Bennett H35 Series Maintenance Manual
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Bennett H35 Series Maintenance Manual

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Maintenance Manual
High Flow H35 Hydrogen Series
155211 Rev. B, 12.20.2023
Dual Cabinet Configuration

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  • Page 1 Maintenance Manual High Flow H35 Hydrogen Series 155211 Rev. B, 12.20.2023 Dual Cabinet Configuration...
  • Page 2 This manual contains important information for the safe maintenance of this equipment. Read and understand this manual before applying power. All service personnel should read this manual before performing service activities. The material included in this manual is accurate at the date of publication. Failure to follow these instructions could result in bodily injury, damage to the equipment, or death.

  • Page 3: Table Of Contents

    TABLE OF CONTENTS ....... 11 YDROGEN ISPENSING 1 SAFETY INSTRUCTIONS ........1 4.3.1 D ...... 11 ISPENSER 4.3.2 S ....... 12 ISPENSING ......... 1 AFETY MESSAGES 4.3.3 I ..... 12 NACCURATE RESSURE EADING 4.3.4 D ........12 2 INTRODUCTIONERROR! BOOKMARK NOT DEFINED. ISPENSER 4.3.5 V ....

  • Page 4: Safety Instructions

    Safety Instructions 1 SAFETY INSTRUCTIONS Please read and understand the following grouped safety messages that contain safety symbols and safety words. They are defined as: RED AND WHITE. IF YOU DO NOT FOLLOW THE INSTRUCTIONS, SEVERE INJURY OR DEATH WILL OCCUR. Orange and black.
  • Page 5 Safety Instructions 1. WARNING: To prevent electric shock, keep the electrical parts of the dispenser dry. 2. WARNING: Electronic components are static sensitive. Use proper static precautions (static straps) before working on the equipment. 3. WARNING: Only technicians who have been trained in operation and programming of this dispenser should perform programming and maintenance.
  • Page 6 introduction 2 INTRODUCTION The following table lists the tags that identify each component in the dispenser. Please also refer to these drawings. Some installations may vary: • P6883, General Overview, H35 HF Main • P6801, Piping and Instrumentation Diagram Cabinet (P&ID) •...

  • Page 7: Service, Maintenance Procedures

    Service, Maintenance Procedures 3 SERVICE, MAINTENANCE PROCEDURES 3.1 PIPING & INSTRUMENTATION 3.1.1 LOCK-OUT PROCEDURES The following procedures must be performed before proceeding with any service or maintenance work on the piping and instrumentation system. • Isolate the dispenser from sources of pressure. Close the HV-100 Hydrogen Supply Shutoff valve.

  • Page 8: Changing Filter Element

    Service, Maintenance Procedures 3.1.3.2 LOK TUBING & FITTINGS LOK tubing and fittings connect parts of the system with lower pressure requirements (such as vent and coolant lines). These connections are a tapered ferrule, permanently attached to the end of a tube that seals against a mating surface inside the fitting or component.

  • Page 9: 819 Electronics , User D Controls

    Service, Maintenance Procedures 3.3 819 ELECTRONICS, USER DISPLAYS, CONTROLS 3.3.1 LOCK-OUT PROCEDURES The following procedures must be performed before proceeding with any service or maintenance work on any electronics. • Isolate the dispenser from sources of pressure. Close the HV-100 Hydrogen Supply Shutoff valve.

  • Page 10: Troubleshooting Guide

    Troubleshooting Guide 4 TROUBLESHOOTING GUIDE For all electrical troubleshooting please refer to the wiring diagrams. 4.1 PROGRAMMING AND COMMUNICATION 4.1.1 PROGRAMMABLE LOGIC CONTROLLER (PLC) The PLC, as seen in Figure 3.2, is linked to a remote I/O board responsible for managing the modules on the rack, depicted in Figure 3.3.

  • Page 11: Dispenser Communication

    Troubleshooting Guide 4.1.3 DISPENSER COMMUNICATION Problem Solution The dispenser is in Stand Alone Program the dispenser in Mode 21 for the correct communication mode. type. See the Hydrogen Operation Manual. Make sure the handle switch is working properly by running The handle switch is not diagnostics mode 5.

  • Page 12: Power And Display

    Troubleshooting Guide 4.2 POWER AND DISPLAY 4.2.1 NO POWER If the dispenser has no power, follow these steps to diagnose and resolve the issue: Step Action Description Confirm that the power switch on the 819 Power Board is in the Check the Power Switch ON position.

  • Page 13: Blank Display

    Troubleshooting Guide 4.2.3 BLANK DISPLAY Problem Solution The dispenser is turned OFF. Check the power switch inside the dispenser. Turn it on. Check the system fuse on the Power Board. Refer to the Power Blown Fuse Board section. The dispenser has been turned Turn on the breaker for this dispenser inside the building.

  • Page 14: Hydrogen Dispensing

    Troubleshooting Guide 4.3 HYDROGEN DISPENSING 4.3.1 DISPENSER HAS NO FLOW Problem Solution Verify that the hydrogen supply pressure Supply Pressure: No Pressure is within the required range No flow, no power. The dispenser is OFF Turn ON the dispenser Inspect the valves to make sure they are open and not clogged.

  • Page 15: Low Dispensing Flow

    Troubleshooting Guide 4.3.2 SLOW DISPENSING FLOW Problem Solution Pressure Verify that the hydrogen supply pressure is within the required range. Valves Check that the manual shut off valve at the inlet of the dispenser is fully open. Power Confirm that the dispenser's power source is operational. Hoses Verify that the hoses are properly connected and not kinked or damaged.

  • Page 16: Seconds

    Door Lock brackets are bent. Adjust door lock brackets or replace. Reuse of gasket when a Always replace the gasket when installing a new component. component is replaced. Unknown water intrusion Call Bennett Technical Support (800) 423-6638. H35 Maintenance Manual...

  • Page 17: Dispenser Error Messages

    Dispenser Error Messages 5 DISPENSER ERROR MESSAGES Common solutions to error code messages: • Power Cycle: Try turning the dispenser OFF and ON again to clear minor errors. • Reboot Dispenser: Use Mode 49 to reboot the dispenser. • Clear Memory: Use Mode 58 to wipe the memory including all programming and calibration values.
  • Page 18 Dispenser Error Messages Error Error Description Troubleshooting Steps Code HIPRES: The pressure is above the limit of Lower the pressure before continuing. the dispenser Verify the wiring is correct. MtCOMM: Communication issue with the Check the meter Modbus settings on the meter mass flow meter transmitter.
  • Page 19 Dispenser Error Messages Error Error Description Troubleshooting Steps Code Try to clear the error following the acknowledgement procedure. ACK Needed: Acknowledgment needed for ESTOP error Check the wiring of the ESTOP circuit and control relays. Compare the readings of the two thermocouples. rcGTEM: The gas temperature redundancy check has failed Check wiring and calibrate sensors if needed.
  • Page 20 Dispenser Error Messages Error Error Description Troubleshooting Steps Code Verify valve stays closed by monitoring pressure sensors before and after the fill valve. When the valve is open those pressure sensors should be the same. When the valve is closed the pressure can be FVCLFA: Fill valve failed to close vented down on outlet side of the valve.

  • Page 21: Meter Zero Offset Procedure

    Meter Zero Offset Procedure 6 METER ZERO OFFSET PROCEDURE The following instructions will show how to perform a zero offset calibration using the RHE26/27 Coriolis mass flow transmitter, see Figure 6.1 . 6.1 PASSCODES AND MENU SELECTION To configure and carry out certain functions in an RHE26/27 transmitter, it is necessary to enter a predetermined passcode.
  • Page 22 Meter Zero Offset Procedure Main Screen Figure 6.2. RHE26/27 Menu – Zero Offset Calibration To perform the zeroing procedure, press NEXT at the Y/N confirmation screen to change the “N” to “Y”. Press ENTER to start the procedure or ESC to cancel. Once started, a countdown timer will begin.

  • Page 23: Gas Detectors

    Gas Detectors 7 GAS DETECTORS RESPONSE CHECK AND CALIBRATION Before each day’s usage, sensitivity must be tested on a known concentration of Hydrogen equivalent to 25-50% of full scale concentration. Accuracy must be within 0-20% of actual. Accuracy may be corrected by calibrating the equipment. It is recommended to periodically carry out a gas response check on the Sensepoint XCD RFD to ensure correct operation.
  • Page 24 Gas Detectors is present then the background air can be used to perform the zero calibration. Contact your Honeywell Analytics representative for details of suitable calibration kits. To calibrate the detector, follow the procedure below. 7.1.1.1 ZERO CALIBRATION 1. If the ambient air is NOT considered reliable to use to set the ZERO, then remove the weather protection and fit the Gassing Cap accessory (see Section 4.3) onto the sensor and apply a clean source of zero gas or compressed air.
  • Page 25 Gas Detectors WARNING: When calibrating the Flammable IR or CO IR sensors, it is essential that the span calibration is done after a zero calibration. 7.1.1.2 SPAN CALIBRATION The display shows the current calibration span gas concentration while flashing the ‘ ’...
  • Page 26 Gas Detectors The display alternates between “Purg gAS” and the gas reading to indicate that the unit is expecting the span gas to be removed from the sensor. Promptly switch off the calibration span gas and remove the Sensepoint XCD Gassing Cap from the sensor to allow the gas to disperse.

  • Page 27: Fill Termination Reason Codes

    Fill Termination Reason Codes 8 FILL TERMINATION REASON CODES The dispenser will transmit the fill termination reason to the station PLC via the Modbus protocol. This information assists the station in understanding why the fill operation ended, guiding them towards potential troubleshooting requirements. The station's PLC should continuously monitor and log this data to aid in troubleshooting efforts.
  • Page 28 Fill Termination Reason Codes Code Reason Description 0032 Clear mass totals failed 0033 Vent valve failed to open 0036 No flow timeout 0035 Fill valve failed to close 0034 Fill valve failed to open 0038 Pressure redundancy check failed 0037 Temperature redundancy check failed 0041 Invalid receptacle for hose type...

  • Page 29: Appendix A: Maintenance Log

    Appendix A: Maintenance Log 9 APPENDIX A: MAINTENANCE LOG 9.1 EXTERIOR Dispenser Description Frequency Notes Components Check for proper Dispenser Doors orientation, scratches Semi-Annually and dents. Check for proper Dispenser Panels orientation, scratches Semi-Annually and dents. Inspect for any scratches or evidence of mistreatment.

  • Page 30: Electrical

    Appendix A: Maintenance Log Dispenser Description Frequency Notes Components broken parts. Inspect for any scratches, dents, debris, or evidence of Valance Semi-Annually mistreatment. Make sure all valances are secure. Inspect all weather seals on the Electronics Door. Inspect for cracks Weather Seals Semi-Annually and look for evidence...

  • Page 31: Piping And Instrumentation

    Appendix A: Maintenance Log screws). 9.3 PIPING AND INSTRUMENTATION ID # Component Description Frequency Notes Visually inspect for If any of the descriptions physical damage, Hand Valves Quarterly are present, take it out of contamination, leaks, service immediately. or malfunctions. Visually inspect for physical damage, contamination, leaks,...
  • Page 32 Appendix A: Maintenance Log ID # Component Description Frequency Notes Visually inspect for leaks and verify Inspect Yearly Pressure operation by testing Replace 3 years Transmitter Test Every 5 years against known pressure. Verify operation by Temperature testing against known Semi-Annually Transmitter temperature.

  • Page 33: Other Equipment

    Appendix A: Maintenance Log 9.4 OTHER EQUIPMENT ID # Component Description Frequency Notes Inspect for signs of damage, corrosion, Replace every Breakaway Devices Monthly partial separation, 3 years wetness, or staining. The gas detection system must remain functional during maintenance Visually inspect for operations on Gas Detection Equipment...

  • Page 34: Dispenser Tests

    Appendix A: Maintenance Log 9.5 DISPENSER TESTS Component Description Frequency Notes Refer to the Bennett Pump SSP Verify that it is Programming, Card Reader Test working properly Annually Service, and Parts (if applicable). Manual for service information. Verify dispenser Communication Test...

  • Page 35: Appendix B: Filter Service Manual

    10 APPENDIX B: FILTER SERVICE MANUAL EVFL-SM-064 FTH-080 Filter Service Manual Issue #1 Issued 13/12/2022 - CF Applies to FTH-080-LF6 / LF9 / LF12 Read the complete manual before disassembling H35 Maintenance Manua...
  • Page 36 10.1 PARTS WARNING: Before disassembling any part of the filter, take all necessary precautions to ensure there is no gas pressure inside. Outlet Inlet Head O-ring Filter Cartridge / Element Bowl 10.2 FILTER CARTRIDGES Part Number Description FIE-1025 Stainless Fibre Felt, 5 micron FIE-1005 Stainless Mesh, 25 micron FIE-1006...
  • Page 37 10.3 SPECIFICATIONS MAWP 1000barg Hydrostatic Proof Test Pressure >2482barg Housing Material Stainless Steel, AISI 316 Port Connections MP Cone and thread / autoclave type: LF12 (standard) LF9 (optional) LF6 (optional) Flow Capacity (Cv) 3.3 (same for all elements, when clean) Bowl Tightening Torque 40 Nm (30 ft-lb) Mounting hole thread...
  • Page 38 10.4 1.1 REPLACING THE FILTER CARTRIDGE 1. Ensure all pressure has been vented from inside the filter before disassembly. If the filter bowl is unreasonably difficult to unscrew, this may indicate there is still pressure inside. 2. Unscrew the bowl using the hex on the bottom. Note: Make sure the filter head is securely mounted, or adequate care is taken to prevent excessive torque loading of any connected components, fittings or tubes during the loosening of the filter bowl.
  • Page 39 3. Remove the filter element by pulling it out. Discard the used element and o-ring. 4. Remove the new filter cartridge from its packaging, and gently push it into place on the spigot inside the filter head, being careful not to cut the o-ring inside the filter cartridge. Simple Secure Payment Manual...
  • Page 40 5. Replace the o-ring on the bowl and lightly lubricate with silicone grease, PFPE grease, or other grease that is compatible with the system and o-ring. Check the bowl is clean inside, and free of debris. O-ring (replace) 6. Check there is sufficient anti-seize grease on the threads. If in doubt, add more, being careful not to get anti-seize grease inside the bowl where it may contaminate the system fluid.
  • Page 41 Simple Secure Payment Manual...

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