Spectronik MGPR User manual

MINIATURE GAS
PRESSURE REGULATOR
MGPR
USER GUIDE
VERSION 2.2 SEPTEMBER 2022

Failure to follow these safety instructions could result in gas leakage, injuries, damage
to the Miniature Gas Pressure Regulator (MGPR) or other property.Read all the safety
information below before using MGPR.
Handling Handle MGPR with care.MGPR is not designed for extreme conditions, rough handling, vibration, shock
or drop.Keep MGPR away from heat, flame, strong sunlight, water, dust, soil or mud.Do not use adamaged
MGPR.
Repairing Do not troubleshoot, disassemble or tamper with MGPR.Do not attempt to repair or replace any
component by yourself.
Hydrogen Follow all local rules and regulations for safe handling, storage and usage of Hydrogen gas.Do not
smoke when operating MGPR.It is recommended to operate in awell-ventilated environment.
Pressure Never operate beyond MGPR’s rated inlet pressure of 350bar.
Connectors and ports Never force a connector into a port or apply excessive pressure.If the connector and port
do not join with reasonable ease, they probably do not match.Check for obstructions and ensure that the
connector matches the correct port.
High-consequence activities MGPR is a customized system with pending safety tests and certifications. It is not
intended for use where the failure of the system could lead to death, personal injury or severe environmental
damage.
Disclaimer Every effort has been made to ensure that the information in this manual is accurate.This manual
serves to adequately recommend safe operating procedures but shall not be treated as comprehensive.Do not
use MGPR in any other way than the one recommended in this manual. Spectronik reserves the right to change
system specifications, appearance or discontinue the product at any time.
Warranty Spectronik warrants the included hardware product and accessories against defects in materials and
workmanship for 1 year after delivery. Spectronik does not warrant against normal wear and tear, nor damage
caused by accident or abuse.
To obtain service, contact [e-mail]
SAFETY, HANDLING & SUPPORT
© 2022 Spectronik Pte. Ltd., All Rights Reserved.
Spectronik, the ‘S’ logo, and PROTIUM are registered trademarks of Spectronik Pte. Ltd.
WARNING:

ITEM DESCRIPTION
1MGPR 6Gas outlet port
NPT ¼ to PU 8mm
2On/Off manual valve 7Refueling port with cap
M12 x 1.25
3Carbon fiber cylinder plug
M18 x 1.5 8Refueling adapter
4Gas pressure transducer socket 9Refueling hose mating plug
M12 x 1.25
5
Gas pressure transducer
NPT 1/8 (to MGPR)
M12 x 1 (to receptacle)
10 Refueling port mating plug
M12 x 1.25
1OVERVIEW
CHAPTER 1 | OVERVIEW
* ID17 CS3 EPDM O-ring may or may not be required depending on user’s gas cylinder thread. Included
as spare part in the shipment.
2
1
3
4
5
6
8
9
10
*
7

ITEM DESCRIPTION
11 Gas pressure transducer receptacle
M12 x 1 14 Threaded socket to Hydrogen source
NPT 1/4
12 Stainless steel refueling hose 15 Spare O-rings
13 Refueling hose mating socket
to (9) M12 x 1.25
CHAPTER 1 | OVERVIEW
15
14
13
11
12

MGPR
Gas media Hydrogen
Rated inlet pressure 350bar
Min inlet pressure 10bar
Gas outlet pressure (@ rated flow) 0.45-0.75bar (factory set during order)
Max outlet pressure (@ zero flow) Gas outlet pressure + 0.3bar
Rated flow rate 40 SLPM
Operating temperature [-20,85]oC
Operating lifetime 10,000 cycles
Outer body material Al 2A14-T6
Core internal material SS 316/ H62/ TC4
Core sealing material PTFE
Sealing gasket material NBR
Dimension 75 x 85 x 58 mm
Weight 270g
Connection to gas cylinder M18 x 1.5
Connection to pressure sensor NPT 1/8
Connection to refueling hose M12 x 1.25
Gas outlet connector NPT 1/4 to PU 8mm
2SPECIFICATIONS
CHAPTER 2 | SPECIFICATIONS

1. Prepare the necessary adapter to link the threaded socket to Hydrogen source (14). This adapter is
not provided due to the different connector standards of Hydrogen source cylinders worldwide.
Warning:the pressure gauge provided has amaximum pressure of 25MPa.It is assumed that the
Hydrogen source will be standard industrial steel cylinder with pressure of less than 20MPa and that filling
the carbon fiber cylinder will be by means of pressure cascade.If you are connecting directly to a gas
booster pump or higher source pressures, change the pressure gauge or bypass it completely.At any time,
do not operate higher than 35MPa.
2. Connect the refueling hose mating socket (13)to the refueling hose mating plug (9).
3. Open the refueling cap.Keep it in asafe place, do not lose it.Connect refueling port mating plug (10)
into the refueling port (7) of MGPR.Do not use excessive force at the end of the turns.
4. Turn on your Hydrogen source.
5. Slowly turn On the On/Off manual valve by turning it anti-clockwise.Hissing sound can be heard as gas
rushes in from the source into the carbon fiber cylinder. Continue turning the valve anti-clockwise until it is
fully opened (i.e. cannot be turned anymore).Do not use excessive force at the end of the turns.
6. The gas will now fill into the carbon fiber cylinder until it reaches equilibrium with the source.
7. If you are using agas booster pump, it can now be turned on.
8. At the end of the filling process, turn off your Hydrogen source.Close the On/Off manual valve by turning it
fully clockwise.Caution: at this point, there is still high pressure gas remaining in the refueling hose.Remove
your blocker at gas outlet port to release the remaining gas through the MGPR low pressure gas outlet
port.
9. Once all the gas is released, fully remove refueling port mating plug from the refueling port and put back the
refueling cap.
10. The carbon fiber cylinder is now ready for usage.
1. Visually check MGPR for obvious cracks or other physical damage.Warning:never use a faulty regulator.
2. Ensure that On/Off manual valve (2) is in the Off state (fully clockwise).Do not over-tighten.
3. Ensure that gas pressure transducer (5) is securely connected.If you do not wish to use the gas
pressure transducer, then ensure that the gas pressure transducer socket is sealed with the plug
provided.
4. Block the gas outlet port (6) either with the blocker provided or gas tubing and valve.
5. Connect MGPR to the carbon fiber cylinder by manually turning the threaded carbon fiber cylinder plug
(3) into its corresponding female socket at the cylinder neck.There is no need to apply excessive force at
the end of the turns.The carbon fiber cylinder is now ready for gas filling.Note:an ID17 CS3EPDM O-ring
(provided) may or may not be needed depending on your carbon fiber cylinder thread design.
3OPERATING PROCEDURES
3.2 FILLING THE CARBON FIBER CYLINDER
3.1 SETTING UP MGPR
CHAPTER 3 | OPERATING PROCEDURES

1. Remove the blocker at gas outlet port that was in place during gas filling process.
2. Connect the gas outlet port to your desired application, e.g. to the inlet of the supply valve of a fuel cell
system.
3. Open the On/Off manual valve by turning it anti-clockwise slowly until the end.Gas from inside the carbon
fiber cylinder will now flow out through the gas outlet port.
4. To turn off the gas at the end of usage, shut off the On/Off manual valve by turning it clockwise.
3.3 USING THE FILLED CARBON FIBER CYLINDER
CHAPTER 3 | OPERATING PROCEDURES
The MGPR can be used as alab bench-top equipment without being connected to a carbon fiber cylinder.
1. The low regulated output pressure at the gas outlet port is always open.Put ablocker to prevent gas from
coming out.
2. The On/Off manual valve serves to open or close the connection between your Hydrogen source which
enters the MGPR through the refueling port and the carbon fiber cylinder which is connected at the carbon
fiber cylinder plug.If you are not going to use acarbon fiber cylinder, make sure that the On/Off manual
valve is turned OFF (fully clockwise).Caution: unregulated high pressure gas will gush out from the carbon
fiber cylinder plug if the On/Off manual valve is not fully turned OFF.
3. Turn on your Hydrogen gas supply.Hydrogen gas will now flow through the refueling hose and enter the
MGPR through the refueling port.
4. Remove the blocker from the gas outlet port.Regulated low pressure Hydrogen gas will now come out
from the gas outlet port and can be channeled to your desired application, e.g. to the inlet of the supply
valve of a fuel cell system.
5. To turn off the gas at the end of usage, shut off your Hydrogen source directly.Reminder: the On/Off
manual valve on the MGPR is not in use in this configuration and shall be fully OFF (clockwise) at all times.
3.4 USING THE MGPR WITHOUT CARBON FIBER CYLINDER
Low
Pressure
Outlet
1st Stage Pressure
Regulator
On/Off
Manual Valve
Carbon Fiber Cylinder
Hydrogen
Source
2nd Stage Pressure
Regulator

CHAPTER 3 | OPERATING PROCEDURES
REMINDER
When not in use, keep MGPR in its original box and store it in a cool, dry place.
3.5 STORAGE
•Wear safety goggles and gloves at all times.
•Ensure connections are firm and secure, but do not use excessive force to over-tighten.
•Never operate MGPR at inlet pressure beyond 350bar.
•Carbon fiber cylinder will become warm when filled with Hydrogen gas.Never fill a carbon fiber cylinder too
quickly.If you are using a booster pump, it is advisable to pause the filling process every 30-50bar to prevent
over temperature.

Stainless steel 316 body
Welded configuration without sealing o-rings
10-90% proportional voltage output
Voltage reversal protection
Hydrogen gas pressure measurement
Hydraulic system pressure measurement
Pressure range: 0-50 MPaG
Output voltage (Io): 0.5-4.5VDC
Precision (including non-linearity, hysteresis, repeatability and calibration
error, 25oC and Vcc 24VDC): +/-0.5% F.S.
Long term stability: +/-0.25% F.S. per year
Pressure cycling: >= 5 x 106
Operating temperature: -40 to 120oC
Storage temperature: -40 to 105oC
Over pressure: 1.5X
Burst pressure: 2X
Response time: 10ms
Supply voltage (Vcc): 4.75-5.25VDC
Output load resistance: >= 10k.ohm
Over voltage: 16VDC
Reverse over voltage: -16VDC
Insulation resistance: >= 20M.ohm @ 100VDC
Ingress protection: IP65
Vibration: X/Y/Z, 20g, sine 11ms
Shock: 10g, 5-2000Hz
4GAS PRESSURE TRANSDUCER
CHAPTER 4 | GAS PRESSURE TRANSDUCER
4.1 FEATURES AND APPLICATIONS
4.2 TECHNICAL SPECIFICATIONS

CHAPTER 4 | GAS PRESSURE TRANSDUCER
Ensure that all system connections are secure and leak free. Hydrogen leakage may cause fire or explosion in
extreme cases.
If the pressure port of the transducer is blocked by a foreign object, do not use asharp tool to clear the
passage.It is recommended to dissolve the foreign object in asolvent instead.
Do not tamper with the device. Contact us for re-calibration purposes.
Dimensions in mm
Signal
(white)
5V+
(brown)
5V-
(blue) NC
1/8NPT
10.0
53
M12x1
Ø 14
1. Pin definition
V
2. Wiring diagram
Shield
Load Power
Supply
4.3 NOTES