Proton HOGEN GC4800 Maintenance and service guide

PD-0100-0063 Rev A CONFIDENTIAL –Do not copy Page 1 of 11
HOGEN®GC4800
External Desiccant Dryer Accessory
Installation / Maintenance
Manual

GC 4800 Desiccant Holder
Installation and Maintenance Manual
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SIC 3569-901 Gas Generating Equipment
NAICS 333-999-8556 Gas Generating Equipment
November 2011
Proton OnSite
10 Technology Drive
Wallingford, CT 06492
Phone [phone] • Fax [phone]
www.protononsite.com
[email protected]
© 2011 Proton Energy Systems, Inc. d/b/a Proton OnSite
All rights not expressly granted herein are reserved.
Information in this document is provided in connection with Proton Energy Systems Inc. d/b/a Proton OnSite
(“Proton”) products and services. No license, express or implied, by estoppel or otherwise, to any intellectual property
rights is granted by this document. Except as provided in Proton Terms and Conditions of Sale for such products and
services, Proton assumes no liability whatsoever, and Proton disclaims any express or implied warranty, whether
written or oral, relating to sale and/or use of Proton products or services including liability or warranties relating to
fitness for a particular purpose, merchantability, or infringement of any patent, copyright or other intellectual property
right. Proton products are not intended for use in medical, life saving, or life sustaining applications.
Proton may make changes to specifications and product descriptions at any time, without notice.
This document as well as any software, processes or procedures described in it is furnished under license and may
only be used or copied in accordance with the terms of the license. The information in this document is furnished for
informational use only, is subject to change without notice, and should not be construed as a commitment by Proton.
Proton assumes no responsibility or liability for any errors or inaccuracies that may appear in this document or any
software that may be provided in association with this document.
Except as permitted by such license, no part of this document may be reproduced, stored in a retrieval system, or
transmitted in any form or by any means without the express written consent of Proton.
® Proton , Proton OnSite , Proton Energy Systems , the Proton design, StableFlow , StableFlow Hydrogen Control
System and design, HOGEN, and FuelGen are trademarks of Proton Energy Systems, Inc.
Any other brands and/or names used herein are the property of their respective owners.

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Key definitions, acronyms, and abbreviations that may be used in this
document
µS/cm –MicroSiemen per centimeter, a measure of water conductivity
Bar –14.5 PSI or 100 KPa (KiloPascals or Newton/cm), a unit of system pressure. All pressures are at gauge
pressure unless otherwise specified.
cc –Cubic centimeter
CPI –Chemical Process Instrumentation
FPT –Female Pipe Thread
FuelGen® - Registered TM of Proton Energy Systems, Inc. for hydrogen systems, comprised of a hydrogen
generator, hydrogen storage container, hydrogen dispensers and parts and accessories
HCS –H Series Control System
HGMS –Hydrogen Gas Management Subsystem
HOGEN® - Registered TM of Proton Energy Systems Inc. for packaged water electrolysis based hydrogen
generators
kVA –Kilovolt -ampere
kW –Kilowatt
L/m –Liters per minute flow (for hydrogen, calculated at a standardized temperature & pressure)
LAN –Local Area Network
LFL –Lower Flammability Limit
NEC –National Electric Code, NFPA 70
NFPA –National Fire Protection Association, a Standards Organization
Nm3/h –Normal cubic meter per hour (International Normal conditions are 1.01325 bar and 0 Celsius)
NPT –National Pipe Thread
NRTL –Nationally Recognized Testing Laboratory
P&ID –Piping and Instrumentation Diagram (Fluid Schematic)
PEM - Proton Exchange Membrane
PPE –Personal Protective Equipment
PPM –Parts per Million
PSI –Pounds force per square inch (lbf /in2=6894.7 Pa), a unit of pressure. All pressures are at gauge pressure
unless otherwise specified.
SCFH –Standard cubic foot per hour (US Standard conditions for air are 1 atmosphere and 70°F)
Standard atmosphere = 1.01325 bara = 14.696 psia
TCU –Thermal Control Unit
TVSS –Transient Voltage Surge Suppressor
VAC –Volts Alternating Current
VDC –Volts Direct Current
WOMS –Water/Oxygen Management Subsystem
- Notes contain helpful suggestions or references.
- Indicates a potentially hazardous situation, which, if not avoided, may result in minor or moderate
injury. It may also be used to alert against unsafe practices. This could result in equipment damage or
loss of data.
- Indicates a potentially hazardous situation, which, if not avoided, could result in death or serious injury.
The reader is in a situation that could cause bodily injury.

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1INTRODUCTION
The purpose of this manual is to provide an overview of the installation and maintenance of the
external desiccant dryer that accompanied your hydrogen generator. This manual is meant to
supplement the Installation and Operation Manual that was included with the hydrogen
generator.
IT IS THE CUSTOMER’S RESPONSIBILITY TO CONSULT WITH THE
LOCAL AUTHORITY HAVING JURISDICTION (AHJ) REGARDING LOCAL
CODE REQUIREMENTS FOR INSTALLATION AND OPERATION OF THIS
EQUIPMENT.
DO NOT USE THIS EQUIPMENT IN A MANNER NOT SPECIFIED BY
PROTON.
Figure 1 - TBD
This manual attempts to answer most of the frequently asked questions regarding the operation
of the unit. PROTON technical staff is also available to answer questions and support the
successful deployment of this equipment. Please call [phone] and ask for technical
service support or email [email protected]. Please have the model number
and serial number of your unit available.
PROTON offers a full range of installation and training services. Contact PROTON
Customer Service at 203.949.8697 or your local service provider/supplier for more
information.
It is the customer’s responsibility to organize a backup hydrogen supply to bridge critical
times during maintenance and service.

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2GENERAL DESCRIPTION
The desiccant dryer is the second component that comprises the GC4800 hydrogen
generator system. The purpose of the dryer is to receive the product gas from hydrogen
generator, pass it through a desiccant column, further reducing the moisture content of
the product gas stream to less than one ppmv water content. The hydrogen generator
portion of the GC4800 is capable of producing gas of this quality, but may produce
output with as much as five ppmv moisture content.
The desiccant cartridge holder is only to be supplied hydrogen from a HOGEN
hydrogen generator. Any other use is prohibited.
3INSTALLATION OF DESICCANT HOLDER ASSEMBLY
The desiccant cartridge assembly should be securely mounted to a wall or structure
capable of supporting the weight of the assembly, 35 lbs (15.9 kg). The unit should be
located in close proximity, within 10 feet (3 meters), to the hydrogen generator and
within a space that has the same ventilation requirements outlined in the Installation and
Operation Manual for the hydrogen generator. The desiccant cartridge assembly shall not
be directly mounted to the hydrogen generator. The mounting pattern for the mounting
Panel is shown in the following Figure 2.
Figure 2 Mounting Panel Layout

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3.1 Hydrogen Gas Connections
On the Desiccant cartridge holder, there are two ¼” compression fittings. The fitting on
the lower block is the inlet and receives gas from the hydrogen generator. The fitting on
the top block is the product out and is to be connected to the process or hydrogen
distribution system, see Figure 3.
Figure 3 Desiccant Holder Connections
If the GC4800 system is to be used in conjunction with a crossover manifold or any sort
of back-up supply for uninterrupted gas flow, a ASME stamped pressure relief valve set
to no greater than 275 psig must be installed in the line and properly vented to protect
against an over pressurization of the desiccant cartridge holder.
The HOGEN hydrogen generator has its own integrated ASME stamped pressure
relief device installed.
Outlet, ¼”
Swagelok
Compression
Inlet, ¼” Swagelok
Compression

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3.2 Desiccant Cartridge Installation
DO NOT DISSASSEMBLE THE HOLDER ASSEMBLY. DO NOT
LOOSEN THE NUTS SECURING THE TIE RODS. SERVICE
DESICCANT CARTRIDGE BY REMOVING THE APPROPRIATE
FASTENERS OUTLINED IN THIS SECTION.
1. The service cap is located n the bottom of the desiccant holder. The cap is
secured in place with 6 screws, Figure 4. Using a ¼” hex drive. Remove the six
(6) screws.
Figure 4 Cartridge Holder Bottom with Serviceable Screws
2. With the cap removed, prepare the desiccant cartridge, Part Number: 02-3001-
0040, for installation by removing the peel back lids on both ends of the cartridge,
Figure 5. Do not remove the ends from the cartridge until it is ready to be used
within the desiccant holder.
Remove Only
These Screws

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Figure 5 Removal of Cartridge Seal Prior to Installation
3. Slide the desiccant cartridge up into the desiccant holder assembly, Figure 6.
Figure 6 Installation of Desiccant Cartridge
4. Push the cartridge all the way up into the holder as far as it will go.
5. Install the desiccant cartridge support ring with the spring and bottom cap as
shown in Figure 7.

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Figure 7 Installation of Support Ring, Spring and Cap
6. While holding the cap install the six (6) hex head screws finger tight, Figure 8.
Figure 8 Installation of Socket Head cap Screws
7. Using a ¼” hex drive, tighten the six screws up to 1 full turn or until tightened.
8. The unit is now ready to be used.
Cartridge Support Ring
O-Ring
Spring
Cap

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4MAINTENANCE
When connected to a GC4800 hydrogen generator under normal operating conditions, the
operational life of the desiccant cartridge should be one year if handled as described in this
manual. However, the desiccant cartridge should be changed out if there is any reason to
suspect that the cartridge is no longer removing moisture to adequate levels regardless of the
operational duration.
Replacement desiccant cartridges can be purchased by contacting Proton OnSite Customer
Service and ordering Part Number 02-3001-0040.
Please follow the instructions outlined in Section 3.1 of this manual for changing the desiccant
cartridge.

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NOTES