Peak Scientific Precision Hydrogen SL User manual

Precision Hydrogen SL
Service Manual
Copyright © Peak Scientific Instruments Ltd 2020 — Precision Hydrogen SL Service Manual Rev 2 RSID 3518 EN —03/08/2020

Page 2
Contents
Service Manual 1
Change History 3
How to use this Manual 3
Safety Notices 4
Symbols 4
Safety Notice to Users 4
Safely Isolated Condition 5
Safe State After Repair 5
Health and Safety Data 6
Deioniser Resin 6
Desiccant 8
Molecular Seive 10
Technical Specification 12
Precision Hydrogen SL 12
Service Requirements 13
Service Schedule 13
Replacement Parts 13
Principle of Operation 14
Product Overview 15
Electrical Panel Layout 16
Circulation Pump Replacement 17
Cell Replacement 18
Load Pump Replacement 19
Deioniser Column Replacement 20
Replacement of Desiccant Column 21
Pneumatic Diagram 23
Electrical Diagram 24
Cleaning 29
Troubleshooting 30

Page 3
Change History
Rev Comment Name Date
How to use this Manual
This manual is intended for Field Service Engineers and technically competent end
users has been written as a reference document where you can skip to the relevant
information.
Users can refer to the contents page to find the relevant information.
Please review each of the following sections carefully.
Thank you for selecting Peak Scientific to meet your gas generation needs, and should
you require any further assistance or support please do not hesitate to contact Peak
Scientific or the Peak Partner from which you purchased your generator.

WARNING
WARNING
WARNING
CAUTION
Page 4
WARNING
Safety Notices
Peak Scientific Instruments cannot anticipate every possible circumstance which may
represent a potential hazard. The warnings detailed within this manual refer to the most
likely potential hazards, but by definition cannot be all inclusive. If the user employs
an operating procedure, item of equipment or a method of working which is not
specifically recommended by Peak Scientific, the user must ensure that the equipment
will not be damaged or become hazardous to persons or property.
Symbols
This manual uses the following symbols to highlight specific areas important to the safe
and proper use of the generator.
A WARNING notice denotes a hazard. It calls attention to an operating procedure,
process or similar, which if not correctly performed or adhered to, could cause
personal injury or in the worst case death. Do not proceed beyond a WARNING
notice until the indicated conditions are fully understood or met.
A CAUTION notice denotes a hazard. It calls attention to an operating procedure,
process or similar, which if not correctly performed or adhered to, could cause
damage to the generator or the application. Do not proceed beyond a CAUTION
notice until the indicated conditions are fully understood or met.
Caution, risk of electric shock. Ensure power to the generator has been removed
before proceeding.
Safety Notice to Users
These instructions must be read thoroughly and understood before
installation and operation of your Peak Generator. Use of the generator
in a manner not specified by Peak Scientific MAY impair the SAFETY
provided by the equipment.
When handling, operating or carrying out any maintenance, personnel
must employ safe engineering practices and observe all relevant local
health and safety requirements and regulations. The attention of UK
users is drawn to the Health and Safety at Work Act 1974, and the
Institute of Electrical Engineers regulations.
If the equipment is used in a manner not specified by the manufacturer,
the protection provided by the equipment maybe impaired.

Page 5
Safely Isolated Condition
Definition: The unit is in a Safely Isolated Condition when it is disconnected from its
application, fully de-pressurised and isolated from the Electrical Supply. Directions for
isolating the Generator are shown below.
Failure to place the Generator in a safely isolated condition when
instructed to do so may lead to personal injury or injury to others and
even death.
Isolating the Generator:
The generator may be restored to a depressurised state by pressing and holding the
front button for at least three seconds. This will cause the generator to cease hydrogen
production, illuminate the water tank blue, and exhaust any stored hydrogen through
the exhaust port at the rear of the generator.
At this point you may switch the generator o at its rear power switch.
Safe State After Repair
To guarantee the generator is in a safe state after a repair, please ensure the following
conditions are met;
• The electricity cable has been correctly refitted.
The mains cable should be plugged into the IEC power inlet located on the rear
panel of the generator. This unit is classified as SAFETY CLASS 1. THIS UNIT MUST
BE EARTHED.
WARNING

Page 6
Health and Safety Data
Deioniser Resin
This sheet to be retained by the ‘Health & Safety Ocer’
The recipient of this Health & Safety Data sheet is required to ensure that all personnel
handling, using or likely to come into contact with the material are made aware of the
Health & Safety information contained herein.
General Description
Bag containing ion exchange resin. 60% Cation and 40% Anion by mass.
Chemical Components
Polystyrene divinylbenzene cation and ion exchange resin.
Form Solid beads
Flash Point N/A
Colour Ta n
Ignition Temperature 427 °C (Estimated)
Odour None
Explosion Limits N/A
Decomposition Temperature Over 220 °C
Vapour Pressure @ 25 °C 17mm CFH @ 20 °C (Water)
Viscosity @ 25°C N/A
Solubility in Water Negligible
Specific Gravity @ 25°C 1.1-1.3
pH @ 25 °C 7-9.5 in aqueous slurry
Eye Protection Safety Glasses (BS2092C)
Storage Store in a cool place above 0 °C, out of direct sunlight
Fire & Explosion Hazards Toxic combustion products may include sulphur dioxide
and sulphur trioxide
Disposal This product can be disposed as ordinary waste if local
regulations permit
Emergency & First Aid Procedures
Spillages
Floor may be slippery. Use care to avoid falls. Wear protective glasses.
Sweep up and transfer to containers for recovery and disposal.
Extinguishing Media
Carbon Dioxide (CO2), Water Fog and Dry Powder.
Fire Fighting and Protection
Wear HSE approved, pressure demand, self-contained breathing apparatus or equivalent.

Page 7
First Aid
Skin Contact
Wash eected areas with soap and water. Consult doctor if irritation persists.
Eye Contact
Product can cause severe eye irritation. Flush eyes with large amounts of water for at
least 15 minutes. Consult a doctor if irritation persists.
Inhalation
This product should present no hazard if operated under normal conditions. If irritation
persists, move patient to fresh air.
Ingestion
If resin has been confined to the mouth, administer 250 ml. of water as a mouthwash.
Avoid swallowing. This product is considered non-hazardous if ingested in small
amounts; however, it is advisable to seek medical advice.
Toxicological Data
No toxicity data available on this product
Occupation exposure limits
STEL/TLV = None established.
Incompatible Materials (to avoid hazardous reactions)
Avoid contact with concentrated nitric acid and any other strong oxidising agents at all
times.

Page 8
Desiccant
This sheet to be retained by the ‘Health & Safety Ocer’
The recipient of this Health & Safety Data sheet is required to ensure that all personnel
handling, using or likely to come into contact with the material are made aware of the
Health & Safety information contained herein.
General Description
Column containing orange to green indicating silica gel.
Chemical Components
Amorphous silica 98.2%, activated colouring agent 0.2% max.
Form Beads
Flash Point N/A
Colour Dry: yellow/orange Saturated: Green
Ignition Temperature >1000 °C
Odour Odourless
Explosion Limits N/A
Decomposition Temperature Over 155 °C
Vapour Pressure @ 25 °C 17mm CFH @ 20 °C (Water)
Viscosity @ 25°C N/A
Solubility in Water less 1.0% in weight
pH @ 25 °C 2-10 at 5% w/w in water
Eye Protection Safety Glasses (BS2092C)
Storage All containers must be closed air tight and kept in a dry
place.
Fire & Explosion Hazards N/A
Disposal This product can be disposed as ordinary waste if local
regulations permit.
Emergency & First Aid Procedures
Spillages
Contain spillage. Collect in suitable containers for recovery or disposal. During
collection avoid creating dust.
Extinguishing Media
N/A. Inorganic compound. Not combustible.
Fire Fighting and Protection
Wear HSE approved, pressure demand, self-contained breathing apparatus or
equivalent.

Page 9
First Aid
Skin Contact
Wash spillage from skin with soap and water.
Eye Contact
Wash immediately with copious amounts of water and obtain medical attention.
Inhalation
Remove from source of exposure.
Ingestion
Wash out mouth with water. If large amount swallowed or symptoms develop obtain
medical attention.
Toxicological Data
The lethal dose for humans for synthetic amorphous silica is estimated at over 15,000
mg/kg
Occupation exposure limits
DNEL/PNEC < 1 = No immediate concern.
Incompatible Materials (to avoid hazardous reactions)
None known.

Page 10
Molecular Seive
This sheet to be retained by the ‘Health & Safety Ocer’
The recipient of this Health & Safety Data sheet is required to ensure that all personnel
handling, using or likely to come into contact with the material are made aware of the
Health & Safety information contained herein.
General Description
Column containing white to tan molecular sieve.
Chemical Components
Quartz (SiO2) <10%, balance Zeolite.
Form Spheres
Flash Point N/A
Colour White to tan
Ignition Temperature N/A
Odour Odourless
Explosion Limits N/A
Decomposition Temperature N/A
Vapour Pressure @ 25 °C N/A
Viscosity @ 25°C N/A
Solubility in Water Insoluble
pH @ 25 °C N/A
Eye Protection Safety Glasses (BS2092C)
Storage All containers must be closed air tight and kept in a dry
place.
Fire & Explosion Hazards N/A
Disposal This product can be disposed as ordinary waste if local
regulations permit.
Emergency & First Aid Procedures
Spillages
Contain spillage. Collect in suitable containers for recovery or disposal. During
collection avoid creating dust.
Extinguishing Media
N/A. Inorganic compound. Not combustible.
Fire Fighting and Protection
Wear HSE approved, pressure demand, self-contained breathing apparatus or
equivalent.

Page 11
First Aid
Skin Contact
Wash spillage from skin with soap and water.
Eye Contact
Wash immediately with copious amounts of water and obtain medical attention.
Inhalation
Remove from source of exposure.
Ingestion
Wash out mouth with water. If large amount swallowed or symptoms develop obtain
medical attention.
Toxicological Data
The lethal dose for humans for synthetic amorphous silica is estimated at over 15,000
mg/kg
Occupation exposure limits
DNEL/PNEC < 1 = No immediate concern.
Incompatible Materials (to avoid hazardous reactions)
None known.

Page 12
Technical Specification
Precision Hydrogen SL
Environment
100 cc 200 cc
Minimum Operating Ambient Temperature 10°C (50°F)
Maximum Operating Ambient Temperature 35°C (95°F)
Maximum Altitude 3000 m
Maximum Relative Humidity 90% Non-Condensing
Minimum Storage Temperature* 10°C (50°F)
Maximum Storage Temperature* 25°C (77°F)
Generator Outlets
Max Flow Rate 100 cc/min 200 cc/min
Purity 99.9995%
Gas outlet 1 x 1/8” Swagelok compression fitting
Delivery pressure 100 psi (6.9 bar)
Electrical Requirements
Voltage 100-240VAC +/-10%
Frequency 50/60 Hz
Current 6A Max.
Input Connection C14 Connection
Power Cord (Supplied) C13 socket to local connection (10A minimum)
Pollution Degree 2
Installation / Over Voltage Category II
General
Generator Dimensions cm 16.0 (6.3”) x 38.5 (15.2”) x 25.0 (9.8”)
Generator Weight 8 kg (17.6 lbs)
Shipping Crate Dimensions cm 23.4 (9.2”) x 59.4 (23.4”) x 34.2 (13.5”)
Shipping Weight 11 kg (24.2 lbs)
Noise Level @ 1 m <55 dB
Heat Output 1000 BTU / Hr
Water Purity Requirement ASTM Type II (<1 µS/cm / >1 MΩ-cm)
* When taken out of storage the Generator should be allowed to acclimatize at room
temperature for a minimum of 3 hours before operation.

Page 13
Service Requirements
Service Schedule
Purchase Interval Component Visit
12 Months Precision Hydrogen SL 100cc 12 Month Kit
www.peakscientific.com/ordering
Precision Hydrogen SL 200cc 12 Month Kit
24 Months Precision Hydrogen SL 100cc 24 Month Kit
Precision Hydrogen SL 200cc 24 Month Kit
Note: Only Peak approved components should be used.
Replacement Parts
All parts shown as replaceable in this document can also be ordered by visiting:
www.peakscientific.com/ordering
Page 13

Page 14
Principle of Operation
The Peak Scientific hydrogen generator produces high purity hydrogen gas, H2.
Hydrogen does not occur naturally on earth and must be formed via the decomposition
of other molecules, in this case via the splitting of water molecules into hydrogen and
oxygen in a process known as electrolysis.
The electrolyser used in the Peak Scientific hydrogen generator is known as a Proton
Exchange Membrane (PEM) electrolyser. This type of electrolyser was first described
in the mid-1960’s by General Electric as a method for producing oxygen for the Gemini
space program. PEM electrolysis has been continually developed since its introduction
and has remained the state-of-the-art technology for water electrolysis and the
production of high purity hydrogen ever since.
The most important element of the generator is the electrolyser cell where the
electrolysis reaction takes place. This consists of two electrodes (an anode and a
cathode), which are separated by the proton exchange membrane which gives the
technology its name. During operation deionised water is fed to the anode of the
electrolysis cell where it is split into oxygen, protons and electrons with the aid of a
precious metal catalyst. The oxygen is vented to atmosphere from the generator. The
protons travel across the membrane and simultaneously the electrons travel around
the external electrical circuit. These protons and electrons then recombine at the
cathode of the electrolyser, again with the aid of a precious metal catalyst to produce
the hydrogen gas. The high purity of the hydrogen is assured by the membrane which
completely separates the hydrogen produced at the cathode from the oxygen being
produced at the anode. These processes are described by the following equations:
Anode Reaction
H2O(l) ½O2(g) + 2H+
(aq) + 2e-
Cathode Reaction
2H+
(aq) + 2e-H2(g)
Deionised water is critical to the operation of the system and must have a purity of
1μS/cm or better to prevent damage to the membrane. Failure to use this grade of
deionised water will invalidate the 2 year warranty of your generator. The water is
automatically loaded (either at power up or periodically during operation) and the rate
at which the water is consumed depends on the amount of hydrogen being produced.
A small amount of the electrical energy input is lost as heat and this is removed from
the generator by the ventilation system.
The Peak Scientific hydrogen generator generates hydrogen on demand. By
maintaining the pre-set pressure and using this as a reference value, the generator will
produce the precise amount of hydrogen required. As soon as the demand ceases, no
further hydrogen will be sent to the user’s application. During this time bubbles may
still be observed in the water tank. This is due to the generator maintaining its internal
pressure and ensuring that clean, dry hydrogen is available immediately on demand
when the user requires it.

Page 15
Product Overview
Hydrogen Cell
Electrical Panel
Deioniser Column
Pressure Regulator
Water Tank
Hydrogen Output
Water Drain
Power Inlet & Switch
Desiccant Column

Page 16
Electrical Panel Layout
Risk of electric shock, accessing the electrical panel without safely
isolating the generator should only be carried out by trained service
personnel.
For instructions on how to replace the PCB Assembly, please refer
to WI-1608.
WARNING
PCB
Circuit Breaker
Power Supply

Page 17
Setting Precision SL100 model
To set generator to SL100 model, generator must be programmed first! Once programmed
follow steps below:
1. Power up the generator.
2. Simultaneously press and hold three pushbuttons: DB USER PB, MB USER PB and MB
RESET PB.
3. While observing PSU On LED, release MB RESET PB whilst still holding DB USER PB and
MB USER PB. Hold both pushbuttons for about 5 seconds until PSU On LED blink once
indicating SL100 model has been set successfully.
To confirm, power cycle generator while observing PSU On LED. One blink indicates
Precision SL100 and two blinks SL200 model.
Note: Alarm LED may blink/illuminate during above process, this is a normal operation.
For pushbutton position see figure 1 below.
Figure 1 – Precision SL PCB assembly Figure 1 – Precision SL PCB assembly

Page 18
Circulation Pump Replacement
Ensure that Generator is in a Safely Isolated Condition.
1. First drain the water from the generator, using the drain connection on the rear of
the generator. The DI Cartridge should be removed to allow the system to drain
properly. Connect to an empty tank of at least 3 litres to ensure the tank can hold all
the water from the generator.
2. Disconnect the 4-way Molex connection between the pump and the electrical panel.
3. Un-clip the pump from its bracket.
4. Disconnect the old pump from the system tubing.
5. Use fresh tubing provided to fit to the new pump.
6. Fit the new pump to the support bracket by clipping it into place.
7. Re-connect the tubing from the pump into the generators pneumatic circuit, as
shown on the pneumatic schematic provided later in the manual and re-connect the
electrical connection.
8. Return the generator to a Safe State of Repair, installing the DI Cartridge and
connecting the generator to a clean fresh supply of deionised water.
9. Check all water connections to ensure there are no leaks and that the pump is
circulating water towards the electrolyser stack.
WARNING

Page 19
Cell Replacement
Ensure that Generator is in a Safely Isolated Condition.
1. First remove the DI cartridge and drain the water from the generator, using the drain
connection on the rear of the generator. Connect to an empty tank of at least 3 litres
to ensure the tank can hold all the water from the generator.
2. Now disconnect the power cables from the electrolyser cell.
3. Remove the 4x M5 Nyloc nuts from the underside of the generator, retain for later
use,, and disconnect the tubing connected to the cell.
4. Disconnect the separation tank valve, separation tank sensor and pressure switch
connection on the electrical panel.
5. Remove the old cell and fit a new cell to the bracket, using a 1/8" Allen key. Then
fit the sub assembly to the generator, ensuring the M5 Nyloc nuts are securely
tightened. Refit the positive and negative power supply cables ensuring that they
are securely tightened.
6. Finally, reconnect all water and gas hoses as per the schematic provided later in this
manual.
7. Reconnect the separation tank valve and sensor as well as the pressure transducer.
8. Install a fresh DI cartridge prior to returning the generator to a safe state of repair
WARNING

Page 20
Load Pump Replacement
Ensure that Generator is in a Safely Isolated Condition.
1. First remove the DI cartrisdge and drain the water from the generator, using the
drain connection on the rear of the generator. Connect to an empty tank of at least 3
litres to ensure the tank can hold all the water from the generator.
2. Disconnect the tubing connected to the pump.
3. Disconnect the electrical connection at the pump.
4. Unclip the pump from it's bracket.
5. Hardwired pump wires should be connected to the PCB.
6. Clip the new pump into the already installed bracket.
7. Re-connect the tubing as per the schematic provided later in this manual.
WARNING