PD-0100-0034

PD-0100-0034
REVISION A
HOGEN H SERIES
HYDROGEN GENERATOR
Installation & Operation Manual
==================== Hydrogen By Wire ======================

PROTON, HOGEN, Hydrogen by Wire, and Transforming EnergyTM are trademarks or registered trademarks of Proton Energy Systems, Inc.
2003 Proton Energy Systems, All Rights Reserved
HOGEN H Series Hydrogen Generator


Output:
2, 4, 6 NM3/Hour
Serial Number: ___________________
January 2007
Proton Energy Systems, Inc.
10 Technology Drive
Wallingford, CT 06492
(203) 949-8697
www.protonenergy.com
customerservice@protonenergy.com
SIC 3569-901
NAICS 333-999-8556
Gas Generating Equipment

Gas Generating Equipment
This document is the property of Proton Energy Systems, Inc. and is delivered on the express condition that it is
not to be disclosed, reproduced in whole or in part, or used for any purpose other than the operation and
servicing of the HOGEN H Series hydrogen generator without Proton Energy Systems, Inc written consent and
that no right is granted to disclose or so use any information contained in said document. This restriction does
not limit the right to use information obtained from another source.
PD-0100-0034 REV A
CONFIDENTIAL Do not copy
Page 2 of 90


INSTALLATION & OPERATION MANUAL
Prepared by
PROTON ENERGY SYSTEMS, INC.
CONTENTS
1
Introduction .......................................................................................................................................... 8
1.1
Key Definitions, Acronyms, and Abbreviations Used in this Document .................................. 10
1.2
General Description................................................................................................................... 11
1.3
Classification of the HOGEN Hydrogen Generator .................................................................. 12
1.4
Subsystems ................................................................................................................................ 13
1.4.1
Water and Oxygen Management Subsystem ................................................................... 13
1.4.2
Hydrogen Gas Management Subsystem .......................................................................... 14
1.4.3
Control and Power Distribution ....................................................................................... 14
1.5
Enclosure................................................................................................................................... 15
1.5.1
Fluids Enclosure .............................................................................................................. 15
1.5.2
Electrical Enclosure ......................................................................................................... 15
1.5.3
Enclosure Integrity........................................................................................................... 16
1.6
2
Product Specification ................................................................................................................ 17
Safety................................................................................................................................................... 19
2.1
General Information .................................................................................................................. 19
2.2
Using Hydrogen Gas ................................................................................................................. 19
2.3
References ................................................................................................................................. 20
Installation .......................................................................................................................................... 21
3.1
Top-Level Steps of Installation ................................................................................................. 22
3.2
Facility Air Ventilation Requirements ...................................................................................... 22
3.3
Operating Environment ............................................................................................................. 25
3.4
Site Preparation ......................................................................................................................... 25
3.5
Instructions on Unpacking the HOGEN Hydrogen Generator .................................................. 27
3.6
Lifting and Moving ................................................................................................................... 28
3.7
Anchoring Instructions .............................................................................................................. 30
3.8
Electrical Interfaces................................................................................................................... 31
3.8.1
Cabling Procedure............................................................................................................ 31
3.8.2
Remote Alarm Contact and Shutdown Connections........................................................ 34
3.9
Mechanical Interfaces................................................................................................................ 35
PD-0100-0034 REV A
Page 3 of 90

3.9.1
3.9.2
3.9.3
3.9.4
3.9.5
3.9.6
3.9.7
Physical Layout, Connections and Dimensions ............................................................... 36

Hydrogen Vent Interface.................................................................................................. 38
Vent Line Installation ...................................................................................................... 39
Product Hydrogen Interface ............................................................................................. 39
Air Dilution Interface and Integrated Oxygen Disposal .................................................. 40
Coolant Water Interfaces ................................................................................................. 41
Feed Water Interfaces ...................................................................................................... 43
3.10
Connecting the Cell Stack(s) ..................................................................................................... 46
3.11
Calibration Gas Cylinder Installation ........................................................................................ 51
3.12
Inlet and Exit (Optional) Air Filter Housing Installation .......................................................... 51
3.13
External Shroud Installation (Optional) .................................................................................... 55
3.14
Guard Bed Installation Instructions........................................................................................... 57
3.15
First Time Startup Instructions .................................................................................................. 58
3.15.1
High-Powered Connection Torque Requirements ........................................................... 58
3.16
Remote Monitoring Software Installation ................................................................................. 59
3.16.1
Network Specifications.................................................................................................... 62
3.16.2
Cabling............................................................................................................................. 62
3.17
Configuring the System for Network Interface ......................................................................... 63
3.17.1
Resetting Network Settings.............................................................................................. 63
3.18
LAN Installation........................................................................................................................ 66
3.18.1
PC Parameters.................................................................................................................. 66
3.18.2
LAN Configuration Instructions ...................................................................................... 67
3.18.3
Electrical Connections for LAN Installation.................................................................... 69
3.19
Remote Monitoring Setup ......................................................................................................... 69
3.19.1
Remote Software Monitoring Feature.............................................................................. 69
3.19.2
Data Logging Feature ...................................................................................................... 70
3.20
4
Remote Monitoring Upgrade Instructions ................................................................................. 72
Operation ............................................................................................................................................ 74
4.1
Operating Modes ....................................................................................................................... 74
4.1.1
Normal Mode................................................................................................................... 74
4.1.2
Service Mode ................................................................................................................... 74
4.1.3
Keys ................................................................................................................................. 74
4.2
Pre-Start Startup Instructions .................................................................................................... 75
4.3
Applying Power......................................................................................................................... 75
4.4
Control Panel............................................................................................................................. 76
4.5
Generating Hydrogen ................................................................................................................ 77
4.6
Manual Shutdown...................................................................................................................... 78
4.7
Automatic Shutdown................................................................................................................. 79
User Interface ..................................................................................................................................... 82

5.1.1
LCD Display Areas.......................................................................................................... 82
5.1.2
Display Screens................................................................................................................ 82
APPENDIX A: Options ....................................................................................................................... 83
PD-0100-0034 REV A
Page 4 of 90

6.1
Pressure Reducing Regulator Option ........................................................................................ 83
6.2
Coolant Isolation Kit Option (Installed) .................................................................................... 84
6.3
Dewpoint Transmitter Option.................................................................................................... 84
6.4
Backup Manifold Auto Crossover Option................................................................................. 85
6.5
Combustible Gas Sensor Assembly Option............................................................................... 85
6.6
Lab Purity Option...................................................................................................................... 86
6.7
StableFlowTM Performance Optimization Option...................................................................... 86
APPENDIX B: Installation Checklist.................................................................................................. 88
LIST OF FIGURES
Figure 1 HOGEN H Series Hydrogen Generator .......................................................................................... 8
Figure 2 HOGEN H Series Interface Connections....................................................................................... 11
Figure 3 HOGEN H Series Hydrogen Generator WOMS Piping and Instrumentation Document (P&ID). 13
Figure 4 HOGEN H Series Hydrogen Generator HGMS P&ID.................................................................. 14
Figure 5 HOGEN H Series Hydrogen Generator Interface Connections .................................................... 21
Figure 6 HOGEN H Series Hydrogen Generator Plan View for Installation .............................................. 26
Figure 7 Removing Bolt from the Shipping Beam ........................................................................................ 27
Figure 8 Additional Beam Location ............................................................................................................. 28
Figure 9 Removing Screws from Bottom Front Panel.................................................................................. 28
Figure 10 Removing Base Fastener Cover Plate ......................................................................................... 29
Figure 11 Lifting the Unit using a Forklift................................................................................................... 29
Figure 12 Anchoring Diagram ..................................................................................................................... 30
Figure 13 Anchoring Holes .......................................................................................................................... 30
Figure 14 Electrical Interface Locations ..................................................................................................... 31
Figure 15 Internal Power and Ground Connections.................................................................................... 32
Figure 16 HOGEN H Series Hydrogen Generator Electrical Interface Locations...................................... 33
Figure 17 Remote Alarm Relay Location ..................................................................................................... 34
Figure 18 Terminals to Wire External Contacts .......................................................................................... 35
Figure 19 TB 3 Location .............................................................................................................................. 35
Figure 20 Left Side View
Figure 22 Front View
Figure 21 Right Side View............................................................................. 36

Figure 23 3-D View .............................................................................. 36
Figure 24 HOGEN H Series Hydrogen Generator Interface Connections .................................................. 37

Figure 25 Condensate Drain Trap Flow ...................................................................................................... 39
Figure 26 Product Hydrogen Interfaces....................................................................................................... 40
Figure 27 Coolant Water Interfaces............................................................................................................. 41
Figure 28 TB 4 Location .............................................................................................................................. 42
PD-0100-0034 REV A
Page 5 of 90

Figure 29 TB4 Wiring Locations.................................................................................................................. 42
Figure 30 DI Water Feed Port ..................................................................................................................... 43
Figure 31 Water Feed Valve on Bulkhead ................................................................................................... 45
Figure 32 A200 Tank with Bungee Cord...................................................................................................... 46
Figure 33 Removing the Tie Wrap from the Cell Stack Outlet Fitting ......................................................... 47
Figure 34 Removing the Cap from the Cell Stack Outlet Fitting ................................................................. 47
Figure 35 Tightening the Outlet Fitting on Cell Stack A.............................................................................. 48
Figure 36 Cell Stack and Connection Locations .......................................................................................... 49
Figure 37 Calibration Gas Cylinder Installation ......................................................................................... 51
Figure 38 Filter Element .............................................................................................................................. 52
Figure 39 Removing the Screws ................................................................................................................... 52
Figure 40 Removing the Filter Retaining Clip ............................................................................................. 53
Figure 41 Filter Housing Installed on the HOGEN H Series Hydrogen Generator .................................... 53
Figure 42 Sliding Air Filter into Filter Housing .......................................................................................... 54
Figure 43 Reinstalling Filter Retaining Clip................................................................................................ 54
Figure 44 Installing Screws.......................................................................................................................... 55
Figure 45 Sliding External Shroud over Filter Housing .............................................................................. 55
Figure 46 Tightening Screw on Top of External Shroud.............................................................................. 56
Figure 47 Guard Bed Filter Cartridge and Housing ................................................................................... 57
Figure 48 Guard Bed Cartridge inside Guard Bed Housing ....................................................................... 57
Figure 49 Tightening the Filter Housing...................................................................................................... 58
Figure 50 First Screen in Installation Wizard.............................................................................................. 60
Figure 51 Second Screen in Installation Wizard .......................................................................................... 60
Figure 52 Installation of Software Screen.................................................................................................... 61
Figure 53 Installation Initializing Screen..................................................................................................... 61
Figure 54 Installation Completed Screen..................................................................................................... 62
Figure 55 Ethernet Cable Pinout ................................................................................................................. 63
Figure 56 Server IP Address Location ......................................................................................................... 64
Figure 57 Choosing Settings ........................................................................................................................ 64
Figure 58 Select Set Config Params............................................................................................................. 65
Figure 59 Configuration Parameters Menu ................................................................................................. 65
Figure 60 Remote Monitoring Wiring .......................................................................................................... 66
Figure 61 HCS Monitoring Folder Location................................................................................................ 67
Figure 62 Support Files Folder Location..................................................................................................... 68
Figure 63 MODBUS TCP Configuration.ini Location................................................................................. 68
PD-0100-0034 REV A
Page 6 of 90

Figure 64 IP Address Location .................................................................................................................... 69
Figure 65 Default Screen ............................................................................................................................. 70
Figure 66 Enable/Disable Switch for Data Logging Feature ...................................................................... 71
Figure 67 .CSV File Example....................................................................................................................... 71
Figure 68 Data Log Example in Excel ......................................................................................................... 71
Figure 69 Uninstall Wizard.......................................................................................................................... 72
Figure 70 System Uninstalling Software ...................................................................................................... 73
Figure 71 Uninstall Process Completed....................................................................................................... 73
Figure 72 Control Panel Overview .............................................................................................................. 74
Figure 73 LCD Display Areas...................................................................................................................... 82
Figure 74 Example Schematic of the Pressure Reducing Regulator ............................................................ 83
Figure 75 Coolant Isolation Option Installed .............................................................................................. 84
Figure 76 Dewpoint Transmitter.................................................................................................................. 84
Figure 77 Backup Manifold Auto Crossover................................................................................................ 85
Figure 78 Combustible Gas Sensor Assembly.............................................................................................. 85
Figure 79 Lab Purity Kit .............................................................................................................................. 86
Figure 80 StableFlow Process ..................................................................................................................... 87
LIST OF TABLES
Table 1 HOGEN H Series Specifications ..................................................................................................... 18
Table 2 HOGEN H Series Hydrogen Generator Interface Connections ...................................................... 21
Table 3 Electrical Interface Connections Reference Dimensions ................................................................ 33
Table 4 Materials to Avoid Contact with DI Water Feed............................................................................. 44
Table 5 Preferred Materials in Contact with DI Water Feed....................................................................... 44
Table 6 High-Powered Connection Torque Requirements........................................................................... 59
Table 7 Network Specifications .................................................................................................................... 62
Table 8 Standard Ethernet Cable Wiring Connections for Normal and Crossover Cables ......................... 62
Table 9 Controller Default Network Settings ............................................................................................... 63
Table 10 Recommended Computer Network Settings................................................................................... 63
Table 11 Error and Warning Codes ............................................................................................................. 81
Table 12 Pressure Drop Data for Pressure Reducing Regulator................................................................. 83
PD-0100-0034 REV A
Page 7 of 90

1 INTRODUCTION
The HOGEN H Series industrial hydrogen generator (see Figure 1) is a Proton Exchange
Membrane, or PEM, water electrolysis system packaged for rapid onsite installation and
ease of use. Configured with up to three PEM stacks, the HOGEN H Series hydrogen
generator is designed to deliver up to 6 NM3/h (228 SCFH) of 99.9995 percent pure
hydrogen at a maximum pressure of 15 barg (225 psig). The HOGEN H Series hydrogen
generator may be configured with one, two, or three cell stacks to meet customer
hydrogen need through the range of 0 to 6 NM3/h. Hydrogen generation is continuously
available and follows customer demand as long as power and deionized, or DI, water are
available. The HOGEN H Series hydrogen generator is designed to operate in a wellventilated, non-classified, indoor environment.
Proton Energy Systems, Inc. (PROTON) has provided these instructions to guide the
installation and operation of a HOGEN H Series hydrogen generator. These instructions
provide technical product information, installation requirements, detailed mechanical and
electrical interface specifications, and operating instructions. Important safety
information is also included in this manual. Please take time to familiarize yourself with
the system and the manual.
IT IS THE CUSTOMERS RESPONSIBILITY TO CONSULT WITH THE
LOCAL AUTHORITY HAVING JURISDICTION (AHJ) REGARDING LOCAL
CODE REQUIREMENTS FOR INSTALLATION AND OPERATION OF THIS
EQUIPMENT.
DO NOT USE THE HOGEN H SERIES HYDROGEN GENERATOR IN A
MANNER NOT SPECIFIED BY PROTON ENERGY SYSTEMS.
Fluids
Compartment
Electronics
Compartment
Figure 1 HOGEN H Series Hydrogen Generator
PD-0100-0034 REV A
Page 8 of 90

This manual attempts to answer most of the frequently asked questions with regards to
the installation and operation of the unit. However, should you have any questions, the
PROTON technical staff stands ready to answer them and support the successful
deployment of this equipment. Please call (203) 949-8697 and ask for technical service
support or email customerservice@protonenergy.com. Please have the model number
and serial number of your unit available.
PROTON offers a full range of installation and training services. Contact PROTON
Customer Service at 203-949-8697 or your local service provider/supplier for more
information.
If freezing conditions exist at your site, you must take measures to prevent
condensation from freezing and obstructing the H2 vent line and freezing the water
supply and drain lines.
After performing any service or maintenance work, make sure the doors to the
enclosure are completely closed prior to the startup operation of your generator.
Do not remove or install the flash card provided with the unit while the unit is
powered.
It is the customers responsibility to organize a backup hydrogen supply to bridge critical
times during maintenance and service.
PD-0100-0034 REV A
Page 9 of 90

1.1 Key Definitions, Acronyms, and Abbreviations Used in this

Document
PROTON Proton Energy Systems, Inc.
ASME American Society of Mechanical Engineers
NM3/h - Normal cubic meter per hour (International Normal conditions are 1.01325 bar
and 0 Celsius)
SCFH - Standard cubic foot per hour (US Standard conditions for air are 14.7 psia and
70F)
Bar - 14.5 PSI or 100 KPa (KiloPascals or Newton/cm), a unit of system pressure.
Standard atmosphere = 1.01325 bar = 14.696 psi
PSI - Pounds force per square inch (lbf /in2=6894.7 Pa), a unit of pressure
L/m - Liters per minute flow (for hydrogen, calculated at normal conditions)
cc - Cubic centimeter
KW - Kilowatt;
KVA - Kilovolt-ampere
S/cm - MicroSiemen per centimeter, a measure of water conductivity
HOGEN - Registered TM of Proton Energy Systems Inc. for packaged water
electrolysis based hydrogen generators
FNPT Female National Pipe Thread
NPT National Pipe Thread
NFPA National Fire Protection Association, a Standards Organization
CPI Chemical Process Instrumentation
VDC Volts Direct Current
VAC Volts Alternating Current
NEC National Electric Code, NFPA 70
LAN Local Area Network
HGMS Hydrogen Gas Management Subsystem
WOMS Water/Oxygen Management Subsystem
UI User Interface
HCS H Series Control System
PSU Power Supply Unit
- Notes contain helpful suggestions or references.
- Indicates a potentially hazardous situation, which, if not avoided, may result in minor or
moderate injury. It may also be used to alert against unsafe practices. This could result
in equipment damage or loss of data.
- Indicates a potentially hazardous situation, which, if not avoided, could result in death
or serious injury.
PD-0100-0034 REV A
Page 10 of 90

1.2 General Description

The HOGEN H Series hydrogen generator is a fully integrated, packaged
electrolysis system that produces high purity hydrogen from water and electricity.
The system includes up to three electrolyzer cell stacks, as well as the support
systems necessary for regulating electrolyzing operations and pressurizing
hydrogen. The support systems are used to aid in the functions of the system:
circulating water, drying hydrogen, cabinet dilution, liquid cooling and shutting
down the system. The unit contains all of the required sensors and controls to aid
in monitoring the safety, performance and automatic operation of the system and
to allow for optional remote monitoring and diagnostics. The unit is designed to
operate in a well-ventilated, non-hazardous (non-classified), indoor environment.
The recommended customer supplied interfaces are outlined in Figure 2.
Figure 2 HOGEN H Series Interface Connections
PD-0100-0034 REV A
Page 11 of 90

1.3 Classification of the HOGEN Hydrogen Generator

The HOGEN H Series hydrogen generator is a source of hydrogen, a combustible
gas. When the unit is running, it can convert water to hydrogen and oxygen.
When it is not running, the production of the combustible gas, hydrogen, stops.
Protection against the ignition of a potentially explosive atmosphere inside the
generator is accomplished using basic protection techniques described in NFPA
69, Standard on Explosion Prevention Systems and EN 1127-1, Explosive
atmospheres Explosion prevention and protection Part 1: Basic concepts and
methodology.
The primary protection used is containment of the hydrogen. It is contained as
much as possible inside the plumbing in the generator and is not allowed to mix
with air to form a potentially explosive atmosphere.
Dilution is the second protection. A blower moves air through the section of the
enclosure where the hydrogen is generated at a rate sufficient to dilute the largest
credible hydrogen leak to a level below the lower flammable limit (LFL) of
hydrogen. The dilution rate is enough to reduce the area classification inside this
section of the enclosure to non-hazardous (Zone 2 NE [negligible extent]). This is
confirmed using analysis and testing per IEC 60079-10. Additionally, the power
source that drives hydrogen generation is interlocked by sensor(s) that confirm the
operation of the dilution blower.
The third protection that is provided is the elimination of ignition sources in any
potentially explosive atmospheres inside the generator. All of the internal power
distribution equipment and as many other electrical components as possible are
located in a separate section of the enclosure that is sealed from the section where
the hydrogen is generated. The electrical components that remain in the hydrogen
generation section are located outside any dilution zones. Again, this is
confirmed using analysis and testing per IEC 60079-10.
TUV Rheinland, an independent third party testing agency that is both an NRTL
for the U.S. and Canada (like UL and CSA) and a Notified Body for the European
Union, reviewed this approach to protection against potentially explosive
atmospheres. The agency expressed their opinion stating that the H Series
hydrogen generator employs primary protection means against potentially
explosive atmospheres in the generator and that, since the generator is not
designed to be placed inside a (existing) potentially explosive atmosphere, no
additional certification or approval is required.
As noted above, one of the primary protections against possible explosion is
dilution with air. For this to be effective it is essential that the source of the air be
non-hazardous (non-classified). Consequently, if fresh (non-hazardous) air is
PD-0100-0034 REV A
Page 12 of 90

supplied as required, the exhaust from the generator is non-hazardous as any
hydrogen is diluted below the LFL. Therefore, due to the extent of the previously
mentioned protection and prevention of explosive atmospheres, the hydrogen
generator does not change the area classification of the area it is installed.
1.4 Subsystems
1.4.1 Water and Oxygen Management Subsystem
The Water and Oxygen Management Subsystem (WOMS) (see Figure 3)
separates a two-phase mixture of oxygen gas and water from the electrolysis cell
stacks. The oxygen may normally contain up to 0.5 percent hydrogen by volume.
A combustible gas sensor (P&ID Tag CG220) monitors percent LEL of hydrogen
in oxygen. In the event of a failure, the system shuts down if 50 percent LEL is
detected. The WOMS subsystem:
Minimizes Evaporation
Allows Draining of Water
Maintains and Monitors Water Quality
Manages Water Inventory
Prevents/Accommodates Hazard from Cell Stack Failure
Accepts Two-Phase Water and Hydrogen Stream from the Hydrogen
Management System (HGMS)
Delivers Cooled and Filtered Water Streams to the Three Cell Stacks
Rejects Heat via a Process Water Interface
Vents Oxygen
Figure 3 HOGEN H Series Hydrogen Generator WOMS Piping and Instrumentation Document
(P&ID)
PD-0100-0034 REV A
Page 13 of 90

1.4.2 Hydrogen Gas Management Subsystem
The Hydrogen Gas Management Subsystem (HGMS) (see
Figure 4) separates product hydrogen from water and delivers high purity dry
hydrogen product at pressure. The HGMS subsystem:
Accepts a Two-Phase Pressurized Hydrogen/Water Stream
Delivers a Single-Phase Hydrogen Gas Stream of at Least 99.999 Percent
Purity
Delivers a Liquid Water Stream (Which typically includes Dissolved
Hydrogen Gas) to the WOMS
Figure 4 HOGEN H Series Hydrogen Generator HGMS P&ID
1.4.3 Control and Power Distribution

The controls affect the automatic startup, product delivery rate, safety monitoring,
and operational control for all modes of operation. The control system:
Provides an Easy-to-Use User Interface for Equipment Operators, Service,
and Maintenance Personnel
Provides Optional Remote Monitoring, Diagnostics, Service, and Remote
Operation Functions
Provides a Safety Circuit, Including Pressure Monitoring and Cutoff
Switches such as E-Stop, Flood, and Main Disconnect, to De-Energize
Circuits in Process Enclosure for Type X Pressurization Per NFPA 496
PD-0100-0034 REV A
Page 14 of 90

1.5 Enclosure
The enclosure element of the HOGEN H Series hydrogen generator:
Protects the Internal Elements of the Generator from Shipment Damage
and the Environment
Provides Structural Mounting and Support
Consists of both Fluids and Electrical Enclosures and Optional Filter
Housing and Shrouds
Prevents Unauthorized Access
1.5.1 Fluids Enclosure
The fluids enclosure largely contains the following elements and provides the
listed functions:
Dilution Blower, Cell Stacks, WOMS, and HGMS
Bulkhead with Requisite Fluid Interconnect Locations
Dilutes and Disposes Vents of Waste Oxygen via Air Flow
Provides Dilution to Reduce Internal Environment to Non-Hazardous
(Non-Classified) Per IEC 60079-10
CONTACT WITH HIGH VOLTAGE MAY RESULT IN DEATH OR SERIOUS
INJURY.
1.5.2 Electrical Enclosure
The electrical enclosure provides the necessary input and output electrical
connections and top-level control.
The electrical enclosure contains elements that:
Provide DC Power to the Cell Stacks based upon Hydrogen Requirements

Include Test Points for Diagnostic Purposes
Provide Control to the Various Subsystems
Provide a User Interface Panel for Unit Operation
Provide 380-480 VAC Power to Pump, Blower and 24 VDC Power
Supply
Provide 24 VDC to Control Circuits and Cell Stack Power Supply Fans
CONTACT WITH HIGH VOLTAGE MAY RESULT IN DEATH OR SERIOUS

INJURY.
PD-0100-0034 REV A
Page 15 of 90

1.5.3 Enclosure Integrity
Visually inspect the enclosure element for any signs of damage, particularly if it is
subject to direct impact or wet conditions. Please keep water, dust and other
foreign particles out of the enclosure area. Also, verify that the seals on the doors
and panels are not compromised or damaged. Contact PROTON or your local
service provider/supplier with questions.
PD-0100-0034 REV A
Page 16 of 90

1.6 Product Specification

Hydrogen Production
Net Production Rate
Delivery Pressure Nominal
Power Consumed/Volume of Hydrogen
Gas Produced
Purity
Concentration of Impurities:
Turndown Range
Upgradeability
DI Water Requirement
Rate at Max Consumption Rate
1.83 L/hr
3.66 L/hr
5.50 L/hr
.50 gal/hr
.96 gal/hr
1.42 gal/hr
5 C to 50 C
41 F to 122 F
1.5 to 4 barg
21.8 to 58.0 PSIG
ASTM Type II Deionized Water Required (< 1 micro Siemen/CM)
ASTM Type I Deionized Water Preferred (< 0.1 micro Siemen/CM)
Temperature
Pressure
Input Water Quality
Heat Load and Coolant Requirement
Cooling
Heat Load from System
Coolant
Electrical Specifications
Recommended Breaker Rating
Electrical Specification
Interface Connections
H2 Product Port
H2/H2O Vent Port
DI Water Port
Calibration-Gas Port
Cooling Supply Port
Cooling Return Port
Drain Port
Electrical
Communications
PD-0100-0034 REV A
H 2m
H 4m
H 6m
3
3
2 Nm /h
4 Nm /h
6 Nm3/h
76 SCF/hr
152 SCF/hr
228 SCF/hr
15 barg
225 PSIG
8.3 kWh/Nm3
7.0 kWh/Nm3
6.8 kWh/Nm3
3
3
21.2 kWh/100 ft
18.5 kWh/100 ft
17.8 kWh/100 ft3
99.9995 Percent
Water Vapor < 5 PPM Water (-65 C/ -85 F Dewpoint)
N2 < 2 PPM, O2 < 1 PPM, All Others Undetectable
0 to 100 Percent Net Product Delivery
N/A
Field Upgradeable to Field Upgradeable to
a Max of 6 Nm3/h
a Max of 6 Nm3/h
(228 SCF/hr)
(228 SCF/hr)
Liquid-Cooled
8.1 kW Max
16.1 kW Max
23.7 kW Max
0 to 50 Percent Anti-Freeze, Non-Fouling
1.4 to 6.9 barg (20 to 100 PSIG)
5 C to 35 C (41 F to 95 F)
15 to 87 L/min (4 to 23 GPM), Depends on Model and Coolant
Temperature
22 kVA
40 kVA
380 - 480 VAC, 3 Phase, 50 - 60 Hz
58 kVA
CPI Compression Tube Fitting, SS

FNPT, SS
FNPT, SS
1/8 FNPT, Brass
1 FNPT, Brass
1 FNPT, Brass
3/8 FNPT, Brass
Connect to On-Board Circuit Breaker
Ethernet
Page 17 of 90

Control Systems
Standard Features
H 2m
H 4m
H 6m
Fully Automated, Push Button Start/Stop, E-Stop. On-Board H2
Detection. Automatic Fault Detection and System Depressurization.
Form C Relay (5A, 250V, 150W Max Rated Switching)
Safety Circuit Trip
Remote Alarm
Remote Shutdown
Enclosure Characteristics
Dimensions (L x D x H)
180 cm x 80 cm x 180 cm
71 x 32 x 71
700 kg
747 kg
794 kg
1500 lbs
1600 lbs
1700 lbs
IP43 for Fluids Compartment; Upgradeable to IP55; IP66 for
Electronics Compartment.
Weight
Rating
Environmental Considerations
Standard Siting Location
Storage/Transport Temperature
Ambient Temperature Range
Altitude Range Sea Level to:
Ventilation
Safety and Regulatory Conformity
Cabinet Ventilation with Environment
Noise
dB(A) at 1 Meter
Approvals
Options
Indoor, Level 1, 0 to 90 Percent RH Non-Condensing, NonHazardous/Non-Classified Environment

5 C to 60 C
41 F to 140 F
5 C to 50 C
41 F to 122 F
2400 m
7874 ft
Proper Ventilation must be Provided from a Non-Hazardous Area at
a Rate in Accordance with IEC60079-10, Zone 2 NE
NFPA 69 and EN 1127-1, Clause 6.2
Vent Fan Draws Fresh Air up to 28 Nm3/min
1000 ft3/min
< 83
NYFD Approval Pending
PROTON offers a wide range of options to tailor your HOGEN
hydrogen generation system to meet your specific operational
requirements. Please contact your local Proton Energy
representative to discuss the current list of options available to best
fit your needs.
Table 1 HOGEN H Series Specifications
Specifications are subject to change. Consult factory for latest spec and tolerances on
figures specified without ranges.
PD-0100-0034 REV A
Page 18 of 90

2 SAFETY
The safety guidelines below may not cover all situations. If there are concerns or
questions, please call PROTON or check with local authorities.
2.1 General Information

This system produces hydrogen and dilutes oxygen into the ventilation air stream.
It is important for users to be aware, understand, and comply with all local safety
requirements related to the handling of hydrogen and compressed gases. It is
important to operate the HOGEN in a ventilated, non-hazardous (non-classified)
area. (The HOGEN complies with NFPA 70, NFPA 79, and NFPA 496.)
2.2 Using Hydrogen Gas

Hydrogen is odorless, tasteless, colorless, and highly flammable. It is highly
combustible in the presence of oxygen and burns with a colorless flame.
If you are not in danger, stop the flow of gas and use water to cool the area. The
lower flammability limit of hydrogen is 4 percent hydrogen in air by volume. If
fire occurs, do not attempt to extinguish flames, allow the fire to burn out.
Hydrogen gas is lighter than air.
Prevent overexposure to hydrogen. Hydrogen is non-toxic, but it can act as a
simple asphyxiant by displacing the oxygen in the air. Effects of oxygen
deficiency, resulting from simple asphyxiants, include rapid breathing, diminished
mental alertness, impaired muscular coordination, faulty judgment, depression of
all sensations, emotional instability, and fatigue. As asphyxiation progresses,
nausea, vomiting, prostration, and loss of consciousness may result.
The HOGEN H Series hydrogen generator is equipped with a pressure relief valve
(P&ID Tags RV308 and RV351). If the system experiences an over-pressure
condition, the relief valve opens and allows the system to depressurize by
allowing hydrogen to flow out the H2/H2O vent. (Refer to Section 3.9.2 for
Pressure Relief Valves and Vent Lines.)
FIRE OR EXPLOSION! KEEP ALL SOURCES OF IGNITION AWAY FROM
HYDROGEN.
IT IS ESSENTIAL THAT THE SAFETY SYSTEM IS NOT BYPASSED.
CONTINUED OPERATION COULD RESULT IN SERIOUS INJURY AND/OR
DAMAGE TO THE GENERATOR.
PD-0100-0034 REV A
Page 19 of 90

2.3 References
Refer to Section 3.2 for Ventilation Requirements.
Refer to Section 3.5 for Lifting and Moving.
Refer to Section 3.8.2 for Remote E-Stop and Remote Alarm
Refer to the Maintenance Manual for Lock Out/Tag Out Procedure.
PD-0100-0034 REV A
Page 20 of 90

3 INSTALLATION
The HOGEN H Series hydrogen generator is a fully integrated system. To install the
HOGEN generator, mechanical, electrical, fluid, and communication interface
requirements must be met. This section describes the interface and installation
requirements. Figure 5 illustrates the hardware, mounting points and connections for
system integration and packaging.
L
A
B
C
D
JK
E
F
G
H
Figure 5 HOGEN H Series Hydrogen Generator Interface Connections
Reference
A
B
C
D
Interface Connection
Calibration Gas Port
H2/H2OV Vent Port
H2 Product Port
Air Inlet Filter
Reference
H
I
J
K
E
F
G
DI Water Feed Port

Cooling Water Inlet Port
Cooling Water Outlet Port
Interface Connection
Drain DI H20 Port
AC Power Feed in this Area
Communications in this Area
Remote Alarm & Shutdown in
this Area
Lifting Eyebolts
Table 2 HOGEN H Series Hydrogen Generator Interface Connections
PD-0100-0034 REV A
Page 21 of 90

3.1 Top-Level Steps of Installation

The top-level steps of installation are as follows:
1. Installing proper ventilating schemes within the area the HOGEN generator is to
occupy.
2. Verifying the proper environmental conditions the HOGEN generator is to be
exposed.
3. Siting the unit.
4. Connecting electrical interfaces.
5. Connecting mechanical interfaces.
6. Calibrating the combustible gas detector.
Each of these steps is described in further detail in their sub-sections within this
section.
3.2 Facility Air Ventilation Requirements

The HOGEN H Series hydrogen generator design implements ventilation in
accordance with NFPA 496, Type Z pressurized ventilation scheme. A blower at
the inlet air filter forces 400 to 1000 cubic feet per minute (CFM) of fresh purge
air through the fluids compartment. The blower is of sufficient power to maintain
an internal positive static air pressure in excess of 0.25 in (5.08 mm) of water
column. A pressure switch within the cabinet detects any loss of ventilation
pressure and will produce a safety shutdown of the generator upon loss of
pressure. Further, the air purge rate is such that it dilutes any internal hydrogen
leakage to a concentration below 1 percent hydrogen in air (25 percent of the
lower flammable limit (LFL)).
Although the unit will not be able to make hydrogen when the safety circuit is
triggered, the safety circuit does not shutdown the system entirely. Fans and other
areas of the safety circuit will remain engaged.
As an additional benefit, this air ventilation rate excessively dilutes byproduct
oxygen to a safe concentration below 23.5 percent, precluding any hazards
associated with enriched oxygen atmospheres.
PROTON recommends an installation area air change rate of several hundred
times the maximum generation rate of the HOGEN H Series hydrogen generator
to preclude any possible build up of hydrogen or enriched air concentrations in
the facility. In the event the ventilation system fails or the air inlet is restricted,
the HOGEN H Series hydrogen generator is equipped with a safety circuit to
detect the loss of ventilation and stop any further generation of hydrogen by
automatically shutting down. The small amount of hydrogen left on-board is
PD-0100-0034 REV A
Page 22 of 90

automatically vented through the vent stack port; however some residual
hydrogen remains in the system. The circuit also disconnects power to all
electrical equipment in the process (fluids) enclosure, though the fans and other
areas of the safety circuit remain energized.
Additionally, an internal hydrogen detector produces an automatic alarm if
excessive hydrogen is detected. If required, the HOGEN H Series system can
interface with facility fire detection systems, combustible gas sensor or other
external facility alarms as required.
THE HOGEN H SERIES HYDROGEN GENERATORS ARE DESIGNED TO
OPERATE IN NON-EXPLOSIVE, NON-HAZARDOUS, NON-CLASSIFIED
ENVIRONMENTS. THE EQUIPMENT CABINET IS VENTILATED WITH
FRESH AIR TO MAINTAIN A SAFE, NON-EXPLOSIVE INTERNAL
OPERATING ENVIRONMENT (US PATENT 5980726).
Coal dust environments require an optional external filter and shroud kit from PROTON
(KT-1000-0037).
Always refer to local code requirements to determine minimum facility ventilation
requirements. A worksheet for estimating minimum ventilation at your facility is
given below.
How to calculate the ventilation requirements for your site:
1. Record net hydrogen generation rate (P) for your selected generator.
(Refer to Table 1):
P = ________ NM3/h (SCFH)
If there is a plan to have multiple hydrogen generators in the room, P must be the
sum of all generators.
2. Calculate the gross hydrogen generation rate (G). (Add 10 percent):
G =P x 1.1 = ________ NM3/h (SCFH)
3. Calculate recommended ventilation rate (F). (Several hundred times gross
generation rate):
F > 100 x G/60 = ________ NM3/min (SCFm)
4. Confirm if actual room ventilation (FA) is adequate, FA =_______________:
a. Is actual room ventilation (FA) greater than or equal to F?
YES/NO
PD-0100-0034 REV A
Page 23 of 90

If you answered YES for 4a, then you may install the unit in the room. If you
answered NO for 4a, then you may not site the unit in the room until improvements
are made to the ventilation system.
Example Calculation:
1. Record net hydrogen generation rate (P) for your selected generator. (Refer
to Table 1):
P = 228 (SCFH)
2. Calculate the gross hydrogen generation rate (G). (Add 10 percent):
G = 1.1 x P = 250.8 (SCFH)
3. Calculate recommended ventilation rate (F). (Several hundred times gross
generation rate):
F > 100 x G/60 = 25080 (SCFH) / 60 = 418 SCFM
4. Confirm if actual room ventilation (FA) is adequate, FA = 950 cfm
a. Is actual room ventilation (FA) greater than or equal to F? YES
PD-0100-0034 REV A
Page 24 of 90

3.3 Operating Environment

The HOGEN H Series hydrogen generator is designed for indoor use. It shall be
situated on a grade of no more than 1 degrees. The area that the system
occupies shall have the ventilation schemes described in Section 3.2.
The standard HOGEN H Series hydrogen generator is rated for ambient
temperatures and is not designed for freezing conditions (per H Series
Specifications discussed in Table 1). If the system is introduced to freezing
conditions, damage to the system occurs.
Consult PROTON for information on placing the unit in a freezing environment.
The HOGEN H Series hydrogen generator contains a systems thermocouple that
monitors the water temperature in the process water circulation loop of the
system. The unit runs 100 percent hydrogen output at 59C. If the system water
temperature reaches 60C, the unit begins reducing the maximum hydrogen
output and triggers a warning. If the warning is undetected, the unit continues
reducing hydrogen output until it shuts down at 65C. If the cooling feed water
temperature exceeds 35C, the unit may overheat and shutdown.
The HOGEN H Series hydrogen generator can be stored and transported in certain
environments (per H Series Specifications discussed in Table 1). In the event that
the unit is to be transported in a freezing environment, water must be drained
from the system and the cell stack(s) must be taken out of the system and
transported separately. Instructions for the decommissioning of the system are
detailed in the Service Manual).
THE GENERATOR IS TYPICALLY SHIPPED WITH THE PEM CELL STACK
(S) ALREADY INSTALLED. FOR THIS REASON, DO NOT EXPOSE THE
STACK (S) TO FREEZING CONDITIONS WHEN THE UNIT IS NOT
RUNNING. PLEASE CONSULT THE FACTORY FOR SPECIAL STORAGE
AND HANDLING INSTRUCTIONS IF THE UNIT WILL BE EXPOSED TO
FREEZING CONDITIONS PRIOR TO INITIAL START UP.
3.4 Site Preparation

The HOGEN H Series hydrogen generator is designed for indoor installation on a
level concrete pad. AC power, deionized water and cooling water that meets the
specifications outlined in Table 1 are the key utilities required. Ensure the
generator is located so that it is safe from vehicle traffic and is in compliance with
local safety regulations. PROTON recommends the use of barriers if placing the
unit near a vehicle traffic area.
PD-0100-0034 REV A
Page 25 of 90

A level floor, 1 degrees, capable of supporting the generator is required. The
minimum clearance requirements of the area around the generator are shown in
Figure 6. There is a zero minimum clearance requirement on the back of the
generator. The minimum clearance requirement on the front, left and right panels
of the generator is 1 meter or 3.3 ft. It is the customers responsibility to verify
that the local code requirements for this type of equipment are met when
installing this equipment.
All facility connections are identified in Figure 5. Leave sufficient clearance to
permit adequate air movement in and out of the generator from the front and the
left side of the unit.
Front access is very important for operation, ventilation and maintenance. The
generator is controlled from the front control panel, which has start and stop
switches, E-Stop, main disconnect, keypad, and service bypass key switch.
Opening the door of the fluid compartment permits access for routine
maintenance.
Figure 6 HOGEN H Series Hydrogen Generator Plan View for Installation
PD-0100-0034 REV A
Page 26 of 90

3.5 Instructions on Unpacking the HOGEN Hydrogen Generator

The HOGEN hydrogen generator arrives with shipping beams used to support the
unit during shipment. Please use the following instructions to unpack the
hydrogen generator:
1. Using a 9/16 wrench with a socket and a ratchet, unscrew the four (4) nuts
from the beam in the front of the unit.
2. Using a 9/16 wrench with a socket and a ratchet, unscrew the two (2) nuts
from the beam on the right side of the unit. Repeat this step for the two (2)
nuts located on the left side of the unit.
3. Once all nuts are unscrewed, push down on each bolt (there are eight {8} bolts
total) and take each bolt from the bottom. (Refer to Figure 7.)
Figure 7 Removing Bolt from the Shipping Beam
4. Remove the shipping beams from the unit.

5. Remove the additional shipping beam from the unit, which is located behind
the bolted beam in the front of the unit.
PD-0100-0034 REV A
Page 27 of 90

Shipping Beam
Figure 8 Additional Beam Location
3.6 Lifting and Moving

The HOGEN H Series hydrogen generator is delivered on a pallet and weighs
approximately 1750 lbs. (794 kg). The generator can be transported on a pallet
using a forklift or by a hoist or overhead crane.
To lift and move the generator using a forklift, refer to the following instructions:
1. Using a Number 30 TORX bit, remove the four (4) screws on the bottom front
panels at the base of the unit (see Figure 9).
Base Fastener
Cover Plate
Figure 9 Removing Screws from Bottom Front Panel
2. Press down and remove the four (4) black, base fastener cover plates.
PD-0100-0034 REV A
Page 28 of 90

Figure 10 Removing Base Fastener Cover Plate
3. Using a screwdriver, pry out the bottom front panels.

4. Repeat Steps 1 4 for the rear of the unit.
5. Using a forklift/hand truck, lift the unit from under the floor. Make sure the
forks extend passed the back of the unit.
Forks Extending
Beyond the Rear
Figure 11 Lifting the Unit using a Forklift
6. Once the unit is in final position, re-install the base panels and the base
fastener cover plates.
If transporting by hoist, align all eyebolts (Item L in Figure 5) down both sides of
the unit. Place solid (appropriately sized) bar stock inside the eyebolts to run the
entire length of the unit. Lift the enclosure from the bars, as they facilitate an
even weight distribution. Attach appropriately sized harness, chain or sling for a
more even weight distribution.
PD-0100-0034 REV A
Page 29 of 90

3.7 Anchoring Instructions

It is required to properly secure an H Series hydrogen generator to a concrete pad
when siting the equipment outdoors. The drawing provided below should be used
to locate the anchor points needed to perform the installation. All materials and
methods used should be appropriate for anchoring the H Series hydrogen
generator in the intended environment.
Figure 12 Anchoring Diagram
Anchoring Holes
Figure 13 Anchoring Holes
If the HOGEN H Series hydrogen generator is placed in a freezing environment and

there is a loss of power, take necessary provisions to keep the unit from freezing.
PD-0100-0034 REV A
Page 30 of 90

3.8 Electrical Interfaces

Once the HOGEN H Series Hydrogen Generator is properly located, electrical
connections can be made. All user supplied I/O cables that interface with this
system must not exceed 30 meters (98.4 feet) in length.
3.8.1 Cabling Procedure
Ensure that the electrical connections
conform to IP66/NEMA4 and are
compliant with the local electrical
codes. The electrical power
connection and data communications
connections must be weather-tight to
keep out water and dust for reliable
and safe operation. The electrical
and data connections can be installed
on the right side of the generator, in
the approximate location indicated by
the red arrows in Figure 14. The
reference dimensions are listed in
Table 3.
Electrical
Data
Figure 14 Electrical Interface Locations
It is important to verify that the input voltage to the generator maintains stability between
380 to 480 VAC to sustain reliable operation. If the input voltage falls below 360 VAC or
rises above 500 VAC, an on board voltage monitoring relay trips the HOGEN hydrogen
generator to the OFF position.
PD-0100-0034 REV A
Page 31 of 90

The cabling procedure is as follows:
1. Size the AC power conductors according to the service rating listed on the
nameplate (Refer to Table 1).
2. Ensure that connections conform to IP66/NEMA 4 standards and are
compliant with the local electrical codes.
3. Remove the right side panel from the unit if required.
4. Verify that the selected connectors are appropriately sized for the pre-drilled
holes.
5. Install the appropriate IP66/NEMA 4 connector into the hole drilled in the
side of the panel.
6. Feed the power and ground conductors through the AC power feed connector.
7. Connect the power conductors to the top of the main circuit
breaker/disconnect in side the unit.
8. Bring the protective earth ground conductor into the unit along with power to
the conductors.
3-Phase
Input
Protective
Earth Ground
Figure 15 Internal Power and Ground Connections
PD-0100-0034 REV A
Page 32 of 90

Figure 16 HOGEN H Series Hydrogen Generator Electrical Interface Locations
Reference
Dimension
A
B
C
D
Main Power Feed

Units
Inches
mm
5.50
139.70
13.00
330.20
6.14
155.90
8.50
215.90
Data Communications
Reference
Units
Dimension Inches
mm
E
8.50
215.90
21.00
533.40
F
5.50
139.70
G
43.03
1903.10
H
Table 3 Electrical Interface Connections Reference Dimensions
PD-0100-0034 REV A
Page 33 of 90

3.8.2 Remote Alarm Contact and Shutdown Connections
An external alarm from the HOGEN H Series hydrogen generator may be
connected to announce system availability status. Only Normally Open (NO)
contacts are available on the remote alarm relay, located on the right side of the
controller assembly, as shown in Figure 17. The form C alarm relay contacts are
rated for 1 230V, 5 amps max. DO NOT exceed this rating.
Remote
Alarm
Figure 17 Remote Alarm Relay Location
A normally open contact is available for the remote alarm relay. The contact is
rated for 230V, 5 Amp max. DO NOT EXCEED this rating.
The remote alarm contact must be wired to 4TB terminals seven (7) and eight (8).
The user may shut down the system remotely by connecting an external contact
closure to terminal block 3TB. (Reference XPE2544.) This feature permits the
user to interconnect facility alarms to cause the generator to stop operation.
Contacts must be rated to 50 W, 1 amp min. Multiple switches can be wired in
series to form a user-safety circuit. For installation of all electrical connections to
the unit follow the general guidelines as outlined Section 3.8.1.
External contacts must be wired across 3TB terminals 17 and 18. A second external
contact can be wired across 3TB terminals 16 and 19.
PD-0100-0034 REV A
Page 34 of 90

Figure 18 Terminals to Wire External Contacts
The two jumpers (wired across TB 3 on terminals 16/19 and 17/18) installed in
the unit represent customer remote E-Stop switches. To install a remote E-Stop,
simply remove one of the jumpers, 5-6 or 37-38, and replace it with remote e-stop
wiring. Terminal block TB 3 is located in the upper right area of the power panel
(see Figure 19).
Figure 19 TB 3 Location
3.9 Mechanical Interfaces

This section provides a detailed description of the mechanical interface
requirements. The physical layout and dimensions of the HOGEN H Series
hydrogen generator are shown. Detailed interface connections for the hydrogen
outlet, DI feed water and cooling water supply are also supplied.
PD-0100-0034 REV A
Page 35 of 90

3.9.1 Physical Layout, Connections and Dimensions
The physical layout of the HOGEN H Series hydrogen generator is shown in the
following figures (Refer to Section 3.1).
Figure 20 Left Side View
Figure 21 Right Side View
Figure 22 Front View
PD-0100-0034 REV A
Figure 23 3-D View
Page 36 of 90

Figure 24 HOGEN H Series Hydrogen Generator Interface Connections
PD-0100-0034 REV A
Page 37 of 90

3.9.2 Hydrogen Vent Interface
The HOGEN H Series hydrogen generator vents hydrogen during startup, system
depressurization, dryer purging cycles, and overpressure relief. The HOGEN H
Series hydrogen generator vents up to 12.3 liters of hydrogen per minute to purge
and condition the Hydrogen Gas Management Subsystem (HGMS).
In the GENERATE-VENT mode, the H Series hydrogen generator shall operate at
approximately 6 percent generation while discharging generated hydrogen to vent. This
operation purges the phase separation portions of the HGMS with hydrogen to eliminate
any air gases that may be present.
At the end of GENERATE-VENT (130 seconds min/10 minutes max), the vent
valve (P&ID Tag SV329) closes and the system begins to pressurize. During
system shutdown, the on-board inventory hydrogen (< 1.4 SCF/0.036 Nm3) is
vented to atmospheric pressure, leaving some residual hydrogen in the system.
Depressurization occurs when gas generation stops and the vent valve (P&ID Tag
SV329) is opened, allowing hydrogen to flow out of the H2/H2O vent.
The internal dryer of the HOGEN H Series hydrogen generator is a pressureswing dryer. Each bed operates alternately in two half-cycles of equal duration:
pressurization followed by adsorption and depressurization, followed by a purge
with product hydrogen from the alternate bed. It is during this purge that
desorbed water vapor with hydrogen is blown out of the non-operating bed and
directed out the H2/H2O vent. During these purge cycles, approximately 13.8
liters per minute (max) of hydrogen exits the H2/H2O vent port with desorbed
moisture.
The H2/H2O vent port uses FNPT connection. Figure 5 shows the connection
location. The vent line to be attached to the port should be installed per best
practice for hydrogen vent lines and must not be reduced or restricted. Refer to
local standards, NFPA 50A, CGA G5.5, and ASME B31.3.
DO NOT ALLOW HYDROGEN TO VENT INDOORS, NEAR VENTILATION
INTAKES, WORK AREAS, OR ANY SOURCE OF IGNITION.
THE HYDROGEN VENT LINE AND VENT STACK TO ATMOSPHERE MUST
REMAIN FREE FROM OBSTRUCTIONS AND KEPT FROM FREEZING.
A condensate drain trap (As shown in Figure 25) is recommended to remove condensate
from the vent stack and can be purchased from PROTON (Part Number 02-2000-0002).
PD-0100-0034 REV A
Page 38 of 90

Figure 25 Condensate Drain Trap Flow
3.9.3 Vent Line Installation

The connection for the hydrogen vent is FNPT. The vent port is located at the
top of the bulkhead panel and is clearly labeled. For proper hydrogen dryer
operation and compliance with pressure safety codes, 3/8 tubing (10mm) or
larger is required.
The vent line shall not be restricted by excessive length of tubing or by the use of check
valves. Vent backpressure adversely affects the moisture content of the hydrogen
produced.
In applications operating below freezing, precautions must be taken to prevent
freezing of the vent lines.
The vent line must be installed to minimize the possibility of restriction or blockage
due to animals, insects, dirt, rust, etc
3.9.4 Product Hydrogen Interface
The HOGEN H Series hydrogen generator is designed to produce hydrogen that
contains no more than < 5 PPM of water and <1 PPM of other contaminants.
Hydrogen is delivered at a maximum pressure of 15 barg (225 psig) and up to the
units rated flow rate.
PD-0100-0034 REV A
Page 39 of 90

The product hydrogen port uses a Parker CPITM compression tube fitting for
OD stainless steel tubing with .035 wall. Figure 5 shows the connection location.
Figure 26 Product Hydrogen Interfaces

Parker CPITM is a trademark of the Parker Hannifin Company
3.9.5 Air Dilution Interface and Integrated Oxygen Disposal

The HOGEN H Series generator is shipped with an air inlet grill on the left side of
the unit and air dilution discharge grills on the front face of the unit. This
configuration is designed to IP 43. An optional outlet filter housing and shroud kit
is available and is designed to IP 56. The installation area (the source of the
HOGEN ventilation air) must be non-hazardous (non-classified) and well
ventilated. It is very important that the inlet and exhaust dilution grills are not
blocked or restricted in any way. Section 3.2 describes the air dilution protection
scheme inside the HOGEN H Series hydrogen generator, which recommends the
minimum facility air dilution requirements.
Byproduct oxygen is diluted and disposed into the HOGEN H series air dilution
stream, so there is no need for an oxygen port on the HOGEN H series. During
maximum operation, the oxygen concentration increase is only 0.5 percent.
The air inlet grill needs to be replaced with an air filter housing at installation. Refer to
Section 3.11 for instructions.
ADEQUATE DILUTION AND INDOOR AIR EXCHANGES MUST BE
PROVIDED TO ASSURE THAT OXYGEN AND HYDROGEN
CONCENTRATIONS DO NOT BUILD TO UNSAFE LEVELS (REFER TO
SECTION 3.2).
PD-0100-0034 REV A
Page 40 of 90

3.9.6 Coolant Water Interfaces
The coolant water supply and return are 1 FNPT connections. Figure 5 shows
the connection locations of these ports. It is recommended that the user provide
isolation valves to permit maintenance and servicing of the coolant loop. Proton
has an Automatic Coolant Isolation Kit (KT-1000-0017) available. The following
instructions guide the wiring of the automatic valve. Complete instructions are in
PD-0101-0019, which are included in the kit.
A strainer must be installed on the fluid inlet to prevent clogging of the system
with particulate. Typically, strainers have low holding capacities and are only
designed for a low numbers of particles. Facilities with high particle counts in the
cooling water may require additional filtration to prevent frequent clogging of this
strainer. PROTON recommends a 50 mesh filter element.
Figure 27 Coolant Water Interfaces
PROTON also recommends using pressure gauges to monitor filter/strainer

pressure drops and available facility cooling water.
Never operate the unit without the inlet strainer installed!
PD-0100-0034 REV A
Page 41 of 90

To wire the automatic isolation valve, use the following instructions:
1. Use a minimum14 AWG cable suited for the environment (600V, 90 C,
UL/CE Approved).
2. Lockout/Tagout the unit.
3. Route the cable the unit through the right hand panel of the electrical
enclosure (see Figure 5).
All connections through the electrical panels must be made with an IP66-rated strain
relief to maintain the integrity of the electrical enclosures environmental rating.
4. With the solenoid valve in position, make an electrical connection to terminal
7 and 8 on terminal strip block TB4, which is located on the right hand side of
the electrical enclosure door (see Figure 28).
Figure 28 TB 4 Location
The positive wire should be connected to unused terminal 2 and the negative wire
to unused terminal 5. Refer to Figure 29.
Figure 29 TB4 Wiring Locations
PD-0100-0034 REV A
Page 42 of 90

3.9.7 Feed Water Interfaces
The DI water Feed port is a FNPT connection. Figure 5 shows the connection
locations of this port. Polypropylene plastic tubing is highly recommended for
the water feed line. FEP and PFA plastics are also acceptable. The only
recommended metal line is clean, passivated 316SS. The drain line should be
appropriately plumbed based on your specific facility requirements. Postdeionization water tanks should be constructed from polypropylene only as
stainless steel tanks will leach out impurities that will damage the system.
Figure 30 DI Water Feed Port
The HOGEN H Series hydrogen generator uses de-ionized water to produce

hydrogen and to actively cool the cell stack. It requires a minimum of ASTM Type
II de-ionized water. ASTM Type II de-ionized water calls for a resistivity of at least
1.0 M-cm (or conductivity below 1 Siemen /cm) and a maximum 50-g total
organic carbon per L of water. Other qualities of the water can be found in ASTM
designation D1193-99: Standard Specification for Reagent Water. Although
ASTM Type II water is required, ASTM Type I de-ionized water is recommended.
By using the highest quality water recommended, the life of the guard bed cartridge
and the cell stack will be extended. The water quality sensor will trigger a fault if
water quality drops below 1 M-cm (or the water conductivity exceeds 1 Siemen
/cm). Therefore, it is highly recommended that ASTM Type I de-ionized water be
used to prevent this fault.
DO NOT USE: copper, aluminum, iron or other metal for de-ionized water inlet tubing as
this will result in significant contamination and performance loss over time. PVC plastics
are not acceptable, as they will damage the electrolyzer cell stacks.
In order to assure integrity of structure and fluid containment and minimize ionic and
particle contamination please follow the guidelines outlined below. Preferred materials
PD-0100-0034 REV A
Page 43 of 90

for DI water feed plumbing and connections are given in Table 5. Materials to avoid are
given in Table 4.
DI water treatment options are available. Please consult PROTON or your service
provider/supplier with any questions.
Copper
Brass
Bronze
Aluminum or Aluminum Alloy (Bare,
Conversion-Coated, or Anodized)
Pure Nickel
Nickel Plating
Carbon Steel
High Strength Low Alloy Steel (e.g. 4130,
4340, etc)
Cast Iron
Cadmium
PVC
Table 4 Materials to Avoid Contact with DI Water Feed
Material
Polypropylene
Polyethylene Plastic
Titanium, Commercially Pure
CRES 316L (Or Equivalent)
Surface Treatment
Passivate per AMS-QQ-P-35
Type VI or Equivalent
CRES 316 (Or Equivalent)

Type VI or Equivalent
Type VIII or Equivalent
-
CRES A286 (Or Equivalent)

INCONEL 718 (Or Equivalent)
INCONEL 625 (Or Equivalent)
Common Uses
Tube
Vessels, Plumbing, Fittings, Valve
and Sensor Bodies Where
Welding or Brazing is Used
Vessels, Plumbing, Fittings,
Valves, and Sensor Bodies
Moderate Strength Fasteners,
Manifold
High Strength Valve Bodies, Pins
Heat Exchanger, Valve Body
Table 5 Preferred Materials in Contact with DI Water Feed
The HOGEN H Series hydrogen generator controller controls water levels. When
the water level drops below a set point in the Oxygen/Water Phase Separator, the
Water Feed Valve (P&ID Tag SV510) opens to allow water into the system
through the water inlet. (Refer to Figure 31.) Water may drain from the system
during startup and when water quality is not maintained.
PD-0100-0034 REV A
Page 44 of 90

Figure 31 Water Feed Valve on Bulkhead
The drain line should not be raised overhead. The unit must drain downward to a drain,
or a pumping station is required. The unit drain is pump assisted during operation,
however when the water level gets low, it is a gravity only drain, and must go to a lower
level than the system.
During normal unit operation the maximum volume of DI water drained from the unit is
approximately 2.5 gallons at a maximum flow rate of 1.5 gallons per minute. The
maximum volume of DI water in the A200 is approximately 10 gallons and may need to
be drained entirely during a service or maintenance operation (at the same rate).
An obstructed drain line could prevent the HOGEN H Series hydrogen generator from
draining properly and may result in permanent damage.
PD-0100-0034 REV A
Page 45 of 90

3.10 Connecting the Cell Stack(s)

Use the following instructions for connecting the cell stack(s) on the HOGEN H Series
hydrogen generator:
Customers with 4Nm- or 6Nm units have up to two additional cell stacks (Cell Stack B
and Cell Stack C, respectively).
1. Shut down the unit.
2. Remove power to the unit.
3. Ensure the system is fully drained before connecting the cell stack(s).
Connect one stack at a time to avoid a connection mix-up.
4. Remove and discard the bungee cord used to secure the A200 during shipment.
(Refer to Figure 32.)
Bungee Cord
Figure 32 A200 Tank with Bungee Cord
5. Starting with Stack A, using shears, cut the tie wrap from around the cell stack
outlet fitting. (Refer to Figure 33.) (Refer to Figure 36 for stack locations.)
PD-0100-0034 REV A
Page 46 of 90

Figure 33 Removing the Tie Wrap from the Cell Stack Outlet Fitting
6. Using a 7/8 wrench, remove the cap from the cell stack outlet fitting. (Refer to
Figure 34.)
Figure 34 Removing the Cap from the Cell Stack Outlet Fitting
7. Connect the outlet hose to the cell stack. Tighten the fitting with a 7/8 wrench.
PD-0100-0034 REV A
Page 47 of 90

Figure 35 Tightening the Outlet Fitting on Cell Stack A
8. Still working on Stack A, using shears, cut the tie wrap from the around the cell
stack inlet fitting.
PD-0100-0034 REV A
Page 48 of 90

FSW250B
FSW250C
FSW250A
Inlet Hose from

FSW250C to
Cell Stack C
Cell Stack
B
Outlet Hose
Fitting on Cell
Stack A
Cell Stack
C
Cell Stack
A
Negative Buss
Plates
Positive Buss
Plates
Figure 36 Cell Stack and Connection Locations
9. Using a 7/8 wrench, remove the cap from the cell stack inlet fitting.
10. Connect the inlet hose from FSW250 A to the cell stack. Tighten the fitting with a
7/8 wrench.
Verify the inlet and outlet hoses are connected properly.
Do not over-tighten the fittings.
11. If one or more additional cell stacks need to be installed (Stacks B and C), repeat
steps 4 through 9.
PD-0100-0034 REV A
Page 49 of 90

Refer to Section 3.15 in the H Series Installation and Operations Manual, PD-0100-0030,
for instructions on starting up the system for the first time.
PD-0100-0034 REV A
Page 50 of 90

3.11 Calibration Gas Cylinder Installation

The combustible gas sensor, which is calibrated at 50 percent of LFL (and
provides an alarm at the same value), needs to be calibrated every three months
for proper operation of gas detecting equipment within the hydrogen generator.
Auto calibration permits the hydrogen generator to calibrate automatically with
minimal user prompting and eliminates the need for manual calibration, a process
where the unit triggers the user to apply 50 psig of Cal gas to the Cal gas port.
Upon installation of the hydrogen generator, install the calibration gas cylinder
using the following instructions,
1. Remove the plastic dust cover cap from the new bottle.
2. Thread the new bottle to the Cal subassembly by turning clockwise.
3. Secure the bottle with the strap clamp. (Refer to Figure 37.)
Strap
Clamp
Figure 37 Calibration Gas Cylinder Installation
3.12 Inlet and Exit (Optional) Air Filter Housing Installation

The HOGEN H Series hydrogen generator uses an air filter to protect the inside of
the system from contamination from the outside environment (ingress protection).
The HOGEN generator uses one disposable air filter to remove contaminants
from the dilution air entering the system, and uses one disposable air filter to
prevent water from entering the unit when it is not running.
Units placed in excessive dust or water locations should use an optional filter and shroud
to protect the inlet and exit filters.
PD-0100-0034 REV A
Page 51 of 90

The filter housing for the inlet air filter is required and supplied with the unit.
To install the air filter housings, use the following instructions:
1. Pull off the pop-off standard filter louver. Lift up on the bottom of the louver.
2. Once the pop-off standard filter louver is off, you can see the filter element.
Remove the filter element from the inlet air filter. Discard filter element.
Figure 38 Filter Element
Save filter element for use on the outlet vent if the HOGEN H Series generator does not
utilize the extended filter/external shroud option and is not installed in a coal dust
environment.
3. Using a 25 TORX screwdriver, unscrew the four screws surrounding the filter.
Be sure to save the four screws you remove from the filter. You will need
them to screw the filter housing in to the unit.
Figure 39 Removing the Screws
4. Remove the filter retaining clip and wing nut.
PD-0100-0034 REV A
Page 52 of 90

Figure 40 Removing the Filter Retaining Clip
5. Slide filter out of filter housing.

6. Take the filter housing and line up the holes with the holes in the inlet filter.
Replace the screws into the four holes and tighten the screws.
Figure 41 Filter Housing Installed on the HOGEN H Series Hydrogen Generator
7. At the base of the filter housing, slide the pleated 16x 20x 2 air filter up
into the filter housing. Ensure the direction arrow is pointed inward toward the
unit.
PD-0100-0034 REV A
Page 53 of 90

Arrow
Pointing
Inward
Figure 42 Sliding Air Filter into Filter Housing
8. Install the filter retaining clip with the wing nut. (Refer to Figure 43.)
Figure 43 Reinstalling Filter Retaining Clip
PD-0100-0034 REV A
Page 54 of 90

3.13 External Shroud Installation (Optional)

To install the external shrouds on the inlet and exit filter housings, use the
following instructions:
1. Refer to Section 3.10 to install the filter housings.
2. Attach two screws to the right and left sides of the inlet and exit filter
housings using screwdriver or nutdriver. (Refer to Figure 44.)
Figure 44 Installing Screws
3. Slide the external shroud down over the inlet and exit filter housings, aligning
keyed portions of the external shroud with the bolts.
Figure 45 Sliding External Shroud over Filter Housing
4. Install the third screw through the top of the external shroud into the inlet and
exit filter housings. Tighten remaining two screws.
PD-0100-0034 REV A
Page 55 of 90

Figure 46 Tightening Screw on Top of External Shroud
Placing labels on the external shrouds is the last step in both sets of instructions.
There are two airflow stickers. One is placed on the inlet shroud and one is
placed on the exit shroud. There are also two dust protection stickers that should
be placed on both the inlet and exit shrouds as well.
PD-0100-0034 REV A
Page 56 of 90

3.14 Guard Bed Installation Instructions

Use the following instructions to install the guard bed:
1. Shut down the unit.
2. Remove power to the unit.
3. Ensure the system is fully drained before installing the guard bed. (Refer to
Section 2.1 in the H Series Maintenance Manual, PD-0200-0005.)
Guard Bed
Filter
Cartridge
Guard Bed
Housing
Figure 47 Guard Bed Filter Cartridge and Housing
4. Remove the plastic from the new filter cartridge.

5. Insert the cartridge into the guard bed housing with the rubber ring facing up.
O-Ring
inside
Grooves
Figure 48 Guard Bed Cartridge inside Guard Bed Housing
6. Verify the O-ring for the housings is on. Lube with Krytox if dry.
PD-0100-0034 REV A
Page 57 of 90

Make sure the O-ring is fitted in the grooves of the guard bed filter housing before
installing the filter. The O-ring should sit in the filter housing with no buckling or
deformation.
7. Attach the guard bed housing to the top of the guard bed housing assembly.
8. Hand-tighten the housing and then apply a turn more using the filter
wrench. (Refer to Figure 49.)
Top of
Guard Bed
Housing
Assembly
Figure 49 Tightening the Filter Housing
3.15 First Time Startup Instructions

3.15.1 High-Powered Connection Torque Requirements
In order to verify the integrity of all high-powered connections, complete the checklist
below prior to Pre-Start Startup. (Reference XPE 2544 Schematic, Power Panel.)
Item
LC1D09BD
LOC
2M
3M
Wire
Strip
5/16
Torque (IN-LB)
15
LRD07
2OL
3OL
8 AWG
10 AWG
5/16
3/8
SDN30-24-480
1 PWS
1/3
5.0
KAL36125
1CB
250
LC1D1506BD
4MA
3/8
13/16
10
100
LC1D18BD
6CON
5/16
15
PD-0100-0034 REV A
Small
Large
Inspector
Page 58 of 90

Item
MG24506
LOC
14CB
MG17426
Wire
Strip
3/8
Torque (IN-LB)
22
9CB
3/8
22
MG24500
15CB
3/8
22
RE7TP13BU
1TR
5/16
5.0
FN3258-180-40
1EMI
1 1/16
120
US3J31
1 FU
2 FU
4 FU
5 FU
5/8
35
460-VBM
1CR
3/8
XPSAK311144
1SR
Use Ferrule
DS150E-480
1 SUP
2 SUP
3 SUP
9/16
64
FS PDB3C
1TB
3/8
1
18
220
Small
Large
Inspector
Table 6 High-Powered Connection Torque Requirements
3.16 Remote Monitoring Software Installation

To install the remote monitoring software, use the following instructions:
1. Load the software CD onto your computer.
2. Open the ZIP folder and double click on the setup.exe file.
3. Run the Installation Wizard. (Refer to Figure 50.)
PD-0100-0034 REV A
Page 59 of 90

Figure 50 First Screen in Installation Wizard
4. Click Next> to continue to the next screen.

5. Select a folder where the software application will be installed. (Refer to Figure
51.) Click Next> to continue to the next screen.
If you do not choose a folder through the Browse button, the software will be installed
in the default folder, which in this case is C:\Program Files\H-Series Remote Comm\.
Figure 51 Second Screen in Installation Wizard
6. Install the software. (Refer to Figure 52.)
PD-0100-0034 REV A
Page 60 of 90

If you need to change the destination of where you plan to save installation, click
<Back.
Figure 52 Installation of Software Screen
7. The next screen shows the system processing the installation request. (Refer to
Figure 53.)
Figure 53 Installation Initializing Screen
8. Click Finish when the installation is completed. (Refer to Figure 54.)
PD-0100-0034 REV A
Page 61 of 90

Figure 54 Installation Completed Screen
3.16.1 Network Specifications

Specifications
Network Interface
10BaseT and 100BaseTX Ethernet
Compatibility
IEEE802.3
Communication Rates
10 Mbps, 100 Mbps, Auto-Negotiated
Maximum Cabling Distance
100 m/Segment
Maximum Power to Connected I/O Modules
9W
Maximum Number of Banks
Determined by Network Topology
Table 7 Network Specifications
3.16.2 Cabling
Utilize shielded Ethernet cable.
Pin
Connector 1
Connector 2 (Normal)
1
2
3
4
5
6
7
8
White/Orange
Orange
White/Green
Blue
White/Blue
Green
White/Brown
Brown
White/Orange
Orange
White/Green
Blue
White/Blue
Green
White/Brown
Brown
Connector 2
(Crossover)
White/Green
Green
White/Orange
Blue
White/Blue
Orange
White/Brown
Brown
Table 8 Standard Ethernet Cable Wiring Connections for Normal and Crossover Cables
PD-0100-0034 REV A
Page 62 of 90

Figure 55 Ethernet Cable Pinout
3.17 Configuring the System for Network Interface

The H Series controller default network settings are listed in Table 9.
IP Address
Subnet Mask
Gateway
172.16.48.98
255.255.240.0
172.16.48.1
Table 9 Controller Default Network Settings
3.17.1 Resetting Network Settings

Use of an Ethernet crossover cable is recommended between the computer and the
controller. The computer network settings need to be changed in order to communicate
with the HCS controller for configuration purposes.
IP Address
Subnet Mask
172.16.48.2
255.255.240.0
Table 10 Recommended Computer Network Settings
To install the HCS Administrative Software (57-9901-0023), use the following

instructions:
1. Unzip the file in the following folder C:\PROGRAM FILES.
2. The application is located in the HCS ADMINISTRATIVE TOOL
subfolder and can be accessed by double clicking the HCS
ADMINISTRATIVE TOOL shortcut.
PD-0100-0034 REV A
Page 63 of 90

To reset the network settings, use the following instructions:
1. Connect the crossover cable between the computer and the controller.
2. Start the H Series Win Application and set the server IP Address to the H
Series Controller IP Address. (Refer to Figure 56.)
Figure 56 Server IP Address Location
3. Choose the settings and select OK. (Refer to Figure 57.)
Figure 57 Choosing Settings
4. Select SET CONFIG PARAMS. (Refer to Figure 58.)
PD-0100-0034 REV A
Page 64 of 90

Figure 58 Select Set Config Params
5. Select Get Present System Data to retrieve the current settings for the
controller. (Refer to Figure 59.)
6. After retrieving the date, change the network settings as needed.
7. After the new network settings are chosen, select UpDate. (Refer to Figure
59.)
8. After the network settings are loaded, cycle power to the system and verify the
new network settings. This can be done by pinging or viewing the Network
Configuration menu.
Set Network
Settings
Select to
Retrieve
Current
Controller Data
Figure 59 Configuration Parameters Menu
PD-0100-0034 REV A
Page 65 of 90

If the user is unable to communicate with the controller, refer to Appendix _ for
temporarily setting the Controller IP Address.
3.18 LAN Installation

3.18.1 PC Parameters
To change the IP address for the H-Series Remote Monitoring Software (once the
unit is installed per PROTON requirements for facility power), use the following
instructions:
1. Plug the crossover cable in the Central Processing Unit (CPU).
Remote
Monitoring
Figure 60 Remote Monitoring Wiring
2. Hookup the crossover cable to the PC using the Ethernet port.

Ensure that the H Series Remote Monitoring Software (57-9901-0022) is loaded onto the
PC before configuring the unit to operate on the Local Area Network (LAN).
PD-0100-0034 REV A
Page 66 of 90

3.18.2 LAN Configuration Instructions
To configure the Remote Monitoring Software for the LAN, use the following
instructions:
1. Locate the folder labeled HCS Monitoring on the local drive under the
Program Files folder. (Refer to Figure 61.)
Figure 61 HCS Monitoring Folder Location
2. Open the HCS Monitoring folder and locate the folder labeled Support
Files. (Refer to Figure 62.)
PD-0100-0034 REV A
Page 67 of 90

Figure 62 Support Files Folder Location
3. Open the Support Files folder and double-click on MODBUS TCP

Configuration.ini to open the file. (Refer to Figure 63.)
Figure 63 MODBUS TCP Configuration.ini Location
4. Add the new IP address and delete the old IP addresses.
PD-0100-0034 REV A
Page 68 of 90

Figure 64 IP Address Location
5. Go to File at the top of the page and scroll down to find Save. Click
on Save to save the changes.
3.18.3 Electrical Connections for LAN Installation
Refer to Section 3.8 for the electrical connections.
3.19 Remote Monitoring Setup

Remote monitoring software (54-0901-0008) allows the HOGEN H Series
hydrogen generator to connect to a Local Area Network (LAN) via Ethernet for
remote monitoring and diagnostics. Remote monitoring software also includes a
data logging feature for trending and troubleshooting.
3.19.1 Remote Software Monitoring Feature
Monitoring can be done using the Default (Figure 65) of the remote monitoring
software.
PD-0100-0034 REV A
Page 69 of 90

Data
Logging
A300
Valves
CG
Values
Dryer
Inputs and
Outputs
Stack
Voltages
Comm
Link
Active
Errors and
Warnings
Current
Control Values
Figure 65 Default Screen
3.19.2 Data Logging Feature

To use the data logging feature, refer to the following instructions:
1. Double click on your desktop icon for the latest software to bring up the remote
monitoring software main screen. (Refer to Figure 65.)
2. Initiate data logging by clicking on the Log Data switch located on the main
screen. (Refer to Figure 65 and Figure 66.) The Enable and Disable switch
enables the system to take data or disables the system so it does not log
information.
The default data rate (the fastest sampling rate) is once a second. The data logging rate
can be modified with the up and down arrows. The recommended rate is 60 seconds.
If the valves are energized, the node is turned green, like the Comm Link active node in
Figure 65.
PD-0100-0034 REV A
Page 70 of 90

Figure 66 Enable/Disable Switch for Data Logging Feature
Figure 67 .CSV File Example
Figure 68 Data Log Example in Excel
PD-0100-0034 REV A
Page 71 of 90

3. Move the lever to Enable. The system generates a default filename and places
the data automatically into the folder titled HCS Log Files on the C: drive.
The user may change the naming of the file and a location to save the file as
preferred. Name file and click OK. (Refer to Figure 67.)
4. The system begins to log information.
5. The data file can be open and viewed using Microsoft Excel. (Refer to Figure
68.)
3.20 Remote Monitoring Upgrade Instructions

To install the remote monitoring software upgrade, use the following instructions:
1. Load the upgraded software CD onto your computer.
2. Open the ZIP folder and double click on the setup.exe file.
3. Run the Uninstall Wizard. (Refer to Figure 69.)
If you are upgrading from one software version to another, the Uninstall Wizard
uninstalls the old software before you can install the new software.
Figure 69 Uninstall Wizard
4. Click Next> to continue to the next screen.

5. The old software version is removed from your computer. (Refer to Figure 70.)
PD-0100-0034 REV A
Page 72 of 90

Figure 70 System Uninstalling Software
6. Click Finish to complete the uninstall process.
Figure 71 Uninstall Process Completed
7. Open the ZIP folder and double click on the startup.exe file.
8. Run the Installation Wizard. (Refer to Figure 50.)
9. Follow the steps 4 through 8 in Section 3.16.
PD-0100-0034 REV A
Page 73 of 90

4 OPERATION
The HOGEN H Series hydrogen generator is a fully automated system. Upon pressing
the green START key, the system starts a control sequence that leads to the generation
of hydrogen gas. The user interface displays error codes. The figure below provides a
brief overview of the various components required for the operation of the H Series Unit.
Up/Down/Left/
Right Buttons
Start
Emergency
Stop
Service Bypass
Switch
Stop/Reset
Enter
Figure 72 Control Panel Overview
Graphical
Display
4.1 Operating Modes

4.1.1 Normal Mode
Normal mode is the conventional hydrogen generation mode.
4.1.2 Service Mode
Various system actions occur in service mode. This mode is used by authorized
factory personnel for configuring the system during manufacturing, maintenance
and service procedures.
4.1.3 Keys
The Start and Stop control keys are used to start and shut down the generator
during normal operation. The Start key has the primary function to commence
hydrogen generation. The Enter, Left, Right, Up and Down keys are used for
entering and exiting menus and selecting and modifying parameters. Use the
Enter key to enter a menu selection and to confirm new values. The Left key is
also used for exiting menus.
PD-0100-0034 REV A
Page 74 of 90

4.2 Pre-Start Startup Instructions

Pre-Startup Startup is performed by a Proton Certified Technician (at time of
commissioning is preferred).
1.
2.
3.
4.
5.
6.
7.
8.
9.
Turn facility DI water supply on to the unit.

Turn facility power on to the unit.
Turn the cooling water supply on to the unit.
Switch the service bypass key to the SERVICE mode. (Refer to in the
Installation and Operation Manual, PD-0100-0034.)
Open the fluid side doors of the generator.
Turn the main power disconnect switch to the ON (I) position.
If an error code, E40 (CG Cal expired + 2 weeks), is displayed on the graphical
display, the unit must be calibrated. (Refer to Section 4.3.1 in the Maintenance
Manual, PD-0200-0005.) Once calibrated, proceed to Step 10.
Press the green start button. (Refer to in the Installation and Operation Manual,
PD-0100-0034.) The HOGEN hydrogen generator is now ready to go through prestart checks and attempt to start up. This step may take as long as 30 minutes. At
the end of the 30-minute time period, unit performs an automatic shutdown and
communicates an error code. During this 30-minute period, inspect the fluid side
cabinet for any water leaks. If any water leaks are found, shut off power to the
unit, fix the leaks, and begin Pre-Start Startup at Step 6.
Document the error codes displayed on the Errors and Warnings screen of the
User Interface (UI). (Refer to in the Installation and Operation Manual, PD-01000034.) Record all error codes
displayed______________________________________________________.
If an error code or warning appears that is not listed above, please contact Proton Energy
Systems for further information.
10. Pre-Start Startup is completed. Turn the main power disconnect to the OFF (O)
position.
11. Remove facility power to the unit.
12. Proceed to Section 4.1 for routine startup and operating instructions.
4.3 Applying Power

Turning on the main power to the cabinet initiates the on-board air purge blower.
The blower pressurizes the cabinet. The cabinet doors must remain closed and
secured in place, as the cabinet must maintain a minimum of 0.25 water column
(7 Pa) pressure in order for the system to operate.
PD-0100-0034 REV A
Page 75 of 90

Procedure:
1.
2.
3.
4.
5.
6.
7.
Confirm the Service Bypass Switch is in Normal mode.

Verify all cabinet doors are closed and secured.
Verify the air inlet and exhaust openings are not blocked.
Confirm that room is non-classified.
Verify the DI water supply is on.
Verify coolant supply is on.
Turn the Main Power Disconnect Switch from OFF (O Position) to ON (I
Position).
The H Series generator is equipped with a Surge Protection Device (SPD), which
is located in the central area of the power panel, for each phase of incoming
power. An auxiliary contact on each SPD is incorporated into the generators
safety circuit. In a normally operating unit, the SPD contact is closed. In a
faulted condition (i.e. lightening strike or other high transient voltage on the
incoming line), the SPD activates the contacts, which opens the safety circuit and
shuts down the generator. Each SPD is fused. The generator does not shut down
in the unlikely event of a fuse failure. In the event of a fuse failure, a light is
displayed on the fuse holder of the power distribution panel to indicate a failed
fuse. It is recommended to inspect the SPD fuses (1FU-1, 2, and 3) on a monthly
basis and replace any fuses that indicate a failure.
An open fuse prevents an SPD from properly protecting the generator.
POWER WILL STILL BE PRESENT IN THE GENERATOR UNTIL THE MAIN
POWER DISCONNECT SWITCH IS TURNED TO THE OFF (O) POSITION.
THE UNIT CAN BE LOCKED OUT/TAGGED OUT AT THE MAIN POWER
DISCONNECT.
DO NOT REMOVE POWER FROM THE UNIT UNTIL THE DISPLAY SCREEN
SAYS READY TO START. SHUTTING OFF THE UNIT PREMATURELY
CAN CORRUPT THE CONTROLLER.
4.4 Control Panel

The HOGEN H Series hydrogen generator control panel contains all the buttons
required to operate the unit. Figure 72 shows the layout of the user interface.
The user interface employs a graphical display and push buttons for enabling the
operator to monitor and to control the equipment. Service and maintenance
personnel also use the interface for carrying out respective functions. Text
information for the operation of the equipment is in English.
PD-0100-0034 REV A
Page 76 of 90

4.5 Generating Hydrogen

During operation, the HOGEN H Series system provides hydrogen through its
product hydrogen port. The unit runs in load following mode. This mode
maintains pressure at the set point as long as the demand for hydrogen does not
exceed the rated capacity of the product.
The following sequence of events occurs once power from the Main Power
Disconnect is applied to the unit:
1. The unit displays several screens on startup.
a. Booting Up System
b. HOGEN SPLASH
c. Version Info
d. Built in Test stated below (Display does not show individual checks
a failure prevents the system from entering Ready to Start. If an
error occurs, a corrective action is required.)
i. Fuse Check
ii. Read A200 Switches
iii. Verify A300 Switches
iv. Verify CG220 Level
v. Verify Water Quality Resistance
vi. Verify System Pressure
2. At the conclusion of these checks, the Display shows Ready to Start,
indicating that the unit is ready to generate hydrogen.
3. Hydrogen generation is initiated by pressing the Start button. The system
checks the A200 water level. If the water level is below the low level, Setting
Up the System is displayed. The very first startup or applications with low
water pressure may take significantly longer periods of time to start the
equipment.
4. The A200 is filled via the external DI water feed. The system proceeds to the
next state when the water level is above the low level switch plus 45 seconds.
The cell stack water flow switches are verified to be in their proper state. If at
least one is found in the proper state, the system pump CP205 energizes.
5. After the pump is started, the system proceeds to the next state and applies
current to the cell stack(s). M15 (Generate to Vent) is visible on the User
Display. The system remains in this state for 135 to 600 seconds or until the
A300 water level is at the midpoint level.
6. Upon success, the vent valve closes and the system pressure increases to the
BPR310 settings. Hydrogen is now available at the product output. At this
point, the User Display shows M01 (Load Following State) and the product
pressure is visible.
PD-0100-0034 REV A
Page 77 of 90

4.6 Manual Shutdown

Manual shutdowns of the HOGEN H Series hydrogen generator occur in three
ways: by pressing the red STOP/RESET button, engaging the E-Stop, or
switching the main power disconnect switch to the OFF position.
E-Stop and main power disconnect cause an immediate stop and do not allow the unit to
go through the normal shutdown process. Preferred method of shutdown is to hit the red
STOP/RESET button on the keypad.
By pressing the red STOP/RESET button, the following sequence will occur:
The system de-energizes all outputs, except the circulation pump and the
purge fan.
The power supplies are disabled.
Water is circulated for 60 seconds after the button is pressed.
The system displays Stopping.
The unit goes to Ready to Start at end of System Stopping screen after
one minute.
The vent solenoid SV329 is opened to vent stored hydrogen.
The operator is not allowed to reset the unit until the 60-second circulation of water is
complete.
By switching OFF the main power disconnect switch all power for the system is
disconnected simultaneously, and the HOGEN generator depressurizes.
The E-stop is a NORMALLY CLOSED circuit. Engaging the E-Stop trips the contactor,
which stops hydrogen production and removes power to safety-critical components and
circuits, but leaves some components and circuits inside the electrical enclosure
energized. The generator safely depressurizes when the E-Stop is engaged.
PD-0100-0034 REV A
Page 78 of 90

4.7 Automatic Shutdown

In the event the control system detects a fault that may require the unit to cease
operation, the unit will automatically shutdown. The graphical display will output
any one of the following warnings and error codes. Please contact the Customer
Service department immediately at (203) 949-8697 and ask for field service
technical support or email customerservice@protonenergy.com
Warnings do not shut down the unit. Warnings alert that an undesirable condition exists
and may result in an error. A corrective action should be taken to eliminate the warning
before an error code results.
Code
W01
W02
W03
W04
W05
W06
W07
W08
W09
W10
W11
W12
W13
W14
W15
W16
W17
W18
W19
W20
W21
W22
E01_A1
E01_A2
E01_A3
E01_B1
E01_B2
E01_B3
E01_C1
E01_C2
E01_C3
E02_A1
Abbreviated Description
Poor Water Quality

A200 Low Fill Rate
Bad Guard Bed
Low Coolant Temperature
High Coolant Temperature
System Temperature Warning
CG in O2 (CG220) Level High
Calibration Gas Pressure Low
System Pressure Low

Cabinet Temperature High
CG Calibration Canceled
CG Calibration Due
CG in O2 Low Reading
Low Stack Voltage - A1
Low Stack Voltage - B1
Low Stack Voltage - C1
High Stack Voltage - A1
PD-0100-0034 REV A
Detailed Description
Reserved
Reserved
System has detected poor water quality. The warning is generated after three A200
drain and fill cycles have been completed.
System has detected a low incoming DI water rate (below 9.3 liters/hr)
Three water recovery attempts were made within a 24 hr period
Low System Coolant Temperature (less than 3 C)
High System Coolant Temperature (greater than 35 C)
System Temperature Exceeds 60 C
Hydrogen Concentration in A200 exceeds 30% LFL
Reserved
Calibration Gas Bottle Pressure is less than 150 psi
Reserved
Reserved
Reserved
Reserved
Reserved
System Pressure never reaches 12.4 bar (4, 6 NM) or below 11.7 bar (2NM)
Electrical Enclosure Temperature Exceeds 60 C
Reserved
CG Calibration was manually canceled
CG Calibration is due in two weeks
Hydrogen Concentration in A200 is reading less the -5% LFL
Cell Stack A Voltage is Low (less than 1.2 Volts/cell)
Cell Stack B Voltage is Low (less than 1.2 Volts/cell)
Cell Stack C Voltage is Low (less than 1.2 Volts/cell)

Cell Stack A Voltage is High (greater than 2.8 Volts/cell)
Page 79 of 90

Code
E02_A2
E02_A3
E02_B1
E02_B2
E02_B3
E02_C1
E02_C2
E02_C3
E03_A
E03_B
E03_C
E04_A
E04_B
E04_C
E05_A1
E05_A2
E05_A3
E05_B1
E05_B2
E05_B3
E05_C1
E05_C2
E05_C3
E06
E07
E08
E09
E10
E11
E12
E13
E14
E15
High Stack Voltage - B1
High Stack Voltage - C1
Low Cell Stack Current - A
Low Cell Stack Current - B
Low Cell Stack Current - C
High Cell Stack Current - A
High Cell Stack Current - B
High Cell Stack Current - C
Power Supply Fault - A1 (PS1)
Power Supply Fault - B1 (PS4)
Power Supply Fault - C1 (PS7)
Power Supply Error
Power Supply Communications Error
High System Pressure
Low System Pressure
High System Temperature
Water Frozen Shutdown
A200 Empty
A200 Flooded
E16
Bad Water Quality
E17
E18
E19
E20
E21
E22
E23
E24
E25
E26
A200 Pre-Start Timeout

A300 Empty
A300 Flooded
Bad Water Quality Sensor
CG in O2 High
CG Sensor Error
PD-0100-0034 REV A
Cell Stack B Voltage is High (greater than 2.8 Volts/cell)
Cell Stack B Voltage is High (greater than 2.8 Volts/cell)

Low Cell Stack Current in Stack A (Less than 1 Amp)
Low Cell Stack Current in Stack B (Less than 1 Amp)
Low Cell Stack Current in Stack B (Less than 1 Amp)
High Cell Stack Current in Stack A (Greater than 165 Amp)
High Cell Stack Current in Stack B (Greater than 165 Amp)
High Cell Stack Current in Stack C (Greater than 165 Amp)
Cell Stack A Power Supply 1 Fault
Cell Stack B Power Supply 1 Fault
Cell Stack C Power Supply 1 Fault
Communications Error between system controllers during Start-up
Communications Error between system controllers during Generation
Reserved
System Pressure is above 17.9 bar
System Pressure falls below the 12.4 bar (4, 6 NM) or below 11.7 bar (2NM)
Reserved
System Temperature Exceeds 65 C Limit
System Temperature is less than 2 C
A200 Level Sensor Reads Empty Condition (Abnormal State)
A200 Level Sensor Reads Flooded Condition (Abnormal State)
System has detected bad water quality. The error is generated after five A200 drain
and fill cycles have been completed.
A200 Takes in excess of 30 minutes to reach High Level during Start-up
A300 Level Sensor Reads Empty Condition (Abnormal State)
A300 Level Sensor Reads Flooded Condition (Abnormal State)
Water Quality Sensor Output (RS209) is out of range
Reserved
Reserved
Reserved
Hydrogen Concentration in A200 exceeds 50% LFL
Reserved
Calibration values for CG Sensor are out of range
Page 80 of 90

Code
E27
E28
E29
E30
E31
E32
E33
E34
E35
E36_A
E36_B
E36_C
Stack Water Flow
Checksum Failure
Unhealthy 24V, 5V, 3.3V Supply
Failed Digital Fuses
A200 Level Switch Failure
A300 Level Switch Failure
Low Water Flow to Stack A
Low Water Flow to Stack B
Low Water Flow to Stack C
E37
Previous Reset Error
E38
E39
E40
E41
E42
E43
E44
E45
E46
E47
E48
No Stacks Present
CG Sensor Calibration Error
High Electrical Cabinet Temperature
Bad Coolant Temperature Sensor
Bad System Temperature Sensor

Bad System Pressure Sensor
Reserved
All Cell Stack Flow Switches are detecting flow prior to Pump Start-up
System Controller Memory Storage Error
Input Power Source to System Controller is Out of Range
Digital Output Fuse Failure
Reserved
lnvalid A200 Level Sensor States
lnvalid A300 Level Sensor States
Reserved
Flow Switch has not detected required flow condition for Cell Stack A
Flow Switch has not detected required flow condition for Cell Stack B
Flow Switch has not detected required flow condition for Cell Stack C
Water Frozen Error (E13) has not been cleared by the trained personnel or failed
System Controller
No Cell Stacks have been enabled
Reserved
Validity of CG Sensor Calibration has elapsed (in excess of 104 days)
Electrical Enclosure Temperature Exceeds 65 C Limit
Coolant Water Temperature Sensor Value is out of Range
Reserved
Reserved
Reserved
System Water Temperature Sensor Value is out of Range
Invalid State for PT307 Pressure Sensor (Out of Range)
Reserved
Table 11 Error and Warning Codes
PD-0100-0034 REV A
Page 81 of 90

5 USER INTERFACE
5.1.1 LCD Display Areas
Menu Title
Data Display
System Mode
Warnings and Errors
Figure 73 LCD Display Areas
5.1.2 Display Screens

Title
Ready to Start
Setting Up System
Default
Menu
Warning Screen
Error Screen
Set Parameter
View Service Screen
Network Configuration
Contrast Control
CG Calibration
PD-0100-0034 REV A
Description
The system is ready for hydrogen generation.
The system is initializing for hydrogen generation.
The default menu displays:
System Pressure
CG in Oxygen
Hydrogen Flow
System Uptime
The Menu screen is selectable when a system mode is displayed. The system mode is
displayed on the left-hand side of the status bar and has the form M##.
The Warning Screen displays all system warnings since the last power cycle. The screen
utilizes a circular buffer and retains the last 15 (fifteen) warnings.
The Error Screen displays all system errors since the last power cycle. This screen resets
system errors.
This screen allows the user to select the system pressure unit to display
This is a password-protected screen for use by authorized factory personnel.
This screen provides the current network configuration settings. These settings cannot be
modified from this menu. The settings are provided for only verifying the system network
settings.
This screen adjusts the LCD darker or brighter. There is no effect on back lighting.
Select either Auto or Manual.
Page 82 of 90

6 APPENDIX A: OPTIONS
6.1 Pressure Reducing Regulator Option
The HOGEN H Series hydrogen generator can reach a maximum of 225 psi
during normal operation. The hydrogen product line pressure can be reduced
from 225 psi to ambient pressure using a pressure reducing regulator. The
pressure reducing regulator may be installed anywhere between the product outlet
on the HOGEN H Series unit and the point of use.
A pressure reducing kit (KT-1000-0011 BRS or KT-1000-0018 SS) is available from
PROTON. The kit includes a bracket for mounting the regulator to the unit.
The selection of the regulator must be rated for hydrogen service.
The pressure reducing regulator should be sized for desired pressure drop and maximum
flow rate.
H Series
M6
M4
M2
Pressure Drop
29 psi (2 bar)
19 psi (1.3 bar)
10 psi (.07 bar)
Table 12 Pressure Drop Data for Pressure Reducing Regulator
The unit can only produce its rated output of flow. If flow requirements exceed the units
rated output flow, the unit cannot maintain the desired delivery pressure.
Figure 74 Example Schematic of the Pressure Reducing Regulator
PD-0100-0034 REV A
Page 83 of 90

6.2 Coolant Isolation Kit Option (Installed)

Automatic
Isolation Valve
Coolant Strainer
Coolant Inlet
Pressure
Gauges
Coolant Exit
Mechanical
Isolation Valves
Check
Valve
Figure 75 Coolant Isolation Option Installed
6.3 Dewpoint Transmitter Option

The dewpoint transmitter continually monitors air dryer performance, compressed
air quality and dry gas moisture from ambient dewpoint levels to as low as 148
F (-100 C). Equipped with an aluminum oxide moisture sensor, the dewpoint
transmitter provides better sensitivity, better repeatability, and faster response
times.
Figure 76 Dewpoint Transmitter
A dewpoint transmitter kit is available from PROTON. The kit includes a state-of-the-art
dewpoint transmitter with an aluminum oxide moisture sensor (KT-1000-0013).
PD-0100-0034 REV A
Page 84 of 90

6.4 Backup Manifold Auto Crossover Option

The backup manifold allows for 24/7 backup of the HOGEN H Series hydrogen
generator. It also allows for the generator to be turned off during service or
maintenance without disturbing the gas flow or pressure to the application.
Figure 77 Backup Manifold Auto Crossover
The backup manifold auto crossover is designed to augment the generator flow
during peak flow demands or to automatically replace the flow from the generator
if it is taken out of service. PROTON offers a backup manifold auto crossover kit,
available in brass (02-3500-0000) or stainless steel (02-3500-0001), which
includes a wall mount panel, a pressure regulator, a generator inlet with isolation
valve and a flexible connection for high pressure cylinder supply with isolation
valve.
6.5 Combustible Gas Sensor Assembly Option

The combustible gas sensor is a non-intrusive Smart sensor designed to detect
and monitor combustible gas in air over the range of 0100 Percent LFL (Lower
Flammability Limit). The combustible gas sensor assembly (KT-1000-0029 or
KT-1000-0030) consists of a matched pair catalytic bead sensor in stainless steel
housing, a plug-in control transmitter circuit, a base connector board, and an
explosion-proof enclosure.
Figure 78 Combustible Gas Sensor Assembly
PD-0100-0034 REV A
Page 85 of 90

6.6 Lab Purity Option

The lab purity kit (KT-1000-0034) is a panel-mounted assembly comprised of a
user connection manifold, pressure reducing regulator, gas-monitoring dewpoint
sensor, backup desiccant bed column, gas filter, controls, alarm relay, and a threeway gas diverter valve. It is installed upstream of the users process. If the
dewpoint monitor senses moisture in the hydrogen in excess of the control set
point, a three-way valve diverts the gas to the users hydrogen vent system. As an
extra measure, a desiccant column captures any trace moisture before it reaches
the end user. If desired, the user may connect a backup hydrogen supply to a port
provided on the kit. This provides uninterrupted hydrogen flow in the event of any
hydrogen generator purity or operational upset.
Figure 79 Lab Purity Kit
6.7 StableFlowTM Performance Optimization Option

By ensuring adherence to manufacturers specifications for hydrogen dewpoint,
purity and pressure, Protons StableFlow (KT-1000-0036) process minimizes
windage loss, ensures availability of full electric generation capacity, and
maximizes the life of generator windings. Further, plant productivity, safety and
security are greatly enhanced through elimination of high volume, high pressure
flammable gas storage. The combination a HOGEN hydrogen generator and a
StableFlow purity optimization system provides for the highest possible electric
generation efficiency, capacity and life. (Refer to Figure 80.)
The package is designed as an integrated solution, which facilitates ease of
installation and maintenance. All necessary interfaces for gas and power are
included. One StableFlow controller is required for each electric power generator
optimized. The implementation of a HOGEN hydrogen generator to supply a
steady flow of ultra-high purity hydrogen is also required.
PD-0100-0034 REV A
Page 86 of 90

Figure 80 StableFlow Process
PD-0100-0034 REV A
Page 87 of 90

7 APPENDIX B: INSTALLATION CHECKLIST

This checklist is intended to guide installation personnel during the initial installation of a
HOGEN H Series hydrogen generator at a customer site. This form should be completely
filled out and faxed back to Proton personnel arriving on-site for the installation
verification and initial start-up phase. Please call customer service or your local service
provider/supplier if you have any questions. PROTON: Tel: 203-949-8697, Fax: 203949-8016.
1. Electrical Connections
1.1. Power
1.1.1. Provide the plated electrical service including Protective Earth ground to
the hydrogen generator following local wiring codes for industrial
equipment installation. (Refer to Section 0)
Initial
Date
1.1.2. Verify proper electrical service is provided for the installation

Volts
kVa
Amps
Phase
Hz
2m
380-480
22
32
3
50/60
4m
40
58
6m
Actual
58
85
Date
Initial
1.2 Communications (If Any)

(Refer to Section 3.9)
Initial
PD-0100-0034 REV A
Date
Page 88 of 90

1.3 Ventilation
(Refer to Section 3.2)
Initial
Date
2. Fluids Hookup
2.1 General Guidelines
All water, drain and vent lines should be heat traced and insulated if freezing
temperatures may be experienced.
All plumbing materials should conform to the guidelines outlined in Section 3.9.7. Listed
below are the fluid connections that need to be connected prior to system operation.
2.1. Feed water in accordance with ASTM TYPE II (>1 M-cm, or < 1 Siemen/cm)
Initial
Date
2.2. DI water drain

Initial
Date
2.3. Verify the air / oxygen vent is free from obstruction.

Initial
Date
2.4. Hydrogen vent in accordance with local codes free from obstruction and freezing
Initial
Date
2.5 Hydrogen product

Initial
PD-0100-0034 REV A
Date
Page 89 of 90

2.6 Cooling water inlet
Date
Initial
2.7 Cooling water return

Initial
Date
Site Information
Generator Model:
Customer Name:
Customer Site:
Site Contact:
Site Phone #:
Signature:
Serial Number:
Date:
Please fax Installation Checklist to:

ATTN: Customer Service at 203-949-8016
Any changes pertaining to the specific unit installation are superseded by additional
documentation received from PROTON.
PD-0100-0034 REV A
Page 90 of 90

PD-0100-0034 - Rev - A Hogen H Eng

Caricato da

Informazioni sul documento

Titolo originale

Copyright

Formati disponibili

Condividi questo documento

Condividi o incorpora il documento

Opzioni di condivisione

Hai trovato utile questo documento?

Questo contenuto è inappropriato?

Copyright:

Formati disponibili

PD-0100-0034 - Rev - A Hogen H Eng

Caricato da

Copyright:

Formati disponibili

Installation & Operation Manual

==================== Hydrogen By Wire ======================

HOGEN H Series Hydrogen Generator

HOGEN H Series Hydrogen Generator

Gas Generating Equipment

CONFIDENTIAL Do not copy

HOGEN H Series Hydrogen Generator

HOGEN H Series Hydrogen Generator

Key Definitions, Acronyms, and Abbreviations Used in this Document .................................. 10

Classification of the HOGEN Hydrogen Generator .................................................................. 12

Product Specification ................................................................................................................ 17

General Information .................................................................................................................. 19

Using Hydrogen Gas ................................................................................................................. 19

Top-Level Steps of Installation ................................................................................................. 22

Facility Air Ventilation Requirements ...................................................................................... 22

Operating Environment ............................................................................................................. 25

Site Preparation ......................................................................................................................... 25

Instructions on Unpacking the HOGEN Hydrogen Generator .................................................. 27

Lifting and Moving ................................................................................................................... 28

Anchoring Instructions .............................................................................................................. 30

CONFIDENTIAL Do not copy

HOGEN H Series Hydrogen Generator

Physical Layout, Connections and Dimensions ............................................................... 36

Connecting the Cell Stack(s) ..................................................................................................... 46

Calibration Gas Cylinder Installation ........................................................................................ 51

Inlet and Exit (Optional) Air Filter Housing Installation .......................................................... 51

External Shroud Installation (Optional) .................................................................................... 55

Guard Bed Installation Instructions........................................................................................... 57

Remote Monitoring Upgrade Instructions ................................................................................. 72

Pre-Start Startup Instructions .................................................................................................... 75

Generating Hydrogen ................................................................................................................ 77

User Interface ..................................................................................................................................... 82

APPENDIX A: Options ....................................................................................................................... 83

CONFIDENTIAL Do not copy

HOGEN H Series Hydrogen Generator

Pressure Reducing Regulator Option ........................................................................................ 83

Coolant Isolation Kit Option (Installed) .................................................................................... 84

Dewpoint Transmitter Option.................................................................................................... 84

Backup Manifold Auto Crossover Option................................................................................. 85

Combustible Gas Sensor Assembly Option............................................................................... 85

Lab Purity Option...................................................................................................................... 86

StableFlowTM Performance Optimization Option...................................................................... 86

APPENDIX B: Installation Checklist.................................................................................................. 88

Figure 21 Right Side View............................................................................. 36

Figure 24 HOGEN H Series Hydrogen Generator Interface Connections .................................................. 37

CONFIDENTIAL Do not copy

HOGEN H Series Hydrogen Generator

CONFIDENTIAL Do not copy

HOGEN H Series Hydrogen Generator

CONFIDENTIAL Do not copy

HOGEN H Series Hydrogen Generator

Figure 1 HOGEN H Series Hydrogen Generator

CONFIDENTIAL Do not copy

HOGEN H Series Hydrogen Generator

CONFIDENTIAL Do not copy

HOGEN H Series Hydrogen Generator

1.1 Key Definitions, Acronyms, and Abbreviations Used in this

CONFIDENTIAL Do not copy

HOGEN H Series Hydrogen Generator

1.2 General Description

Figure 2 HOGEN H Series Interface Connections

CONFIDENTIAL Do not copy