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Summary of Contents for Proton G200
- Page 1 PD-0100-0074 Revision A G200, G400, and G600 LABORATORY HY DROGEN GAS GENERATORS Installation, Operation & Maintenance Manual...
- Page 2 (“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...
- Page 3 Installation, Operation & Maintenance Manual Disclaimer Proton OnSite has written this manual to be an easy to use guide for the G200/G400/G600 Hydrogen Gas Generators. All statements, technical information, and recommendations in this manual and in any guides or related documents are believed reliable, but the accuracy and completeness thereof are not guaranteed or warranted.
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Page 4: Limited Warranty
System such as, but not limited to, power or air conditioning failure or voltage irregularities. REMEDY: BUYER’S sole and exclusive remedy in the event of defect, and the liability of PROTON hereunder is limited to the adjustment, repair, or replacement of the defective item or part with a similar item or part free of defect. -
Page 5: Table Of Contents
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual G200, G400, and G600 Laboratory Hydrogen Generators & M NSTALLATION OPERATION AINTENANCE ANUAL Prepared by PROTON ONSITE® CONTENTS Introduction ........................ 10 General Information..................... 11 Product Specifications ....................13 Safety .......................... - Page 6 G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual Customer Configuration ..................... 36 Auto-Fill ........................36 Maintenance ....................... 38 Maintenance Schedule ....................38 Ion-Exchange Resin Bag....................39 Water Quality ....................... 41 Desiccant Replacement ....................42 Circulating Pump Replacement ................... 45 Associated Spare Parts and Components ..............
- Page 7 G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual TABLE OF FIGURES 1: S ................... 12 IGURE ERIAL UMBER DENTIFICATION LATE 2: C ........................15 IGURE ABINET IMENSIONS 3: L ..................19 IGURE IFTING ENERATOR UT OF...
- Page 8 G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual LIST OF TABLES 1: T G200/G400/G600 H ....... 14 ABLE ECHNICAL PECIFICATIONS FOR THE YDROGEN ENERATORS 2: G ............16 ABLE ENERATOR AS AND LECTRICAL NLET UTLET ONNECTIONS 3: M .........................
- Page 9 G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual This Installation, Operation & Maintenance Manual of the Hydrogen Generator uses the following safety symbols and conventions to alert you to information intended to help you operate your laboratory hydrogen generators correctly and safely.
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Page 10: Introduction
Installation, Operation & Maintenance Manual Introduction Congratulations on your purchase of a G200, G400, or G600 hydrogen generator, the most capable family of laboratory hydrogen generator products available today. The ultimate cylinder alternatives, the G200, G400, and G600 laboratory hydrogen generators provide ultra high purity-grade hydrogen on demand, combining caustic-free PEM electrolysis technology with an easy to refill desiccant bed cartridge. -
Page 11: General Information
An example of the serial number identification plate, attached to the back of the G200, G400, or G600 hydrogen generator, is shown in Figure 1. The serial number contains an embedded date code, which is the date of system manufacture. -
Page 12: Figure 1: Serial Numberi
Figure 1: Serial Number Identification Plate Detailed technical data is found in Product Specifications (Pg. 13), below. Dimensions for the G200/G400/G600 enclosure, are found in Figure 2 (Pg. 15). Required fittings are displayed in Table 2 (Pg. 16). PD-0100-0074 Rev. A... -
Page 13: Product Specifications
<180 watts <250 watts 120-230 VAC, 50/60 HZ, Single phase Input Voltage/Current Rating Hydrogen G200 5A, Hydrogen G400 5A, Hydrogen G600 10A Enclosure Characteristics External Dimensions 36.8cm (H) x 5cm (D) x 52cm (W) (HxDxW) 14.5" (H) x 9" (D) x 20.5" (W) -
Page 14: Table 1: Technicals
Gas Chromatography, detector feed FID, NPD, FPD, Applications TCD, HWD or to supply carrier gas 1. Operation time outside desired directly linked to unit life expectancy. Table 1: Technical Specifications for the G200/G400/G600 Hydrogen Generators PD-0100-0074 Rev. A --UNAUTHORIZED COPIES PROHIBITED-- Page 14 of 57... -
Page 15: Figure 2: Cabinet Dimensions
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual H2 Vent Low Pressure H2 Vent H2 Product DI Inlet DI Drain Figure 2: Cabinet Dimensions PD-0100-0074 Rev. A --UNAUTHORIZED COPIES PROHIBITED-- Page 15 of 57... -
Page 16: Table 2: Generator Gas Ande
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual Substance Flow Direction Fitting Mating Information Fitting Location 1/8” (3.175 mm) 1/8” OD Stainless Hydrogen Female Parker CPI™ Steel Tubing Middle Rear Product Compression Fitting 1/8" (3.175 mm)- Hydrogen 1/8"-OD Metal or... -
Page 17: Safety
As asphyxiation progresses, nausea, vomiting, prostration, and loss of consciousness may result. The G200, G400, or G600 hydrogen generator, in addition to generating pressurized hydrogen product, also produces a small flow of byproduct oxygen at just over atmospheric pressure. This oxygen is vented from an outlet in the top of the internal water tank and swept from the cabinet with the cooling air. -
Page 18: Safety Devices
MAXIMUM PRESSURE: An internal safety valve prevents the generator pressure from exceeding 9 barg (130 psi). The hydrogen is vented out the hydrogen vent connection. 2.3 Technical Service Contact Information Proton OnSite Technical Service can be contacted as follows: Proton OnSite 10 Technology Drive... -
Page 19: Placement
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual Placement 3.1 Unpacking the Generator Figure 3: Lifting Generator Out of Shipping Box Enclosed with the generator are the following items: · An Appropriate Cord Set for your Electrical Supply Type ·... -
Page 20: Positioning The Generator
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual If you must ship the G200, G400, or G600 hydrogen generator for any reason, please follow these steps: Drain all the water from the DI water tank, remove the ion-exchange resin bag, and reinstall the water tank cap. - Page 21 G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 11. Before filling the generator with DI water, always check the quality of the DI water and ensure it is equal to or better than the DI water feed specification of > 1 Megohm/cm and <...
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Page 22: Ventilation Grill
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual Figure 5: Hydrogen Generator—Recommended Clearances Hydrogen Vent Ventilation Grill Hydrogen Low Pressure Vent Hydrogen Product Alarm Output DI Water Inlet Connection Power Switch and DI Water Drain Receptacle Figure 6: Hydrogen Generator—Back View... - Page 23 G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual Figure 7: Hydrogen Generator—Angled View PD-0100-0074 Rev. A --UNAUTHORIZED COPIES PROHIBITED-- Page 23 of 57...
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Page 24: Installation Procedure
It is not necessary to connect this to any vent. Hydrogen Vent Hydrogen Phase Vent Hydrogen Product Figure 8: G200, G400, or G600 Hydrogen Connections THE HYDROGEN VENT PORTS CONTAIN WATER DURING NORMAL OPERATION. PD-0100-0074 Rev. A... -
Page 25: Electrical Setup
DO NOT BYPASS GROUND PIN. 3. Proton OnSite recommends using an uninterruptible power supply in locations where power failures are common to assure reliable hydrogen generation. 4. Connect the supplied cord set to the back of the unit. -
Page 26: Figure 9 Power Cord Connection Figure 10: Water -Drain Fitting
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual DI Water Supply DI Water Drain Figure 10: Water-Drain Fitting 3. Obtain a supply of the required quality of DI (de-ionized) water (Refer to Product Specifications, Table 1. Page 14). For manual fill, remove the External Water Tank and fill from a suitable source of DI. -
Page 27: Operation
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual Operation 5.1 Startup—System Operation or Interface The Factory Default for automatic refill is from the installed EXTERNAL WATER tank. If auto-refill is desired from a site DI water supply see section 6.1 for customer configuration steps. -
Page 28: Figure 13: System Boot Up Screen Figure 14: Main Operating Screen Figure 15: Pressure Set -Point
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 2. Notice that the Startup Splash Screen is shown in the display (Figure 13) for 3 seconds and then the display shifts to the main operating screen (Figure 14). -
Page 29: Steady State Operation
100 psig (6.9 barg), even in systems where the generator requires less than 100 psig. The G200, G400, or G600 system operates with the steadiest hydrogen output pressure at delivery pressures above 100 psig. The generator is capable of delivering hydrogen at pressures up to 200 psig (13.8 barg) with no sacrifice of hydrogen quality, hydrogen flow... -
Page 30: Standby Mode
Installation, Operation & Maintenance Manual 5.3 Standby Mode Standby Mode allows the G200, G400, or G600 hydrogen generator to idle at the pressure set point without delivering the hydrogen product to your process. Standby Mode is ideal for short durations when hydrogen is not needed, such as overnight. -
Page 31: Shutdown
Installation, Operation & Maintenance Manual 5.5 Shutdown Under normal circumstances, no special procedures are required for shutdown of the G200, G400, or G600 hydrogen generator. Simply use the electronic controls as follows: Normal shutdowns—To stop hydrogen flow and shut down all internal generation and purification systems: 1. -
Page 32: Alarm Contact Output
Installation, Operation & Maintenance Manual 5.6 Alarm Contact Output The G200, G400, or G600 hydrogen generator is equipped with a set of Form C normally- open/Common/normally closed dry alarm contacts to trigger an external alarm in case of any shutdown or warning condition. The alarm contacts change state on any alarm condition and may be wired to trigger an external (remote) alarm or warning light. -
Page 33: Desiccant Timer
Installation, Operation & Maintenance Manual 5.7 Desiccant Timer The G200, G400, or G600 hydrogen generator is equipped with a removable desiccant dryer with a set lifetime. During hydrogen generation the desiccant removes moisture from the hydrogen gas stream and eventually will become full. An internal timer tracks the generation time and will display warning W04 Replace Descnt. -
Page 34: Additional Information Screens
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 5.8 Additional Information Screens 5.8.1 Alarms and Warnings If the Hydrogen Generator shuts down automatically in an error condition, the Main Operating Screen will show the Error Code (Figure 21) and an alarm tone will be annunciate. -
Page 35: Input Output Status
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 5.8.2 Input Output Status From the Select Screen (Figure 24), pressing the “INPUT-OUTPUT” button will bring up the Select IO Status Screen. Figure 29: Select IO Status Pressing any of the buttons will bring up the associated display screens which will give the active status of the selected components. -
Page 36: Customer Configuration
Auto-fill from site DI operates best with at least 10 psig (0.689 Barg) minimum of DI water supply pressure. Auto-fill operates on gravity-fed DI water as long as height of the water reservoir is at least 8 feet (2.5m) above the G200, G400, or G600 system; however this extends the tank refill time. - Page 37 G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual During auto-fill from the installed External Water Tank, the water level in the tank will go down during generation. When level reaches empty as indicated by no water within the tank, remove the tank, refill from an approved DI water source and replace.
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Page 38: Maintenance
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual Maintenance 7.1 Maintenance Schedule Part Proton OnSite Part Number Replacement Cycle Ion-Exchange Resin KT-0200-0014 6 Months or as Needed Bag Assembly Desiccant Replacement KT-0500-0023 Upon receipt of W 04 Desiccant... -
Page 39: Ion-Exchange Resin Bag
Installation, Operation & Maintenance Manual 7.2 Ion-Exchange Resin Bag The G200, G400, or G600 hydrogen generator is equipped with an ion-exchange resin bag, which is similar in appearance to a teabag, and is used to ensure that the re-circulated water within the generator is maintained as pure (i.e. -
Page 40: Figure 35 Resin Bag Removal
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 3. Remove the exhausted ion-exchange resin bag by lifting straight up on the black plastic pull tab on the resin bag cap. Use caution not to drip water on the control board. -
Page 41: Water Quality
Please use fresh ASTM Type II DI water. Start the G200, G400, or G600 unit up as soon as possible after filling it with Type II DI water that meets the requirements shown in Table 1 (Refer to Product Specifications, 1.2., Page 13). -
Page 42: Desiccant Replacement
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 7.4 Desiccant Replacement 1. On the Main Operating Screen press the “Stop” button to stop Generation. 2. Turn off Hydrogen Generator with main power switch and remove power cord. -
Page 43: Figure 38 Desiccant Cartridge Figure 39 Desiccant Level
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 6. Remove the top of the desiccant cartridge and dispose of the old desiccant. Use a strap wrench if necessary. Figure 38 Desiccant Cartridge Disassembly 7. Fill the desiccant cartridge with new desiccant. ENSURE desiccant does not cover inside lip. - Page 44 G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 8. Replace the top of the desiccant cartridge and tighten all the way. Loosen cap as necessary to line up fittings. Ensure fittings on top and bottom of cartridge face the same direction. The o-ring seal of the cartridge is not dependant on full tight threads.
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Page 45: Circulating Pump Replacement
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 7.5 Circulating Pump Replacement 1. On the Main Operating Screen press the “Stop” button to stop Generation. 2. Turn off Hydrogen Generator with main power switch and remove power cord. -
Page 46: Figure 41 Circulating Pumpl
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual Figure 41 Circulating Pump Location 7. Carefully remove the tubing from the pump assembly noting which tube goes where. 8. Connect tubing to new pump assembly. 9. Reinstall the pump in the Hydrogen Generator. -
Page 47: Associated Spare Parts And Components
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 7.6 Associated Spare Parts and Components Part Proton OnSite Part Number Replacement Cycle Ion-Exchange Resin KT-0200-0014 6 Months or as Needed Bag Assembly Pump Replacement Kit 54-0500-0149 ~ 2 Years or as Needed... -
Page 48: Troubleshooting
The status of the generator, when the leak signal is triggered, can assist in locating the leak either inside or outside the G200, G400, or G600 box. The System Leak Warning (W01) is displayed if the Hydrogen Generator cannot reach or maintain the System Pressure Set point (-10PSI) and the Output Valve is CLOSED. -
Page 49: Replacing Di Water
The internal tank will automatically refill the next time the Hydrogen Generator is started. The G200, G400, or G600 generator contains approximately 0.75 liters of water. Never refill the generator with contaminated water that has been drained from the generator. We recommend that a generator that has a shutdown due to bad quality DI water be flushed three times (fill, drain, and refill) with Type II-DI water before being restarted. -
Page 50: Error And Warning Codes At Startup Or Operation
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 8.3 Error and Warning Codes at Startup or Operation The G200, G400, or G600 hydrogen generator is equipped to detect problems that arise during startup or operation. Code... -
Page 51: Table 6: Error Codes
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual Code Description System Impact Default Limit E 20 VREF Tolerance Shutdown VCC Tolerance Shutdown E 22 Vin Tolerance Shutdown E 23 State Fault Shutdown E 24 System Water Temperature Shutdown >70°C (158°F) -
Page 52: Frequently Asked Questions
Frequently Asked Questions What is a “System Pressure Leak” warning? If the G200, G400, or G600 generator is unable to achieve or maintain the system pressure set point with the product valve closed, System Pressure Leak flashes in the display read-out. - Page 53 What is an E-02 error (poor water quality)? The G200, G400, or G600 hydrogen generator is designed to operate using DI water that has a resistivity of 1 Megohm·cm or better. If lower quality DI or distilled water is used in the unit, it shuts down the system and triggers the audible alarm and digital error code display.
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Page 54: Appendix A-Forms
G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual 10 APPENDIX A—FORMS 10.1 Ion-Exchange Resin Bag Change-Log Use the form below to record the resin bag change date. The recommended change interval is six months. Resin Bag Change Date of Change PD-0100-0074 Rev. -
Page 55: Customer Registration Form
Installation, Operation & Maintenance Manual 10.2 Customer Registration Form Please fill out the form on the last page, tear it out of the manual, and fax it to Proton OnSite (Fax Number: 1-203-949-8016) to ensure that your G200, G400, or G600 Hydrogen Generator is properly registered. - Page 56 G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual This page is intentionally left blank. PD-0100-0074 Rev. A --UNAUTHORIZED COPIES PROHIBITED-- Page 56 of 57...
- Page 57 G200, G400, and G600 Laboratory Hydrogen Generators Installation, Operation & Maintenance Manual CUSTOMER REGISTRATION FORM Laboratory Hydrogen Generator Generator Model Name? Generator Serial Number? From what supplier did you purchase the generator? Name of your company? Company website address? The application for your hydrogen generator?
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