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User Manual for LAUPER INSTRUMENTS models including: 0020-03 Hydroxychrom, 0020-03, Hydroxychrom
STANDARD USER MANUAL n° #0020-3 SMU#0020-03 Page 5/25 CHAPTER 2. GENERAL INFORMATION & COMPATIBILITY TO NORMALISATIONS 2.1. CE CONFORMITY This equipment was built in compliance and is compatible with EC recommendations concerning electrical
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DocumentDocumentCHROMATO-SUD STANDARD USER MANUAL SMU n° #0020 Date d'application : 14 December 2018 Revision : N° 3 Gas-Detection Lauper Instruments AG Irisweg 16B CH-3280 Murten Tel. +41 26 672 30 50 info@lauper-instruments.ch www.lauper-instruments.ch HYDROXYCHROM Revision N° 0 Creation 1 Revision 2 Revision 3 Revision Historic Modification nature Application date 24/10/2012 25/10/2012 22/04/2015 14/12/2018 Modified chapters All Ch.3 & 4 Ch.4.6.2 Ch. 3.1 & 4.3 Editor: S. GUTIERREZ, JP.AMIET, Checked by: K.TRAULLE Visa : Visa : SMU #0020-01 Approved by: Visa : Page 1/25 STANDARD USER MANUAL n° #0020-3 CONTENTS CHAPTER 1. INTRODUCTION ......................................................................................................................... 4 CHAPTER 2. GENERAL INFORMATION & COMPATIBILITY TO NORMALISATIONS ........................................... 5 2.1. CE CONFORMITY ..................................................................................................................................... 5 2.2. W.E.E.E. PRODUCT RECYCLING DECLARATION........................................................................................... 5 2.3. SECURITY INSTRUCTIONS AND CORRECT USE ............................................................................................. 5 CHAPTER 3. SPECIFICATIONS AND DESCRIPTION ........................................................................................... 6 3.1. SPECIFICATIONS ...................................................................................................................................... 6 3.2. INSTRUMENT PRESENTATION ................................................................................................................... 7 3.3. FUNCTIONING PRINCIPLE ......................................................................................................................... 8 CHAPTER 4. INSTALLATION AND OPERATION................................................................................................9 4.1. RECEIPT OF INSTRUMENT AND CHECK....................................................................................................... 9 4.2. DELIVERY CONTENT ................................................................................................................................. 9 4.3. GENERATOR INSTALLATION...................................................................................................................... 9 4.4. CONNECTIONS ...................................................................................................................................... 10 4.4.1. Fluidic connections ......................................................................................................................... 10 4.4.2. Electric connections........................................................................................................................ 11 4.5. FACTORY SETTINGS ............................................................................................................................... 11 4.6. REMOTE CONTROL SOFTWARE: HYDROXYCHROM VIEWER FOR USB ................................................... 12 4.6.1. SPECIFICATIONS ............................................................................................................................. 12 4.6.2. INSTALLATION PROCEDURE ........................................................................................................... 13 4.6.3. INSTRUMENT INFORMATION STATUS AND OPERATION MODE .................................................... 22 CHAPTER 5. MAINTENANCE, ALARMS + TROUBLESHOOTING ...................................................................... 24 5.1. REGULAR MAINTENANCE ....................................................................................................................... 24 5.2. LED AND BUZZER INDICATIONS ............................................................................................................... 24 5.3. ALARMS + TROUBLESHOOTING .............................................................................................................. 25 SMU#0020-03 Page 2/25 STANDARD USER MANUAL n° #0020-3 WARNING The described material in this manual contains one or several confidential computer programs that are the property of CHROMATO-SUD. CHROMATO-SUD authorize the instrument owner to use the program (s) for what it has been designed to the exclusive of any other use. The total or partial copyright, the dismantle, the retro-compilation or transcription or the above mentioned program for the use of the owner of a third party are strictly forbidden. GENERAL WARRANTY CHROMATO-SUD guarantees these instruments against the manufacturing defaults during a twelve month period from the delivery date. The replacement of the defective components will be free except the transport or travel fees that will be invoiced according the current tariffs. CHROMATO-SUD accepts no liability for damages or possible incurred losses. CHROMATO-SUD provides a spare part service and After Sales Service. Please contact the service engineer responsible for the repair or the spare part repair. The serial number of the instrument as well as the description of the trials done and the estimated reasons of the breakdown should be given to provide you the quickest service. CHROMATO-SUD reserves the right to modify the prices and the characteristics of these products. Copyright © 2005, CHROMATO-SUD 15 Rue d'Artiguelongue, 33 240 SAINT ANTOINE, FRANCE In case of warranty particular conditions, the general warranty will not be applied. SMU#0020-03 Page 3/25 STANDARD USER MANUAL n° #0020-3 CHAPTER 1. INTRODUCTION This document provides all necessary information for the installation and operation of your HYDROXYCHROM High Purity Hydrogen generator; it also describes the simple maintenance operations, alarms as well as troubleshooting. It is applicable to the below generation models and software HYDROXYCHROM Viewer Version 1.0 produced since October 2012: HYDROXYCHROM-100 HYDROXYCHROM-160 The operating manual considers and describes an instrument generally equipped with the most complex configuration ; should the explanation concerning the most complex instrument be too different from the simpler instrument, both cases will be described. SMU#0020-03 Page 4/25 STANDARD USER MANUAL n° #0020-3 CHAPTER 2. GENERAL INFORMATION & COMPATIBILITY TO NORMALISATIONS 2.1. CE CONFORMITY This equipment was built in compliance and is compatible with EC recommendations concerning electrical safety and electromagnetic emissions. It complies with 89/336/EWG, 93/98/EWG, standards EN 50 081-1, in 50 081-2, EN 50 082 - 1 and EN 50 082 - 2. Note Any modifications on the instrument which have not been approved in writing by the manufacturer will automatically cancel the manufacturer warranty. If such modifications are nevertheless undertaken, they are under the user responsibility; the manufacturer will under no circumstances be responsible for any damages direct or indirect which they would cause 2.2. W.E.E.E. PRODUCT RECYCLING DECLARATION In agreement with the European EC/2002/96 directive on electrical and electronic equipment recycling, this product may not be disposed in the garbage. For recycling information, contact the company who sold this product. If you want to get rid of this instrument, identify it as such and direct it to a certified recycling centre. 2.3. SECURITY INSTRUCTIONS AND CORRECT USE This Hydrogen generator has been designed in order to produce small quantities of Hydrogen for instrumentation applications. This device must only be used for such applications respecting the specifications and recommendations for its proper use described in this operating manual. The main recommendations are: Instrument can only be use indoors, at temperatures above 4°C and in a well-ventilated room. In case of maintenance inside the instrument, always unplug it before opening the casing(s). HIGH VOLTAGE inside. SMU#0020-03 Page 5/25 STANDARD USER MANUAL n° #0020-3 CHAPTER 3. SPECIFICATIONS AND DESCRIPTION 3.1. SPECIFICATIONS Models HYDROXYCHROM-100 HYDROXYCHROM-160 H2 Outflow @ 1013/20°C HYDROXYCHROM-100 = 100 Nml/min HYDROXYCHROM-160 = 160 Nml/min H2 purity Dew point Maximum Hydrocarbon content: 0.1ppm -40°C / -40°F Outlet Pressure From 0.5 to 7 bar (7 to 102 psig), adjustable by software. Pressure resolution 10 mbar Pressure stability Better than ±10 mbar H2 generation technology Drying technology Proton Exchange Membrane (PEM), Solid Polymer Membrane No maintenance static dryer Water quality Water capacity High purity distilled & filtered water. TOC free. Conductivity < 0.20 µS/cm 5L tank outside, 0.4L tank inside. Water consumption 5L water generates about 6000L Hydrogen Safety Low H2 stored volume; over pressure valve; internal leak test; automatic shut down; maximum current limit, water quality. Manual control Display ON-OFF power switch By Hydroxychrom Viewer Communications USB H2 outlet fitting Functioning conditions : Temperature Humidity Stainless steel 1/8" OD compression +10°C to +35°C max 80%, non condensing Transport and storage conditions: Temperature Humidity Duration +4°C to +40°C Max 90% Maximum 30 days. Instrument should run 5 minutes every month Power supply Power consumption (max at full flow) Automatic switching from 90VAC to 260VAC, 47 to 63 Hz HYDROXYCHROM-100 and HYDROXYCHROM-160: maximum 150W Sound pressure < 40dB (A) SMU#0020-03 Page 6/25 Dimensions Net weight (Kg) Certification STANDARD USER MANUAL n° #0020-3 W=482mm/19ins, H=180mm/7.1ins, D=600mm/23.6ins 10 kg CE 3.2. INSTRUMENT PRESENTATION The front panel contains a functioning LED (see chapter 5 for the signification). The rear panel' left side has: Mains plug with fuse and switch DB9 interface connectors for RS485, remote control USB, dry relay. The rear panel' in the center has: ZEROWATER input from external tank, fitting for 6mm tube Output hydrogen by dual ring fitting stainless steel 1/8" Dry air inlet, fitting brass 1/8" O2 output fitting, fitting for 8mm tube Mild Air outlet after cooling internal structures View of rear's face: SMU#0020-03 O2 + H2O output Dry air inlet H2 output Water inlet Page 7/25 STANDARD USER MANUAL n° #0020-3 3.3. FUNCTIONING PRINCIPLE The self-priming water pump1 sucks water from the ZEROWATER tank (external tank), and keep the internal tank filled up between the two Infra-Red water level detectors. The internal tank contains a circular deionization cartridge with minimum 1 year lifetime. The circulating water pump2 aspires ZERO WATER from the internal tank, and make water circulating through the electrolysis cell with PME membrane. Mixed with oxygen generated by electrolysis, the water return to the internal tank. O2 is separated and flows outside the instrument through a 8mm exhaust fitting. After creation during the electrolysis, hydrocarbon free wet hydrogen passes through the membrane and is dried a first time in the liquid-gas separator, then a second time by a static dryer without maintenance. The Hydrogen pressure is measured and regulated to the desired value by a current feedback to the H2-cell. HYDROXYCHROM-100 and HYDROXYCHROM-160 are equipped with a single layer H2-cell. Static dryer 24" H2 GENERATION MODULE Stainless steel Swagelok 1/8" H2 Outlet Outlet E-valve H2 pressure sensor 1 0-10 bar rel O2 Outlet Quick Connect Fitting 8mm Water Inlet Water pump 1 Quick Connect Fitting 6mm Manual OneWay valve Water Flow restrictor Internal tank capacity (500cm3) IR Level sensors 2X Deionisation Resin (80-100cm3) Circulating pump Water pump 2 Water + O2 Over-pressure valve (9.5 to 12 bar) External 5L Water Tank ZERO WATER box Max: 45 Amp 6V 600 to 640 Nml/min H2 Max: 45 Amp 3V 300 to 320 Nml/min H2 Gas liquid separator SMU#0020-03 Page 8/25 STANDARD USER MANUAL n° #0020-3 CHAPTER 4. INSTALLATION AND OPERATION 4.1. RECEIPT OF INSTRUMENT AND CHECK Each instrument is inspected and packaged prior to transport with great attention. Immediately after receipt, we recommend to perform a quick visual inspection of the package. If the package is damaged, report it in writing to the carrier at the time of delivery. The HYDROXYCHROM is packed in a wood box with protection and maintaining foams placed above and below the instrument. The HYDROXYCHROM packaging extraction begins with the opening of the wood box; at this stage, it is possible to verify the visual integrity of the instrument. Any damages must be immediately identified and photographed; it should be reported to the carrier as well as to your local Distributor or to CHROMATOTEC. For major damages, the HYDROXYCHROM shall be returned to the manufacturer after synchronization with the service department, which can be reached by e-mail at: support@chromatotec.com. In case of non-respect of this procedure, CHROMATOTEC cannot be kept in charge of the caused damage and cost will be charged to the customer. It is well recommended to keep the wood box for future shipments. 4.2. DELIVERY CONTENT Quantity Description 1 Hydrogen Generator HYDROXYCHROM with its factory communication option assembled 1 Connection tube from ZEROWATER tank to HYDROXYCHROM. 1 ZEROWATER tank (5L) 1 USB key including operating manual and HYDROXYCHROM Viewer software. If the generator is supplied with an analyzer, these elements are supplied with the USB key of the analyzer. 1 QC and verification certificate 1 USB cable for connecting the device to a PC 1 Power cable 230V, CE or according to your country 1 Shipping box 4.3. GENERATOR INSTALLATION The HYDROXYCHROM generator must be installed on a flat surface, without vibrations, avoiding potential shocks and excessive heat source; it should not be in contact with other devices on any of its walls. Operate the instrument in an open and well-ventilated area, in which the temperature does not go below +4°C. Good functioning of the instrument is guaranteed for a temperature between +10 and +35°C. To ensure proper ventilation, a clear space of at least 5 cm is required on the top of the instrument and around the ventilation outlet. The cooling air intake is located directly on the top and the rear of the instrument; under no circumstances this part should be obstructed. SMU#0020-03 Page 9/25 STANDARD USER MANUAL n° #0020-3 4.4. CONNECTIONS 4.4.1. FLUIDIC CONNECTIONS ZEROWATER Inlet: Disconnect the tube assembly which connects the inlet and outlet of the water circulation circuit. This assembly is made for transport. Place the ZEROWATER tank close to the H2-generator Connect the tube to the device. Lubricate the end of tube with distilled water and introduce it in the fitting, (labeled ZEROWATER INLET), push it firmly and screw the nut. REMARK The ZEROWATER tank has been designed to be placed on the floor at a maximum distance of 1.2 m from the generator. It can, nevertheless, be placed at the same level or above the instrument. The maximum difference in height between the generator and the ZEROWATER tank is 1m. Hydrogen Outlet: Hydrogen pressure is available at the OUTLET H2 output on the back of the instrument. This outlet is equipped with a stainless steel Swagelok 1/8" fitting. Oxygen outlet: remove the 8mm tube from the transport tube assembly and connect it to the O2 Outlet. The O2 outlet must be kept at atmospheric pressure and without restriction. Some droplets of water condensation are sometime present at the tube's end. This is normal; water could be collected by a small plastic glass. Air inlet: Air inlet must be dry air at 3 bar. SMU#0020-03 Page 10/25 STANDARD USER MANUAL n° #0020-3 Warnings: 1) Oxygen outlet must be maintained at atmospheric pressure. 2) If H2 outlet under pressure is suddenly opened, in certain circumstances H2 could be mixed with water. Switch OFF device before disconnecting H2 Outlet. CAUTION: your HYDROXYCHROM generator has been tested for several hours at the factory and all its tubes have been cleaned of ambient air contaminants. After a break of several days to several weeks of operation, Air ambient has slightly dirt the circuit of the instrument. The walls of the tubes need again to be cleaned. Before connecting to the consumer, please let your H2-generator running during a couple of hours to the atmosphere. 4.4.2. ELECTRIC CONNECTIONS Mains: Connect the HYDROXYCHROM generator with the electrical cable provided; if it was not possible, verify that the cable use has a sufficient section and has a ground wire (3X1 mm2 minimum). Make sure laboratory differential circuit breaker can absorb an inrush current of at least 6A without switching off. 4.5. FACTORY SETTINGS During one of the last phases of QC, your HYDROXYCHROM has been programmed with a set of values called "factory settings". Those settings will help you to start the generator without troubles: Set H2 Pressure: 2000mbar Timeout Pressure Alarm: 0 second (timeout disabled) Functioning Mode: Continuous on At this step, the HYDROXYCHROM is ready for startup. Switch power ON After a few seconds due to generator initialization, the water pump1 sucks ZEROWATER and fill up the internal tank When upper water level is reached, current is applied to the hydrogen cell. Electrolysis process is initiated and some H2 is available at the H2 outlet. The H2 generator's configuration could be modified according to your needs via its USB connection and a PC with HYDROXYCHROM Viewer software. SMU#0020-03 Page 11/25 STANDARD USER MANUAL n° #0020-3 4.6. REMOTE CONTROL SOFTWARE: HYDROXYCHROM VIEWER FOR USB OVERVIEW HYDROXYCHROM Viewer software provides User Interface to control Gas Generator Network through USB interface 4.6.1. SPECIFICATIONS Requirements PC or Laptop under WinXP SP2 or higher / Win Vista / Win 7 At least 5Mb of free space on the Hard drive USB port Performance Reporting Instrument Status, Parameters and Settings Connection The Instrument is connected to a PC using USB port. SMU#0020-03 Page 12/25 STANDARD USER MANUAL n° #0020-3 4.6.2. INSTALLATION PROCEDURE HYDROXYCHROM VIEWER : To install HYDROXYCHROM Viewer you must log the computer in "administrator" Remark: If you want work with HydroxychromViewer in Russian start by installing the "Cyrillic code page" (procedure below) and then come back here (only available with HydroxychromViewer V2.0). Step 1: Run "install_hydroxychromviewer.exe" Step 2: Select your preferred language for this installation SMU#0020-03 Page 13/25 STANDARD USER MANUAL n° #0020-3 Step 3: Choose destination folder or use default. Step 4: Complete installation SMU#0020-03 Page 14/25 STANDARD USER MANUAL n° #0020-3 Remarks: - If you just installed Hydroxychrom Viewer V1.0, when the installation is complete you have to do a "commit cf" (procedure below). - If you just installed Hydroxychrom Viewer V2.0, when the installation is complete, this window will appear: click on "yes", the computer will restart automatically saving the modification you just made. SMU#0020-03 Page 15/25 STANDARD USER MANUAL n° #0020-3 CYRILLIC CODE PAGE INSTALATION: Step 1: Run "install_cyrillic_codepage.exe" Step 2: Select your preferred language for this installation SMU#0020-03 Page 16/25 Step 3: Complete installation STANDARD USER MANUAL n° #0020-3 When the installation is complete, this window will appear: clic on "yes", the computer will restart automatically saving the modification you just made. Remark: After the computer restarted you can install the HydroxychromViewer software (go back to the procedure above). SMU#0020-03 Page 17/25 STANDARD USER MANUAL n° #0020-3 COMMIT CF PROCEDURE FOR COMPUTER UNDER EMBEDDED WINDOWS: Open the program named "command prompt" in the toollbar In this program, write "commitcf" as shown in the picture below and press enter. The program asks you to restart, write "Y" for yes as shown in the picture below and press enter. SMU#0020-03 Page 18/25 CHANGING LANGUAGE: STANDARD USER MANUAL n° #0020-3 Step 1: Open Application partition. Step 2: Open Hydroxychrom folder. Step 3: Open Hydroxychrom_v2.ini file with "Notepad". SMU#0020-03 Page 19/25 STANDARD USER MANUAL n° #0020-3 Step 4: Modify the second line of the code: - LanguageFile=Hydroxychrom_UK.lng for English language - LanguageFile=Hydroxychrom_FR.lng for French language - LanguageFile=Hydroxychrom_RU.lng for Russian language And then save the file. Step 5: Exit Hydroxychrom viewer: SMU#0020-03 Page 20/25 And open it again: STANDARD USER MANUAL n° #0020-3 USAGE: Step 1: Connect USB Step 2: Start HYDROXYCHROM Viewer Step 3: Adjust the COM port number that is associated with USB port Step 4: Left Click on Connect SMU#0020-03 Page 21/25 STANDARD USER MANUAL n° #0020-3 4.6.3. INSTRUMENT INFORMATION STATUS AND OPERATION MODE MODE: Instrument working mode could be chosen from one of following: Off No gas generation; On Gas generation is running but will be stopped after power off; Continuous On Gas generation is running but will be automatically started every time after power on; Remote control Gas generation Started/Stopped depending on the Digital Input signal at the rear side of the instrument. Leak check allows to check internal H2 leaks SMU#0020-03 Page 22/25 INSTRUMENT INFORMATION: STANDARD USER MANUAL n° #0020-3 Instrument information section provides Firmware Version, Instrument Serial Number, Run time and Cell total current. PRESSURE INFORMATION AND SETTINGS: Actual Pressure shows the pressure measured at the outlet of the instrument; Set Pressure is a parameter, where user could see and/or modify desired value of the pressure; Timeout is time in seconds showing for how long the Actual Pressure does not match the Set Pressure; Timeout Alarm is time in seconds given to the instrument after start to reach the Set Pressure. IMPORTANT NOTE: For security reasons, the Instrument stops generation when the Timeout value became equal to Timeout Alarm. FLOW INFORMATION: Consumption shows current water consumption in ml/h; Production shows actual production of H2 in percentage from the maximum capacity; Estimated Flow shows actual H2 flow in ml/min. Please note that this value is not directly measured but calculated inside the instrument. Use it only for estimation purposes. CELL INFORMATION: Cell information section provides Run time and Cell total current. SMU#0020-03 Page 23/25 STANDARD USER MANUAL n° #0020-3 CHAPTER 5. MAINTENANCE, ALARMS + TROUBLESHOOTING 5.1. REGULAR MAINTENANCE The Hydrogen generator HYDROXYCHROM does not need regular maintenance; it needs ZEROWATER and electrical power. If the instrument is used according to recommendations made by the constructor, the deionizing bags (internal and external tanks) should be exchanged once every 1 year and the internal tank filter should be exchanged once every 3 years. In order to keep the instrument in its original conditions, please use exclusively distilled and filtered water. 5.2. LED AND BUZZER INDICATIONS Green Red ON OFF FAST OFF FAST OFF OFF FAST FLASH OFF FLASH OFF FLASH SLOW FAST FAST Variable OFF Buzzer OFF OFF FLASH FAST SLOW OFF FAST OFF OFF STBY (by user), REMOTE STBY, ON, CONTINEOUS ON, REMOTE ON STBY with Warning ON with Warning, CONTINEOUS ON with Warning, REMOTE ON with Warning STBY with Error LeakTest in process LeakTest success LeakTest Fail USB-CABLE-CONNECTED H2 Flow Production indication versus maximum capacity STBY = STAND-BY SMU#0020-03 Page 24/25 STANDARD USER MANUAL n° #0020-3 5.3. ALARMS + TROUBLESHOOTING Alarm # 1 2 3 4 Alarm Name Water Level H2 Output pressure H2-Cell Voltage Internal communication Cause Cure Internal tank could not be filled up to External tank is empty, add maximum level detector. water. Tube between external tank and Push tube in the INLET device is leaky. WATER quick connector. Actual H2 pressure could not reach set value, because there is a leak inside your generator or on the line between generator and GC. Proceed to a leak check with HYDROXYCHROM Viewer software and verify if fittings are screwed correctly. Volume between H2 generator and consumer too big. Pressure value could not be reached on time. Increase value of timeout. H2 flow consumed by your GC is superior to the generator's capacity. Verify capacity consumption, consumption of GC. and reduce Bad quality of water. Replace actual water exclusively by distilled and filtered water. Deionisant bags inside internal and external tank are not any more efficient. Exchange deionisant bags. H2-cell is dry. Verify if water is correctly circulating. Circulating pump should not be stopped. One or several cable(s) inside device is(are) disconnected or damaged One board inside device is damaged. If a cable is simply disconnected due to vibrations during shipment, please switch of the device and reconnect simply the cable. If one board is damaged, please call your local distributor for repair. SMU#0020-03 Page 25/25