Matheson NM Series User manual

MATHESON TRI-GAS
Keystone Drive
Montgomeryville, PA 18936
Phone: [phone]
Fax: [phone]
Email: [email protected]om
Hydrogen generator model NM Series II
User’s manual
Rev. E March 2008
This manual provides operation and maintenance instructions for model NMH2-100, NMH2-
160, NMH2-250, NMH2-300, NMH2-500, NMH2-600 and NMH2-1000 hydrogen generators.

Hydrogen Generator NM Series 2 User’s Manual
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Index
INDEX.................................................................................................................................................................... 1
INTRODUCTION................................................................................................................................................. 2
SPECIFICATIONS .................................................................................................................................................. 2
NOTES ON FCC COMPLIANCE.............................................................................................................................. 3
CORRECT USE...................................................................................................................................................... 3
PACKING LIST...................................................................................................................................................... 4
DESCRIPTION..................................................................................................................................................... 5
INSTALLATION.................................................................................................................................................. 6
RECEIVING THE GENERATOR ............................................................................................................................... 6
PLACING THE GENERATOR................................................................................................................................... 6
GAS CONNECTIONS.............................................................................................................................................. 6
ELECTRICAL CONNECTIONS................................................................................................................................. 7
INITIAL START-UP............................................................................................................................................ 8
FILLING THE WATER TANK................................................................................................................................... 8
INSTALLING THE DEIONIZER BAG......................................................................................................................... 9
OPERATION ...................................................................................................................................................... 10
LAYOUT OF THE START UP DISPLAY .................................................................................................................. 11
MENU TREECONFIGURE PARAMETERS.............................................................................................................. 13
CONFIGURE PARAMETERS................................................................................................................................. 14
DIAGNOSTIC DISPLAY ........................................................................................................................................ 15
SPECIAL FUNCTIONS .......................................................................................................................................... 15
LIST OF MESSAGES ........................................................................................................................................ 16
STATUS MESSAGES............................................................................................................................................ 16
PRE-ALARM MESSAGES..................................................................................................................................... 16
ALARM MESSAGES............................................................................................................................................ 17
MAINTENANCE................................................................................................................................................ 18
ROUTINE MAINTENANCE ................................................................................................................................... 18
CLEANING ......................................................................................................................................................... 18
WATER REFILLING............................................................................................................................................. 18
DEIONIZER BAG REPLACEMENT......................................................................................................................... 18
LONG TIME STORAGE ........................................................................................................................................ 18
OPTIONS............................................................................................................................................................. 19
REMOTE CONTROL ............................................................................................................................................ 19
CASCADING....................................................................................................................................................... 21
AUTO REFILL..................................................................................................................................................... 24
RETURNING THE UNIT.................................................................................................................................. 25
SPARE PARTS LIST.......................................................................................................................................... 26

Hydrogen Generator NM Series 2 User’s Manual
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Introduction
Specifications
Model NMH2-100 0-100 cc/min at STP
Model NMH2-160 0-160 cc/min at STP
Model NMH2-250 0-250 cc/min at STP
Model NMH2-300 0-300 cc/min at STP
Model NMH2-500 0-500 cc/min at STP
Model NMH2-600 0-600 cc/min at STP
Hydrogen flow rate at STP.
STP: Standard temperature and
pressure:
(20°C / 1 bar absolute)
(68°F / 14.4 PSI absolute)
Model NMH2-1000 0-1000 cc/min at STP
Max outlet pressure 10.5 bar (155 psi)
Purity 99.9999%
Weight (dry) NM 100 - 160 – 250 - 300 17.5 kg
NM 500 - 600 19 kg
NM 1000 20 Kg
Power consumption Heat Dissipation
BTU/h
Model NMH2-100 090 VA 184
Model NMH2-160 115 VA 235
Model NMH2-250 160 VA 328
Model NMH2-300 200 VA 410
Model NMH2-500 300 VA 615
Model NMH2-600 340 VA 697
Model NMH2-1000 480 VA 984
Input voltage 120 or 240V / 50-60Hz selectable
Fuse (5x20) 4A SLB @ 240VAC / 6.3A SLB @120 VAC
Pressure accuracy 0.1 bar (± 0.5 %) (1.4 PSI)
Microprocessor controlled display Graphic display, 128 x 64 pixels
Index of protection IP2x
Operating conditions:
- Temperature
- Relative humidity 15°C to 40°C ( 59°F to 104°F) 0-80%, non condensing
Storage Temperature 2°C to 60°C (35°F to 140°F)
Over voltage category II
Pollution degree 2
Sound pressure level 46 dB(A)
Case dimensions 230 x 355 x 410 mm (WxDxH)

Hydrogen Generator NM Series 2 User’s Manual
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Notes on FCC compliance
This equipment has been tested and found to comply with the limits for a Class B
digital device, pursuant to part 15 of the FCC Rules. These limits are designed to pro-
vide reasonable protection against harmful interference in a residential installation. If not in-
stalled and used according the “Installation Instructions”, the instrument may cause harmful in-
terference to radio communication equipment or other electronic devices. If there is any indi-
cation of interference, just turn the instrument off and see if the problem(s) disappears. If the
problem remains, consult with the instrument supplier for corrective action
WARNING!
Any changes or modifications to this equipment not expressly approved by Matheson Tri-
Gas’ will void the Warranty obligation and in no case will Matheson Tri-Gas be liable for
incidental or consequential damages, loss of use, loss of production or any loss incurred.
Correct use
The Hydrogen generator is designed to produce hydrogen for laboratory use. The unit must
only be operated for this purpose, according to the specifications and instructions provided in
this manual. In particular, the following rules should be observed at all times:
Indoor use only
Never store the unit in temperatures below 2°C (35°F) This will cause irreversible
damage to the electrolysis cell !!!
Only use pure water (see “Filling the water tank”)
Only operate the unit in a room with sufficient ventilation (see “Placing the unit”).
Always depressurize (put in standby) before shutting down the unit.
Unplug the unit from the mains power supply before accessing the internal compo-
nents for replacement. Note: Service should only be done by qualified technicians.

Hydrogen Generator NM Series 2 User’s Manual
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Packing list
List of items included in the shipment
Quantity Description
1 Hydrogen generator
1 Instruction manual (on CD)
1 Deionizer triangle bag MDI-TBAG
1 Water drain with flexible tubing MHSE-0059-XX
1 Power cable MLCD-0004-XX

Hydrogen Generator NM Series 2 User’s Manual
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Description
The hydrogen generator produces pure hydrogen (and oxygen as a by-product) by the elec-
trolysis of water. The key element of the generator is an electrochemical cell assembly which
contains a solid polymer electrolyte. No free acids or alkalines are used. De-ionized or pure,
distilled water is the only liquid which may come into contact with the cell. As water is con-
sumed it must be refilled from time to time as required.
The generated hydrogen gas is accumulated in the hydrogen/water separator and is dried by
passing through the automatic dryer. The internal pressure (11.0 Bar / 160PSI) is controlled
by the amount of hydrogen generated by the cell. The outlet pressure is controlled by a pro-
portional valve.
Safe operation is guaranteed by the following safety features:
- Overpressure Valve
- Intelligent pressure monitoring
- The hydrogen production is automatically stopped, when no hydrogen is needed,
or there is a large leak in the output line.
Fig. 1
Water
Tank
H2GLS
low
press.
H2GLS
high
press.
O2GLS
low
press.
Dryer
Cell
Int. Press. Sens.
Ext. Press. Sens.
H2
Pressure
relief
H2Outlet
H2Vent
O2Vent
Drain port / Autorefill
connector

Hydrogen Generator NM Series 2 User’s Manual
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Installation
Receiving the generator
All units have been carefully inspected before transport. Visual checks for damage and func-
tional tests should be performed upon receipt. Any damage has to be immediately noted and
reported to the shipping agent and supplier. The generator has to be returned according to
the shipping instructions provided.
Placing the generator
The hydrogen generator should be placed on a flat, level, vibration-free, shock-free surface.
Do not place the generator over or near a source of heat, as this may cause the device to
overheat. The unit should not be in contact with any other objects on any side, and the air
inlet must not be blocked. Leave at least 30 cm of free space at the rear for ventilation.
Do not operate the generator in a sealed or unventilated room, or in close proximity to open
flame or other sources of ignition. The ambient temperature (preferable stable) has to be be-
tween 15°C. (59°F) and 40°C (104°F).
WARNING!
Compared to cylinders, the gas volume of the generator is very small.
However precautions for any hydrogen supply should be taken when using the generator.
DO NOT use the generator in sealed or unventilated rooms, neither use it in close
proximity of open flames or other sources of ignition.
Gas connections
Pure dry hydrogen at regulated pressure is available at the hydrogen outlet port at the rear
of the generator. This port must be connected to 1/8" SS or copper tubing using the appro-
priate Swagelock fittings. Teflon tubing is not suitable. The pressure at this port is adjusted
via the keyboard and shown on the display. The hydrogen relief port at the rear of the unit
can be connected to an exhaust hood or other vent system.
WARNING!
The line from the relief port (over pressure) should never be connected in such a way that
back pressure can develop.

Hydrogen Generator NM Series 2 User’s Manual
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Fig.2
Electrical connections
Check the setting of the voltage selector on the rear of the unit. The set voltage is indicated
by the white arrow. To change the voltage, proceed as follows:
Using a small screwdriver, remove the voltage selector insert.
Replace the voltage selector insert so that the white arrow points to the correct volt-
age.
Use only 240 VAC or 120 VAC setting!
Fig. 3 Fig. 4
Fig. 5
IMPORTANT!
Remove the plugs from the oxygen vent and
hydrogen vent before operating the unit.
Keep these plugs for transporting the unit.
(For return of the unit to the factory)

Hydrogen Generator NM Series 2 User’s Manual
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Initial start-up
Filling the water tank
To fill the water, remove the cap under the slider on the water tank (Fig. 6). Carefully fill the
tank with distilled or deionized water. The conductivity of fresh water, used in the generator,
should not exceed 2S.
Note : During operation the conductivity can increase. This is normal, but if the value
succeeds 20 uS, it is recommended to replace the deionizer bag.
Fill the tank to the maximum level indicator. Close the slider cap.
WARNING!
Do not fill the water tank higher than the marked max level.
CAUTION!
It is important to use only deionized or distilled water in the generator. Standard water
containing impurities will contaminate and damage the cell, and will void the warranty.
Fig. 6 Fig. 7
Note: The blue light produced by LED’s on the Main board make it easier to see the
water level in the tank.

Hydrogen Generator NM Series 2 User’s Manual
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Installing the deionizer bag
The triangle deionizer bag has been designed for a higher water purifying capacity. It is rec-
ommendable to use this bag for new generators, in the first 4 to 6 months of operation.
After this time you can use the standard deionizer bag (see “spare parts”).
Fig. 8 Triangle deionizer bag Fig. 9 Standard deionizer bag
After having filled the tank with water, the triangle deionizer bag (supplied) must be placed in
the tank. Inspect the bag thoroughly for holes or tears, indicated by loose deionizer beads on
the outer surface. If the bag is damaged in any way, discard and replace it with a new one.
Only use original parts (see Spare Parts). Wash the deionizer bag in deionized water before
proceeding.
Insert the free end of the “T” fastener through one of the holes of the holder, until it is se-
curely fastened (Fig. 10). Insert the bag in the opening of the tank (Fig 11).
Fig. 10 Fig. 11

Hydrogen Generator NM Series 2 User’s Manual
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Operation
First turn on the main power switch at the rear of the unit. The display will show the software
version installed followed by a “self checking” period of 20s.
Fig.12
Than the main screen appears
Function buttons description
LED 2 Function buttons LED 1
Fig. 13
LED 1 (green)
This LED has two states : flashing or continuously on
1. Flashing
– the generator is powered up
– the unit is in Standby mode
– the unit is building up internal pressure
– the main valve is closed
2. Continuously on
- the main valve is “Open” and the unit is in “Normal” operation.(Fig.17)
LED 2 (red)
This LED flashes in case of an error. See Alarm List to find out more details.

Hydrogen Generator NM Series 2 User’s Manual
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Layout of the Start up display
Fig. 13
First row, status information
The Status: shows current information on the operating status of the generator.
Second row, pressure information
“Press Act”: is the actual pressure of the hydrogen outlet.
Third row, set pressure
“Set” is the adjusted pressure in the pressure set menu.
Forth row, hydrogen flow Bar Graph
This row displays the current quantity of hydrogen being produced. Each segment
represents around 10 % of maximum capacity. This graph also indicates how much
hydrogen is being consumed by the connected equipment.
Note: during initial build up of the internal and external pressure and to maintain the
internal pressure, the displayed flow will temporarily go to maximum and deviate
from the actual flow on the gas outlet.
Fifth row, water quality Bar graph
This graph shows the quality of the water in the reservoir.
With more than 7 segments illuminated, water quality is good.
If only 3 or less points are illuminated, the conductivity of the water is around 30 uS
(pre-alarm level). If only 1 segment or no segments are illuminated, the conductivity of the
water is equal to or greater than 40 uS (alarm). The generator will shut down.

Hydrogen Generator NM Series 2 User’s Manual
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Function buttons
The functions of these buttons depend on the place in the Menu tree.
The actual function is displayed just above each button. Fig.13
Start button
Pushing this button will start the hydrogen production.
The display will show “Reaching Int. Pressure” Additionally the percentage of internal pres-
sure reached will be displayed.(Fig.14).
When the final internal pressure is reached (11 bar /160 PSI), the display will show “Ready”.
Fig.15
Fig.14 Fig.15
Open button
This function will appear after the generator has been started. When this button is pushed
the proportional valve slowly opens, in order to reach the external pressure, as defined in the
“Pressure Adjust” Menu. The display shows “Reach Ext. Press (”Fig.16).
When the button is pushed before the internal pressure has been reached, it will flash, and
the valve will start to open as soon as the internal pressure has been reached.
Fig.16 Fig.17
Note : The proportional valve may need up to two minutes to build up the adjusted
pressure.
Menu button
With this buttons the user can enter the Menu tree.

Hydrogen Generator NM Series 2 User’s Manual
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Start Open Menu
Flow
Water
Press act: 6.2 set: 6.2 Bar
Pressure Adjust
Exit
6.2 Bar
Configure
Exit
Utilities
ExitScroll Scroll
Select
Set Clock
Pressure Rise
Pressure drop delay
Alarm list
Diagnostics
Special functions
Set Clock
Pressure Rise
Pressure drop delay
Auto start
Beeper
Cascading mode
N. Gen H2 in cascading
ID number
Remote start /stop mode
Remote relay mode
Autorefill
Pre alarms in alarm list
Pressure units
Temp units
Volume units
Lock keyboard
Display contrast
Set default values
Exit
Alarm Number: 1
21.01.03 17:00
Low water
Alarm list
Exit
Diagnostics
Scroll
Special Functions
Select Exit
Prod. Tot. : 10000 scm
Oper. time : 100 H
W. Quality : 2.5 uS
Int. Press. : 11 Bar
Cell Volt. : 3.6 V
Cell Curr. : 33 A
PS Temp: 40°C
Cell Vpeak: 3.8 V
PS Temp peak : 45°C
Status: Normal Flow
System test
Exit ExitScroll
Dryer Status
System Test
Hardware options
Scroll Select
Internal Leak Test
External Leak Test
Flow Test
Exit
Pressure adjust
Configure
Utilities
Scroll Select
Menu
Prod. Tot. : 10000 scm
Oper. time : 100 H
W. Quality: 2.5 uS
Select
Hardware options
Internal Leak Test
External Leak Test
Flow Test
Heater Test
Rinse Flow Test
Complete System Test
Toggle Valve
Enable Heater Test
Enable Moisture Alarm
Select Valve Bloc Type
Autorefill
Set autorefill time
Autorefill
Exit
SelectScroll
Exit
Off
Autorefill
Scroll Select Exit
Auto
Manual
Set autorefill time
Exit
Auto
3s
Exit
3s
Manual
Start Stop
Enable Heater Test
Enable Moisture Alarm
Select Valve Bloc Type
Release P. in Standby
Select
Menu Tree “Configure Parameters”
Fig. 18

Hydrogen Generator NM Series 2 User’s Manual
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Configure Parameters
Item Description Options / Range Default
Set Clock Allows to set the internal Clock - -
Pressure rise Sets how fast the pressure has to in-
crease. If the pressure increases at a
slower rate, a low output pressure
alarm is activated.
0.01 – 4.2 bar/min
0.2 - 60 psi/min 0.09 14
Pressure drop
delay Sets a delay in minutes before a low
output pressure alarm is triggered 2 - 10 min 2
Auto start Sets whether or not the unit auto-
matically starts production when
power is switched on.
YES / NO NO
Beeper Sets whether or not the audible signal
is activated in the event of an alarm. ON / OFF ON
Cascading
mode Sets the cascading mode. (see cas-
cading for more details) None/ Normal / Ext. P control None
N Gen H2 in
cascading Sets the number of generators in the
Cascading chain 1-10 1
ID number Sets the ID number 1-10 1
Remote
start/stop mode Configures the remote start/stop
function (For more details see Re-
mote option)
Start/stop, Start only, Direct
control start/stop
Remote relay
mode Configures the remote relay contacts. Normally open (NO)
Normally closed (NC) NC
Autorefill If set to ON, the pre-level water alarm
is used to trigger an external pump or
valve to refill the water tank
ON / OFF OFF
Pre alarms in list If set to Yes, the pre alarms are also
shown in the alarm log. YES / NO NO
Pressure units Sets the desired unit of measure for
the pressure bar / psi / kPa bar
Temp. units Sets the desired unit of measure for
the temperature °C and °F °C
Volume units Sets the desired unit of measure for
the volume scm (standard cubic meters)
scf (standard cubic feet) scm
Lock Keyboard If set to Yes, the keyboard will be
locked automatically after the genera-
tor is in the main window for more
than 20s. To unlock the keyboard,
press the unlock button and hold for
5s.
YES / NO NO
Display contrast Adjusts the contrast of the display. 0 - 10 5
Set default
values Sets all configuration parameters to
default

Hydrogen Generator NM Series 2 User’s Manual
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Diagnostic display
Item Description
Production Tot. Total production of hydrogen
Operating time (h) Total number of hours the unit has been in operation
Wat. quality (S) Actual water conductivity
Int. Press.: Actual internal pressure of the unit
Cell voltage (V) Actual cell voltage
Cell current (A) Actual cell current
PS. temp. Actual temperature of the power supply
Cell voltage peak (V) The maximum cell voltage since last power up
PS. temp. peak The max. temp. of the power supply since last power up
Special functions
Item Description
Dryer status Shows the temperatures of the drying columns and the position of the
cycle
System test This offers several test functions see below
Important: this function will only work if the generator is in
standby
Internal leak test The outlet valve is closed, the pressure is set to the max. When the
pressure reaches the max., production is stopped and the pressure
drop is measured over 2 minutes. The pressure drop should be below
0.7 bars or 10 PSI
External leak test Works similar to the leak “ internal leak test” except the outlet valve is
open and the test pressure is equal to the set pressure
This function can be used to test the external gas lines
Flow test This function sets the outlet valve to provide a certain flow
Adjustable from 0 to 100% of maximum flow.
Note: It will take approx. 2 minutes to get a stable flow!
Heater test This test checks if there is a reaction of the heaters when power is
applied.
Rinse flow test This test checks the amount of gas flow, for the dryer regeneration
Complete system test Combination of all tests above
Toggle Valve Used to switch the valves manually ( for advanced diagnostics only)
Important : after exiting this window, the valves will return to the
status prior to entering this test
Hardware options not available for user (password protected)

Hydrogen Generator NM Series 2 User’s Manual
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List of messages
These messages are just for information of the user. No action needs to be taken.
Status messages
MESSAGE DESCRIPTION
Standby The generator is powered up but not started
Reaching int. Press. Building up internal pressure after pressing the start button
Ready The Generator has reached internal pressure
Reaching ext. Press. The generator is producing H2
and pressure increases until the
set value is reached
Normal Pressure The generator is producing H2and has reached the set pres-
sure value
Normal Flow The generator is producing H2and has reached the set pres-
sure value with H2flowing
Master This unit is the master in the cascading chain
Slave This unit is a Slave in the cascading chain
Pre-alarm messages
These Alarms will not shut down the Generator, but action must be taken to avoid shut
down.
MESSAGE DESCRIPTION ACTION
Refill Water Water level approaching alarm
threshold Fill the tank with water
Change Water The conductivity of the water has
exceeded 30 uS Drain and then refill the tank; change the deionizer bag
Power supply Temp The temperature inside the genera-
tor is too high Check for proper ventilation
space
around the generator
Check Slave One or more slave(s) are not work-
ing properly (cascading mode) Check error messages of slaves, configuration settings, cables
Clock failure The clock is not set.
(If the generator is shut down for
more than a week, the time setting
may
b
e lost)
Set clock

Hydrogen Generator NM Series 2 User’s Manual
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Alarm messages
These alarms will shut down the generator.
MESSAGE DESCRIPTION ACTION
Low internal pressure The internal pressure cannot be
reached Notify service agent
Low out pressure The set pressure can not be
reached
Check for leaks in the external
tubing, or H2consumption is
higher than the generator capacity
Low Water The water level in the reservoir is
too low Refill the reservoir
Bad Water The conductivity of the water has
exceeded 40 uS Drain and then refill the
tank; change the deionizer bag
bag
High Cell Voltage The cell voltage is too high Notify service agent
Over current The current for the cell is too high Notify service agent
Over pressure The output pressure is too high
Check if any gas is fed back into
the generator from an external
source
Check int. press. in the Diagnos-
tics, if higher than 11.2 bar
(163 PSI) notify service agent
Over PS Temp
The temperature of the generator is
too high
Check for proper ventilation space
around the generator
Dryer Failure Communication failure between
dryer module and main board Notify service agent
Check auto refill
The water is not refilled in time with
auto refill Check water supply, tubing, filter and configuration settings
Heater Failure 1 Heater 1 does not work properly Notify service agent
Heater Failure 2 Heater 2 does not work properly Notify service agent

Hydrogen Generator NM Series 2 User’s Manual
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Maintenance
With proper care and maintenance, your hydrogen generator should provide you with years
of trouble-free operation. There are no adjustments to be made to the generator. The only
routine service operations are those described below.
Nonetheless, it is recommended to have the generator inspected approximately every 2
years or more frequently if the generator is installed in a rather dusty environment. Contact
your service agent.
Routine maintenance
The following section describes the maintenance operations required for the correct opera-
tion of the hydrogen generator.
Cleaning
The internal components of the hydrogen generator do not need to be cleaned and should
not be accessed by the user for cleaning. To clean the outside of the unit, only use a damp
cloth (no detergents, acids or aggressive or abrasive substances.
Water refilling
The tank must be refilled when the water level approaches the lower level, and the Refill
Water pre-alarm message appears.
Deionizer bag replacement
Rinse the water tank and replace the deionizer bag approximately every six months,
and whenever the “Change Water” message appears.
See installing the deionizer bag.
Long time Storage
If the Generator is not used, or stored for more than 2 weeks, it is very important to fill
the water tank at least to half full. This will avoid the dry-out of the cell.
Don’t leave new generators in the packing for more than a week, this can damage the cell.
WARNING!
Dried out cells will cause irreversible damage, which is not covered by warranty!

Hydrogen Generator NM Series 2 User’s Manual
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Options
Remote control
The hydrogen generators can be fitted with an I/O board. There are two possibilities with this
board:
1) Analog remote control with potentially free relay contacts to check the status of the
machine, and an input to start/stop the production of hydrogen.
The contacts can be configured via the Configuration Menu as normally-open or nor-
mally-closed (see the Configuration section). The maximum voltage and current rat-
ings for the relay contacts are 1A / 48V (outputs).
The input signal can be configured in 3 different modes:
a) start/stop: In this mode a pulse (positive edge) starts the generator and opens the
main valve after the internal pressure is reached. (during building up
the internal pressure, the “open” button is flashing). The next pulse will
put the generator in Standby
b) start only: In this mode the generator can be started by a pulse (positive edge)
or continuous signal. The main valve will be opened when the internal
pressure is reached. (During build-up of the internal pressure the
“open” button is flashing). The Stop action is via the key board.
c) direct control:In this mode the generator is producing hydrogen and the valve is
open as long as the input signal is high. When the signal goes low the
generator goes in Standby.
Remote connector pin configuration
Pin Description
1+2 Start 12-30 VDC (pin.1 = 0V, pin. 2 = positive)
3+4 Standby
5+6 Reaching external pressure
7+8 Refill water
09+10 Low water level
11+12 Bad water
13+14 Change water