Enapter EL2.0 User manual

EL2.0
Hydrogen Generator (35 bar)
Installation Manual
Rev. 08 –Mar 2020

Version
Document Title
Release Date
08
EL2.0 –Installation Manual
2020-03-18
EL 2.0 Installation Manual
Rev. 08
March 2020
Enapter Srl
Registered office: Via Lavoria 56/G
56040 Crespina (PI) Italy
VAT no. 13404981006
All rights reserved. No parts of this manual may be reproduced, stored in a data retrieval system or transmitted by
any means without the prior written permission of the issuer.
The following exception applies: photocopying pages from the manual for instruction for or by lecturers is allowed.
Subject to change without prior notice.

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CONTENT
CONTENT ..................................................................................................................................................3
WELCOME.................................................................................................................................................5
Scope of the Document.............................................................................................................................................5
Approved Use............................................................................................................................................................ 5
WARNINGS AND HAZARDS .................................................................................................................6
General Safety Instructions....................................................................................................................................... 7
Hazards Description ..................................................................................................................................................8
Hydrogen Hazards.....................................................................................................................................................8
Mechanical Hazards ..................................................................................................................................................9
Electrical Hazards ....................................................................................................................................................10
Chemical Hazards....................................................................................................................................................11
Thermal Hazards .....................................................................................................................................................12
Environmental Hazards...........................................................................................................................................12
Acoustic Hazards.....................................................................................................................................................12
UNPACKING........................................................................................................................................... 13
PRODUCT OVERVIEW........................................................................................................................ 14
EL2.0 - Front View ...................................................................................................................................................14
EL2.0 - Rear View.....................................................................................................................................................15
ASSEMBLY ............................................................................................................................................. 16
Required Tools ........................................................................................................................................................ 16
Accessories/Spare Parts ..........................................................................................................................................17
Gas and Water Connections....................................................................................................................................18
Gas Connections...................................................................................................................................................... 19
Water and Purge Connections ................................................................................................................................ 19
Electrical Connections............................................................................................................................................. 21
Ground Connection................................................................................................................................................. 21
COMMISSIONING ................................................................................................................................. 22
Preparation of the Conditioning Solution ............................................................................................................... 22
First Filling of the Process Tank............................................................................................................................... 23
Further Refills.......................................................................................................................................................... 23
INSTALLATION..................................................................................................................................... 24
Safety Area.............................................................................................................................................................. 24
EL2.0 –MANUAL OPERATION......................................................................................................... 26
ELECTROLYSER MONITORING TOOLS ......................................................................................... 27
Mobile Application..................................................................................................................................................27
Programming Ports .................................................................................................................................................27
TRANSPORT, MAINTENANCE AND RECYCLING ........................................................................ 28
Maintenance Routine..............................................................................................................................................28

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Cleaning...................................................................................................................................................................28
Transport.................................................................................................................................................................28
Disposal................................................................................................................................................................... 28
TECHNICAL SPECIFICATIONS.......................................................................................................... 29
APPENDIX A: SYSTEM INTEGRATION .......................................................................................... 30
Management of Air Flows....................................................................................................................................... 30
Cabinet.................................................................................................................................................................... 30
Gas and Water Connections....................................................................................................................................31
Electrical and Signals Connections.......................................................................................................................... 31
Hydrogen Storage ................................................................................................................................................... 31

Version
Document Title
Release Date
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EL2.0 –Installation Manual
2020-03-18
EL2.0 Installation Manual –Rev.08 Mar 2020 5
WELCOME
Thank you for choosing the EL2.0 hydrogen generator. Please read through this Installation Manual carefully before
performing any operation.
If you have any further question on the installation of the device, please contact the Enapter Srl Help Centre. Quote
the system serial number when contacting us; you will find the serial number on the type plate placed on the rear
side of the module.
Enapter Srl
Headquarters: Via di Lavoria 56/G
56040 Crespina (PI) –Italy
T. : [phone]
Email: [email protected]m
Website: www.enapter.com
SCOPE OF THE DOCUMENT
This installation manual provides the installer with the information needed to carry out the installation of the EL 2.0.
The information contained in this manual will help you to install the hydrogen generator safely and correctly.
Keep this installation manual in a safe place and readily available. Always follow its instructions. It is the operator’s
responsibility to ensure that an installed EL2.0 is in a proper condition at all times. Please observe any additional
local requirements applicable to the installation of the EL2.0.
APPROVED USE
The EL2.0 hydrogen generator has been designed to produce pure hydrogen that can be used directly for fuel cells
or other hydrogen consuming applications.
The unit must only be operated for this purpose, according to the specifications and instructions provided in this
manual.
Adherence to this installation manual is part of “normal use”.
Danger of injury due to improper use!
Improper use of the product can result in serious injuries.
•Ensure that the manual is accessible at all times.
•Make sure you have read and understood this manual in its entirety.
•Comply with all safety instructions and warnings.
•Store the manual and other documentation in a safe place and pass them on to future owners
of the product.
•Comply with all local regulations.

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WARNINGS AND HAZARDS
The following terms and symbols are used in this manual to indicate important text passages which must be given
particular attention:
Warns of dangers of fatal/serious injury
Warns of danger of injury
Warns of physical damage to the product
Do not open or dismantle
Keep away from sources of heat and ignition
No naked flames
No smoking
Minimum two persons required to handle the item
Wear Personal Protective Equipment

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GENERAL SAFETY INSTRUCTIONS
The following rules should always be observed:
1. Keep the work area clean. If the work area is busy or the surface is untidy the probability of injuries is higher.
2. Do not use the machine in dangerous environment conditions. In order to prevent electric shock, do not
expose the machine to rain and do not use it in a damp area. Keep the work area illuminated. Do not use
the machine near gas or flammable substances.
3. Keep unknown persons and children away from the machine. All unknown persons and children must keep
a safe distance from the work area.
4. Protect yourself from electric shock. Ensure proper grounding and do not touch any live connectors.
5. Handle the power supply cable with care. Do not pull the electric cable to disconnect the plug from the
socket. Keep the electric cable away from heat, oil and sharp edges.
6. Always use personal protection devices: Wear protective goggles. Wear ear muffs or plugs in noisy areas.
Wear gloves when handling parts with sharp edges or the conditioning solution.
7. Disconnect the machine from electricity if you do not use it, before maintenance and change of accessories.
8. Use the machine, the tools and accessories in the way and for the purposes mentioned in this manual.
Different uses and parts may cause risks for the operator.
9. The machine must be repaired only by qualified people using original spare parts, otherwise risks may arise
for the operator.
10. Never store the unit at temperatures below 2 °C with liquid inside the internal pipeline. This will cause
irreversible damage to the electrolytic cells.
11. Only use demineralized water according to the specification stated in this manual.
12. Only operate the unit in a room with sufficient ventilation.

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HAZARDS DESCRIPTION
The owner/operator and the user of a device operated with hydrogen needs to be aware of the potential dangers
and know what to do in case of an accident or emergency. It must be ensured that the system is installed and
operated in compliance with local regulations and standards.
HYDROGEN HAZARDS
Hydrogen itself is not a hazardous substance –its properties, however, can make it hazardous in interaction with
other substances.
It is the user’s responsibility to implement a proper safety area (see specifications on par. “Safety Area”).
✓Danger of death due to explosion!
✓Escaping hydrogen can ignite and burn the skin.
✓Escaping hydrogen can reduce the oxygen concentration and cause respiratory difficulties.
✓Do not inhale hydrogen.
✓The lab/room must be equipped with a suitable ventilation system for the use of hydrogen.
✓Incorporate the unit, especially the vent line, into the operational safety concept.
✓The lab/room must be equipped for hydrogen monitoring.
✓Avoid heat in the vicinity of the system and the hydrogen source.
✓No smoking, no naked flames.
✓Comply with local safety regulations.
✓Comply with regulations for handling of compressed hydrogen cylinders.
✓In the case of escaping gas, keep away and keep inflammable materials away.
✓Prevent electrostatic charges.
✓Ensure proper installation of the hydrogen supply.
✓Check the hydrogen lines and connectors regularly for leak tightness.

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MECHANICAL HAZARDS
As for the generic mechanical hazard that can occur during operations requiring the use of hand tools, Enapter Srl
recommends wearing appropriate Personal Protective Equipment (PPE) and to use suitable tools.
Operator’s protection
When performing any operation, the operators must wear the appropriate PPE, such as cut
resistant gloves, safety shoes, protective goggles etc.
The preliminary steps of the installation phase do not necessarily need to be performed by specifically trained
personnel. A general training on how to transport heavy and bulky objects, the use of electrical equipment and the
application of general safety principles is sufficient.
There are residual risks associated with the manual handling of the packaging and of the device during installation
that can result in:
✓impacts due to uncontrolled movements of the load,
✓entanglements,
✓falling of the load,
✓loss of stability,
✓overturning.
To prevent these risks, the packaging/device must be handled by at least two people.
Operators must comply with the general safety principles during the handling phases.
In particular, before moving a load:
✓Operators must allow for sufficient clearance when using aisles and passageways with
openings/doorways with at least 500 mm of free space in width and height, to grant the easy
transit of the packaging and/or machine parts.
✓Operators must verify that there are no people on the passageways.
✓Operators must verify that there is sufficient visibility to grant a safe moving of materials.

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ELECTRICAL HAZARDS
The unit poses no special electrical hazards as long as the following instructions on safety measures are followed:
✓Use only the supply voltage specified on the rating plate.
✓Do not short-circuit inputs and outputs.
✓Do not reverse the polarity of inputs and outputs.
✓Equip the power supply line with proper protections.
✓Do not to short-circuit the cables of the stack.
✓Do not place the stack on conductive surfaces.
✓Do not insert any mechanical parts, especially metal parts, into the product through
the ventilation slots.
✓Do not use liquids near the product.
✓Never use the product if any part of it has been immersed in water.
WARNING!
Any servicing, other than cleaning and user maintenance, must be performed by specialist
personnel and with the power supply switched off.

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CHEMICAL HAZARDS
The hydrogen generating process requires the use of potassium hydroxide in order to perform the electrolysis of
water.
This substance can be delivered as a powder or already diluted. The potassium hydroxide powder must be dissolved
in demineralized water in order to obtain a concentration of 1 % in weight, while the aqueous solution is ready for
use (see par. “Preparation of the Conditioning Solution”).
The potassium hydroxide is not harmful for people, however, carefully read the following precautions and avoid
contact with eyes and skin.
Please find below some precautions to be taken in the event of physical contact with the undiluted substance.
First Aid Recommendations
✓In the event of skin contact, take off contaminated clothing immediately. Wash off with
soap and plentiful water. Consult a doctor.
✓In the event of eye contact, rinse carefully with plentiful water for at least 15 minutes,
and consult a doctor.
✓If ingested, do not administer anything to people that have fainted. Rinse mouth with
water. Consult a doctor.
Chemical products information
Substance: Potassium Hydroxide
CAS no.: 1310-58-3
EC no.: 215-181-3
Classification: C, R22 –R 35
(see Safety Material Data Sheet included in the shipment)
Conditioning solution
When emptying the process tank, wear appropriate PPE as specified in the previous paragraph. Collect liquid in an
appropriate container and place in a chemical waste container. Do not flush to sewer. Dispose of the liquid in
compliance with local and national regulations.
WARNING!
Handle in accordance with good industrial hygiene and safety practice and wear appropriate PPE as
specified by the Material Safety Data Sheet included in the shipment. Avoid any contact with eyes and
skin.
WARNING!
Observe all warnings and precautions listed in the accompanying Safety Material Data Sheet.

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THERMAL HAZARDS
Thermal hazards such as burns and scalds from contact with high temperature surfaces (which can be caused by the
failure of some internal components of the device) can be easily prevented by adhering to the following safety
instructions:
-Make sure the device can be accessed by authorized and trained personnel only.
-Operators must wear appropriate PPE.
-In case of testing, installers must operate with closed enclosures.
-Any servicing, other than cleaning and user maintenance must be performed by specialist personnel and
with the power supply switched off.
ENVIRONMENTAL HAZARDS
The device has been designed for use in standard ambient conditions.
The EL2.0 has not been designed for outdoor use and it is the user’s responsibility to protect the system and all its
accessories against exposure to direct sunlight, rain, snow, lightening and the impact of seismic or hydrogeological
events of particular intensity.
ACOUSTIC HAZARDS
According to the requirements stated in the European Machine Directive 2006/42/EC, the following topics have
been considered:
i. The noise level at a workplace of a machine (the emission sound pressure level) needs to be mentioned
and specified in the user manual if it exceeds 70 dB(A).
ii. Sound power has to be determined and declared if the emission sound pressure level exceeds 80 dB(A).
During normal operation, the noise emission is below the maximal acceptable threshold for long time exposure
(80 dB(A)). However, a sudden purge (either caused by system shut down or unforeseen error) can be louder than
85 dB (A) but only for 1 second.

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UNPACKING
The unit has been carefully inspected before shipping. Visual checks for damage and functional tests should be
performed upon receipt. Any damage must be immediately noted and reported to the shipping agent and supplier.
The unit must be returned according to the shipping instruction provided in this manual.
In case there are any faulty or damaged parts, do not use them in order to not compromise the EL2.0 efficiency
and safety. Address to an after-sales centre to replace faulty parts.
IMPORTANT!
Please keep the original packaging material for possible future transport.
WARNING!
Keep packaging and packing parts out of the reach of children.
WARNING!
The EL2.0 package weights on average 63 kg. All packages are designed for easy handling.
However, due to the weight, is recommended to use an auxiliary device to move the box.
The manual moving of the box is possible but needs to be done by at least two people.
The EL2.0 module net weight is ca. 53 kg.
Removing the single units from the package and placing them into the end-use position
needs to be done by at least two people.

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PRODUCT OVERVIEW
EL2.0 - FRONT VIEW
The front features all ports, plugs and connectors for safe operation of the hydrogen generator.
H1.1 - H2 Output
1/4” stainless steel pipe Swagelok connector
H1.2 - Purge
1/4” stainless steel pipe Swagelok connector
W1.1 –O2 Vent
John Guest push fit 10 mm pipe
W1.2 - Water Refill
John Guest push fit 8 mm pipe
W1.3 - Drain
John Guest 6 mm quick coupling connector
References:
Swagelok parts: www.swagelok.com
John Guest parts: www.johnguest.com
H1.1
Status LEDs
W1.2
Power
Antenna
H1.2
W1.1
W1.3
Start/Stop
Programming
Ports
Fan Intake
Fan Intake

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EL2.0 - REAR VIEW
The rear of the electrolyser features two hot air fan exhausts and a factory reset button.
Fan Outlet
Fan Outlet
Reset

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ASSEMBLY
REQUIRED TOOLS
Gas connections:
9/16 combination wrench
5/8 combination wrench
Stainless steel pipe cutter
¼” stainless steel hand tube bender
Water connections:
Plastic pipe cutter
Electrical connections:
Flat-blade screwdriver
Crimping plier
Cable section: 26 → 22 AWG
Modules installation:
Phillips head screwdriver

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ACCESSORIES/SPARE PARTS
Gas and purge connections:
Stainless steel AISI 136- ASTM A269
-1/4” X 0,89
Water connections:
8 mm (outer diameter) LLDPE pipe
10 mm (outer diameter) LLDPE pipe
Conditioning solution:
KOH Potassium Hydroxide
99.99 % purity
40 g
PC-EL communication
Ethernet cable (LAN cable)

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GAS AND WATER CONNECTIONS
Operators must perform the following actions:
1. Insert the supplied pipe labelled W1.2 (Water Refilling) into the corresponding port and connect it to the
user’s external water tank;
2. Connect a ¼ inch stainless steel tube to port H1.2 (Hydrogen Purge) and vent it to an external safety area
(see par. “Safety Area”).
3. Connect port H1.1 (Hydrogen OUT) to the user’s gas line or storage tank with a ¼ inch stainless steel tube;
WARNING:
After working on the external gas line we recommend that the user performs a hydrogen
leakage test.
4. Connect the supplied pipe labelled W1.1 (O2 Vent/Overfilling) to the corresponding port. This pipe must
lead into an appropriate container placed in an external safety area. The collected liquid must be disposed
of in compliance with local and national regulations. Ensure that the vent pipe cannot be blocked.
5. The W1.3 (Drain) port is equipped with a quick coupling connector. It can be accessed by the operator
only in case it becomes necessary to empty the process tank.
WARNING
In order to supply the EL2.0 with clean DI water for refilling, water must be present in the
electrolyser water refilling pipe at a pressure between 0.75 bar and 4 bar.
If the EL2.0 does not detect the water pressure the system may not be able to refill itself.
W1.2
H1.2
W1.1
W1.3
H1.1

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GAS CONNECTIONS
Bulkhead unions for ports H1.1 (Hydrogen outlet) and H1.2 (Hydrogen purge)
Assembly description:
1. Fully insert a ¼ inch stainless steel tube into the bulkhead union.
2. Rotate the nut finger-tight.
3. While holding the fitting body steady with one wrench, tighten the nut with another wrench rotating
clockwise.
WATER AND PURGE CONNECTIONS
✓Bulkhead union 10 mm Ø for W1.1 (O2 Vent/Overfilling port)
✓Bulkhead union 8 mm Ø for W1.2 (Refilling port)
Assembly description:
1. Cut the tube and remove sharp edges. Ensure the outside diameter is free of score marks.
2. Push the tube into the fitting, to the tube stop (the pipe diameter must be 8 or 10 mm according to the
respective port).
3. Pull on the tube to check it is secure. Test the system before use.
4. To disconnect, ensure the system is depressurized, push the collet square against the fitting. With the collet
held in this position the tube can be removed.

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Quick coupling connector for W1.3 (Water drain port)
Assembly description:
1. Attention: the unit must be completely switched off. Wear appropriate PPE.
2. Push the tube into the fitting to the tube stop (the pipe diameter must be 6 mm).
3. Insert the supplied quick male connector into the water drain port (W1.3).
4. The solution starts flowing out immediately. Collect liquid in an appropriate container and place in a
chemical waste container. Do not flush to sewer. Dispose of the liquid in compliance with local and national
regulations.
5. To disconnect, push the button and pull the connector.