Horizon Educational HYDROSTIK PRO User manual

HYDROSTIK PRO
Metal Hydride Canister
User’s Manual
Updated 31 Oct. 2012
HYDROSTIK PRO_UM_121031

HYDROSTIK PRO_UM_121031
Contents
I. NOTICE.....................................................................................................................
● REGARDINGTHISMANUAL........................................................................
● REGARDINGPROTECTION,SAFETY,ANDPROHIBITIONAGAINST
UNAUTHORIZEDMODIFICATION...............................................................
● DISCLAIMER.................................................................................................
II. INTRODUCTION.......................................................................................................
● GENERALPRECAUTIONS...........................................................................
● PRODUCTSPECIFICATION........................................................................
III. SAFETYINSTRUCTIONS.........................................................................................
● HYDROGENOPERATINGPROCEDURES...................................................
● Personnel.....................................................................................................
● Storage….................................................................................................... 
● TRAINING...................................................................................................... 
● EMERGENCYPROCEDURES......................................................................
IV. REQUIREMENTSHYDROSTIKPROCARTRIDGE..................................................
● PROVIDEDBYHORIZON..............................................................................
● OTHERITEMSREQUIRED...........................................................................
V. BEFOREOPERATION...............................................................................................
● CHECKLISTBEFOREOPERATION..............................................................
● CHECKLISTDURINGOPERATION..............................................................
VI. (RE)FILLINGHYDROSTIKPROCARTRIDGE..........................................................
● OPTIONI-DIRECTCARTRIDGE(RE)FILLING............................................
● OPTIONII-SWAGELOKREFILLING............................................................
VII. MAINTENANCE..........................................................................................................
1. EMPTYHYDROSTIKPROMetalHydrideCartridges........................
2. FILLEDHYDROSTIKPROMetalHydrideCartridges.........................
VIII. FAQ.............................................................................................................................
1
1
2
2
3
3
4
5
5
5
5
5
5
6
6
6
6
6
6
7
7
10
14
14
14
15

HYDROSTIK PRO_UM_121031 1
I. Notice
● Regarding This Manual
Pleasereadandkeep
theseinstructions
Keeptheseinstructionswiththisappliance
BewahrenSiedieseBedienungsanleitung
zusammenmitdemGerätauf
Gardezcesinstructionsavecl’appareil
Mantengaquestomanualeinsiemeall’apparecchio
Bewaardezehandleidingbijhetapparaat
FurthercopiescanbeobtainedfromHorizonFuelCellTechnologiesorbyemailing
[email protected]
PleaserefertotheHorizonwebsiteforlatestinformationwww.horizonfuelcell.com
Specicationsanddescriptionsinthisdocumentwereineffectatthetimeofpublication.HorizonFuel
CellTechnologiesreservestherighttochangespecications,productappearanceortodiscontinue
productsatanytime.
1. ThisManualshouldbepassedontotheenduser.
2. Readthismanualcarefullyandfullyunderstandhowtooperatethisproductbefore
youstartoperation.
3. HorizonFuelCellTechnologiesmakesnowarrantyofanykindwithregardtothis
material,butnotlimitedto,impliedwarrantiesofmerchantabilityforparticular
purpose.
4. Allrightsreserved.Nopartofthismanualmaybereproducedinanyformwithout
HorizonFuelCellTechnologies’writtenpermission.
5. Greatefforthasbeenexpendedtoensurethatthedescriptionsinthismanualare
correct.Shouldyou,however,comeacrossaquestionableareaornotean
inconsistency,atelephonecalloremailtoHorizonFuelCellTechnologiesnotingthe
questionableareawouldbehighlyappreciated.
6. Thecontentsofthismanualaresubjecttochangewithoutpriornotice.

HYDROSTIK PRO_UM_121031
● Regarding Protection, Safety, and Prohibition against Unauthorized
Modication.
1. Fortheprotectionandsafeuseoftheproductandthesystemcontrolledbyit,besureto
followtheinstructionsonsafetydescribedinthismanualwhenhandlingtheproduct.In
addition,ifyouhandletheproductincontradictiontotheseinstructions,our
companydoesnotguaranteesafety.
2. ThefollowingsafetysymbolmarksareusedontheproductconcernedorinthisManual:
● Disclaimer
1. Thismanualincorporatessafetyguidelineandrecommendations.However,itisnot
intendedtocoverallsituations.Itisresponsibilityofcustomertomeetall
localsafetyrequirementsandtoensuresafetyduringoperation,maintenance
andstorageoftheHYDROSTIKPROcanister.
2. HorizonFuelCellTechnologiesassumesnoliabilitytoanypartyforanylossordamage,
directorindirect,causedbytheuseoranyunpredictabledefectoftheproduct.
3. Althoughalleffortshavebeenmadetoensuretheaccuracyandcompletenessofthe
informationcontainedinthisdocument,Horizonreservestherighttochangethe
informationatanytimeandassumesnoliabilityforitsaccuracy.
2
WARNING
AWARNINGsigndenotesahazard.Itcallsattentiontoaprocedure,pratice,condition
orthelike,which,ifnotcorrectlyperformedoradheredto,couldresultininjuryor
deathofpersonel.
CAUTION
ACAUTIONsigndenotesahazard.Itcallsattentiontoaprocedure,pratice,conditionorthe
like,which,ifnotcorrectlyperformedoradheredto,couldresultindamagetoordestruction
ofpartoralloftheproduct.
IMPORTANT
Indicatesthatoperatingthehardwareorsoftwareinthismanner
maydamageitorleadtosystemfailure.
NOTE
Drawsattentiontoinformationessentialforunderstandingtheoperationandfeatures.
TIP
Givesinformationthatcomplementsthepresenttopic.

HYDROSTIK PRO_UM_121031
II. Introduction
ThankyouforpurchasingtheHYDROSTIKPROMetalHydrideCartridges.
PleasereadthefollowingrespectivedocumentsbeforepreparingandusingtheHYDROSTIK
PROMetalHydrideCartridges.
●General Precautions
● Readallinstructions.
● Provideadequateventilationandrefrainfromplacingitemsonoraroundtheappliance
duringoperation.Refrainfromplacingtheapplianceinenclosuresorcausingtheapplianceto
notventfreely.
● Donotuseanattachmentnotrecommended,asitmayresultinariskofre.
● Donotdisassembleortamperwithappliance.
● Keepawayfromchildren.
● Keepawayfromalkalineandacidicenvironment.
● FireHazard!
● Thisisnotatoy–keepawayfromchildren.
● Undernocircumstanceisthecartridgetobedisassembled.Exposuretoairwillrender
thehydridematerialuselessandrequirereplacement.Materialswithinthehydrideare
potentiallydangerous.
●Thecartridgemustbeplacedhorizontallywhenitisbeingchargedotherwisethe
cartridgecancrack!
● Donottamperwithdevice.ReadandunderstandOperationInstructions.
● Contentsareammable.Donotdisassemble.
● Avoidcontactwithcontents.
● Donotexposetotemperatureabove50°Coropenames.
● Followusageinstructions.
●Removefromfuelcelldeviceimmediatelyafteruse.
● Whenusingtheappliance,basicsafetyprecautionsshouldalwaysbefollowedtoreduceriskof
re,orpersonalinjury.
● Hydrogenshallbestored,handled,andusedsolifeandhealtharenotjeopardizedandtherisk
ofpropertydamageisminimized.
● Thisapplianceisnottestedforusewithmedicaldevices.
● Savetheseinstructionsandreviewfrequentlyduringuse.
3
WARNING
CAUTION
NOTE
TIP
IMPORTANT

HYDROSTIK PRO_UM_121031
●Product Specication
4
* The Specications are subject to change without notice.
HYDROSTIK PRO for Hydrogen Storage
HYDROSTIKPROCartridgesdevelopedandmanufacturedbyHorizonFuelCellTechnologiesare
designedwithanaluminumalloymaterialsenclosureandaAB2alloyforhydrogenabsorption.
Afteractivation,theAB2alloyiscapableofabsorbinghydrogen,expandingandreleasingheatuntil
saturation.Theinternalpressureofthefullychargedcartridgeremainsat30Bar(435PSI)atambient
temperaturesof20˚C-25˚Candtheweightisaround0.9gramhigher.Oncethecartridgevalveis
openedandpressureisreduced,hydrogenwillbecontinuouslyreleasedfromthealloythatwillabsorb
heat.Iftheheatabsorptionratedecreases,sowillthehydrogenreleaserate.Thecartridgeenclosure
materialsaremadeofanaluminumalloythathasexcellentheatconductivitypropertiesthatcan
facilitateheatconductionofthealloyduringgasabsorptionandreleaseprocesses.Gasabsorption
efciencyofthealloycanbesignicantlyimpactedbyoxidizationduetohumidity;therefore
dryhydrogengaswithapurityofnolessthan99.99%isrequiredforcharginguse.
SPECIFICATIONS
ModelHYDROSTIK PRO
Hydrogen Storage
Capacity 10NL Dimensions(mm) Weight Appr.90g
Cylinder Material
Cylinder CoatingColor
Operating
Temperature
GasPurity
GasDew Point
Charging Pressure
Charging
Temperature
300-500ml/min(basedonH-cell)
Discharging
Safety
Compactsize
Scalable
Reversible
Long life
Easy handling
No extraheat
needed
Discharging
Temperature
Thestorage devicescan be discharged andrecharged with speed,efficiencyand control.
Thecanisters arerobustand aredesignedtohavealong servicelife.
TypicalDischarging
Performance
Features
Hydrogen gasisstoredinsolid metalpowderunder lowpressure. It is saferthanconventional
methodsfor storingliquidand compressedhydrogen.
General
Hydrogen
Charging
Hydrogen
Discharging
Aluminum6061
White&Blue
>99.99%(CO <1ppm, CO2<10ppm,O2<4ppm)
<-50°C
3.0MPaG @20°C
0～30°C
DischargingCondition/outletpressure:0MPaG;Ambient:15°C
Dischargingflowrateismaintainedupto95%ofthewholestoragecapacity.
0～3.0MPaG @25°C(Depends on theremaining H2 amount.)
Thestorage devicescan supply fuel forany size hydrogen-based application-smallorlarge,
vehicular,portable,on-boardorstationary.
Ourstorage devicesholdmorehydrogenthancompressedhydrogencylinders,readilyaccept
hydrogenfromreformers,electrolyzersand othersources,andcan be used safely in more
applications than liquidhydrogen.
Fullyoperableatanambient temperature,with amoderatepressuredifferencefor absorbing
anddischarging hydrogen gas.
5～50°C(Whenthetemperatureisbelow5°C,thedischarginghydrogencapacitywillbeless
thanthisspecification.)
10NL of hydrogen canfit in your hand. 350NL caneasilybeassembled on theHydrobike.
8
0
-
35 °C

HYDROSTIK PRO_UM_121031 5
III. Safety Instructions
ThesafeandsuccessfuluseoftheHYDROSTIKPROandhydrogeningeneralstartswithknowing
ofandadheringtoappropriatestandardsandguidelinesforthedesignofthehydrogenfacilities.
● Safetyshallbeconsideredinallphasesofahydrogenfacilitylifecycle,beginningwith
itsinitialdesignandcontinuingthroughitsfabrication,construction,operation,maintenance,
andendingwithitsdecommissioning.
● Regardlessofquantity,allhydrogensystemsandoperationsmustbedevoidofhazards
byprovidingadequateventilation,designingandoperatingtopreventleakage,and
eliminatingpotentialignitionsources.
● Safetysystemsshouldbeinstalledtodetectandcounteractorcontrolthepossibleeffects
ofsuchhazardsascartridgefailures,leaksandspills,collisionsduringtransportation,
vaporizationsystemfailures,ignitions,resandexplosions,clouddispersions,andthe
exposureofpersonneltocryogenicorametemperatures.Undetectedhydrogenleakscan
leadtoresandexplosions.
● Cartridges(lledwithhydrogen)shallbekeptawayfromre,andtemperaturesabove50˚C
whilelling,storageandusing.
● Themaximumoutletpressureofthepressureregulatorshouldnotexceed40Bar(580PSI)toavoid
anycomplicationsorfailureswiththecartridges.
● Whenusingacylindertorelloractivatethecartridge,theinletpressurefromthecompressed
cylindershouldbeatleast1.5timesthatoftheoutletpressure.
● Hydrogen Operating Procedures
Operatingproceduresalongwithinstrumentationandcontrolsystemsshallbeevaluatedfortheir
capacitytoprovidetherequiredsafety.Analysisorcerticationtestingshallverifyequipment
performance.
● Personnel
*Personnelhandlinghydrogenorhandlingequipmentforhydrogensystems
mustbecomefamiliarwiththephysical,chemical,andspecic
hazardouspropertiesofhydrogengas.
*Trainingshouldincludedetailedsafetyprogramsthatrecognizehuman
capabilitiesandlimitations.
● Storage
*Storethecartridgesinasafeandsecureplace.
*Storethecartridgesinadryandcoolplace.
*Donotstorethecartridgesinsunlight.
● Training
Operatortrainingshallbereviewedanddemonstratedtobeadequatebeforeoperationscommence.
Operatortrainingshouldbeevaluatedcontinuously.
● Emergency Procedures
Thesafetyofpersonnelatandnearthehydrogenlabshallbecarefullyreviewedandemergency
proceduresdevelopedattheearliestplanninganddesignstages.Advanceplanningforavarietyof
emergenciessuchasresandexplosionsshallbeundertakensotherstpriorityisthereductionof
risktolife.
CAUTION

HYDROSTIK PRO_UM_121031 6
IV. Requirements HYDROSTIK PRO Cartridge
● Provided by Horizon
● HYDROSTIKPROmetalhydridecartridge
● Rellingtubingconnectsthecartridgetotheregulator
● AHorizon-designedadaptorthatconnectstheSWAGELOKconnectortotheHYDROSTIK
PRO
● Other Items Required
● Acompressedhydrogencylinderwithpressureof150-200Bar(1276–2900PSI).
● AH2pressureregulatorthatcanhandleaninputpressureofatleast200Bar
(2900PSI)anddeliveroutputpressuresthatcanbeadjustedfrom10Bar
(145PSI)to40Bar(580PSI).Thisregulatorshouldinclude2pressure
gaugesthatcandisplaytheinputpressureandtheoutputpressure.
● Male&FemaleSWAGELOK1/8”quickconnectorstypeQC4-B-200andQC4-D-200.
● A40Bar(580PSI)resistanthoseassemblyconnectingtheoutputoftheregulatortothe
SWAGELOKquickconnector.
● Awaterbasinthatisbigenoughtoholdthecartridgeunderwaterinahorizontalposition.
● Adjustablewrenches.
V. Before Operation
Beforestartingtheoperationprocess,regardlessofquantity,itiscrucialtocheckallhydrogen
systemsonthesafetyandoperationalaspectsinordertoruleoutandexcludeanypossiblehazards,
failuresorsetbacksduringtheprocess.Therefore,itishighlyrecommendedthatthewholeoperation
willbecarriedoutadequateandwillfollowallinstructionsprovidedhere.Doingsowillalsomaintain
thecycleandlifetimeoftheHYDROSTIKPRO.
● Checklist before operation
● Dothelabandoperationenvironmentcomplyandconsistwithallthesafetystandards
regardingtheusageofhydrogenandHYDROSTIKPRO?
● Isthetrainingoftheoperatorsufcient,andistheoperatorawareanddoeshe/she
understandallthesafetyaspectsregardingtheoperationoftheHYDROSTIKPRO
andhydrogeningeneral?
● Isthesafetyofthepersonnelatandnearthehydrogenlabtakenintoaccount,andareall
emergencyproceduresclearandintelligible?
● AretheHYDROSTIKPROcartridgescheckedforanytracesofdamage,deformation,
leakage,orimpactofanykind?
● Areallthetubeconnectionsandnutscheckedregularly,sonocontaminationofanykindwill
interfereintheprocess?
● Checklist during operation
● Operationsagainstrulesstatedinthisusermanualarestrictlyprohibited.
● Strictlycomplywiththesafetyoperationregulations.Keepcloseattentiontothe
changingoftheworkingpressure,temperatureandworkingmedia,etc.
● DisassemblinganypartsoftheHYDROSTIKPROunderpressureisstronglyprohibited.
● Itisstronglyprohibitedtousethepressurecartridgesbeyondtheoperationconditions.

HYDROSTIK PRO_UM_121031 7
VI. (Re)Filling HYDROSTIK PRO Cartridge
Therearetwooptionsfor(re)fillingtheHYDROSTIKPROMetalHydrideCartridge.Howthese
operationsarecarriedoutisstatedinthisparagraph.
NotethatalldirectionsarebasedontheequipmentusedasstandardbyHorizonFuel 
CellTechnologies.Wecannotfeasiblycoverallinternationalvariationsofequipment,
threadsanddimensionsandthereforeomitthesedetailstoreduceconfusion.Therefore
wehighlyrecommendthatyoureadthroughtheinstructionswithoutputtingtheequipment
togethertofamiliarizeyourselfwiththeprocessandmakesureyouhaveallthecorrect 
components.Itisveryimportantthattheconnectionsequipmentmatch,asanyleakageis
verydangerous.
● Option I - Direct Cartridge (Re)Filling
(1) Useawrenchto(anti-clockwise)screwsecurelythedualheadedpressureregulatortothe
pressurizedhydrogencylinderthatcanbeobtainedfromalocalgascompany(Fig.1&2).
(2) Againusingawrench,screwthenutonthehydrogencabletothedualheaded
pressureregulatorprovided.Thenutneedstobetightenedbyturningthewrench
anticlockwise(Fig.3&4).
IMPORTANT
Fig.1 Fig.2
Fig.3 Fig.4

HYDROSTIK PRO_UM_121031 8
(3) Turntheduelheadedpressureregulatorhandleanti-clockwiseuntilitistight.Makesure
itisintheclosedcondition,sothatthedualpressureregulatorshowsazeroreadingon
bothdials(Fig.5&6).
Inspecttheconnectionsforleaksbyapplyingsomesoapwateronallconnections.
Ifyounoticebubblesappearingpleaseclosethecylindervalve,stopthe 
procedureandcontactyourprofessionalsuppliersfortechnicalsupport.
Alsoifthecylinder’spressureislowerthan30Bar(435PSI),stopusingthiscylinder
becausethepressureistoolowtochargethecartridge.
BeforeconnectingtheHYDROSTIKPRO,turnonthedualheadedpressureregulator
valveclockwiseto1Bar(14.5PSI)toreleasetheimpuregasesoutofthetube.Repeat
this2-3timesforpuregasesusedinthenexthydrogenchargingprocess.
(4) Prepareaplastictubthatthemetalhydridecartridgecanlieinhorizontally,withenough
water(ambienttemperature)tocoverthemetalhydridecartridge.Holdingtheotherend
ofthehydrogencable,connecttheHYDROSTIKPROmetalhydridecartridgetothe
cablebyturningthecartridgeclockwiseuntilitissecurelyfastenedtothecable(Fig.
7&8).
CAUTION
NOTE
IMPORTANT
Fig.5 Fig.6
Fig.7 Fig.8