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Successful operation requires the generator to be configured with correct input source and output connector.These installation requirements have been described in Section II.Check in advance to determine whether the equipment source and interface are appropriate.This should be done before each startup.Before the generator is initially started, several additional checks need to be done.The start-up and operation of this HM are fully automatic.When the system needs to be operated, only the start/reset and pressure release touch switches need to be manually input on the touch screen display.The process controls and procedures to guide the start-up and operation of the generator are described in Section 1.Section 1 also describes the use of input and output lights for monitoring system operation on the programmable controller.All operating conditions are continuously monitored in case they deviate from the normal value. If the system stops in operation start or operation mode, these problems should be identified and corrected before the system starts again.The troubleshooting guide for various parking on the touch screen display is very useful.The guide is also published in Section 5 of this manual to help identify the reasons for parking.
2.Initial startup 
In order to ensure the safe operation of the generator during the initial startup or subsequent continuous shutdown, several prior procedures should be improved. Prior inspection must be carried out to determine whether the system still maintains its integrity during shipping or continuous shutdown. Verification is the standard procedure described in Section 4.The list of procedures completed before initial startup is as follows:
System pressure test
Appearance inspection of electrolytic cell
Tighten the electrolytic cell again
Inject electrolyte and check
Feed water pump injection
3.Startup mode
The startup mode enables the system to establish the internal pressure required for hydrogen output under pressure. The startup mode includes the pre-pressure period to force the electrolyte collected in the hydrogen half-cell of the electrolytic cell to return to the oxygen side. Only when the system is started from 0 or near 0, the system needs to undergo preloading. When the system starts from the preloading state, the preloading can be omitted.
Equipment power and water supply must be used during system operation. The main circuit breaker to the power supply must be closed to receive electric energy, and the programmable controller must be in operation mode. Unscrew the control switch of the power contactor to energize the two control circuits of the generator and power supply. Press the "alarm reset" touch switch on the parking screen, and the "generator preparation" screen will appear. Then press the "start/reset" touch switch, and the system will start running.
At the beginning of system operation, purge the oxygen side pipe valve system of the generator with 30 seconds of nitrogen. With purging, the tube valve system at the hydrogen side of the generator has also been pre-pressed to the required pre-pressure. On the "purge" screen of the generator, the hydrogen side pressure begins to rise, and the oxygen pressure should keep up with and maintain a pressure difference of about 3-10Psi.When the hydrogen pressure reaches 20Psig (1.4kg/cm2), the 15-minute preloading period begins and the 900-second countdown is displayed on the "preloading" screen.After preloading, DC power is added to the electrolytic cell with the values indicated by the voltmeter and ammeter of the power supply.The production rate is directly displayed on the "generator operation" screen of the display.The pressure of hydrogen and oxygen rises to the rated system pressure. Now the system is in operation mode and ready for air supply. The rated system pressure is set at 100Psig (7.0kg/cm2) at the factory.
4.Operation mode
The generator has been programmed to control the electrolytic production rate under the relevant system pressure and temperature. Before the electrolyte temperature control reaches the operating temperature range.The maximum yield of HM is limited until the control temperature of the electrolyte reaches the operating control range.This limit is proportional to the difference between the electrolytic cell outlet temperature and the minimum electrolyte control temperature.The electrolytic yield is variable to continuously maintain the rated system hydrogen pressure. At 17-100% of the hydrogen demand of the maximum capacity of the generator, the current to the electrolytic cell changes in a positive proportion, so that while maintaining the rated system pressure, the yield and demand are matched.If the production demand is less than 17%, the generator will adjust the demand at 17% capacity to maintain the system pressure.When the production demand is greater than 100%, the generator produces at the maximum rate, and the system pressure is allowed to fall below the set point of the back pressure regulating valve BPR2.
5.Standby mode
Because the internal pressure of the system starts to rise without gas supply, when the pressure reaches 115Psig (8.1kg/cm2), gas production will stop.The light 6 on the controller module in slot 2 goes out.The system will maintain pressure, be in standby state and be ready to supply air as required. The touch screen will display the "generator standby" screen of hydrogen and oxygen pressure. When the system internal pressure drops below the rated system pressure, gas production will resume.
6.General operation
During operation, the ammeter on the power supply shall be indicated between 50-280A according to the user's demand.The corresponding voltage will be determined according to the specification of the electrolytic cell and several operating factors. The electrolytic cell voltage shall be indicated within the range of the following table.
Electrolyser voltage at 250A
Electrolyser specification voltage range
HM50 66-72
HM100 123-135
HM1250 146-162
HM150 176-195
HM200 230-254
When the system is running, the KOH temperature leaving the heat exchanger (TC1) is kept within the allowable KOH temperature control range.The temperature regulator proportionally controls the original program, and the KOH temperature is within the range of 60-65 ℃.The temperature regulating valve BV1 will be opened and closed in steps as required.The valve position and electrolyte temperature can be monitored on the "temperature control valve position" screen, which is selected from the "system information" screen of the display.In normal operation, the water supply system replenishes water intermittently.The water supply is replenished to the storage tank regularly as required, as shown by slot 1 input light 3 and slot 2 output light 1 and 3.The water feeding is indicated by the 30-second injection image of the touch screen display.The frequency of feed water addition depends on the rate of consumption, which varies with the gas output and the rate of electrolysis.The feed water quality monitor shall indicate the permitted green light for the minimum resistivity of 200 Ω - cm.The temperature rise of hydrogen in oxygen shall be less than 20 ℃ when the generator is running and the gas supply is close to full load.When the system is in standby mode, the temperature rise will increase significantly. The hydrogen sensor in oxygen needs a constant oxygen flow of 100CC/min.During normal operation, the pressure gauge of at least one dryer should be under pressure.Press the "dryer program" touch switch on the "generator operation" screen to monitor the status of the dryer program.In addition to the 30-minute pre-pressure period before drying switching, the output light 4 of slot 6 module should be on to indicate that the dryer purge valve is open. According to the program timing, lamp 2 or lamp 3 should be on to indicate that the dryer heater is working.The data and workday method shall be assigned to the generator to document the daily operation data. The recorded data provides useful information for routine maintenance and general diagnosis of operational problems. Such information shall be recorded within 24 hours at least.
7.Pressure relief
The generator can stop at any time by simply disconnecting the power contactor control switch.The generator remains under pressure after power failure. In order to remove the pressure from the system, you must turn on the power and then press the pressure release switch.The touch screen will display a "pressure release" screen indicating the pressure of hydrogen and oxygen.The output lights 2 and 5 of slot 2 will light up to indicate that the vent valve is open.
8. Parking
In order to maintain the safe and reliable operation of the HM generator, its critical operating parameters must be monitored.There are 17 conditions that will cause the system to stop when running.The flashing parking screen on the display can identify various parking conditions.Obviously, the parking condition has been clarified, but the actual cause needs to be checked again.Press the "Troubleshooting Guide" touch screen on the parking screen to provide possible reasons for specific parking conditions.In addition, the troubleshooting guide provided in Section V of this manual can also determine the cause of shutdown.The cause of the shutdown condition and the list of alarm setpoints initially programmed at the time of air supply are as follows:
System shutdown
Parking condition alarm input setpoint
High KOH temperature TC2 85 ℃
KOH liquid level high LS2
KOH liquid level low LS1 for 90 seconds
KOH flow low FS1 10l/min
H2 pressure high PT1 120Psig
H2 depression PT1 49Psig
High O2 pressure PT12 115Psig
O2 pressure lower PT12 39Psig
Low differential pressure PT1-PT2 3Psig
Pre-pressure low PT1 5Psig
H2 in O2 high TC3-TC4 200 ℃
Power alarm
Feed water resistance low FQM 200 Ω - cm
External alarm
Power loss PLC
High ambient temperature TC4 50 ℃
Low ambient temperature TC4 5 ℃.
