regulator BPR1 is set to maintain a system pressure of

approximately 130 psig (9.1 kg/cm2) which is below the nominal system (150 psig)
hydrogen pressure. It prevents damage to the electrolysis module in the event of a
hydrogen dryer fill failure. If the system switches into an empty dryer, BPR1 will
prevent a reverse differential pressure on the module.

approximately 140 psig (9.8 kg/cm2) which is below the nominal system hydrogen
pressure. It prevents loss of system pressure when the hydrogen demand is
greater than the maximum capacity of the HMXT system.

approximately 160 psig (11.2 kg/cm2) and vent hydrogen when the demand is less
than the minimum capacity of the HMXT system.
2.6.7 Differential Pressure Control System
The differential pressure control system is designed to keep the production gases
at an equal pressure (limit is set at 10 inches of water differential). The system is
comprised of a differential pressure transducer and two differential pressure
control valves, one that vents hydrogen gas and one that vents oxygen gas. Both
valves have electronic actuators that are controlled by the programmable
controller.
The differential pressure between the hydrogen and oxygen sides of the system
is continuously measured by the differential pressure transducer. This
transducer sends the signal to the programmable controller which compares the
value with a control set point of near 0 inches of water. If the differential pressure
is too high on the hydrogen side the controller will send a signal to the hydrogen
control valve to vent some hydrogen gas and likewise on the oxygen side of the
system.
2.6.8 Relief Valves
A relief valve (RV1) in the hydrogen delivery plumbing is used to provide a

redundant safeguard against system over-pressure. A second relief valve (RV2)
in the dryer delivery plumbing is used to provide a safeguard against dryer over-
pressure. Both relief valves are set to open at 180 psig (12.7 kg/cm2).
2.6.9 Vent Valve
Solenoid valve SV2 is the system vent valve for depressurizing the generator.
The vent valve releases hydrogen to the hydrogen vent. SV2 activates
automatically during several of the system shutdowns or it can be manually
actuated by depressing the pressure release button on the system control panel.
20
During venting, the valve pulses to provide a slow, controlled pressure release to
prevent violent pressure fluctuations and possible liquid loss.
2.6.10 Condensers and Traps
Conditioning of the product gases begins at the H2 gas/gas heat exchanger and
the condensers. The H2 gas/gas heat exchanger takes the hot hydrogen gas
from the phase separator and transfers some of the heat to the hydrogen gas
after the condenser. This lowers the humidity of the gas which is necessary for
the catalyst in FIL-4 to function properly. The gas/gas heat exchanger and the
hydrogen and oxygen condensers are plate-type heat exchangers.
The cooled gas leaves the condenser at a temperature approaching the cooling
water temperature and the condensate exits into a trap. The volume in the trap
allows the gas and condensate to separate. The condensate from the traps
returns directly to their respective reservoirs.
The effectiveness of the condensers is directly dependent on the temperature of

the cooling water. The HMXT uses a separate cooling water circuit for the
condensers. Using a small chilled water source to cool the condensers assures
a high rate of condensation and delivery of high purity product gases.
2.6.11 Nitrogen Purge
The HMXT generator includes protocols for purging the gas plumbing with
nitrogen at start-up and pressure releases. A forward pressure regulator (FPR1)
reduces the facility nitrogen pressure input to about 100 psig (7 kg/cm2). A
solenoid valve (SV6) distributes nitrogen gas to the hydrogen and oxygen side
plumbing of the generator. Check valves (CV3, CV4, CV5 and CV6) prevent the
flow of the product gases back into the nitrogen distribution plumbing when the
generator is producing gas.
2.7 Hydrogen Drying
Dryers are included for further conditioning of the hydrogen delivery gas. The
drying process uses a molecular sieve bead material that removes water vapor
by adsorption. The dryers are capable of drying the gas to an atmospheric dew
point of less than -73C (-100F), corresponding to a volumetric concentration of
less than one part per million. After the adsorption process, the molecular sieve
beads are automatically regenerated using a thermal cycling procedure.
2.7.1 Dryers
The HMXT dryer system contains a pair of internally mounted dryers for
21
conditioning the hydrogen. The two dryers automatically alternate through a

12-hour adsorption and desorption cycle. After 6 hours of adsorption, the on-line
dryer is switched off-line to begin a 6-hour regeneration process. The dryer is
depressurized and an electric resistance heater within the dryer heats the
molecular sieve beads to release the adsorbed water vapor. A small purge of
product gas is used to drive the water vapor out through the vent gas tubing.
The purge flow is controlled by an orifice located between the dryers (OR1).
After desorption, the heating element is turned off and the dryer is allowed to cool
before going back on line.
The hydrogen dryers also contain a small amount of catalyst that will recombine
any minute amount of oxygen and hydrogen. The recombined product is water
that is adsorbed in the dryer beads.
2.7.2 Dryer Valves
The dryer valve assembly (MV2) is a four-way ball valve. This valve directs the
hydrogen product gas through the active dryer while directing the hydrogen
purge gas from the regenerating dryer to the gas vent. Every six hours the valve
position is alternated, selecting the opposite dryer for product gas conditioning
and dryer purge venting.
A regenerated dryer must be pressurized to system operating pressure before it

goes back on line. This is done to prevent a sudden pressure transient through
the system. Solenoid valve SV4 controls the hydrogen purge vent. This valve
automatically closes before the dryer switch to bring the regenerated dryer up to
system pressure.
The dryer system includes a solenoid valve (SV5) for venting the dryers during a
system pressure release. Check valves (CV7 and CV8) are provided to separate
product gas from the purge gas following the drying process. A back pressure
regulator (BPR2) is used to prevent the loss of dryer pressure when the
hydrogen demand is greater than the maximum capacity of the HMXT system.
2.8 Cooling and Condenser Cooling Water Subsystems
The cooling water, required to cool the electrolyte, and the water, required for
condenser cooling, flow in separate plumbing circuits. This arrangement allows the
operator to use any economical means of cooling for the majority of the heat load
and only a small chilled water source for condenser cooling if necessary. Chilled
water may be necessary for condenser cooling if maximum condenser
effectiveness and maximum specified product gas purity is desired. Using the
cooling water source for condenser cooling is permissible if minimal moisture
content in the product gas is not necessary.
22
The cooling water system includes heat exchangers and a temperature regulating
valve. An externally mounted strainer is recommended to protect the control valve.
The condenser cooling water system includes a solenoid valve (SV3), the
oxygen/hydrogen condensers, and a flow adjustment valve (HV3).
2.8.1 Temperature Regulating Valve
Temperature control of the electrolyte is important for maintaining an efficient

process and preventing premature failure of the electrolysis module. Operating at a
low temperature can be as detrimental as overheating the module. The
programmable controller maintains the optimal temperature of the electrolyte
entering the module.
The temperature regulating valve controls the electrolyte temperature by varying

the cooling water flow through the heat exchanger. The regulating valve is an
electrically actuated ball valve. The programmable controller monitors the
temperature change versus time response of TC1 at the heat exchanger outlet and
varies the valve position proportionally. As long as adequate cooling water is
available, the PLC determines the correct valve position to maintain the KOH
temperature set point.
i Maintaining the electrolyte within an acceptable

temperature range is important for the electrolysis and
for the safety of the module.
2.8.2 Condenser Cooling and Water Control
Control of cooling water to the condensers is accomplished using two valves. A

solenoid valve (SV3) provides the on and off control and a manual valve (HV3) is
used to adjust the flow. Solenoid valve SV3 opens and allows flow only when the
system is running. The cooling water flow is adjusted as necessary to keep the
cooled gas at or below ambient conditions using HV3.
2.9 Hydrogen System Safety
Operator and system safety has been a primary consideration in the design of the
HMXT system. The system maintains only a small inventory of hydrogen during
operation. This limits any potential danger related to combustible gas storage. The
system is designed to be operated in a well-ventilated environment monitored by a
suitable hydrogen detection device. The system can easily be integrated to the
hydrogen detection device or any other external alarm equipment.
The operational features of the system provide for automatic shutdown of the
23
system should operation deviate significantly from normal parameters.

Temperatures, pressures, and liquid level are continuously monitored throughout
the system to assure system operation within the established design conditions.
Latch-out alarms are used to interrupt gas generation should any of the parameters
which are monitored drift outside the allowable range. The cause for shutdown
must be corrected before system operation can continue.
2.9.1 Hydrogen in Oxygen and Oxygen in Hydrogen Monitoring
The oxygen produced in the system is continuously monitored to determine the

hydrogen content. The amount of hydrogen in the oxygen is a direct indication of
module integrity. Hydrogen will be present in the oxygen if internal module integrity
fails. When the concentration of hydrogen approaches the lower combustion limit
of 4 percent, the system is shut down.
Detection of hydrogen in oxygen is accomplished using a catalyzed electrode that

chemically combines the two gases. The heat of reaction is proportional to the
concentration of hydrogen in the oxygen and is indicated as the temperature rise of
the catalyzed electrode (TC4). If the temperature difference exceeds a preset
maximum of 200C, the system is shut down. Only a small constant flow of the
oxygen produced is used for hydrogen detection. This amount is precisely
controlled by a flow controller (FC1) and indicated by a flow meter (FM1). A filter
tank prevents water vapor from entering the flow stream and a flame arrester
prevents a reaction from traveling back into the system.
Oxygen in the Hydrogen is also monitored to assess system integrity. Filter tank
FIL-4 contains catalyst beads which will recombine any Oxygen in the product
stream with the hydrogen to produce water. This process produced heat which is
monitored by a thermocouple (TC6). If the temperature of the tank exceeds 200°C
the system is shut down.
2.9.2 Hydrogen Detector
A hydrogen detector is recommended to monitor the atmosphere surrounding the

HMXT system. The HMXT can be integrated to a compatible hydrogen detector by
using the available external alarm inputs. The hydrogen detector will shut the
system down if a sufficient amount of hydrogen is present.
2.9.3 Shutdown Alarms
There are several possible alarms that can be indicated on the system control
panel. The alarms are listed in the trouble shooting section of this manual.
When one of these conditions occurs, the appropriate alarm screen will be
indicated on the control panel and the system will shut down. Some of these alarms
24
also cause the system to purge and release pressure.
The purge and pressure release may also be initiated by a manual pressure
release from the generator control panel.
The shutdown condition is indicated by a flashing screen on the touch screen

display. The shutdown will continue to flash until the alarm reset button is pressed.
Operation can continue after the condition is corrected and the system start/reset
button is depressed. If system power is lost or turned off during a shutdown, the
shutdown will resume flashing when the power is restored and the alarm indication
will not be lost.
2.10 Electrical Power and Process Control Subsystems
The electrical conversion and control subsystems link all the components required
to carry out the electrolysis process and operate the generator as a working
system. The AC power input is converted into DC power for the electrolysis module
and also stepped down to 115 VAC for system process and control. After facility
power has been applied to the HMXT system and the start/reset touch switch is
pressed, the electrical control system automatically directs all system functions.
The wiring diagrams in the schematics section show the numbered wire runs for the
generator.
2.10.1 DC Power Supply
25
The power supply is contained in a cabinet separate from the hydrogen generator.
AC to DC conversion is accomplished with a full wave, full control bridge rectifier. A
voltmeter and ammeter are located on the front panel to display the DC voltage and
current applied to the electrolysis module. The power supply also powers the
HMXT pumps and contains auxiliary transformers for supplying 115 VAC to
generator controls. Overload protection devices on the power supply include fuses
for the SCRs, temperature switches for the transformer/SCRs, and several circuit
breakers.
Operation of the power supply is controlled from the generator. The generator's
programmable controller allows, adjusts and inhibits DC current for electrolysis as
necessary to produce gas or shut down safely. The generator emergency stop
button at the front of the generator disables the power supply as well.
2.10.2 Programmable Controller
The HMXT system uses a programmable controller for managing the operation of
the system. The controller allows the system to operate with no need for an
operator to do manual switching, make adjustments, or continuously monitor the
process. The controller has been programmed to do the switching, make the
adjustments, and monitor the system to maintain efficient and safe operation.
System process conditions (temperature, pressure, and level) are input directly to
the programmable controller and output signals are directed to the process control
devices (power supply, valves, and pumps). All the process functions, such as feed
water addition, cooling water flow, and electrolysis rate, are handled by the
controller. Should process conditions stray beyond the allowable bounds, the
controller will stop gas production and indicate the appropriate shutdown alarm.
The programmable controller consists of a din rail mounted CPU located in the
Operator Interface box. Input and output modules are distributed around the
generator. Internal PLC memory is backed up by a memory card installed in the
main processing unit.
The inputs are either 115 VAC on/off signals, 4-20 mA analog signals or direct
thermocouple voltages. The on/off inputs include the KOH flow switches, two
external alarms (normally open, normally closed), and the power supply alarm.
Analog inputs include pressure transducers, differential pressure transmitter, level
transmitter and the feed water quality monitor. Thermocouple inputs include the
temperatures for KOH control, hydrogen side module outlet, oxygen side module
outlet, hydrogen in oxygen catalyst, deoxo catalyst bed, and internal ambient air.
Outputs from the programmable controller are either on/off, triac 115 VAC power or
4-20 mA analog signals. On/off outputs control the KOH pump, condenser water
valve, feed water pump, vent valves, feed water valve, dryer selection and purge
valves, nitrogen purge valves, dryer heaters and power supply inhibit. Analog
26
outputs control the power supply current, MV1 valve position and both differential
pressure control valve positions.
2.10.3 Process Control and Sequencing
The main circuit breaker to the power supply must be closed for the system to
receive electrical power. Turning on the emergency stop switch, which is located
on the HMXT generator will activate a contactor that energizes the circuits in both
the hydrogen generator and the power supply.
When the system is at zero pressure the start sequence will include a pre-
pressurization period. Pressing the "Start Gas Generation" touch switch on the
main screen will begin operation and the following will occur:
1. The "Pre-pressurization" note displays on the touch screen display

showing operational data.
2. Solenoid valve SV6 opens to provide a nitrogen purge of the system. An

increase in the pressures should be seen.
3. The system pressure (PT1) rises.
4. The KOH pumps will turn on.
The pressure continues to rise until it reaches 10 psig (1.4 kg/cm2). At this
pressure, SV6 will close and the system will begin a depressurize sequence. The
generator will depressurize to 5 psig (0.7 kg/cm2) and then reintroduce the purge
gas. It will increase back to 10 and purge down to 5 a few more times before
beginning operation.
After pre-pressurization the following will occur:
1. The KOH pump is energized and the pump begins to circulate KOH. The
flow switches (FS1, FS2) are actuated to indicate proper flow conditions.
2. The condenser cooling shut-off valve (SV3) is energized and opens to

allow flow through the condensers.
3. The “Restart Delay” note will appear. The restart delay will last a
minimum of 15 seconds and will continue until the KOH control
temperature is less than or equal to 66C.
4. The inhibit signal to the power supply actuates and power is applied to the
electrolysis module and gas generation begins.
27
5. The "Generator Operating" note displays on the touch screen display

showing the hydrogen production rate as a percentage of full capacity.
As operation continues, the system pressure builds at the maximum production rate
allowed by the temperature of the electrolyte.
i Full 100% maximum current is not available until the

electrolyte temperature reaches the acceptable operating
temperature of 55°C.
System pressure increases until it reaches the first back pressure regulator (BPR1)
set point. Next, the dryers begin pressurizing. The dryer assembly is filled until the
system pressure reaches the second back pressure regulator (BPR2) set point.
Hydrogen is now available to be delivered. When the internal pressure reaches the
nominal system pressure of approximately 150 psig, the production rate is
regulated to meet the demand rate imposed by the user. If the demand for gas
exceeds the production capacity of the generator, the second back pressure
regulator, BPR2, will maintain the internal system pressure and the flow of gas is
limited to the maximum capacity of the generator. If there is no demand for gas,
standby pressure is reached and gas generation is automatically set to 75 Amps.
When demand for hydrogen resumes and the generator pressure drops to the
nominal system pressure, gas generation starts again and the production rate is
regulated to meet the demand. If the generator is turned off during operation, the
system will purge and depressurize.
When the electrolyte reaches operating temperature, the temperature regulating

valve (MV1) will begin actuating. The valve will rotate back and forth until the
correct position is found to maintain the electrolyte temperature within the
acceptable operating range. A control routine in the programmable controller varies
the valve position to maintain the electrolyte temperature over a wide range of
production rates and cooling water conditions. A "Cooling water system" screen,
which is accessed from the main touch screen display, can be used to monitor the
temperature regulating valve position, from zero to 100 percent open, along with
the electrolyte temperature.
During normal operation, feed water is periodically added to the electrolyte. The
feed water valve (SV1) will open and the feed water pump will supply feed water
when the feed water add level is reached. A graphic will display on the touch
screen display during the water add interval. If there is no feed water supply
available and low feed water level does not reset, then the system will shut down
on a low level alarm. Feed water is not added during the start and pre-
pressurization interval or during a shutdown.
28
2.10.4 Dryer Sequencing
The dryer assembly begins its timing sequence after the online dryer has been
pressurized. The dryers are not pressurized until the generator is running at
pressure and hydrogen can be delivered to the dryers through the generator back
pressure regulator (BPR1). When the pressure transducer (PT3 or PT4) in the
online dryer senses adequate dryer pressure, the dryer sequence begins.
The dryer timing sequence begins with the online dryer delivering hydrogen at
pressure for 6 hours while the regenerating dryer is being heated for 90 minutes at
atmospheric pressure. After 90 minutes of heating, the regenerating dryer is
allowed to cool for four and one half hours before it goes on line. During heating
and cooling a small portion of the dry product gas purges through the regenerating
dryer to the hydrogen vent. Thirty minutes before the regenerating dryer is to go on
line, the vent valve for the purge (SV4) is closed and the regenerating dryer begins
to build pressure. When the dryer valve switches to bring the regenerated dryer on
line, both dryers are at equal system operating pressure allowing for a smooth
transition between dryers. The dryers switch duties for the remaining 6 hours to
complete the 12-hour cycle.
Except for the 30 minute pressurizing period before dryer switch, the actual dryer
sequence will restart wherever the 12 hour cycle was interrupted when the system
was last shutdown. This prevents one dryer from becoming saturated from
repeated, short time on-line duty. When a restart occurs within the 30 minute
pressurizing period, the sequence starts at the beginning of the period to allow time
for both dryers to reach system operating pressure.
The dryer sequence status can be seen by pressing the "Dryer Sequence" touch
button on the main screen. The screen indicates:
 dryer pressures
 dryer sequence (on/off)
 which dryer is online (on/off)
 number of minutes to switch (dryer)
 which heater is on (on/off)
 number of minutes to turn off (heater)
 purge valve (on/off)
29
2.11 Data Display and Process Monitoring
A touch screen display and LED lights on the programmable controller allow the
operator to monitor the gas generating process. The status of various process
conditions can be displayed and operational sequences can be observed. Close
monitoring of the generator operation provides the operator with useful information
for determining overall system conditions and detecting possible problems.
2.11.1 Touch Screen Display
A touch screen display mounted on the front of the generator displays process
conditions. This display is programmed to communicate directly with the
programmable controller to provide operational data monitoring and operator
control input. The display is used to indicate production rate, feed water pump
timing, purge status, pre-pressurization timing, gas pressures, process
temperatures, elapsed time, system data set points, shutdown alarms and
troubleshooting summaries. The touch screen display accomplishes all of these
tasks through a series of mimic diagrams.
During normal operation, the main screen displays the hydrogen production rate
from 30 to 100 percent of capacity as regulated by the controller. The pressure
release is manually activated from this screen by pressing the "Generator
Shutdown" button and pressing “Yes” or “No” to confirm. The status of all the
generator components is shown on the mimic diagrams. If a shutdown occurs, the
display will flash and indicate the specific shutdown condition.
The touch screen display can be prompted to indicate the status of all the various
subsystems by depressing one of a series of buttons on each of the screens. The
pressure release is activated from most screens by pressing the "Pressure
Release" button and pressing “Yes” or “No” to confirm. The system information
screen displays the elapsed time the generator has accumulated while generating
gas and contains options which lead to more system related information or
functions.
Various trends can be accessed from the “System Description” screen, which
can very useful for troubleshooting. The trend data is saved to a memory card in
the touch screen, which allows older data to be viewed or transferred a separate
device.
30
3 GENERATOR INSTALLATION
3.1 System Classification
The HMXT hydrogen generator cabinet has been designed for operation in Class I,
Division 2, Group B locations as defined by the National Fire Protection Association
(NFPA), Document 70, which is the USA National Electrical Code (NEC). The
generator power supply is separate from the generator cabinet. Unless otherwise
specified, the power supply includes standard electrical components and is
intended for installation in an UNCLASSIFIED area.
NFPA 70 definitions are provided in article 500, and equipment requirements begin
in article 501. Teledyne interprets and follows these requirements based on
knowledge of widely accepted practices, specialized training, and exposure to a
variety of installation situations involving hazardous materials.
Under the NFPA, Class I designates the hazardous material as a gas. Group B
pertains to the properties of hydrogen and similar materials regarding the
requirements of an explosion-containing enclosure. Division 2 defines the area as
one in which flammable material is handled in closed systems and is not normally
present in the environment. Flammable material is present only in the event of a
failure leading to leakage, and such failures are not simultaneous with activation of
exposed ignition sources. The presence of hazardous material is assumed to be
for a relatively short time.
The above is analogous to the IEC requirements as defined in IEC 79-0. The
classification is Group IIC, Zone 2, T6. Group II refers to the application as not
mine related. The C is similar to Group B under the NFPA, and Zone 2 is defined
nearly identically to Division 2. T6 refers to the ignition temperature of the material,
which is handled in the specific requirements of the NFPA. The design
philosophies of the NFPA and IEC are the same, as are most of the equipment
requirements. Teledyne follows the NFPA requirements in detail.
In Division 2 (zone 2) locations, the hazardous gas is not normally present in the
environment. The electrical equipment is specified such that a failure is required to
expose an ignition source. Any device that can provide ignition (arcing or hot
surfaces) under normal operation is required to have isolating or protective design
feature. Devices that are not ignition sources in normal operation are permitted in
Division 2 locations within standard electrical enclosures, and are usually not
required to be especially marked. Wiring in Division 2 locations may be in rigid
conduit or via one of several cable types, including tray cable.
31
3.2 Storage
Prior to shipment the HMXT generator is flushed with deionized (DI) water
several times shipping to prevent hazards during shipping and transit. Once the
KOH has been removed, the generator is filled again with deionized water to
keep the membranes in the electrolysis module wet. If the generator is to be in
storage for a period longer than 6-12 months, the generator should be drained
and refilled with fresh DI water. When preparing the generator for initial operation
it is best to flush out with DI water again and then fill the generator with 30%
KOH. It is also important to keep the electrolysis module wet if the generator is
to be off or down due to maintenance for more than a few days.
Protect equipment from freezing. This includes a module

filled with deionized water as well as cooling water and
feedwater trapped in the generator.
3.3 Generator Mounting
Holes in the generator frame base plates are provided for securing the frame with
½-inch anchor bolts. A floor drain should be provided at the rear of the generator
near the plumbing service panel. A minimum access spacing of 3 feet or 1 meter is
required around all sides of the installation. Enough access should be provided on
the front of the installation to allow for the removal and replacement of the
electrolysis module.
The power supply and the generator are shipped in separate crates. The crates
may contain several smaller packages inside. After uncrating the generator and
power supply, inspect for damage to the external components and fittings. Check
that all pressure gauges, meters, control panel components, and plumbing interface
panel fittings have not been damaged during shipment. Open and inspect all small
packages. Report any damage to the shipper. Replace or repair damaged items
before attempting to operate the system.
The generator weighs approximately 1300 LB (590 kg). A floorwalker or

conventional lift truck is recommended for moving the frame. Remove the two
splash trays from the bottom of the generator before attempting to move generator
with a fork truck. Standard fork clearance has been provided at the base of the
frame. When moving, be certain the forks protrude all the way under the frame
structure so that the tips are visible on the other side.
32
3.4 Unpackaging
Each generator system is unique and will have a unique part list included with the
shipment. Components will be divided into the following groups. Consult your
packing list for a comprehensive list of included items. The following items
should arrive with your generator system:
 HMXT generator with drip pans and doors installed and the following
components which require installation:
o H2 in O2 sensor
o TC4
 Power supply
o Power supply manual
o Interconnect cables, power supply spare parts, and hardware
 DC cable spool
 HMXT Manual
 Special tools and tackle
 Commissioning spare parts (Gaskets, Etc.)
 Cross-leak test kit
 Floor plan drawing and mounting hardware
 Cooling water interconnect kit
 Feed water filter
 Module shipping caps (modules are shipped installed in generator)
3.5 Facility Connections
All of the plumbing connections to the HMXT system are made at the plumbing
interface panel located at the rear of the generator. The electrical interconnections
from the power supply to the generator are routed through the rear of the generator
frame. Installation of these connections should conform to the local plumbing and
electrical codes that prevail. The input requirements for the facility connections are
summarized in Table 3-1.
33
Table 3-1 HMXT Generator Input Requirements

Generator Capacity
HMXT- HMXT- HMXT-
50 100 200
Feed water
Minimum resistivity 200k-cm
Maximum consumption
liter per hour 3 6 11
gallon per hour 0.8 1.6 2.9
Process Cooling Water

Max allowable temperature 40C (104F)
Max allowable pressure 100 psig (7 kg/cm2)
Max required flow 40 liter/min (11 GPM)
Pressure drop at max flow 10 psig (0.35 kg/cm2)
Maximum heat load
kW 8 15 25
kBtu/hr 27.3 51.2 85.4
Condenser Cooling Water

Max allowable temperature 40C (104F)
Max allowable pressure 100 psig (7 kg/cm2)
Required flow 4 liter/min (1 GPM)
Pressure drop at max flow 7 psig (0.5 kg/cm2)
Maximum heat load 1 kW (3000 Btu/hr)
Electrical Power Supply

Nominal Input voltage Universal or Made to match supply voltage
(380 Volt Minimum)
Phase Three phase
Nominal AC KVA 30 60 120
Ambient Temperature Range

Minimum allowable 0.6C (33F)
Maximum allowable 50C (120F)
Nitrogen Purge
Pressure Range 50 to 350 psig (3.5 to 25 kg/cm2)
Consumption 100 Std liters / day dependent on number of off / on
cycles
34
3.5.1 Feed Water
The feed water may be prepared by distillation, ion exchange, reverse osmosis or
electrodialysis and must conform to the American Society for Testing and Materials
(ASTM) specification D 1193-72 for Type IV water. The minimum allowable
electrical resistivity is 200k-cm (maximum conductivity of 5.0 S/cm) at 77F
(25C). A minimum static head of 8 feet (2.5 m) of water is required at the feed
water connection.
The feed water connection at the lower rear of the generator is a 3/8-inch Swagelok
bulkhead union. A feed water filter assembly supplied with the generator should be
attached directly to the feed water connection. The feed water source can then be
connected to the filter inlet. All feed water tubing should be either stainless steel or
polypropylene. Steel, black iron, galvanized iron, or copper are not acceptable
materials for feed water supply tubing.
3.5.2 Cooling Water
A source of clean cooling water is required to cool the HMXT generator. The
maximum allowable inlet temperature is 104F (40C). At this temperature the
system requires approximately 11 GPM (40 LPM) of cooling water. At 11 GPM (40
LPM), the inlet to outlet pressure drop is about 5 psig (0.4 kg/cm2).
The cooling water inlet and outlet connections are 3/4-inch NPT pipe fittings. A
strainer should be installed in the inlet line to protect the temperature regulator and
heat exchanger from dirt, scale, or foreign matter that could interfere with the
seating of the valve or clog the heat exchanger. It is also recommended that
isolation valves be fitted in the facility cooling water supply for maintenance
purposes.
3.5.3 Condenser Cooling Water
The condensers use approximately 1 GPM (4 LPM) of water. Generally, the

cooling water source can be used for condenser cooling. However, chilled water
will provide maximum condenser effectiveness and in special cases, may be
required to ensure specified gas purity.
The condenser cooling water inlet and outlet connections are 3/8-inch Swagelok
bulkhead unions.
3.5.4 Hydrogen and Oxygen Vents
Hydrogen and oxygen vent gas must be directed outside before being released to
the atmosphere. The vents should exhaust at least 10 feet (3 m) above the outside
ground level and should be positioned to provide protection of property and
35
personnel from contact with caustic mist or liquid (KOH) in the event of a system
malfunction. The hydrogen and oxygen vents should be separated by a minimum
of 15 feet (5 m). In locations subject to freezing temperatures, water vapor in the
vent gas may condense and freeze. Installation of a thermostatically controlled
heating tape along the vent tube is required to prevent vent blockage. Care should
be taken so that the electrical heating tape does not provide a source of ignition for
the venting hydrogen.
All vent lines should be stainless steel tubing. The hydrogen and oxygen vent
connections are each 3/8-inch Swagelok bulkhead unions. Vent line length should
be minimized to prevent excessive flow restriction during system shutdown. When
using 3/8-inch tube for hydrogen or oxygen vents, each vent line should be no
longer than 33 feet (10 m).
3.5.5 Product Gas Delivery
The dryer delivery port is a ¼ inch Swagelok™ bulkhead union connection. It is

recommended that stainless steel tubing be used for all product gas delivery lines.
Initially the H2 gas product from the generator will have some impurities. The
impure gas should be vented to the atmosphere until the customer purity
requirements have been established. Figure 3-1 Recommended Hydrogen
Delivery Valve Configuration shows the recommended valve arrangement after the
hydrogen delivery connection at the generator. Needle valves are preferred in
order to limit pressure surges. These items are customer supplied.
Figure 3-1 Recommended Hydrogen Delivery Valve Configuration
3.5.6 Electrical Power
A high in-rush capacity breaker or fused switch box for the appropriate sized
service is required for interfacing the generator power supply to the facility main
power service bus. Breaker should be sized according to local code and
environmental conditions by a qualified Electrician. Emergency stop switches are
located on the Generator and the Power Supply.
36
3.5.7 Nitrogen Purge
Nitrogen gas is used as the pressure source for purging. The nitrogen should be of
a high purity industrial grade. A pressure regulator must be used to maintain the
pressure at the connection to the HMXT generator to between 50 to 350 psig (3.5
to 25 kg/cm2. Purges are used in two situations for safety, during initial start-up and
during a shutdown. The consumption of nitrogen for any individual purge event is
approximately 25-40 standard liters. The nitrogen gas connection is a 1/4-inch
Swagelok bulkhead union. It is recommended that stainless steel tubing be used to
connect the generator to the nitrogen gas source.
3.6 Power Supply Electrical Connections
The electrolysis power cables, control power wires and several control circuit wires
must be connected between the generator and the power supply to complete the
installation. Connect the power cables to the DC output terminals in the power
supply.
Make absolutely sure the DC power cables are attached to

the correct positive (+) and negative (-) lugs. Reverse
polarity would result in a very dangerous situation.
The generator frame must be grounded to the power supply cabinet. Ground pads
are provided for this purpose.
The Motor power, Heater power and control circuit wires are all contained in several
multi-conductor cables. They are connected between the power supply and junction
box 7 on the generator. See the field wiring diagram for the proper connections.
Once everything is connected, perform a “point to point” inspection of the wiring.

After powering up the generator for the first time, check each motor for the correct
rotation.
3.7 Optional Connections
3.7.1 External Alarm Connections
The HMXT has connections available for either normally open or normally closed
external alarm contacts. Please connect all external alarms to box #6 according to the
HMXT field wiring diagram XM38008 (see appendix).
37
3.7.2 Instrument Connections
Combustible gas sensor- This optional instrument measures combustible gases in

the room containing the hydrogen system. The sensor is installed in the ceiling and
connected to the PLC in electrical box JB6. For more information on instrument
description and operation, see 7.1.2 and 7.3.2.1 respectively.
Hygrometer- This is an optional instrument to measure moisture content of the

product gas. The sensor is installed in the hydrogen outlet and connected to the
PLC in electrical box JB6. For more information on instrument description and
operation, see 7.1.3 and 7.3.2.2 respectively.
Trace O2- This optional instrument measures oxygen content in the outlet hydrogen
stream. If equipped and enabled, the generator will be shut down when the
concentration reading exceeds the alarm threshold (adjustable). The sensor is
installed in the hydrogen outlet line and connected to the PLC in electrical box JB6.
For more information on instrument description and operation, see 7.1.4 and 7.3.2.3
respectively.
Reference HMXT field wiring diagram XM38008 (see appendix) for specific
connection details.
3.7.3 Plant Communication and Monitoring
With optional hardware and software, the system can be monitored and operated via
an Ethernet connection. This flexible capability is unique to each customer’s use;
contact Teledyne for further information.
38
4 GENERATOR OPERATION
4.1 General
Successful operation requires that the generator be provided with the correct input
sources and output connections. These installation requirements are described in
Section 2. A preliminary check to verify that facility sources and connections are
proper should be made before every startup. Before the initial startup of a
generator, several additional checks are also required.
The startup and run operations of the HMXT generator are fully automatic. The
start\reset and pressure release buttons on the touch screen display are the only
manual inputs required to operate the system. The process control and
sequencing that directs the generator start and run operation is described in
Section 2.
All operational conditions are continually monitored to provide automatic shutdown

should conditions deviate from the norm. If system shutdown should occur during
the start or run modes of operation, the problem should be investigated and
corrected before restarting the system. A troubleshooting guide for each shutdown
is available on the touch screen display and also presented in Section 6 of this
manual to help identify the cause of shutdown problems.
4.2 Initial Startup
4.2.1 Uninterruptible Power Supply (UPS)
The UPS features a LED display to indicate either load

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

automatically transfers the connected load to bypass. Bypass
operation is indicated by an alarm (which will shut down the
generator) and illuminated Bypass LED (other LEDs may be
illuminated to indicate the diagnosed problem).
During normal operation, utility power provides energy to the UPS and the UPS
maintains the batteries in a fully charged state. The four green LEDs indicate an
approximate level of load in 25% increments.
39
Turning off the UPS while in battery mode will result in loss
of output power. Never turn the UPS OFF while the system
is pressurized. A loss of power to the system when
pressurized could result in damage to the equipment.
ON Button
This button controls output power to connected load(s) and has three functions:
 ON - Pressing this button will start up the UPS in order to provide conditioned
and protected power.
 Alarm Silence - To silence alarms, press this button for at least one second.
After the alarm is silenced, the UPS will reactivate the alarm system to alert of
additional problems
 Manual Battery Test – Refer to the manufacturer’s manual for details of this
test.
Manual Bypass/OFF Button
This button controls output power to connected load(s) and has dual functions:
 Manual Bypass - Pressing this button once will cause the load to be transferred
to bypass power.
 OFF - Pressing this button twice within 4 seconds will turn power OFF to the
output receptacles and connected loads. Perform all necessary shutdown
procedures on connected loads before pressing this button twice.
Pressing the Manual Bypass/OFF button once will cause the

load to be transferred to bypass power. Pressing the
Standby/Manual Bypass button a second time within 4
seconds will turn power OFF to the output receptacles and
connected loads. Perform all necessary shutdown
procedures on connected loads before pressing this button
twice.
The UPS provides an alternate path for utility power to the connected load in the
unlikely event of a UPS malfunction. Should the UPS have an overload, over
temperature, or UPS failure condition, the UPS automatically transfers the
connected load to bypass. This also causes the generator to shutdown and
depressurize.
Bypass operation is indicated by an alarm and illuminated Bypass LED (other

LEDs may be illuminated to indicate the diagnosed problem). An alarm signal is
40
sent to the PLC to initiate a pressure release. The system cannot be restarted
until the UPS is returned to normal.
To manually transfer the connected load from the inverter to bypass, press the
Standby button once.
4.2.2 Preliminary Procedures
To ensure safe operation during the initial startup of a generator or following an

extended shutdown, several preliminary procedures should be completed. The
checks are standard procedures that are described in Section 5. The procedures to
be completed before initial startup are listed below:
 System Pressure Test

 External Module Inspection
 Electrolyte Fill or Check
 Feed water Pump Priming
These preliminary checks are necessary to verify that

system integrity has been maintained during shipment or
during prolonged periods of shutdown.
4.3 Start Mode
The start mode allows the system to build up the internal pressure required for
hydrogen to be delivered at pressure. The system goes through pre-pressurization
only when starting from a zero or near zero pressure condition.
Facility power, cooling water, nitrogen purge gas, and feed water must be available
to the system before operation. The main circuit breaker to the power supply must
be closed for the system to receive electrical power and the UPS must be in the
operate mode. Press the "Start/Reset" button on the generator screen.
System operation begins with a nitrogen purge of the plumbing of the generator.
An ABORT button is available on the touch screen to stop the nitrogen purge if
desired. Following the purge, the generator is pressurized to establish pre-
pressurization. When system pressure reaches 10 psig (.7 kg/cm2) the KOH pump
turns ON to circulate electrolyte and the “Restart Delay” is displayed. The
system always goes through at least a 15 second restart delay. If the KOH
temperature is above 66C, the delay continues until the control temp is equal to
or less than 66C.
41
4.4 Run Mode
Following the restart delay, DC electrical power is applied to the electrolysis module
as indicated by the voltmeter and ammeter on the power supply and the production
rate indicated on the "Generator” screen on the display. The hydrogen and oxygen
pressures will increase until the nominal system pressure is reached. The system
is now in the run mode ready to deliver gas. The nominal system pressure is set at
approximately 150 psig (10.6 kg/cm2).
The generator has been programmed to control the electrolysis production rate in
relation to both system pressure and temperature. The maximum production rate
of the HMXT is limited until the electrolyte control temperature is within the
operating control range. The limitation is proportional to the difference in
electrolysis module inlet temperature and minimum electrolyte control temperature.
The electrolysis production rate is varied to constantly maintain the nominal system
hydrogen pressure. At hydrogen production demands of 30 to 100 percent of the
maximum capacity of the generator, the current to the electrolysis module is varied
proportionally so that the production rate matches the demand while maintaining
the nominal system pressure. At production demands of less than 30 percent, the
generator can match the demand by venting any excess hydrogen through BPR3. .
At production demands greater than 100 percent, the generator produces at the
maximum rate and the system pressure is allowed to drop to the set point of back
pressure regulator BPR2.
4.5 Standby Mode
If the internal pressure of the system rises beyond the internal pressure set point
(150 psig, 10.6 kg/cm2), gas generation is set to a minimum production. The gas
not sent to delivery is vented through BPR3 when pressure rises above the
regulator set point (160 psig, 11.3 kg/cm2). The system will remain at pressure
ready to deliver hydrogen on demand. When the internal pressure of the system
drops to the nominal system pressure (150 psig. 10.6kg/cm2), normal generation
will begin again.
4.6 Normal Operation
During operation, the ammeter on the power supply should indicate a module
current of between 75 and 450 amps depending on the gas demand required by
the user. The corresponding module voltage will depend on the module size and
several operating factors. The module voltmeter should indicate within the range
listed below in.
42
Table 4-1 Module Voltage

Module Size Voltage Range
HMXT 50 75-92
HMXT 100 140-173
HMXT 200 140-173
As the system runs, the temperature increases. The temperature regulating valve
opens to control the KOH temperature leaving the heat exchanger (TC1). The
temperature regulating valve, MV1, will open and close as required to maintain the
KOH control temperature set point. Valve position and electrolyte temperature can
be monitored on the "Cooling water system" screen, which is accessed from the
main screen on the display.
The feed water subsystem will intermittently add water during normal operation.
Feed water is periodically added to the reservoir when required as shown by the
control panel display. The frequency of feed water addition is dependent on the gas
delivery demand and the rate of electrolysis. The feed water quality monitor should
be indicating an acceptable green-light condition for a minimum 200k-cm
resistivity.
The Hydrogen in oxygen temperature rise should be less than 90C when the
generator is operating and delivering gas at or near full capacity. The temperature
rise will be significantly more when the system running at low demand. The
Hydrogen in oxygen sensor requires a constant 100 cc/min flow of oxygen.
At least one dryer pressure gauge should be at pressure during normal operation.
Dryer sequence status can be monitored by pressing the "Dryer Sequence" touch
switch on the main screen. Except for the 30 minute pressurizing period before
dryer switch, the screen shows the dryer purge valve open. The screen will also
indicate which dryer is on line and indicate when a dryer heater is on.
A data or log book should be assigned to the generator for documenting daily
operating data. This data should include at least the following:
 Date
 Time
 Generator elapsed time
 Production rate
 Pressures
 Temperatures
 H2 in O2 flow meter flow rate
 Dryer status
 Cooling water valve position
43
 DC current
 DC voltage
Any shutdown(s) should be recorded as well as any corrective actions. The
recorded data provides useful information for routine maintenance and general
diagnostics of operating problems. The information should be recorded on at least
a 24-hour interval.
4.7 Pressure Release
Generator operation can be stopped at any time by simply pressing the emergency
stop switch. To manually relieve system pressure, the pressure release switch must
be pressed (and confirmed). The touch screen will display the “Purge” and then
"Pressure Release" note on the bottom of the screen.
4.8 Shutdowns
The critical operating parameters of the HMXT generator are monitored to maintain
safe and reliable operation. There are many conditions that cause system
shutdown while running. Each shutdown condition is identified by a flashing
shutdown note on the display. Although the shutdown condition is known, the
actual cause may require additional investigation. Pressing the "Help" touch screen
on the shutdown screen provides possible causes for the specific shutdown
condition. Also, section 6 of this manual is provided as a troubleshooting guide for
determining the origin of a shutdown. The shutdown conditions are listed in Table
4-2 with the origin and the set point for the alarm as initially programmed.
44
Table 4-2 System Shutdowns

Alarm
Alarm or Warning Action Input Set Point
LOW KOH LEVEL ALARM Shut Down Pressure Release DPR2 6"
HIGH KOH LEVEL ALARM Shut Down Pressure Release DPR2 17.5"
KOH HIGH TEMP ALARM Shut Down Pressure Release TC2 or TC3 75°C
KOH LOW TEMP ALARM Shut Down Pressure Release TC1 5°C
HIGH AMBIENT TEMP ALARM Shut Down TC5 55°C
PT4-
DRYER 1 PRE-PRESSURE ALARM Shut Down PT3, PT4 PT3<15psig
DRYER 1 CYCLE ALARM Shut Down PT3, PT4 PT4>PT3
DRYER 1 PURGE ALARM Shut Down PT3, PT4 PT4>10psi
PT3-
DRYER 2 PRE-PRESSURE ALARM Shut Down PT3, PT4 PT4<15psig
DRYER 2 CYCLE ALARM Shut Down PT3, PT4 PT3>PT4
DRYER 2 PURGE ALARM Shut Down PT3, PT4 PT3>10psi
HIGH H2 IN O2 ALARM Shut Down Pressure Release TC4 200°C
DEOX TANK TEMP ALARM Shut Down Pressure Release TC6 200°C
PRE-PRESSURE ALARM Shut Down Pressure Release PT1
DIFF PRESSURE ALARM Shut Down Pressure Release DPT1 +/-10" H2O
SYSTEM PURGE ALARM Shut Down Pressure Release PT1
PRESSURE RELEASE ALARM Shut Down Pressure Release PT1
LOW H2 PRESSURE ALARM Shut Down PT1 80psig
HIGH H2 PRESSURE ALARM Shut Down Pressure Release PT1 170psig
LOW O2 PRESSURE ALARM Shut Down PT2 80psig
HIGH O2 PRESSURE ALARM Shut Down Pressure Release PT2 170psig
FEEDWATER QUALITY ALARM Shut Down RES1 5S
KOH LOW FLOW (H2) ALARM Shut Down Pressure Release FS1 3LPM
KOH LOW FLOW (O2)ALARM Shut Down Pressure Release FS2 3LPM
UNDERVOLT ALARM Shut Down Pressure Release PwrSply 130 VDC
LOSS OF POWER ALARM Shut Down Pressure Release PLC
POWER SUPPLY ALARM Shut Down Pressure Release PwrSply
UPS ON BATTERY POWER Shut Down Pressure Release UPS
UPS BATTERY LOW Shut Down UPS 25%
UPS FAULT Shut Down Pressure Release UPS
DEVICENET ERROR ALARM Shut Down Pressure Release
REMOTE ALARM - NO Shut Down Pressure Release closed
REMOTE ALARM - NC Shut Down Pressure Release open
HYGROMETER ALARM * Shut Down Pressure Release
TRACE O2 SENSOR ALARM * Shut Down Pressure Release
COMBUSTIBLE GAS SENSOR ALARM * Shut Down Pressure Release
*Optional Instrument
45
4.9 Emergency Stop Switch
The HMXT generator is equipped with an emergency stop switch located on the
front of the generator. When this button is depressed hydrogen generation is
stopped and all power is removed from the Module. Power is still supplied to the
control system to provide pressure control and purge and pressure release
control. If the button remains depressed for 5 seconds or more, an undervolt
alarm will occur. Pulling the button out resets the switch and restores power to
the generator. The generator will indicate a loss of power alarm. When this is
reset on the power supply the generator will run normally.
i Power is still supplied to the control system to provide

pressure control and purge and pressure release control.
46
5 MAINTENANCE AND CALIBRATION PROCEDURES
5.1 General
Regular scheduling of certain maintenance and calibration procedures is necessary to

assure a reliable and safe operating system. This section lists and describes the
maintenance and calibration procedures with which the operator should become familiar.
Some of the procedures that follow are diagnostic techniques that are used to troubleshoot
operational problems. Other procedures should be regularly scheduled for preventive
maintenance. A service interval is suggested for those procedures that are recommended
as part of the regular maintenance schedule. The maintenance schedule is summarized
in Table 5-1.
Table 5-1 Regular Maintenance Schedule
Interval Maintenance or Calibration Procedure Index Ref

Weekly Bubble Check for Gas Leaks 5.10.1
Check Nitrogen supply
1 Month (during Indoor storage only. Fill or top-off DI water in module

storage only) to make up for evaporative losses. 5.2.2
Every 3 Months Electrolyte Check (specific gravity) 5.2.3

(2000 Hrs) Hydrogen in Oxygen Temperature sensor Check 5.9.3
External Module Inspection 5.3.1
KOH Filter Cleaning or Replacement 5.5
Every 6 Months Electrolyte Change 5.2.2, 5.2.4

(4000 Hrs) Internal Module Inspection 5.3.2
Feed water Filter Replacement 5.6
Cooling Water Strainer Maintenance
Bellville Washer Check / Re-torque 5.3
12 Months Differential Pressure Regulator Inspection 5.8.3

(8000 Hrs) Check and Relief Valve Maintenance 5.8.4
Hydrogen in Oxygen Filter Tank Maintenance 5.9.2
KOH Flow Switch Check 5.12
Dryer Orifice Maintenance 5.15.1
Dryer Gas Filter Replacement 5.15.4
47
There are four general precautions that should be observed before working
on the system:
1. Always turn the electrical power off at the facility breaker. The AC to DC
power supply circuit breaker may still be on line when the system is turned
off at the power supply contactor control switch. A defective electrical part
could allow DC power into the gas generator with the unit turned off. Turn
off the UPS to shut off control power.
Ensure the unit has totally depressurized before turning

off the UPS. Failure to follow this procedure can damage
the module.
2. Allow the system to cool down to room temperature.
The electrolyte subsystem operates at elevated

temperatures that could cause burns.
3. Check that the system hydrogen and oxygen pressures are at zero.
Operational failures can occur which may trap gas in the system.
4. Adequate safety precautions should be observed when handling KOH.

The solution is harmful and a severe irritant to skin and eyes.
Subcomponent manuals may need to be utilized for trouble shooting individual

component problems. These manuals are found in the XM50000 CD included
with this bound manual.
5.2 Electrolyte
The interval of electrolyte change depends mainly on the quality of the feed water
supplied to the system. Acceptable electrolyte purity is based on feed water with a
minimum allowable electrical resistivity of 200k-cm at 25C (77F). If electrolyte
purity is not maintained, system fouling may result, leading to possible electrolysis
module damage. Checking the electrolyte specific gravity periodically is
recommended as a method of monitoring electrolyte concentration. If the specific
gravity is not within the allowable range, the electrolyte should be changed or the
concentration corrected.
Poor electrolyte quality can lead to module damage.
Monitor and maintain KOH per TESI suggested PM schedule
and specification.
48
The KOH used in the electrolyte solution must be the equivalent of a reagent grade
chemical. When mixed to a 30 weight percent solution, the electrolyte must have a
potassium carbonate (K2CO3) content of less than 0.6 weight percent and a total
iron and heavy metals content of less than 10 PPM. Generally, commercial or
industrial grades of KOH do not meet these requirements. Acceptable grades of
KOH are usually available as a 45 weight percent liquid or as 85 weight percent
pellets. The American Chemical Society (ACS) requirements for reagent
potassium hydroxide in the solid form are:
Table 5-2 KOH chemical specification (solid form)

Potassium hydroxide (KOH) Not less than 85.0%.
Potassium carbonate (K2CO3) Not more than 2.0%.
Chloride (Cl) Not more than 0.01%.
Nitrogen compounds (as N) Not more than 0.001%.
Phosphate (PO4) Not more than 5 PPM.
Sulfate (SO4) Not more than 0.003%.
Ammonium hydroxide precipitate Not more than 0.02%.
Heavy metals (as Ag) Not more than 0.001%.
Iron (Fe) Not more than 0.001%.
Nickel (Ni) Not more than 0.001%.
Sodium (Na) Not more than 0.05%.
At 45 weight percent the above requirements would translate into the following:
Table 5-3 KOH chemical specification at 45% by weight

Potassium hydroxide (KOH) Not less than 45.0%.
Potassium carbonate (K2CO3) Not more than 1.1%.
Chloride (Cl) Not more than 0.005%.
Nitrogen compounds (as N) Not more than 5 PPM.
Phosphate (PO4) Not more than 3 PPM.
Sulfate (SO4) Not more than 0.002%.
Ammonium hydroxide precipitate Not more than 0.011%.
Heavy metals (as Ag) Not more than 5 PPM.
Iron (Fe) Not more than 5 PPM.
Nickel (Ni) Not more than 5 PPM.
Sodium (Na) Not more than 0.026%.
i Containers of a suitable material must be used for

handling and storing KOH. Aluminum, zinc, brass,
bronze, copper, and glass are attacked by KOH and are
not suitable for use. Stainless steel or polypropylene
containers are recommended.
49
Adequate eye protection and rubber or plastic gloves

should be worn when handling KOH. Sufficient
ventilation should be available, particularly when
handling hot KOH, which can produce noxious fumes.
A safety shower and an emergency eye wash should be
conveniently located in the event of a major KOH spill. It
is recommended that a 5 to10 liter (1 to 3 gallons)
container of saturated boric acid solution be available for
emergency use on skin irritations. The solubility of boric
acid at room temperature is approximately 50 grams (35
cc) per liter of water. The boric acid solution may also
be used as a wash to neutralize KOH on components or
parts that have been removed and must be disposed of
properly.
50
5.2.1 Electrolyte Mixing
The HMXT system requires a 30 weight percent aqueous solution of KOH for
proper operation. The weight percentage of the freshly mixed electrolyte may vary
by two percent, from 29 to 31 percent. The equivalent specific gravity range at
20C (68F) is 1.275 to 1.300. When measuring the specific gravity, the
temperature of the solution must also be measured. The specific gravity of KOH
solution at various temperatures is listed in Table 5-4.
Table 5-4 Specific Gravity of KOH Solution at Various Temperatures

Wt.% 10oC 20oC 30oC 40oC 50oC 60oC
20 1.191 1.186 1.181 1.177 1.172 1.166
21 1.201 1.196 1.191 1.186 1.181 1.176
22 1.211 1.206 1.201 1.196 1.191 1.186
23 1.221 1.216 1.211 1.206 1.201 1.196
24 1.231 1.226 1.221 1.216 1.211 1.206
25 1.241 1.236 1.231 1.226 1.221 1.216
26 1.251 1.247 1.242 1.237 1.231 1.226
27 1.262 1.257 1.252 1.247 1.241 1.236
28 1.272 1.267 1.262 1.257 1.252 1.246
29 1.283 1.278 1.272 1.267 1.262 1.256
30 1.293 1.288 1.283 1.278 1.272 1.267
31 1.304 1.299 1.293 1.288 1.283 1.277
32 1.314 1.309 1.304 1.299 1.293 1.287
33 1.325 1.320 1.314 1.309 1.304 1.298
34 1.336 1.331 1.325 1.320 1.314 1.308
35 1.347 1.341 1.336 1.331 1.325 1.319
36 1.358 1.352 1.347 1.341 1.336 1.330
37 1.352 1.363 1.358 1.352 1.347 1.352
38 1.380 1.374 1.369 1.363 1.357 1.351
39 1.391 1.385 1.380 1.374 1.368 1.362
40 1.402 1.396 1.391 1.385 1.379 1.373
Diluting concentrated KOH to 30 wt % will require a container of stainless steel or

polypropylene for mixing. A hydrometer with a range of 1.100 to 1.400 and an
appropriate sampling container are required for determining the specific gravity. A
thermometer is needed to determine the temperature at which the specific gravity is
measured. The water used for mixing must be of a quality equivalent to the feed
water required for the system.
The required electrolyte volume for each of the various size HMXT systems is listed
below in Table 5-5. Also listed are the KOH and water quantities required to mix the
electrolyte volume from either the 45 wt % liquid or the 85 wt % solid. The 45 wt %
solution is diluted in a ratio of 0.73 liters of water per liter of 45 wt % KOH. The
51
solid KOH pellets are mixed in a ratio of 1.84 liters of water per kilogram of 85 wt %
KOH.
Table 5-5 Electrolyte Quantities

Electrolyte Volume 45 wt % Mix 85 wt % Mix
30 KOH Water KOH Water
wt %
HM Model Liters liters liters Kg liters
HMX-50 25 14.5 10.5 11.3 20.8
HMX-100 29 16.8 12.2 13.2 24.2
HMX-200 37 21.4 15.6 16.8 30.8
Heat will be produced when diluting concentrated KOH, particularly when solid
KOH pellets are used. Combine the two ingredients slowly, adding the KOH to the
water to prevent a violent reaction. It is recommended to mix with all but a small
amount of the required water quantity and allow this solution to cool. After cooling,
the concentration can be adjusted with water while measuring the specific gravity
until the required 30 wt % is obtained.
5.2.2 Electrolyte Fill
The HMXT is filled with electrolyte through the KOH reservoirs. The fill procedure
requires the proper 30 wt % solution of KOH.
Filling the system with electrolyte proceeds as follows:
1. Loosen the wing nut and remove the hinged Tri-Clover clamp securing the
cap to the top port of the oxygen separator.
2. Place a funnel in the top port of the reservoir.
3. Fill the system with the specified volume of 30 wt % electrolyte (see 5.2.1).
4. Remove the funnel. Check that the gasket on the reservoir port is in the
proper position. If the gasket has been damaged it must be replaced.
5. Replace the cap on the oxygen separator. Attach and hand tighten the
hinged Tri-Clover clamp.
5.2.3 Electrolyte Check
The specific gravity of the electrolyte should be periodically checked. Also at this
time, all the electrolyte plumbing should be inspected for any evidence of leaks. A
significant leak in a fitting or component will usually be obvious as evident by
wetness in the general area. A leak of this size should be attended to immediately
52
as the situation will only get worse with time. A less significant leak is evident by a
white crystalline deposit right at the source of the leak. This potassium carbonate
deposit is a result of a very small KOH discharge. The condition is not serious but
should be corrected during the next scheduled maintenance period.
The procedure for checking the electrolyte specific gravity requires a container that
will hold a one-half liter sample and also accommodate the hydrometer. The
hydrometer must have a range of 1.100 to 1.400. A thermometer will be needed.
A funnel and a short drain line with a 3/8-inch Swagelok fitting are also required.
The procedure is as follows:
1. Release all gas pressure from the system before opening the reservoir.
Do not open the Tri-Clover fitting when there is

pressure in the system.
cap on the oxygen separator. Remove the cap.
3. Attach the drain line to the KOH drain port located in the lower rear of the
unit.
4. Using the drain valve (HV1), remove approximately 500 cc of electrolyte.
5. Measure and record the specific gravity and temperature of the electrolyte
sample.
6. Return the electrolyte sample to the reservoir through a funnel placed in
the reservoir top port.
7. Remove the funnel. Check that the gasket on the reservoir port is in the
proper position. If the gasket has been damaged it must be replaced.
8. Replace the cap on the oxygen separator. Attach and hand-tighten the
hinged Tri-Clover clamp.
The KOH weight percentage of an electrolyte sample from an operating system
may vary by 4 percent, from 28 to 32 percent. The equivalent specific gravity range
at 20C (68F) is 1.267 to 1.309. Table 5-4 can be used to determine acceptable
specific gravities measured at other temperatures. If the specific gravity is not
within the allowable range, the electrolyte must be drained and replaced or
adjusted. Table 5-6 provides a guide for adjusting an out of tolerance solution.
Mixing ratios and quantities to produce 1 liter are listed for mixing a 30% solution by
either diluting a concentrated solution or increasing the concentration of a weak
solution.
53
Table 5-6 Mixing Ratios and Quantities for Producing 30% Solution
Diluting Concentrated Solution with Water
To produce 1 liter
of solution use:
Existing Mixing Ratio cc cc
KOH % cc Water/cc Existing Existing Water
31 0.043 958.5 41.5
32 0.087 919.7 80.3
33 0.132 883.4 116.6
34 0.177 849.3 150.7
35 0.224 817.3 182.7
36 0.270 787.2 212.8
37 0.318 758.7 241.3
38 0.366 731.9 268.1
39 0.416 706.5 293.5
40 0.465 682.4 317.6
Increasing Concentration with 45% KOH

To produce 1 liter
of solution use:
Existing Mixing Ratio cc cc
KOH % cc KOH/cc Existing Existing KOH
15 0.784 560.5 439.5
20 0.545 647.1 352.9
21 0.495 668.9 331.1
22 0.444 692.7 307.3
23 0.391 718.7 281.3
24 0.338 747.3 252.7
25 0.284 778.7 221.3
26 0.229 813.4 186.6
27 0.173 852.2 147.8
28 0.126 888.3 111.7
29 0.059 944.5 55.5
54
Increasing Concentration with 85% KOH

To produce 1 liter
of solution use:
Mixing Ratio
Existing cc grams
grams KOH /cc
KOH % Existing 85%
Existing
15 0.310 890.1 275.5
20 0.215 918.9 197.8
21 0.195 925.5 180.8
22 0.175 932.4 163.3
23 0.154 939.6 145.2
24 0.134 947.2 126.5
25 0.112 955.2 107.1
26 0.091 962.9 87.2
27 0.068 971.7 66.5
28 0.050 909.1 45.1
29 0.023 989.8 23.0
5.2.4 Electrolyte Drain
Do not attempt to drain the system with a positive

pressure in the system.
Using a drain line with a 3/8 Swagelok fitting, drain the system as follows:
1. Attach the drain line to the KOH drain port located in the lower rear of the
unit.
2. Using the drain valve (HV1), slowly begin draining the electrolyte.
There still may be some pressure in the system.
3. When the electrolyte stops flowing freely (a partial vacuum has

developed), close the drain valve.
cap on the oxygen separator. Carefully remove the cap on the oxygen
separator.
5. Open the drain valve to allow the electrolyte to start draining again.
6. After completely draining the system close the drain valve and remove the
drain line.
55
5.3 Module Inspection
Periodic inspection of the electrolysis module is recommended as a means of

monitoring module integrity and performing preventive maintenance for longer
module life. The three procedures that are described here are included in the
regular maintenance schedule. The external inspection is a simple procedure that
should be performed frequently. The module must be drained for the internal
module inspection, so it is convenient to schedule this procedure during the
electrolyte change.
5.3.1 External Inspection
Before proceeding, be sure there is no pressure on the generator. Turn off the
power to the generator at the facility breaker. The outside of the module should be
inspected for the presence of any white crystalline deposits. These potassium
carbonate deposits are a result of a minor KOH discharge. The condition is not
serious but should be corrected. Remove the deposits by wiping the outside of the
module with a boric acid solution followed by distilled or deionized water.
Thoroughly dry the module. After cleaning, the compression and the tie rod
resistance of the module should be checked using the procedures outline below.
The power cable connections to the module end plates should be removed and
inspected. Clean the contact surface of the end plates and the connector lugs with
sandpaper or similar material to remove any oxide layer. Examine the area where
the lug is attached to cable for evidence of corrosion. If required, clean these
surfaces. Reinstall the cable lugs to the end plates and tighten the set screws if
required.
The electrical resistance between each tie rod and the end plate should be checked
to be sure the tie rod insulation is adequate. A megohmmeter operating at 250V
minimum (1000 V maximum) is required to make this measurement. Attach one
lead of the megohmmeter to either end plate. Remove the protective cap on each
tie rod end and measure the resistance. The electrical resistance of each tie rod to
the module end plate should be greater than 50 M. If a tie rod fails this
requirement, the insulating washers must be removed and cleaned or replaced.
i Only remove and replace washers from one tie rod at a

time.
Re-torque the tie rod following the re-torque procedure (5.3.3) before loosening
another. If one or more tie rods are loosened for servicing, the compression of the
module should be checked using the module re-torquing procedure.
56
5.3.2 Internal Inspection
While the system is operating, impurities from the feed water may begin to deposit
in the KOH ports of the negative end plate. If the deposits become large, they may
dislodge into the inlet manifold of the module. Periodically, the inside of the module
should be inspected for accumulation of these deposits and cleaned out if
necessary.
The system must first be drained of KOH. After draining, be sure the power has
been turned off at the facility breaker. Remove the KOH outlet piping to the
electrolysis module. The outlet pipe runs from the module endplate to the KOH
reservoirs. Remove the tube from the hydrogen outlet fitting.
Using a flashlight, inspect the module outlet end plate ports. If a deposit is present
at the ports, clean this area using a soft absorbent cloth over a rubber-gloved finger
or a soft round bristled brush. Avoid pushing the material into the module manifold.
Inspect the O-ring in the each of the fittings before reinstalling the KOH piping.
Replace the O-ring if it is cut or deformed. After reinstalling the KOH piping,
thoroughly clean and dry the module as outlined in the external inspection
procedure.
5.3.3 Re-torque Procedure
The module compression should be checked as part of the 6 month regular

maintenance schedule and following any service work in which a tie rod has
been loosened. Before proceeding, be sure there is no pressure on the generator
and that the module is cool. Turn off the power to the generator at the facility
breaker. A deep well socket with a 3/8-inch drive is provided with the generator
for tie rod tightening. A Belleville washer gauge is provided (ES-XM70029-001)
to confirm the Belleville washer stack height. The Belleville washer gauge is
placed on the washers between the two insulators. If the gauge fit is loose, the tie
rod should be tightened. Using the socket and a wrench, tighten the nut one
quarter turn at the Belleville washer stack while holding the nut at the opposite
end of the tie rod. Insert the gauge and the gauge should not fit. If the gauge fit is
loose, tighten an additional one quarter turn. Photos 1 and 2 show the gauge
position when a tie rod needs tightening or is acceptable. Proceed to the next tie
rod once the gauge no longer fits. Each tie rod should be checked in sequence
as shown in Figure 5-2: Tie rod torquing sequence (positive endplate).
57
Figure 5-1: Belleville washer stacking pattern (positive endplate)
Gauge Distance
Bellville Washer Stack
54.107mm (2.130")
Insulator
Insulator
Figure 5-2: Tie rod torquing sequence (positive endplate)
2
5 8
3 4
7 6
1
i Distance should be fairly constant for all eight tie rods
58
Photo 1: Gap between Belleville Washer Gauge and insulators: need to

tighten stack.
Photo 2: Belleville Washer Gauge does not fit; compression is acceptable.
59
5.4 Cross Leak Check
The cross leak check is a diagnostic procedure used to determine the extent and
location of a suspected hydrogen to oxygen cross leak. This procedure is not part
of any regular maintenance and is recommended to be done only when there is a
suspected problem. A cross leak can occur in the electrolysis module. The
procedure requires a supply of inert gas, such as nitrogen, as a low pressure
source.
The cross leak check proceeds as follows:
1. Drain the system using the electrolyte drain procedure.

2. Temporarily remove the KOH inlet lines from the lower connections.
3. Temporarily remove the KOH outlet lines from the module.
4. Plug the inlet tubes.
5. Slowly fill the oxygen side with DI water.
6. Install the outlet fitting test adaptors.
7. Run a flexible tube from the oxygen outlet to a container filled with
approximately 15 liters of DI water and submerge the end of the tube in
the water.
8. Slowly pressurize the hydrogen side with 1 psig (0.07kg/m2) of inert gas.
9. Allow 10 minutes for gas from a module leak to bubble from the tube of
the oxygen side. If gas flow is observed, measure the flow rate to
determine the extent of the leak. This measurement can be made by
simply measuring the water displaced in an inverted graduate over a
specific time interval.
10. After checking for leaks, remove the plastic tubes, reconnect the KOH inlet
and outlet lines, drain the DI water and refill the system with electrolyte.
5.5 KOH Filter Replacement
The electrolyte filter elements should be changed or cleaned every 3 months,

coinciding with the recommended electrolyte change. The elements are located in
the bottom of the Separator tanks. The procedure for changing the KOH filter
element is as follows:
60
2. Place a plastic basin or tub under the bottom of the separator tanks and
the KOH pump head large enough to fit the piping run between the two.
Loosen and remove the large nut on the CPV fitting on the inlet to the
KOH pump. Loosen the wing nut and remove the hinged Tri-Clover
clamps securing the KOH filter assembly to the bottom port of the tanks.
Carefully remove the filter assemblies from the reservoirs.
3. Refer to the parts diagram, Figure 5-3 KOH Filter. Remove the nut,
washers, and center locating retainer from the center shaft. Remove and
clean or discard the filter element.
4. Install a new or cleaned filter element with new EPT gaskets. Install the
center retainer, washers, and nut. Tighten the nut.
5. Inspect the gasket for the bottom reservoir fitting and the O-ring for the
pump inlet fitting. If the gasket or O-ring has been damaged it must be
replaced.
6. Reposition the filter assembly into the reservoirs. Position the pump inlet
fitting and tighten the CPV fitting nut. Attach and hand-tighten the hinged
Tri-Clover clamps.
61
Figure 5-3 KOH Filter
62
5.6 Feed water Filter Replacement
The feed water filter is located outside of the gas generator cabinet on the plumbing
service panel. Figure 5-4 shows parts of the filter.
The procedure for changing the element is as follows:
1. After turning off the feed water supply, drain the filter by opening the plug
at the bottom of the filter bowl.
2. Remove the tie nut supporting the bowl and remove the bowl.
3. Slide the element retainer off the tie rod. Remove and discard the filter
element.
4. Place a new filter element over the centering boss in the head of the
housing and slide the element retainer onto the tie rod.
5. Place the bowl and the head O-ring against the filter head and thread the
hex nut with O-ring onto the tie rod. Finger-tighten the tie nut
approximately one turn after the O-rings have begun to compress.
Be sure the feed water pump is primed as described in the priming procedure
before starting the system.
Figure 5-4 Feed water Filter
MODEL 58P
125 PSIGRATING
MAX.PRESSURE AT 125 F
FLOW
BALSTON FLOW
FILTER ASSEMBLY
P/N M14195-009
1 Item
1 Bowl
2 Filter Element
3
3 Tie Nut
4 Plug
5 Head
4
63

than 30 seconds.
5.7 KOH Pump Inspection
It is recommended that the KOH pump be periodically inspected for wear. The
procedure requires complete disassembly of the pump and is most conveniently
scheduled during the electrolyte change. Pump inspection may also be necessary
if operational problems within the pump are suspected.
The procedure for removing and disassembling the KOH pump for inspection is
listed below. Refer to the parts diagram, Figure 5-5.

2. Remove the KOH filter assemblies as described in the KOH filter
replacement procedure.
3. Loosen the CPV fitting on the pump outlet.
4. Remove the four screws holding the connecting bracket to the pump
motor. Separate the connecting bracket from the pump motor and remove
the pump housing with the connecting bracket from the generator.
Considerable resistance will be felt when separating the magnetic
coupling between the drive and driven magnets.
5. Place the connecting bracket and pump head assembly on a flat surface,
laying the motor connecting flange of the connecting bracket down flat on
the surface.
6. Remove the 6 screws from the pump head and carefully remove the pump
head. The bonded spindle assembly is attached to the head and is easily
broken.
7. The bonded spindle assembly is connected to the pump head using a left-
hand threaded insert. Rotate the hex head on the insert clockwise to
remove the spindle.
The pump is now apart and can be inspected for excessive wear. Check the
impeller bushing for wear on the thrust bearing surface and within the internal
diameter of the bushing. Check that the bond on the spindle assembly is tight.
Replace any broken or excessively worn parts.
The assembly and reinstallation procedure for the KOH pump is the reverse of the
steps listed above. The spindle assembly can be tightened into the pump head by
64
using a 3/4-inch (19 mm) socket slipped over the spindle and tightening by hand.
Inspect the rubber O-ring for the pump housing before reinstalling and replace if
defective. Also inspect the O-ring seals in the inlet and outlet CPV fittings and
replace if either is cut or deformed. Tighten the 6 pump head screws to 50 inch
pounds (6 Nm). Be careful when reassembling the connecting bracket to the pump
motor. The motor and connecting bracket may bang together from the force of the
magnetic coupling. Tighten the 4 bracket connection screws to 75 inch pounds (8.5
Nm).
65
Figure 5-5 KOH Pump
5.8 Valve and Regulator Maintenance And Calibration
There are several different valves and regulators used in the HMXT system.
Regularly scheduled inspection and maintenance is recommended only for the
differential pressure regulators. Procedures for the remaining valves and regulators
are used when required as a result of operational problems or component failure.
66
5.8.1 Solenoid Valves
The majority of the solenoid valves in the system are constructed of stainless
steel and are a 2-way normally closed (without power) design. These include:
the feed water add valves (SV1), the vent valve (SV2,), the dryer purge and vent
valves (SV4, SV5) and the nitrogen purge valve (SV6).
The H2 in O2 purge valve (SV9) is a stainless steel 3-way solenoid valve. When
this valve is energized, flow is diverted from the exhaust port to the outlet.
The condenser cooling water valve (SV3) is constructed of brass and is a 2-way
normally closed valve. It differs from the other solenoid valves in the system due
to the diaphragm arrangement.
Replacement coils are available for all the solenoid valves. The valve coil is easily
replaced with the valve remaining in line. A repair kit is available to rebuild each
solenoid valve. The internal core, gaskets, and springs can be replaced to restore
a defective valve to working condition.
Both the stainless steel and brass solenoid valves are similar in construction and in
the procedure for repair. Figure 5-6 and Figure 5-7 show the parts and assembly
sequence for these valves. To replace a coil, first remove the top on the junction
box and disconnect the electrical connections. Remove the retaining clip and lift off
the complete solenoid assembly. Replace the solenoid assembly on the valve,
rewire to the electrical connections, and replace the top on the junction box.
67
Figure 5-6 Normally Closed Solenoid Valve
i The valve body (item 10) may look different from the
above sketch.
68
Figure 5-7 Condenser Water Solenoid Valve
69
Inspecting and rebuilding a solenoid valve requires removing the valve from the
system. Remove the top on the junction box and disconnect the electrical
connections. Remove the retaining clip and lift off the complete solenoid assembly.
Loosen the Swagelok fittings and remove the valve from its location. Loosen the
solenoid base using a wrench on the hex shaped shoulder and remove the
subassembly. The internal parts of the valve can now be inspected. Valve SV3
also includes a valve bonnet held down by four screws. To inspect the diaphragm
subassembly, remove the screws and the bonnet.
Clean and inspect all the internal parts. If there is any evidence of KOH or
potassium carbonate (white crystalline deposits), clean the valve body and the
parts with a boric acid solution followed by distilled or deionized water. If any part is
found defective, it is recommended to replace all the parts that are available in the
spare parts kit.
Prior to reinstalling the valve, check for operation and leakage. Connect live
electrical power to the terminals in the junction box and listen for a metallic click that
indicates that the solenoid is operating. Apply a 100 psig (7.0 kg/cm2) gas source
at the valve inlet port and check for leakage with the valve closed. The valve will
leak if an internal part is defective or the parts have not been reassembled in the
correct sequence.
After reinstalling the regulators in the system, check for proper operation and
leakage during system operation. As the system begins to generate gas and
system pressure rises, the pressure differential should remain less than 10” of
water. After the system is in the run mode, check each regulator for external leaks
using a liquid leak detector solution or soap solution.
5.8.2 Back Pressure Regulators
5.8.2.1 Regulator Adjustment

There are 3 back pressure regulators (BPRs) on the HMXT generator. Periodic
adjustment may be necessary to maintain the correct set point. This adjustment
should be done when the generator is running in automatic with H2 gas going to
delivery.
BPR 1 Instructions:
Open BPR 2 (turning counterclockwise) slowly until the online dryer pressure
drops to less than 80 psig (5.6 kg/cm2). Observe System Pressure (H2) and
then adjust BPR 1 for to 130 psig (9.1 kg/cm2). Make adjustments to all BPRs
in very small increments. Allow a few minutes for system pressure to stabilize.
70
BPR 2 Instructions:
Adjust BPR 2 to 140 psig (9.8 kg/cm2). . Allow a few minutes for system
pressure to stabilize.
BPR 3 Instructions:
Close the H2 delivery valve. The system should increase above 150psig (10.5
kg/cm2) . The generator should decrease gas production to minimum. Allow time
for the generator pressure to stabilize. Adjust BPR 3 to 160 psig (11.2 kg/cm2)
while the generator production rate is in minimum.
Open the delivery line (slowly to prevent a delta P or KOH level alarm) and
resume normal operation.
5.8.2.2 BPR Repair

The back pressure regulators BPR1, BPR2 and BPR3 are identical. A spare parts
kit is available for rebuilding the back pressure regulators. If a regulator is
defective, it should be removed for repair or replacement.
The procedure for removal and repair is listed below. Refer to the parts diagram,
Figure 5-8.
1. Remove the hand knob by turning it all the way out.

2. Disconnect the Swagelok fittings on the regulator and remove the
regulator.
3. Loosen the bonnet ring using a 2-inch wrench. Remove the bonnet ring.
The internal parts of the regulator can now be inspected.
4. The diaphragm subassembly can be disassembled by removing the
threaded diaphragm button from the diaphragm backup washer.
5. The stem O-ring is removed from the diaphragm button after removing the
retaining ring.
6. The valve seat is removed by unthreading the seat retainer from the
regulator body using a large screwdriver.
7. Clean and inspect all the internal parts. If there is any evidence of KOH or
potassium carbonate (white crystalline deposits), clean the regulator body
and all the parts with a boric acid solution followed by distilled or deionized
water.
8. Replace all the parts available in the spare parts kit.
71
Figure 5-8 Back Pressure Regulator
72
The assembly and reinstallation procedure for the back pressure regulator is the
reverse of the steps listed above. The valve seat is installed with its chamfered
side towards the diaphragm assembly. The threaded bonnet ring should be
tightened to 50-55 foot-pounds (68 - 75 Nm).
Adjustment of the back pressure regulators is made with the system running at
operating temperature. Turning the knob clockwise raises the set point and counter-
clockwise lowers the set point.
5.8.3 Differential Pressure Regulator
Adjustment and maintenance of the differential pressure regulator can be

categorized in two parts; actuator and valve. The actuator is a 24 VDC powered
electric motor with a NEMA II classified enclosure. Troubleshooting the
differential pressure can be performed with the following steps:
1. Remove the cover of the actuator

2. Observe the color of the LED. A red LED indicates an problem with the
actuator and a green light indicates proper function.
Status
LED
Manual
Override
Hex S1 Test
Wrenches
Button
S2
Adaptation
Button
3. If the previous steps do not resolve a problem with the actuator, contact
TESI for further instruction. The valve was designed for ease of
73
maintenance. All parts of the valve assembly can be serviced or inter-

changed. If a leakage is noted from the valve please follow the directions
outlined in Appendix A for trim set and packing replacement.
5.8.4 Check Valve and Relief Valve
The check valves and relief valves (RV1 and RV2) in the generator are both the
same type of spring loaded poppet valve. There is no routine maintenance for the
check valves. If a problem is suspected with a check valve, it must be replaced.
The relief valves in the generator (RV1) and also in the dryer system (RV2) are
simply adjustable versions of the check valve.
The relief valves should be periodically checked to assure that the 180 psig (12.65
kg/cm2) set point is maintained. The valve is best checked by removing it from the
system. After removing the valve slowly apply a pressurized gas source to the inlet
fitting on the valve and check for gas flow through the valve at 180 psig. If flow is
not evident at 180 psig or the valve opens at a lower pressure, then the valve must
be readjusted.
The procedure for adjustment follows:
1. Refer to Figure 5-9. Insert a 5/32-inch hex key wrench into the locking
screw at the valve outlet and loosen the locking screw.
2. Turn the locking screw until the hex key wrench slides through into the
adjusting screw.
3. Turn both screws until the 180 psig set point is reached. Turning
clockwise increases the set point.
4. Retract the hex key wrench into only the locking screw and lock it against
the adjusting screw.
5. Reinstall the relief valve in the system.
74
Figure 5-9 Relief Valve Assembly
5.9 Hydrogen in Oxygen Monitor Maintenance and Calibration
Accurate monitoring of hydrogen in oxygen requires a constant 100 cc per minute

flow rate of product oxygen through the probe. A regulator (FC1) reduces the
system pressure to a stable pressure between 5-10 psig. A flow meter (FM1) is
provided to monitor the flow rate and verify the accuracy of the flow controller
(FC1). Periodic replacement of the filter tank is necessary. Checking the sensitivity
of the temperature sensor (TC4) should also be included as part of the regular
maintenance schedule.
Under certain conditions, a concentration of hydrogen may accumulate in the

residual gas after system shutdown. During subsequent startup, venting of the high
concentration of hydrogen will cause a momentary high hydrogen in oxygen
temperature and may shut the system down. An immediate restart of the system
should be successful, if the condition persists, the possibility of module cross leak
should be investigated.
5.9.1 Flow Controller
The FC1 is forward pressure regulator set to provide a constant low pressure to
FM1 so the flow will remain constant without frequent adjustment.
If the flow controller is defective, it should be removed for repair or replacement.
75
With the system down and depressurized, remove the tube between FC1 and FM1.
Loosen the Swagelok™ fittings to the inlet of the controller and remove the unit.
All the parts within the controller are shown in Figure 5-10. To inspect the internal
parts, use a large wrench to unscrew and remove the bonnet ring. If there is any
evidence of KOH or potassium carbonate (white crystalline deposits), clean the
controller body and all the parts with a boric acid solution followed by distilled or
deionized water. If any part is found defective, it should be replaced.
There is a repair kit available for this regulator. Contact Teledyne Energy Systems
customer service.
The assembly and reinstallation procedure for the flow controller is the reverse of
the above procedure.
Figure 5-10 Flow Controller
5.9.2 Filter Tank
Periodic replacement of the filter tank is necessary if it restricts the flow to the flow
meter. Since the clamp over the filter tank helps support other components, it is
best to remove FC1 and any tubing on top of the filter before loosening the clamp
and replacing the filter.
5.9.3 Temperature Sensor
The hydrogen in oxygen temperature reading with the generator operating at or

near full capacity will be approximately 50C (122°F). The reading is affected by
76
both the hydrogen percentage and the gas flow rate. The probe has been
calibrated with a known standard to provide a temperature rise of approximately
100C above ambient when there is 2% hydrogen in the oxygen.
A simple check of probe sensitivity should be made periodically. With the system
running, remove the cover over the metering value on the flow controller (FC1).
Using the hex key wrench, increase the oxygen flow rate through the controller and
monitor the temperature reading on the pyrometer. The temperature should begin
to rise, verifying that the catalyzed probe is still active. If there is no response, the
probe must be replaced. Readjust the flow controller so that the flow rate is 100
cc/min as measured by the flow meter (FM1). Replace the metering valve cover.
5.10 Leak Check
5.10.1 Bubble Check
A preventative maintenance schedule should be created to periodically check all

of the gas fittings and valves in the hydrogen plant for leaks. We recommend
that valves and fittings be leak checked once every week. Leak checks should be
done while the generator is operating or when pressurized with nitrogen. Simply
apply soapy water to the valves and fittings and inspecting for bubble formation.
Leaks found on compression fittings can be tightened while the system is

operating. If a valve’s packing or other type of fitting (o-ring sealed) is found to
leak, pressure must be taken off the valve or fitting in order to complete the
repair. Fittings should be hand tightened until snug and then tightened slightly
with a wrench. Ball valves with the following identification can be repaired in the
field: SS-43 (HV1, HV2, HV6, HV7) and SS-45 (MV1, MV2). Remove the
actuator (plastic handle or motorized actuator) and tighten the packing nut.
Reapply pressure to the valve or fitting and bubble check again for leaks. For
more serious pressure losses or after major maintenance, a system pressure test
should be performed.
5.10.2 System Pressure Test
The system pressure test is a diagnostic procedure that is used to verify system
integrity before the system is started. It is typically only performed at
commissioning, after a major repair or maintenance event when significant
plumbing and fittings have been disturbed (normally once a year), or if the system
is experiencing pressure loss issues.
The extent and location of a suspected gas leak on an operating system can be
determined by simply turning the power off, observing the pressure gauges, and
using a liquid leak detector or soap solution to locate the leak. The procedure listed
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below requires a source of pressurized inert gas such as nitrogen.
The pressure test proceeds as follows:
1. Drain the electrolyte following the Electrolyte drain procedure

2. Disconnect the hydrogen and oxygen vent lines at the bulkhead fittings on
the rear of the generator.
3. Using a Tee connection attach a single source of inert gas to the oxygen
and hydrogen bulkhead fittings on the rear of the generator.
4. Using a 3/16” (5mm) Hex wrench inserted in the top of the DPR1 Open the
valve by turning counter clockwise. The valve is open when the stem of the
valve has been raised .25” from the full down position
5. Repeat step 4 with DPR2.
6. Slowly apply nitrogen pressure until the pressure both the oxygen pressure
and hydrogen pressure gages read 100 psig, (7.0 kg/cm2).
7. Isolate the system by closing the nitrogen supply valve
8. If the pressure in the system drops use snoop to check fittings for leaks
Figure 5-11 Differential Pressure Regulators DPR1 & DPR2
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5.11 Pressure Transducer Calibration Check
The accuracy of the pressure transducer calibration must be checked using a very
accurately calibrated pressure gauge. The gas gauges inside the generator
assembly give an approximate indication of the system pressures and can be used
to determine a failed pressure transducer. However, these gauges should not be
relied on to check the pressure transducer calibration. The calibration procedure
requires a calibrated pressure gauge and a source of pressurized inert gas such as
nitrogen.
The pressure transducer calibration check is as follows:
1. Press the "Pressure Release" touch switch to release the system

pressure.
2. Remove the pressure transducer from the Swagelok™ tee in the
generator and hook it up to the pressure source with the calibrated gauge.
3. Press the “Generator” or “Dryer” button on the touch switch to display the
appropriate pressure transducer reading. With no pressure applied, the
transducer should read 0 psig +/- 2 psig.
4. Pressurize the transducer up to 150 psig. Compare the calibration gauge
reading with the pressure reading on the touch screen display. The
transducer should read 150 psig +/- 2 psig.
The pressure display reading should be within two psig of the calibration gauge
reading throughout the entire pressure range. A pressure transducer that fails the
calibration check must be replaced.
5.12 KOH Flow Switch Check
The KOH flow switch (FS1) is located in the KOH plumbing between the heat
exchanger and the electrolysis module. The flow switch is a vane-operated device
that is actuated by the flow of the KOH electrolyte. If the switch is suspected of
being defective, it should be removed to check that the vane is free to actuate.
flow switch assembly to the tee in the KOH plumbing.
3. Remove the flow switch and check that the vane is free to move.
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4. Check that Generator Display screen, FS1should turn green, when the
switch is manually actuated. If the vane is free to move but the switch
does not activate, the internal switch assembly can be replaced.
A parts diagram of the flow switch is shown in Figure 5-12. Note that the
alignment of the switch within the flow switch housing is critical.
5. Mark the orientation of the internal switch assembly before removing it

from the housing.
6. Loosen the set screw using an Allen head wrench and gently pull on the
wiring to remove the switch assembly.
7. After replacing the switch, reinstall the switch assembly to the original
orientation and tighten the set screw.
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Figure 5-12 Flow Switch
Check the flow switch actuation before replacing the flow switch in the system.
Check that the gasket on the Tri-Clover fitting is in the proper position. If the gasket
has been damaged it must be replaced. Insert the flow switch assembly into the
tee in the proper direction. An arrow engraved on the body of the flow switch
housing must be oriented in the direction of the electrolyte flow (towards the
module). Attach and hand-tighten the hinged Tri-Clover clamp.
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5.13 Feed water Pump Priming and Purging
The feed water pump should not be allowed to run dry for more than 30 seconds or
internal damage may occur. Priming the feed water pump assures that the pump is
supplied with water to prevent damage. This procedure is also used to purge the
feed water plumbing of inferior water after a low feed water resistivity shutdown
alarm. The cause of the inferior water must be corrected or the shutdown will be
reinstated.
Priming the feed water pump and feed water purging proceeds as follows:
1. Attach a drain line to the feed water drain port located in the lower rear of
the unit.
2. Open the feed water purge valve HV6.
3. Press and hold the "Manual Feed water Pump Switch" touch button on the
Feed water screen to manually run the pump. When water flows out of
the drain port, the pump has been primed. If the system is shutdown on
low feed water resistivity, allow the pump to run until R1 changes from red
to green.

than 30 seconds.
4. Close valve HV6 and remove the drain line.
5.14 Feed water Monitor Check
A feed water probe that is suspected of not indicating correctly should be removed
and checked. Turn off the feed water supply and open the feed water drain port to
drain the feed water plumbing. Remove the probe by unthreading it out of the
plastic tee. A dry probe in air should indicate green on the Feed water touch
screen. If not, the probe should be replaced.
To check that the probe responds, dip the end of the probe into a container of tap
water. The R1 indicator on the feed water screen should turn red. If not, the probe
should be replaced.
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5.15 Dryer Maintenance
Proper dryer regeneration requires an accurately controlled purge rate. The orifice
and check valves must be periodically removed and cleaned to assure the correct
purge rate is maintained. Components for controlling the dryer purge are all
arranged in a preassembled dryer purge control assembly, shown in Figure 5-13.
Removing the entire assembly provides the easiest access to the individual
components within the assembly.
Periodic replacement of the molecular sieve beads in the dryers is not necessary.
However, if misused, the beads can become saturated to a state in which complete
regeneration of a dryer is not possible. The dryers should then be repacked with
fresh molecular sieve. Monitoring product gas humidity will give the operator a
direct indication of the condition of the dryer beads. If the operator is not measuring
product gas humidity and is still concerned about maintaining minimum moisture
content, then periodic molecular sieve replacement is recommended.
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Figure 5-13 Dryer Purge Control Assembly
(4)
5.15.1 Orifice Maintenance
The dryer orifice is located in Figure 5-13 Dryer Purge Control Assembly adjacent
to the dryers. The orifice connects the output plumbing of the two dryers just below
the dryer filters. To service the orifice, first remove the dryer purge control
assembly. The orifice is in the union fitting connecting the two tees at the filter
outlets. Remove and inspect the orifice fitting. Clean the orifice and the
interconnecting tubing. After cleaning, reassemble all the parts of the assembly
and reinstall in the system.
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Figure 5-14 Dryer Check Valve
5.15.2 Check Valve Maintenance
The check valves which follow the dryer filters (CV7 and CV8) should be serviced
once a year or sooner if a problem is suspected. The yearly service interval allows
the dryer check valves to be cleaned and repaired at the same time the dryer filters
are replaced. After removing the dryer purge control assembly (Figure 5-13), the
valves can be removed for service. Two special tools, an adjusting tool and a nut
driver, are supplied for servicing the check valves. Figure 5-14 shows all the parts
of the check valve.
The cleaning and repair procedure for all of the check valves is as follows:
1. Fit the adjusting tool over the spring guide (3-fingered spider) in the outlet
end of the valve. Place the nut driver inside the adjusting tool, loosen, and
remove the lock nut.
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2. Insert a screwdriver into the slot in the head of the poppet and use the
adjusting tool to remove the spring guide.
3. Remove the spring and poppet.
4. Clean and inspect all the parts. If there is any evidence of KOH or
potassium carbonate (white crystalline deposits) clean all the parts with a
boric acid solution followed by distilled or deionized water.
5. The "Q" ring under the poppet head and the valve spring are available as
replacement parts and should be replaced.
The assembly of the check valve is the reverse of the steps listed above. One side
of the spring guide has a recess on each finger of the spider to center the spring.
The threaded stem of the poppet should be exposed about 1/16 of an inch (1.6
mm) after the lock nut is in place. This will result in a cracking pressure of about 1
psig (0.07 kg/cm2).
5.15.3 Molecular Sieve Change
The dryers must be removed from the system to change the molecular sieve beads
and de-ox catalyst pellets. Before removing, ensure that the internal pressures are
reduced to atmospheric and that dryers are cool. Remove the orifice/filter
assembly from the Swagelok™ tees near the top of the dryers. Disconnect the
tees from the dryers and loosen the Swagelok™ fittings at the bottom inlet port of
the dryers. Remove the protective cover over the heater terminals and disconnect
the electrical leads. Loosen the clamps securing the dryers to the frame assembly
and lift the dryers out of the system.
Refilling a hydrogen dryer requires approximately 14-15 pounds (6.5 kg) of

molecular sieve and 1 pound (0.45 kg) of catalyst. The two materials are filled in
alternating layers. A 1000 ml graduate is required to measure the quantity of each
layer. When handling the molecular sieve beads, avoid contact with water. The
beads become very hot when wet.
The procedure for changing the molecular sieve is as follows:
1. Remove the one-inch fill port on the top of the dryer, invert the dryer, and
empty the contents.
2. Wash the interior of the dryer with clean water to remove dust and broken
beads. Allow the interior to dry before refilling.
3. Using an ohmmeter, check the continuity of the dryer heater. Also, check
that there are no electrical shorts between the heater and the dryer vessel.
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4. Pour 575 ml of molecular sieve into the dryer. The first layer of molecular
sieve should be poured in slowly with the dryer tilted at about 45 degrees.
Upright the dryer in a vertical position after the first layer is poured.
5. Pour 55 ml of catalyst in the dryer.
6. Keeping the dryer vertical, repeat the above two steps until 8 layers of
molecular sieve and 8 layers of catalyst have been added to the dryer.
7. Fill the remaining portion of the dryer with molecular sieve until the level is
3.5 inches (9 cm) below the upper edge of the fill port.
8. Apply two turns of Teflon pipe-sealant tape to the threads of the fill port
plug and install the plug.
Reinstalling the dryers in the system is the reverse of the removal procedure. Keep
the dryer in a vertical position at all times. When positioning, ensure that the small
support bracket welded to the dryer is resting on the rail assembly at the lower
dryer clamp.
5.15.4 Gas Filter Replacement
There is a product gas filter in the outlet plumbing of each dryer in the system.
These filters should be changed once a year or sooner if an acceptable product gas
delivery pressure cannot be maintained.
To replace the filters, first remove the dryer purge control assembly (
Figure 5-13). Remove and replace each filter. Reinstall the completed assembly
into the system and tighten all Swagelok connections.
5.16 Temperature Regulating Valve Check
Maintaining precise position control of the temperature regulating valve is crucial for
accurate cooling water control. The operation of the temperature regulating valve
can be monitored on "Cooling Water System" screen.
Accurate zero positioning of the valve can be checked when the electrolyte
temperature is below the operating control range and the valve position shown on
the touch screen is 0 % open. Verify that the valve is fully closed.
Close the facility cooling water valve. Restart the generator. As the temperature
increases, the valve will begin to open. When the valve position shown on the
touch screen reaches 100%, verify the valve is fully opened (allow for a time lag in
the valve). Slowly open the facility cooling water valve. After a few minutes, the
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temperature and valve position should stabilize.
5.17 Cooling Water Maintenance
Facility cooling water flows through the heat exchangers and condensers; hence,
the inside surfaces are subject to deposits that interfere with flow and heat
transfer. Because such conditions are strongly dependent on quality of the facility
cooling water, the maintenance interval for this procedure should be adjusted
accordingly.
Certain locations may be subject to poor water quality and it is highly

recommended that these sites have cooling water filters installed upstream of the
generator.
To remove the scaling on the heat exchangers the system must be OFF,
depressurized, and purged with nitrogen, since the hydrogen side will be opened.
Remove condenser and inspect the ports. Back flush through the water
connections. If the water ports indicate a lot of fouling, clean with a diluted nickel
scale remover solution. A 5% phosphoric acid or oxalic acid solution may be used.
When back flushing the units, do not heat the acid solution. Flush the condenser
with fresh water after cleaning.
If the KOH heat exchangers are dirty on the KOH side, they can be also be back-
flushed with DI water, however the acid solution should not be used.
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6 TROUBLESHOOTING GUIDE
The following troubleshooting guide is presented to provide the operator with possible causes and recommended action
for diagnosing and correcting system malfunctions. The guide references many of the maintenance and calibration
procedures described in Section 4. Subcomponent manuals may need to be utilized for trouble shooting individual
component problems. These manuals are found in the XM50000 CD included with this bound manual. The following
malfunctions are indicated by the touch screen display:
Indicator Possible Cause Corrective Action

LOW KOH LEVEL Feedwater supply restricted Check feedwater source and
supply plumbing
Feedwater pump not primed See feedwater pump priming procedure
Feedwater pump starter failure Check and replace feedwater motor
starter
Feedwater pump failure Check and replace feedwater pump or
motor
Level indicator (DPT1) defective Check and replace indicator.
Feedwater valve SV1 failure (CLOSED) See valve and regulator maintenance
and calibration; solenoid valves
Feedwater check valve CV1 or CV2 failure Check and replace feedwater check
valves
HIGH KOH LEVEL Reservoir overfilled See electroyle fill procedure
Level transmitter DPT2 defective Check, calibrate, or replace level
transmitter
Feedwater valve SV1 failure (OPEN) See valve and regulator maintenance
and calibration; solenoid valves
Motor contact sticking Replace contactor
LOW KOH TEMPERATURE ALARM Excessively cold Conditioned space required for
generator operation
KOH thermocouple (TC1) is defective Check and replace thermocouple.
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HIGH KOH TEMPERATURE Inadequate cooling water Check facility cooling water source and plumbing
Temperature regulating valve (MV1) failure (closed). Check ball valve and motor actuator.
Repair or replace as required.
KOH control thermocouple (TC1) defective Check and replace thermocouple
Module outlet thermocouple (TC2, TC3) defective Check and replace thermocouple
Clogged module preventing electrolyte circulation Contact TESI
HIGH AMBIENT TEMPERATURE Excessively hot Conditioned space required for generator operation
Ambient air thermocouple (TC5) defective Check and replace thermocouple.
PRE-PRESSURIZATION ALARM Clogged Orifice
(DRYER 1) Inspect and clean with boric acid & DI water
Do not use tools to open the orifice.
SV4 not closed Pressure test SV4.
Clean or replace SV4
MV2 leaking Pressure test MV2
Tighten packing
Pressure transducer fault Check connections to I/O module
Replace pressure transducer
Check valve failure Verify function of check valve
Replace check valve if failed
DRYER 1 CYCLE FAILURE 4-way dryer valve (MV2) failure. See valve and regulator maintenance
Verify connection between actuator and valve
Dryer pressure transducer (PT3 or PT4) defective. See pressure transducer calibration check
Dryer vent valve (SV4) failure See solenoid valve and regulator maintenance
Vent line blocked Open vent lines
DRYER 1 PURGE FAILURE Dryer vent valve (SV4) failure. See valve and regulator maintenance
Dryer pressure transducer (PT3 or PT4) defective See pressure transducer calibration check
90
PRE-PRESSURIZATION ALARM Clogged Orifice

(DRYER 2 ) Inspect and clean with boric acid & DI water
Do not use tools to open the orifice.
SV4 not closed Pressure test SV4.
Clean or replace SV4
MV2 leaking Pressure test MV2
Tighten packing
Pressure transducer fault Replace pressure transducer
Check valve failure Verify function of check valve
Replace check valve if failed
DRYER 2 CYCLE FAILURE 4-way dryer valve (MV2) failure. See valve and regulator maintenance
Verify connection between actuator and valve
Dryer pressure transducer (PT3 or PT4) defective. Replace defective pressure transducer(s)
Dryer vent valve (SV4) failure See solenoid valve and regulator maintenance
Vent line blocked Open vent lines
DRYER 2 PURGE FAILURE Dryer vent valve (SV4) failure. See valve and regulator maintenance
Dryer pressure transducer (PT3 or PT4) defective See pressure transducer calibration check
HIGH HYDROGEN IN OXYGEN High hydrogen concentration at start-up. See hydrogen in oxygen monitor maintenance
and calibration.
Not enough Purge Repeat purge
Hydrogen in oxygen flow rate incorrect See hydrogen in oxygen monitor maintenance
and calibration; flow controller. (80-100cc/s)
Hydrogen in oxygen catalyzed sensor (TC4)
defective See hydrogen in oxygen monitor maintenance
and calibration; temperature sensor.
Open or intermittent thermocouple circuit Check TC4; replace as necessary
Module is cross-leaking Perform module cross leak test.
Contact TESI
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HIGH DeOx FILTER TEMPERATURE Module cross leak See cross leak check.
Repeat Purge
Not enough Purge Repeat Purge
DeOx Filter thermocouple (TC6) defective
Check and replace thermocouple.
PRE-PRESSURE ALARM Differential pressure is unstable Check function of DPR1 or DPR2
Repair/replace as necessary
Solenoid valve malfunction Check function of SV2
Repair/replace component as necessary.
Relief valve malfunction Check function of RV1
Pressure does not increase when N2 is added Check function of BPR1 and BPR3
Defective check valve Check function of CV3, CV4, CV5, and CV6
Replace check valve as required
Low Nitrogen Pressure Supply proper Nitrogen pressure
HIGH DIFFERENTIAL PRESSURE Vent line blocked Open vent lines
Differential pressure regulator (DPR1 or DPR2) failure. differential pressure regulator manual
Module cross leak See cross leak check.
SYSTEM PURGE TIMEOUT ALARM Differential pressure is unstable Check function of DPR1 or DPR2
Solenoid valve malfunction Check function of SV2
Repair/replace component as necessary.
Relief valve malfunction Check function of RV1
Pressure does not increase when N2 is added Check function of BPR1 and BPR3
Defective check valve Check function of CV3, CV4, CV5, and CV6
Replace check valve as required
Low Nitrogen Pressure Supply proper Nitrogen pressure
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PRESSURE RELEASE ALARM Vent line is blocked Clear vent line

Low nitrogen pressure Provide adequate nitrogen pressure
LOW HYDROGEN PRESSURE Back pressure regulator (BPR1) setting is too low Adjust BPR1 to correct pressure
Gas plumbing leak See system pressure test procedure.
System vent valve (SV2) failure. See valve and regulator maintenance and
calibration; solenoid valves.
System relief valve (RV1) failure See valve and regulator maintenance and
calibration; relief valve.
Back pressure regulator failure See valve and regulator maintenance and
calibration; back pressure regulator.
Pressure transducer (PT1) defective Replace pressure transducer if faulty
Check connections to I/O module
HIGH HYDROGEN PRESSURE Hydrogen pressure transducer (PT1) defective See pressure transducer calibration check.
Hydrogen vent line blocked Open Hydrogen vent line.
BPR3 is set too high Adjust BPR3 to correct pressure
LOW OXYGEN PRESSURE Back pressure regulator (BPR1) setting is too low Adjust BPR1 to correct pressure
Gas plumbing leak See system pressure test procedure.
System vent valve (SV2) failure. See valve and regulator maintenance and
calibration; solenoid valves.
System relief valve (RV1) failure See valve and regulator maintenance and
calibration; relief valve.
Back pressure regulator failure See valve and regulator maintenance and
calibration; back pressure regulator.
Pressure transducer (PT1 or PT2)) defective Replace pressure transducer if faulty
HIGH OXYGEN PRESSURE Oxygen vent line blocked. Open oxygen vent line.
Oxygen pressure transducer (PT2) defective. Replace pressure transducer if faulty
93
LOW FEEDWATER RESISTANCE Poor quality feedwater See feedwater pump priming and purging.
Replace filters
Feed water monitor defective See feed water monitor check
of sensor and transmitter
KOH LOW FLOW (H2 SIDE) Electrolyte filter clogged See KOH filter replacement procedure
Electrolyte pump damaged See KOH pump inspection procedure
Electrolyte flow switch failure See KOH flow switch check
KOH pump contactor tripped or defective Check and replace KOH pump contactor
in power supply.
KOH LOW FLOW (O2 SIDE) Electrolyte filter clogged See KOH filter replacement procedure
ALARM
Electrolyte pump damaged See KOH pump inspection procedure
Electrolyte flow switch failure See KOH flow switch check
KOH pump contactor tripped or defective Check and replace KOH pump contactor
in power supply.
LOW VOLTAGE ALARM E-stop depressed Reset E-stop
Module tie rods shorted Inspect tie rods for indications of shorting
Contact TESI for repair/replacement module
Voltage input from power supply incorrect Contact TESI
LOSS OF POWER Momentary loss of power Restart generator
POWER SUPPLY ALARM Check power supply for cause See power supply manual
UPS IS RUNNING ON BATTERY Power loss Restore power to the power supply.
UPS LOW BATTERY Low battery Charge or replace UPS battery
UPS FAULT UPS has faulted See UPS users manual (power supply manual)
Contact TESI for further assistance.
DEVICENET ERROR Devicenet loop connections loose Check connections and tighten as necessary.
Resistor at end of loop is loose Check connections and tighten as necessary.
Component failure Replace failed component
NORMALLY OPEN REMOTE Customer supplied alarm Annunciator panel (if TESI supplied)
ALARM
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NORMALLY CLOSED REMOTE Customer supplied alarm Annunciator panel (if TESI supplied)
ALARM
HIGH MOISTURE ALARM* Dewpoint out of range (typically -20°C) Verify proper dryer function.
Dryer heater not functioning Check heater circuit and solid state relay.
DeOx tank not effective Dry or replace catalyst.
Molecular sieve not effective Replace sieve
Abnormally high cooling water or air temperature Improve site temperature condition
TRACE OXYGEN ALARM* Exceeded O2 threshold, typically 5ppm Purge trace O2 instrument
Failed oxygen sensor check O2 sensor, replace as necessary
COMBUSTIBLE GAS ALARM* Exceeded threshold of 50% LEL Check instrument calibration
There is a hydrogen leak Find and seal hydrogen leak
HIGH MOISTURE WARNING* Dryer heater not functioning Check heater circuit and solid state relay.
Molecular sieve not effective Replace sieve
Abnormally high cooling water or air temperature Improve site temperature condition
TRACE OXYGEN WARNING* Exceeded O2 threshold, typically 3ppm Purge trace O2 instrument
Failed oxygen sensor check O2 sensor, replace as necessary
COMBUSTIBLE GAS
WARNING* Exceeded threshold of 25% LEL Check instrument calibration
There is a hydrogen leak Find and seal hydrogen leak
LOW NITROGEN PRESSURE Low Supply Pressure Check supply pressure
Nitrogen regulator failure (FPR1) Adjust regulator or repair
Nitrogen pressure Transducer Failure (PT5) Replace pressure transducer
Check for loose I/O module connections
*Optional instruments
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The remaining malfunctions are not directly indicated and will not cause system shutdown. These problems are generally
not as severe as the preceding shutdowns. However, the symptoms should be recognized and the problem corrected.
Indicator Possible Cause Corrective Action

Power supply does not turn on Power supply main circuit breaker open. Reset circuit breaker.
Power supply start contactor defective. Check and replace contactor.
Power supply control circuit fuse open. Check and replace fuse.
Power supply temperature switch open. Allow power supply to cool off.
Generator does not start Programmable controller not in run mode Switch controller to run mode.
Program not installed in controller. Load program into RAM or install EEPROM.
No DC power for electrolysis Power supply on/off relay defective. Check and replace relay.
Power supply SCR fuse open. Check and replace fuse.
Power supply SCR or diode failure. Check and replace failed components.
Power supply control board failure. Check and replace control board.
Cannot produce full capacity Restriction in facility delivery line. Check facility delivery plumbing.
Temperature regulating valve (MV1) out of position. See temperature regulating valve check.
Temperature regulating valve (MV1) failure (open). Check ball valve and motor actuator and repair
or replace.
Power supply SCR fuse open. Check and replace fuse.
Power supply SCR or diode failure. Check and replace failed components.
Power supply control board failure. Check and replace control board.
KOH concentration incorrect. See electrolyte check procedure.
High voltage operation. KOH concentration incorrect. See electrolyte check procedure.
Module power cable connections defective. Clean and tighten cable connectors.
Voltmeter inaccurate. Check and replace voltmeter.
96
Abnormal differential pressure Vent line blocked. Open vent line.

Differential pressure regulator (DPR1 or DPR2) failure.
See differential pressure regulator Manual
A gas leak exists Check for gas leaks.
High Differential Pressure at start DPR2 or DPR1 Is wide open due to vacuum on Open Vent valve on DPR1to relive vacuum
up opposite side of system Allow sufficient time for DPR1 or DPR2 to fully
close before restarting
Check valves in nitrogen purge assembly are leaking. Check CV3,CV4,CV5, and CV6 for leaks and
repair as necessary.
If trouble still exists after applying the actions in the troubleshooting table above, please contact your local
representative or TESI at customer.support@teledynees.com . Include the following information with your request so
that we may help as quickly as possible:
 Generator serial number ( XM-###). This number is located on the gas connection panel at the rear of the
generator.
 Alarm(s) if they exist
 Description of issue
 Result of corrective actions described above
 Site location
 Other pertinent information such as recent maintenance performed or changes in site conditions.
Note that TESI normal business hours are 8-4:30 EST Monday-Friday.
97
7 OPTIONAL INSTRUMENTS
7.1 Instrument description
7.1.1 Introduction
A combustible gas detector, a hygrometer, or a trace oxygen analyzer can be added

to the generator as options. One, two or all of these instruments can be connected to
the generator. They each transmit a 4-20 mA signal and are wired directly to the
PLC. The data is then displayed on the touch screen of the generator. The data is
also compared with warning and alarm set points to initiate these if necessary.
7.1.2 Combustible Gas Detector
The combustible gas detector uses a catalytic bead sensor to monitor the presence
of hydrogen in the room. The sensor uses two alumina beads surrounded by
platinum wire and heated to a high operating temperature. One bead is catalyzed to
promote reaction with the combustible gas. The other bead does not react with
combustibles and serves as a reference. The two beads are placed in separate legs
of a wheatstone bridge circuit and are exposed to same conditions. The electrical
resistance of the catalyzed bead increases as the bead heats up in the presence of a
combustible gas. The output of the wheatstone bridge changes to signal the
combustible concentration. The sensor output is 4-20 milliamps corresponding to 0
to 100 percent of the lower explosion limit (LEL) of hydrogen in air. The combustible
gas detector is interlocked with the HM generator, shutting down the generator in the
event of a combustible alarm.
The combustible detector is calibrated with a hydrogen in air mixture. A calibration kit
with a calibration gas is available. More information on the sensor and the calibration
kit can be found in the manufacturer’s manuals.
7.1.3 Hygrometer
Moisture in the hydrogen product from the generator is monitored with an in-line
hygrometer. The hygrometer uses an aluminum oxide moisture sensor. Water
molecules which are absorbed on the oxide structure of the sensor affect the
electrical capacitance of the material. The amount of water absorbed is a function of
the vapor pressure of the gas being sampled which corresponds to electrical
impedance measured by the sensor. The sensor output is 4-20 milliamps
corresponding to -100° to 0° C dewpoint. The hygrometer can be interlocked with the
generator to shut down the generator in the event of a high-moisture alarm. More
information on the hygrometer can be found in the manufacturer’s manual.
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7.1.4 Trace Oxygen Analyzer
An oxygen analyzer is used to monitor trace amounts of oxygen in a sample of the

hydrogen before going to storage. The analyzer uses an electrolytic fuel cell which
produces an electrical output proportional to the amount of oxygen being consumed.
The instrument can be selected to operate within 2 different scale ranges. The
ranges are 0-25% and 0-10 ppm. The instrument output is 4-20 milliamps
corresponding to the full range of the selected scale. The oxygen analyzer can be
interlocked with the generator, shutting it down in the event of a trace oxygen alarm.
The analyzer can be calibrated with ambient air. LED readout on the instrument is
provided for local display. More information on the analyzer can be found in the
manufacturer’s manual.
7.2 Installation
7.2.1 Wiring
Refer to the individual instrument instruction manuals for installation and wiring
details. Individual instruments should be wired to the HMXT generator in accordance
to the schematic section of this manual.
7.3 Operation
7.3.1 General
The instruments each send signals to the PLC and the data is displayed on the touch
screen display. The PLC also compares the signals to previously set warning and
alarm set points. When activated the alarms will shut down the generator. The
instrument screens are accessed using touch buttons.
7.3.2 Instrument Operation
The manufacturers’ instruction manuals with the attachments provide operational

specifications for each of the instruments.
7.3.2.1 Combustible Detector

The combustible gas detector is a self-contained instrument. Calibration of the
instrument should be performed periodically. See the detector and the calibration kit
manual for instrument calibration procedures.
7.3.2.2 Hygrometer
The hygrometer is a self-contained instrument. Field calibration of the instrument is
not possible. See the hygrometer information sheet for factory calibration information.
99
Proper operation for the hygrometer requires a very small sample flow. To set or
verify a suitable flow rate, break the tubing connected downstream of the metering
valve (V013). Connect temporary tubing to the outlet of the valve and submerge the
other end of the tube in a container of water. Apply approximately 10 kg/cm2
pressure to the inlet of the hygrometer and watch for bubbles in the container. Adjust
the flow as necessary to achieve 1-2 bubbles per second and record the meter
reading on the valve (it should be near zero). Leave the valve at this setting and
reconnect the permanent plumbing. The valve setting should not be disturbed after
the check.
7.3.2.3 Trace Oxygen Analyzer

The oxygen analyzer requires a specific sample rate which is controlled at the local
analyzer panel. Set the flow rate to the 1 SCFH level on the flow meter. See the
instrument manual for the specific pressure requirements.
100
8 APPENDIX
1. Figure A-1 Gas System (XM50019 sheet 2)

2. Figure A-2 Liquid System (XM50019 sheet 3)
3. Figure A-3 Dryer System (XM50019 sheet 4)
4. Figure A-4 H2 and O2 Pressure System (XM50019 sheet 5)
5. HMXT Generator Spare Parts Lists XM50013
6. Spare parts request for quotation
7. Installation Drawing - XM21000
8. Piping and Instrumentation Drawing – XM21001
9. Field Wiring Diagram – XM38008
10. Electrical Schematic – XM30000
11. System Warranty
12. Product brochures (on compact disc only)
101

XM50000 HMXT Manual (30%KOH)

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TELEDYNE TITAN HMXT GENERATOR SERIES

Hydrogen/Oxygen Gas Systems

OPERATION AND MAINTENANCE MANUAL

HMXT HYDROGEN GAS SYSTEM

"These commodities, technology or software were exported from the United

United states law prohibits disposition of these commodities, technology or

Electrolysis of water is in principle a simple process. The equipment necessary

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

ALL FOREIGN CUSTOMERS AND REPRESENTATIVES

1. Notify Teledyne Energy Systems Inc. (Attention to Customer Service

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

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

1 System Safety ............................................................................................... 7

2 System Description ..................................................................................... 11

2.6.1 Pressure Transducers ................................................................................................ 18

3 Generator Installation ................................................................................ 31

3.5.4 Hydrogen and Oxygen Vents .................................................................................... 35

4 Generator Operation .................................................................................. 39

5 Maintenance and Calibration Procedures ................................................... 47

5.5 KOH Filter Replacement ........................................................................... 60

6 Troubleshooting Guide ............................................................................... 89

7 Optional Instruments ................................................................................. 98

7.2.1 Wiring ........................................................................................................................ 99

8 Appendix .................................................................................................. 101

Figure 3-1 Recommended Hydrogen Delivery Valve Configuration ............................................. 36

Table 3-1 HMXT Generator Input Requirements .......................................................................... 34

1.1 General Safety Guidelines

TESI has designed your equipment to eliminate as many hazards as possible

An item critical to user safety or equipment

1.2 Specific Hazards associated with the HMXT Hydrogen System

Hydrogen is a colorless and odorless gas that is extremely flammable. With as

In the event of a fire, the flow of hydrogen must be

Oxygen is a colorless and odorless gas. Alone, oxygen is not flammable,

1.2.3 Potassium Hydroxide (KOH)

 Safety goggles or a face shield

 Gloves resistant to KOH

 Clothing resistant to KOH

In addition to PPE, it is recommended to maintain a container of saturated boric

The HMXT Generator normal operating pressure is 147 psig

1.2.4 Compressed Nitrogen

Nitrogen is an inert, colorless, and odorless gas. While nitrogen is non-toxic, if it

1.2.5 Electrical Hazards

1.2.6 High Temperature

1.3 Safety Measures

1.3.1 Shields and Panels

Do not operate the generator with safety shields or panels

NEVER energize the module with the polycarbonate

1.3.2 Safety Devices

1.3.3 Plant design

1.3.4 Operator Training

1.3.5 Personal Protective Equipment

Safety glasses, goggles, and face shield

Appropriate clothing for the task performed

Major HMXT generator system components

Electrolysis of pure water is inefficient because water has a low ionization

4OH-  O2 + 2H2O + 4E-

and at the cathode

4H2O + 4E-  2H2 + 4OH-

the overall reaction is

The HMXT system uses an electrolyte, commonly referred to as KOH, which is a

The electrolyte is a strong caustic requiring specific

2.3 Electrolysis Module