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Enapter Electrolyzer 4.1 Owner's Manual

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Owner's Manual
Electrolyzer 4.1
Please study this manual carefully before unpacking, installing, and operating the device.
Rev. 05– May 2025

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Summary of Contents for Enapter Electrolyzer 4.1

  • Page 1 Owner’s Manual Electrolyzer 4.1 Please study this manual carefully before unpacking, installing, and operating the device. Rev. 05– May 2025...
  • Page 2 VERS I ON D O CU ME N T TI TLE RE LEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 CHANGE HISTORY FOR EL4.1 Rev. Status Date Revision memo Created/changed by 01/10/2023 First version Philipp Endres 06/10/2023 Edited/Proofread for clarity Beth De Felici 06/11/2023 Updated data and fixed formatting...
  • Page 3 Thank you for choosing Enapter. Please study this manual carefully before unpacking, installing, and operating the device. If you have any further questions, please contact the Enapter customer support team. Quote the device serial number and hardware number on the back of the device to help identify your product quickly.
  • Page 4 To simplify reading, this document only refers to the operator to distinguish from Enapter but may also include the user, customer, client, owner, installer, instructor, system integrator, or persons who are responsible for safe operation of the device.
  • Page 5 RE LEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 TABLE OF CONTENTS Change history for EL4.1 ......................I Enapter Srl ............................. II Scope of the document ........................II Approved use ..........................II Terms ............................III Table of Contents ......................... IV Overview of the Electrolyzer ..................
  • Page 6 Safety Heartbeat ......................45 5.11 Troubleshooting ....................... 46 5.12 Draining the chassis ......................46 Enapter Monitoring Tools ..................47 Mobile Application ......................47 Maintenance of the Electrolyzer ................48 Firmware Updates ......................48 Routine Maintenance ....................... 48 5-year Major Maintenance ....................51 Transport .........................
  • Page 7 VERS I ON D O CU ME N T TI TLE RE LEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 Appendix III. Preparing fresh electrolyte ........................55 Appendix IV. Draining the electrolyte ......................... 57 Appendix V. LED Status ..............................58 Appendix VI.
  • Page 8 2025-05-08 1. OVERVIEW OF THE ELECTROLYZER Enapter’s patented anion exchange membrane (AEM) electrolyzer is a standardized, stackable, and flexible device to produce hydrogen. The modular, easily maintainable design – paired with advanced software integration – allows set up in minutes and remote control and management.
  • Page 9 - 802.11a/b/g/n (2.4 GHz only) - 802.12 WEP, WPA, WPA2 Personal (Pre-shared key) Communications - Wi-Fi client isolation must be disabled Bluetooth Modbus TCP via Ethernet@ Enapter Cloud Service, Enapter App, Modbus TCP, Safety chain (dry Remote Control contact) Safety Maximum H contained...
  • Page 10 Device is used for at least one (1) hour at a time, on average At maximum, 8 cycles/day, 50 cycles/week. Ensure Enapter has access to operational data and telemetry of the devices Air Cooled electrolyzers only (Liquid cooled versions excluded) Liquid Cooled electrolyzers only (Air cooled versions excluded) ETL certified electrolyzer versions only.
  • Page 11 VERS I ON D O CU ME N T TI TLE RE LEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 1.2 FRONT PANEL & BOTTOM EL4.1 AC air cooled front side EL4.1 AC liquid cooled front side. <5> EL4.1 air cooled bottom view The front panel includes most of the physical connections of the device.
  • Page 12 The device can be connected to the local network via Bluetooth and Wi-Fi, enabling real-time updates and monitoring for the operator via the Enapter App and cloud. A miniature antenna can be attached to this port to increase the amplification.
  • Page 13 VERS I ON D O CU ME N T TI TLE RE LEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 Handlebars – for easier transport Air Inlets – please refer to the Routine Maintenance section below.  Keep the air inlets free of dust and dirt. LEDs –...
  • Page 14 Modbus interface in the case of non-cloud-connected systems. Enapter may ask for up to two (2) months of data to be transferred to check and verify operating conditions. More information about the required Modbus record can be found online on our handbook.
  • Page 15 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 2. SAFETY INSTRUCTIONS 2.1 WARNINGS AND HAZARDS The following terms and symbols are used in this manual to indicate important text passages which must be given particular attention: Warns of fatal/serious injuries or death Warns of injury...
  • Page 16  Caused by improper installation. Regarding design and installation, the operator must follow Enapter’s installation rules and ensure full compliance with all relevant local safety guidelines, rules, directives, and regulations. The operator must check the device for hydrogen, water, and KOH leakages regularly and ensure that all interfaces are connected correctly.
  • Page 17 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08  Wear appropriate footwear when handling the device.  Use lifting aids if available when lifting the device. Never lift the device alone. Know your local and site-specific health and safety rules and act accordingly.
  • Page 18 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 3. HAZARDS The operator who operates, services, maintains, or installs this device must be aware of the potential dangers associated with its use and set up, the required materials, as well as the inputs and outputs, to implement sufficient countermeasures and processes to prevent accidents and act correctly in case of emergencies.
  • Page 19 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 3.2 MECHANICAL HAZARDS It is always necessary to wear appropriate personal protective equipment (PPE) and use suitable tools when handling the device and packaging material. Some general training regarding lifting heavy loads and safety briefings are required to perform the tasks safely described in this manual.
  • Page 20 Always turn off the power supply when the device is being cleaned, maintained, or transported. Any service, other than cleaning and routine user maintenance, must be performed by trained Enapter-endorsed technicians. EL4.1 - Owner’s Manual - Rev.05 – May 2025...
  • Page 21 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 3.4 CHEMICAL HAZARDS Dissolved Potassium Hydroxide is used in the electrolyzer as the process liquid (electrolyte). The chemical can be purchased as pellets or flakes, or directly in a concentrated solution to be diluted using purified water.
  • Page 22 However, a sudden vent (either caused by device shut down or unforeseen error) can be louder than 85 dB, depending on the vent line installation. Due to this, Enapter recommends wearing PPE (earplugs) while working around the device. EL4.1 - Owner’s Manual - Rev.05 – May 2025...
  • Page 23 Please retain the original shipping materials. Devices must be returned in their original packaging – or in equivalent protective packaging – to ensure safe transport. Enapter will accept returned devices; however, if a device is damaged during transit due to inadequate packaging, repair or replacement costs may be charged to the sender.
  • Page 24 Plastic tubing connections  Tubing Material: Enapter recommends using soft plastic tubing, such as LLDPE (Linear Low- Density Polyethylene), to ensure the push-fit collets can grab the tubing securely. Harder, or more slippery plastics could slide off, increasing the risk of leaks or disconnections. Avoid using tubing that is too soft without reinforcing the tubing.
  • Page 25 Only specific versions of the EL4.1 will have the check valve included in the shipment and must be installed according to the Owner’s manual. Please verify if your system requires its installation. If unsure, please contact Enapter support. EL4.1 - Owner’s Manual - Rev.05 – May 2025...
  • Page 26  ISO/TR 15916:2015: Basic considerations for the safety of hydrogen systems Or follow the recommendations of Enapter for systems consisting of up to ten (eight ) electrolyzers and two dryers. The safety area is cylindrical and has a height of 10 meters and a radius of 5 meters.
  • Page 27 The following diagram shows internal components of the device as well as how it interacts with the Enapter Dryer and the Enapter Water Tank. It is also available here. Please note that this diagram has been simplified to enhance clarity while safeguarding Enapter’s intellectual property.
  • Page 28 Out port, located at the bottom left of the front panel, to a hydrogen storage tank or the Enapter Dryer. It is recommended to fit a shut-off valve between the tank and the dryer to be able to isolate each string of modules during maintenance.
  • Page 29 Safety areas around the O2 vent and H2 vent outlet. If this is not possible, please contact Enapter support, as managing the purge in other ways, such as using a flare stack, burn box or forced dilution is possible, but requires careful consideration.
  • Page 30 Never mix the output of the H purge line with the output of the O vent line. The H2 vent line can be combined with the H2 purge line of the Enapter DR2.1 using the provided check valve downstream from the electrolyzer’s H2 vent port.
  • Page 31 We recommend leading the gaseous outputs from the oxygen vent to a safe area, described in the section "Implementing System Safety". If this is not possible, please contact Enapter support, as EL4.1 - Owner’s Manual - Rev.05 – May 2025...
  • Page 32 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 managing the purge in other ways, such as using forced dilution, is possible, but requires careful consideration. <3> Details Three EL4.1 and a DR2.1 with common O2 VENT <5> EL4.1 - Owner’s Manual - Rev.05 –...
  • Page 33 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 Example of an O Vent line and water trap Warning! Risk of explosion! The gaseous outputs from the oxygen vent and the hydrogen vent must be kept separated.
  • Page 34 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 4.6 INSTRUCTIONS FOR CONNECTING PLASTIC TUBES The device uses simple push-fit connectors, allowing plastic tubing to be quickly and easily installed without the need for additional tools.
  • Page 35 Ensure water pressure on the input line never exceeds the maximum allowed pressure. This can cause irreparable damage to the device and create significant leakages. Enapter is not responsible for any damage or injury resulting from the misuse of the device.
  • Page 36 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 EL4.1 all pipes connected. After performing the first Electrolyte Filling (filling the device with the electrolyte solution), the device will consume water during operation at a rate of around 0.42 L/h. The refilling is triggered automatically from the “H O IN”...
  • Page 37 60°C. To further increase device reliability, install the filter supplied by Enapter on the cooling line inlet of the device. When the cooling agent is no longer showing the necessary physical and chemical requirements, is diluted, or shows any other form of degradation, it must be exchanged.
  • Page 38 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 It is recommended to set up the cooling loop according to the schematic on the left. The return line (from the “COOLING OUT”...
  • Page 39 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 The graph below indicates the operating range of the cooling circuit in terms of allowable inlet temperature of the cooling agent and the ambient temperature depending on the flow rate. Possible cooling agent temperatures depending on the flow rate and ambient temperature.
  • Page 40 Ensure that the cooling agent pressure on the input line never exceeds 4 barg. Make sure that the cooling agent is filtered and free of particles. This can cause irreparable damage to the device and create significant leakages. Enapter is not responsible for any damage or injury resulting from the misuse of Enapter products.
  • Page 41 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 Three EL4.1 and a DR2.1 with common Cooling pipes <5> Details EL4.1 - Owner’s Manual - Rev.05 – May 2025 Revised where <5>...
  • Page 42 Do not exceed the specified voltage and amperage (see battery limits for more details). Enapter recommends installing protective device against overload and short circuits for all device versions on the power supply line. It must be selected in relation to the device’s maximum power consumption and in compliance with all local and national safety requirements.
  • Page 43 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 Three EL4.1 and a DR2.1 power supplied Details 4.8 DRY CONTACT CONNECTION GUIDE (OPTIONAL) (DRY CON.) The device has integrated dry contact sockets to allow emergency stops triggered by external devices e.g., a hydrogen sniffer or emergency stop switch.
  • Page 44 The pins are, from top to bottom, S2, COM2, S1, COM1. This allows the device to not only receive a dry contact signal but also to pass it on to the next Enapter device. The operator can daisy chain as many Enapter devices as wanted to a common loop.
  • Page 45 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 Details Dry Con daisy chain with two electrolyzers and Emergency Switch 4.8.1 DRY CONTACT CONNECTION BYPASS To disable the dry con chain functionality, insert the dry con jumper with the red connection cable in the lower part of the socket labelled with “DRY CON”...
  • Page 46 4.10 ISO 22734 REQUIREMENTS The device is ISO 22734 ready. To reach full conformity to ISO 22734 it is the operator’s responsibility to additionally fulfil the following requirements from ISO 22734 which cannot be covered by Enapter. ISO 22734 Title...
  • Page 47 4.11.3 ELECTROLYTE FILLING When the device is connected to a water supply and to the Web GUI or Enapter app, it is now ready to be commissioned for its first use. Once it is successfully paired to the cloud, it starts in maintenance mode and gives prompts to perform the first-time filling.
  • Page 48 Push CPC connector in to connect Filling instructions: Make sure that the device is online to follow the Enapter App or use the Web GUI instructions to fill the device. Put on PPE. The minimum required equipment are safety goggles to protect from splashes and nitrile gloves.
  • Page 49 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 this does occur, ensure vent line open atmosphere. Follow the steps provided by the app: pour the requested amount (2 L) until the app shows a pop- up to stop the filling process.
  • Page 50 Enapter counts a stack cycle whenever power is applied to the stack and is removed again. 5.2 REMOTE START/STOP The device can be started/stopped remotely using the Enapter app or cloud as well as remotely via the Modbus interface. For more information on this, please refer to the online Enapter handbook.
  • Page 51 2025-05-08 5.4 MAINTENANCE MODE Maintenance mode can be manually enabled using the Enapter App. It is used to safely fill and drain the device, as well as to guide through inspection and other routine maintenance tasks. Please see the chapter Routine Maintenance to know more.
  • Page 52 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 temperature of e.g., 25 °C it will take about 30 min to be fully operational and perform at its maximum efficiency at 55 °C. ...
  • Page 53 5.12 DRAINING THE CHASSIS In the event of a water leak, please contact Enapter Support and follow the instructions below to safely drain the water from the device. If water has entered the chassis from external sources, the system may still be safe to operate; however, a full system check, and factory reset must be performed before resuming operation.
  • Page 54 The device comes with a preinstalled UCM (Universal Communication Module) to monitor and manage the device. Various sensor data from the devices is stored in the Enapter Cloud in a time-series database and provides real-time or on-demand visualization of collected data on customizable dashboards. To support the latest protocols and security fixes, the UCM can be updated over-the-air.
  • Page 55 Testing. Additionally, the proof-tests described in the Safety Manual must be executed successfully once per year. For more information, please look at the Safety Manual or contact the Enapter customer support team. After commissioning, the process tank must be emptied at least once a year and new electrolyte filled into the device.
  • Page 56 The drained electrolyte can also be further analyzed by measuring its conductivity. Please report these findings to Enapter support.  Using a portable conductivity meter, the conductivity of the drained (undiluted) electrolyte can be measured.
  • Page 57 When the device has been drained during maintenance, it might request a flushing process via the Enapter App. Keep the device in maintenance mode while observing it in the Enapter App or the Web GUI. The flushing process will use purified water from the H O In port to flush the internal tank.
  • Page 58 To ensure that the safety system works properly, the device needs to be inspected by Enapter or one of its authorized service partners every five years (mission time) for major maintenance. More details can be found in the Safety Manual.
  • Page 59 7.6 DISPOSAL Enapter is fully committed to recycling the devices and their components. Please return the device to Enapter at the end of life when the device will be fully recycled. By ensuring this product is correctly recycled, you will help to further reduce your impact on the environment and aid us in making the world cleaner and greener.
  • Page 60 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 Please observe the following: a) Remove used batteries immediately and recycle or dispose of them according to local regulations. Keep batteries out of reach of children. Do not dispose of in household trash or incinerate.
  • Page 61 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 8. APPENDIX Appendix I. Hydrogen Leak Testing As part of a hydrogen device, it is of vital importance to check every connection made for leaks. For more information on this matter, please refer to the appendix of ASME B31.12.
  • Page 62 Fresh electrolyte or the necessary KOH granulate can usually be purchased locally. We recommend contacting Enapter to make sure that the purchased product is compatible (support@enapter.com) EL4.1 - Owner’s Manual - Rev.05 –...
  • Page 63 Notice! Chemicals might damage the device! Carefully read the instructions below before starting. Follow the instructions carefully and contact the Enapter customer support team in case of questions. Ensure all material used to store and contain the electrolyte solution is chemically compatible with its contents.
  • Page 64 The module must be drained for transport, installation, and before the routine changing of the electrolyte in the device to prolong its lifetime. To do this, the device must be first switched into Maintenance Mode using Enapter mobile app or cloud. Follow the steps outlined in the app or use the instructions below.
  • Page 65 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 Fully insert the supplied male CPC quick connector into the valve bulkhead labelled "FILL/DRAIN". The solution will start pouring out immediately. Place the container below the port to fully drain the electrolyte.
  • Page 66 VE RS I ON D O CU MEN T TI TLE RELEAS E DAT E EL4.1 – Owner’s Manual 2025-05-08 Appendix VII. Factory Setting Reset After an automatic emergency shutdown (Fatal Error), the system can only be restored through a Factory Setting Reset.