PE9000S Series Hydrogen Purifier Operations Manual

Power + Energy, Inc.

PE9000S Series Hydrogen Purifier

Operations Manual Version 4.1.5


February 2010 Power + Energy, Inc. 106 Railroad Drive Ivyland, PA 18974-1449 Phone: (215) 942-4600 Fax: (215) 942-9300 Sales: [email protected] Support: [email protected] Website: www.powerandenergy.com


PE9000S Control Software Documentation For use with Production Software Version 4.1.5 Safety Information.................................................................................................1

Symbols Used In this Manual ............................................................................1 General Safety Procedures and Precautions ....................................................1

Purification Process ..............................................................................................3 View of Purifier Cabinet ........................................................................................4 Gas Specifications ................................................................................................6

Hydrogen Input: .............................................................................................6 Nitrogen Input: ...............................................................................................6 Nitrogen/Clean Dry Air Input: .........................................................................6 UPH (Ultra Pure Hydrogen) Output: ..............................................................6 Bleed Output:.................................................................................................6 Helium (Leak Check) Input: ...........................................................................6

Important PE9000S Information............................................................................8 Safety features ..................................................................................................8

EMO Operation..............................................................................................8 Resetting the Unit ..........................................................................................8

Installing Filters .................................................................................................8 To begin using the PE9000S.............................................................................9 Setting the Rotometer .......................................................................................9

PE9000S Control System Overview ...................................................................10 Passwords.......................................................................................................11 Main Screen ....................................................................................................12 System Screen ................................................................................................13 Pressure Charts ..............................................................................................14 Temperature Charts ........................................................................................16 Diagnostics......................................................................................................18 Alarms .............................................................................................................19 Configure Controls ..........................................................................................20 PID Control......................................................................................................21 PID Tuning ......................................................................................................22 Configure Users ..............................................................................................23 Shut Down Mode.............................................................................................24 Hydrogen Standby Mode.................................................................................25 Operate Mode .................................................................................................26 Nitrogen Standby Mode...................................................................................27 Leak Check Mode ...........................................................................................28 Ethernet Control ..............................................................................................31 Discrete Inputs ................................................................................................31 Discrete Outputs..............................................................................................33 Alarms .............................................................................................................35

Computer error/ failure.................................................................................35 Appendix A: Electrical Schematic Drawings ......................................................38


PE9000S Operations Manual

4

Electrical Service Connection..........................................................................38 Appendix B: Chassis Dimensional Drawings .....................................................42 Appendix C : Outlet Flow Curves ........................................................................43 Appendix C : Leak Check ...................................................................................45



1

Safety Information Symbols Used In this Manual General Safety Procedures and Precautions Service by Qualified Personnel Only Operating personnel must not remove the instrument’s paneling. Component replacement, servicing or calibration must be performed by qualified individuals, preferably Power and Energy technicians. Purging the Instrument When shutting down for removal from a system or transporting the equipment it is important to purge the unit thoroughly with Nitrogen and cap all I/O Ports. Never disconnect or cut off the Nitrogen supply from the unit unless it has been fully purged and the cell is at ambient temperature. Not following this procedure may cause irreversible damage to the cell. Use Caution When Handling Flammable Gases Observe proper safety precautions and local regulations for the handling of flammable gases. External Devices All External devices that connect to this unit, including those suggested in this manual, must have fittings and usage consistent with the intended use of this product and the handling of hydrogen. Connections All connections to this unit must be made with proper gas fittings or electrical connectors. Gas connections should be leak-checked during installation.

WARNING – The Warning sign denotes a hazard. It calls attention to procedure, practice, condition, or the like, which, if not correctly performed or adhered to could result in injury to personnel or damage to the product.

NOTE – The Note sign denotes important information. It calls attention to a procedure, practice, condition, or the like, which is essential to highlight.



2

Operate at Safe Pressures Adhere to unit specifications and local safety regulations for handling pressurized gases. For safety, a suitable pressure relief valve shall be used when inlet gases are pressure regulated from a compressed source. Avoid Contamination Do not allow dust, dirt or other contamination to enter the unit before or during use. Standard industry practices should be followed to ensure clean connections to the UPH port on the unit.



3

Purification Process The hydrogen purification process has been made simple thanks to your Power + Energy ™ PE9000S Series Palladium Diffusion Hydrogen Purifier. Figure 1 is a flow diagram to illustrate the process. Hydrogen (99.95% or better H2 purity is recommended) is fed into the system via the H2 In connection. It travels through the Hydrogen purification cell, which allows only pure hydrogen to diffuse through the membranes to the Ultra-Pure (UPH) side. It then passes through the UPH out connection. Our hydrogen purification process has been constantly refined, and has been optimized to operate at 380 ºC ~ 410ºC. four heaters (3.6 kW total power) are installed around the cell to achieve this. To improve the thermal (and therefore electrical) efficiency, the UPH passes through a heat exchanger, thus saving costly electricity bills by recycling up to 70% of the heat coming off the heated UPH gas. A facility also exists for you to test your hydrogen purifier for leaks which may reduce the purity of the output. Helium may be injected into the Nitrogen stream via port F and tested on a secondary UPH output called Leak check. If the cell is in good working order, a spectrometer (or other Helium detection device) should register almost no helium in the UPH stream. Finally, it is important to maintain the nitrogen supply to the purifier. This is important, as it will ensure that during the heating up and cooling down processes, conditions are optimal for reducing thermal stress on the membranes. In the event of any electrical or other failure, flowing nitrogen ensures the safety of the purifier surroundings. This gas will pass through the bleed output, with flow control via the rotometer or via V4, the bypass valve. WARNING – Do not disconnect the N2 gas unless the

system has been properly shut down and the cell temperature has reached ambient conditions.



4

View of Purifier Cabinet



5

PE9000S P&ID Drawing



6

Gas Specifications Hydrogen Input:

Minimum pressure: 55 PSIG/ 3.8 Bar (g) Maximum pressure: 220 PSIG/ 15.2 Bar (g) Purity: ~99.95% Recommended

Nitrogen Input:

Minimum pressure: 35 PSIG/ 2.4 Bar (g) Maximum pressure: 90 PSIG/ 6.2 Bar (g) Purity: ~99.95% Recommended

Nitrogen/Clean Dry Air Input:

Instrument grade air Minimum pressure: 72 PSIG/ 5 Bar (g) Maximum pressure: 98 PSIG/ 6.7 Bar (g)

UPH (Ultra Pure Hydrogen) Output: Minimum pressure: Hard Vacuum Maximum pressure: 220PSIG/ 15.2 Bar (g) Maximum Delta P vs. Input 200 psig/ 13.79 Bar Purity: 99.9999999% H2

Rated output: See test certificate. Nominal rated output curves are given in Appendix C

Bleed Output: Flow rate: Typically 1-2% of UPH output

flow rate. See “Setting the Rotometer”, page 10.

Helium (Leak Check) Input: Minimum pressure: 10 PSI greater than N2 Input pressure Maximum pressure: 200 PSIG/ 13.79 Bar (g)

Note – You will not be able to Start up the purifier unless both the N2 input gas and the dry air are connected and are at or above minimum values.



7

Port Diagram



8

Important PE9000S Information Safety features The PE9000S has the following safety features installed:

• Emergency stop button

• Independent secondary thermal protection

• H2 detector in cabinet

• Protection against heating the cell without instrument air for valve actuation

All of these mechanisms will restrict the normal operation of the unit. Please read the following. EMO Operation Should any circumstance dictate a need to immediately cease the operation of the unit’s heaters, press the red EMO button in, located on the front panel (see front panel diagram on page 8). This will break the contactors inside the unit, and will turn off the electrical heaters. PLC and control power will remain turned on. Resetting the Unit To begin operation again:

1) Twist the EMO switch a quarter turn until it pops out. 2) Press the green “Start/Reset” button.

Installing Filters It is highly recommended that two (2) 0.5 micron High Flow Sintered Filter (Swagelok ® part #SS-4F-VCR-05 or equivalent) are installed prior to operating the purifier. These filters should be installed inline with H2 and N2 Inlets.



9

To begin using the PE9000S 1) Plumb the gas connections for input and output lines. 2) Ensure that the unit is properly connected to a 200 ~240VAC, 50/60 Hz

electrical supply. 3) Turn on the main disconnect switch located on the front panel. (see front

panel diagram on page 8). The green “Start/Reset” button should illuminate to indicate that the unit has power.

4) Press the green “Start/Reset” button on the front panel within 10 seconds of turning on the main disconnect switch. If this action is delayed, the PLC controller will display an alarm stating that the EMO has been triggered. If this alarm is triggered before the user has pressed the “Start/Reset” button, the user should press the “Start/Reset” button and clear the alarms. This will bring the system back to normal sequencing.

5) Log on as engineer2 and set and/or verify the operating voltage on screen “Operate Diagnostics” is set to your local conditions. This value may have been pre-set at the factory, but must be verified before running the heaters in the purifier.

A few seconds after power is turned on, the touch screen software will load and the “MAIN” screen will appear. From this screen, the basic modes of operation will be accessible without the need of logging in. The system will begin in shutdown mode, and will not begin to heat up or produce UPH until the user selects another mode.

Setting the Rotometer The rotometer is accessed on the front panel of the cabinet. It is used to set the flow rate on the bleed line. Turning the knob counter-clockwise will open the needle valve in the rotometer, which will increase the flow of gas through the bleed line. The flow rates for Nitrogen and Hydrogen are shown on a chart on the cabinet door, as well as in this manual (Appendix C). Be aware that when purifying hydrogen, the less pure the input gas, the greater the required bleed flow to remove the impurities. A rough guide to this is using 20 times the impurity percentage as a percentage of the UPH flow rate. Example calculation For 99.95% pure H2, the impurity percentage is 0.05%. Thus 20 x 0.05% suggests that 1% should be the percentage of UPH flow set on the rotometer. Suppose that 100 SLPM UPH is required to flow. Then 1 SLPM bleed flow is required. By reading the chart (see the panel of the PE9000S or Appendix C) you



10

will see that 1 SLPM on the red “Hydrogen” line corresponds to about 8mm on the ball. This corresponds to the reading that the center of the ball gives, when at eye level.

PE9000S Control System Overview The following sections provide a description of HMI operator panels and the functions available from each panel. Users must log on to access some machine control functions. Users should log off after changing machine settings to ensure that unauthorized access does not occur. The system does not provide any automatic log-off feature, and each user is responsible for hitting the “Log Off” button before leaving the unit’s HMI.

The Menu Panel Map shows the navigation between panels and the user password level required to access each panel.

OperateBarGSlow 500

OperateTempSlow 500

OperateDiagnostics 510

OperateAlarms 0

Log On Log Off

Operator Interface Panel Map

Operate Main 0

Operate System 500

OperateBarGFast 500

OperateTempFast 500

ConfigureControls 900

ConfigurePID

900

ConfigureUsers 900 Log Off

Edit Users

ConfigurePIDTune 900



11

Passwords The unit is preconfigured with the following ID’s and passwords: ID PASSWORD LEVEL operator 1234 100 engineer1 5678 500 engineer2 56789 510 The operator ID logon is not required to access the basic modes on this version software. The unit will initialize with the “Operate Main” screen visible to the user. The engineer1 and engineer2 ID’s will be required to access screens with levels 500 and 510, respectively.



12

Main Screen The Main screen is displayed when you Power On the PE9000S. It will provide all the functionality and information required for day to day operation. This screen will display an “Alarm Pop Disabled” warning in yellow when the alarm display pop-up function is disabled. This function should only be used when troubleshooting, and alarm pop-up should be enabled for normal operation. Leaving the alarm pop-up disabled will defeat user notification of problems. Alarm pop-up can be enabled by pressing the yellow button when it is visible on this screen.

ACTIVE CONTROLS: Log On Log Off Operate StandbyH2 ShutDown System (when logged on as engineer1 or engineer2) Alm Pop Disable button to re-enable alarm pop-ups

Cell Temp1234

Feed PSIG123.12

UPH PSIG123.12

System

Operate

ShutDown

StandbyH2

Main

Log On

Heat%DutyCycl

1234

Log Off

StandbyN2

H2 O

N2 C

UPHO

HeLC

ByPC

Valve Status

1 2 3 4 5 6 78 9 10 11 1213 14

Alm PopDisabled

Button to access SYSTEM panel. Machine state

sequence indicators

Status indicator buttons show the most recently selected machine mode in green. The normally hidden fourth light indicates Standby N2, which is normally not used.

Valve Status Display: Indicator turns green when a particular valve is open.

Buttons to access Log On and Log Off screens.

Panel name

Operational Data: Displays Heater duty cycle (% on), cell temperature in ºC and both input (feed) and UPH output pressures in psig, MPag, or Barg, factory set for each user.

Status indicator for N2 Standby Mode. Invisible when off.

Button to re-activte alarm display pop-up screen. Invisible when inactive. Should not be visible in normal operation.



13

System Screen The system screen contains access to other modes, as well as information about heater power usage and access to temperature and pressure charts.

ACTIVE CONTROLS: Main Pressure Charts Temp Charts Diagnostics (when logged on with user level of 510 or higher) Alarms Standby

Main: Press to return to the Main screen.

Main

Pressure Charts

Temp Charts

Heater

System

Alarms

Diagnostics

Cell Temp

1234

### StandbyN

Valve StatusH2 C

N2 O

UPHC

HeLC

ByPO

H2 RO

MFM

1234

Operational Data: Press to access pressure and temperature charts.

Diagnostics: Press to access information about flow rate and heater electrical current data. Also can change Standby mode

Displays Cell Temperature in °C

Heater Power: Indicator light turns on when the heater is powered.

Mass Flow Displayed (Factory Testing only)

Standby: Press to move system into Standby Mode


PE9000S Operations Manual 14

Pressure Charts The PE9000S provides pressure charts, enabling the user to see historic data about system pressures. Data may be viewed in charts spanning either a couple of minutes (Fast), or over the period of an hour (Slow). For the fast mode, a data point is taken every second, and in the slow mode, data is taken every 30 seconds.

• Each minor grid marker on the Fast chart is approximately 17 seconds

ACTIVE CONTROLS: System View Change

View change button: Press to change the time span of the chart.

System: Press to return to the System screen.

Real-Time Data: View current readings. Color corresponds to line on chart. Pressure readings are in psig.

Time axis: Measured in either MM:SS (Fast Mode) or HH:MM:SS (Slow Mode). Time is referenced to system clock.



• Each minor grid marker on the Slow chart is approximately 8 minutes and 30 seconds


Fast

--:--:-- --:--:-- --:--:-- --:--:--

1.00

0.78

0.56

0.34

0.12

-0.10

SystemPressureMPa (g) Slow

1234

1234Feed

UPH1234Cell Temp

View change button: Press to change the time span of the chart.

Real-Time Data: View current readings. Color corresponds to line on chart. Pressure readings are in psig.

Time axis: Measured in either MM:SS (Fast Mode) or HH:MM:SS (Slow Mode). Time is referenced to system




Temperature Charts The PE9000S also provides temperature charts enabling the user to see historic data about the system temperature in ºC. Data may be viewed in charts spanning either a couple of minutes (Fast), or over the period of an hour (Slow).

• Each minor increment on the Fast chart is approximately 17 seconds ACTIVE CONTROLS: System View Change

Slow

--:-- --:-- --:-- --:--

500

400

300

200

100

0

SystemTempFast

Cell Temp (ºC)

1234


View change buttons: Press to change the time span of the chart.

System: Press to return to the System screen. Real-Time Data:

View current cell temperature.



• Each minor grid marker on the slow chart is approximately 8 minutes and 30 seconds


Fast

SystemTempSlow

--:--:-- --:--:-- --:--:-- --:--:--

500

400

300

200

100

0

Cell Temp (ºC)

1234


View change buttons: Press to change the time span of the chart.

Real-Time Data: View current cell temperature.




Diagnostics The Diagnostics screen provides sensor displays and the button to perform a helium leak check.

Leak Check mode is provided so that membrane integrity may be examined. This is achieved by attaching a helium source to the Helium Inlet port (Port F) while attaching a helium detection device to the Leak Check port (Port E). Active Controls: System Leak Check Mode Configure Controls (logged on user must have access level 900 or higher)

SystemDiagnostics

Leak Check

Current (A)123.1

P1 (PSIA)123.12

P2 (PSIA)123.12

P3 (PSIG)123.12

T1 1234

H2 Sensor 1234

Configure Controls

T31234

H2 C

N2 C

UPHC

HeLO

ByPC

H2 RC

MFM(SLPM)

123.1


Leak Check: Press to go to the Helium Leak check mode

Configure Controls: used to access configuration panels



Alarms The system constantly monitors conditions for signs of malfunction. Should anything unusual occur, the system alarms page will register an alarm as shown below. Alarms may be examined by pressing the alarms button on the System screen, and should be checked for regularly. In the case of severe alarms, the system will display the alarms screen automatically. This function will be examined in greater detail in the “Alarm Messages” section.

Note: If the independent over temperature alarm is triggered, it can only be reset by opening the front panel and pressing the reset button on the OMRON overtemp monitor. Active Controls:

Return Clear Alarms Pop-up Disable Reset OV Temp

DESCRIPTION TYPE VALUE

XxXxXxXxXxXxXxXxXxXxX YYYY 9999.XxXxXxXxXxXxXxXxXxXxX YYYY 9999.XxXxXxXxXxXxXxXxXxXxX YYYY 9999.XxXxXxXxXxXxXxXxXxXxX YYYY 9999.

ReturnAlarms Clear AlarmsPopupsDisabled

Return: reverts to previous screen Clear Alarms: Removes

displayed alarms Disable Pop-up: Disables the automatic pop-up of this alarm screen when new alarms occur.



Configure Controls Note: This screen is password protected for level 900.

This panel allows the user to select a set up file that is different from the factory pre-set. It is only accessible to field service engineers. Active Controls:

System Back Next Load Configuration File

System Back Next

Load Configuration File

ComboBox1

Current Configuration FileabcdefghijklmnopqrstuvwxyzABCDEF

Configure Controls

System: Returns the display to the System Screen

Back: Returns the display to the previous screen

Next: Displays the next screen in sequence

Load Configuration File: Pressing will load a new configuration file from the memory card



PID Control Note: This screen is password protected for level 900 access.

This panel is used by P+E Engineers for system tuning. It is only accessible to field service engineers. Values on this panel should not be modified by the user.

Dead Band (0.1 C) Output (0.01% Duty)

Gain (0.01% Duty, 0.1 C, Sec) Limit Rate

+ DeadBand1234

- DeadBand-1234

MaxOutput-12345

MinOutput-12345

Kp12345

SlewTime

12345

Ki12345

Kd

12345

Heater (%)

PID Control NextBack

OutputBias

-12345

% On

123

1234 1234Setpoint Active Temp

System

Tune

System: returns the display to the system screen

Back: Returns the display to the previous screen

Next: Displays the next screen in sequence



PID Tuning

This panel is used by P+E Engineers for system tuning. It is only accessible to field service engineers. Active Controls: Back

Back: Returns display to previous screen in sequence

--:-- --:-- --:-- --:--

50.0

37.5

25.0

12.5

0.0

--:-- --:-- --:-- --:--

425418410403395

BackPID Tuning 1234 1234



Configure Users Note: This is a password protected screen for level 900. Active Controls: Edit Users Logout System Back Next

Back NextSystemEdit Users

Logout

Edit Users: Add or remove users, authorizations and passwords

System: Return to System Screen

Back: Return to previous screen

Next: Go to next screen in sequence

Logout: Logs out of password protected screen



PE9000S Operational Modes

The PE9000S is designed to be as simple to use as possible. The only decision that an operator will make is to decide which mode to set the system in, after which all control is automated. The PE9000S controller has three basic operational modes, which may be accessed from the Main screen:

• Operate Mode • Hydrogen Standby Mode • Shutdown Mode

In addition, Nitrogen Standby mode may be selected via the System screen. Leak Check Mode may be accessed from the Diagnostics screen. Shut Down Mode In Shut Down mode, UPH production ceases, nitrogen flows through the system, and after the hydrogen has been purged, the cell cools to room temperature. When the system is shut down, the Main screen should match the screen below:

A Press to activate Shut Down mode. The button will glow bright green if the

system accepts the mode command. B Nitrogen gas will flow into the system. H2 production will cease, as both

the H2 input valve and the UPH output valve are closed.

A

B

C

D



C If the UPH pressure is above 5 PSIA, the bypass valve will open to bypass the rotometer and ensure that UPH exits the system. Ensure that the bleed line is open when shutting down.

D The system heaters will continue to work in Shut Down mode until the UPH pressure falls below 5 PSIA. Cell temperature should then fall until the system is at room temperature.

• Should the UPH pressure not fall after 50 minutes, the heaters will turn off and the bypass valve will close.

Standby Mode In standby mode, the cell will be brought up to operational temperature. This mode is configured to flow either hydrogen or nitrogen through the purifier cell. The UPH valve will never open in standby mode. When the system is in standby, the Main screen should match the screen below:

Cell Temp1234

Feed BarG123.12

UPH BarG123.12

System

Operate

ShutDown

Standby

Main

Log On

Heat%DutyCycl

1234

Log Off

StandbyN2

H2 O

N2 C

UPHO

HeLC

ByPC

Valve Status

1 2 3 4 5 6 78 9 10 11 1213 14

Alm PopDisabled

A Press to activate Standby mode. The button will glow bright green if the

system successfully enters the mode. B Nitrogen will flow through the system until the cell reaches operating

temperature. The H2 valve will open at temperature setpoint. C In H2 standby mode, the UPH pressure will rise as UPH accumulates

behind the closed UPH valve until equilibrating with the feed pressure. The UPH pressure will not exceed the feed pressure.

D The system heaters are turned on, and the cell will heat up to 395ºC. They will then turn on periodically to maintain this temperature.

A

B

C

D



Operate Mode In operate mode, hydrogen flows through the system and is purified. The UPH is then output through the UPH line. To put the system into operate mode, the Main screen should match the screen below:

A Press to activate Operate mode. The button will glow bright green if the system successfully accepts the request.

B N2 will flow through the system until the cell is within 1ºC of operating temperature. H2 will then flow into the system and UPH will be produced.

C The system heaters are turned on, and the cell will heat up to 395ºC. They will then turn on periodically to maintain this temperature.

.

A

B

C



Nitrogen/Hydrogen Standby Mode Toggle

A This button is used to toggle between Hydrogen and Nitrogen feed for the Standby mode. Nitrogen should only be used if it is not possible to maintain the system with Hydrogen. This button should only be toggled when the unit is NOT in STANDBY mode. The setting toggle will be ignored by the system if the unit is already in STANDBY mode. B In Standby mode the heaters will maintain the cell at operating temperature (395 C).

A



Leak Check Mode To Select the Leak Check Mode, the System screen should match the screen below:

SystemDiagnostics

Leak Check

Current (A)123.1

P1 (PSIA)123.12

P2 (PSIA)123.12

P3 (PSIG)123.12

T1 1234

H2 Sensor 1234

Configure Controls

T31234

H2 C

N2 C

UPHC

HeLO

ByPC

H2 RC

MFM(SLPM)

123.1

Heat%DutyCycl

1234Set LineVoltage

123123 When the tubing is at vacuum pressure: A Press to activate Leak Check mode. A warning will be given to ask if you

want to continue. Press [OK] to continue, or close [X] to cancel and return to the current mode.

A

B C

WARNING - IMPORTANT! Remove cap and attach a regulated helium supply to the helium inlet port. Remove cap and attach a helium detection device to the Leak Check port (port E) to test for the presence of helium on the UPH output. 1. Ensure that the tubing between the Leak Check port and the detection device is pumped down to vacuum before continuing. 2. Verify the He pressure is above N2 pressure.

E



. B Helium must be injected into the system via the Helium Inlet port to test for

leaks in the membranes. C A second message will inform you of the current UPH pressure. Press

[OK] to acknowledge this message.. D The user will see a message to press “OK” when finished with the test.

Exit Leak Check Mode by selecting OK on the pop-up box.

• Helium may also be sprayed inside the chassis to check for leaks in welds and seals.

E Set the local line voltage here. It should be set to the supply voltage for the unit. Values are limited between 190 and 260 volts. This setting is used to compensate the heater duty cycle based on local voltage conditions, and should only need to be set once when installing the machine.

Note: Message boxes displayed on the interface have two buttons in the top, right-hand corner: [OK] and [X]. These are the equivalent of [OK] and [Cancel], respectively, on more common operating systems.

Ensure that the Helium pressure is greater than the Nitrogen pressure, otherwise the Helium check valve will not open.

WARNING – Ensure that your detection equipment is capable and prepared to handle the UPH pressure.





External Control

Ethernet Control The system may be configured to fully replicate the operating display over an Ethernet network using GE Fanuc View Runtime software. Contact Power + Energy for more information.

Discrete Inputs The PE9000W allows the user to put the system in Shut Down, Operate or Standby modes using Dry Contacts. See Electrical Specifications. These are four (4) covered terminal connections located on top of the unit, labeled “In” with terminal numbering 1-4. To send a command to the unit a connection must be made between terminal 4 and the terminal of the desired command for duration of 2 seconds. See the table below. EXAMPLE USER CIRCUIT

The system will remain in the selected mode after contacts are reopened and until a subsequent command is given. While a contact remains closed, the command will override any command given via ethernet or touchscreen. Should

Discrete Inputs Signal Terminal

Operate Command 1 Standby Command 2 Shut Down Command 3 Common (+ 24VDC) 4

1

4

switch



more than one contact be closed simultaneously, Shut Down will have the lowest priority, followed by Standby, and then the Operate Command will have the highest.

To ensure proper system operation the discrete inputs shall remain isolated from external circuitry. Power and Energy recommends the use of Dry Contact Mechanical Relays, Opto-isolated Solid State Relays or Momentary Push-Button Switches for switching the discrete inputs.



Discrete Outputs The PE9000W controller allows the user to be notified when the system is in Shut Down, Operate or Standby mode using dry contact outputs. In addition, a number of other status signals are available .Consult the factory for additional information. These are four (4) covered terminal connections located on top of the unit, labeled “Out” with terminal numbering 1-4. When the system is in Shut Down, Standby or Operate mode, 24VDC will be present between the relevant mode connector terminal (terminal 1, 2, or 3) and the common terminal (terminal 4). See the table below. EXAMPLE USER CIRCUIT

Should the system be set by a user to be in a mode other than Shut Down, Standby or Operate, no external signal will be given. Instead, it may be inferred that the system is in Helium Leak Check Mode, Flow Test mode, or is turned off.

Discrete Outputs Signal Terminal

Operate Signal 1 Standby Signal 2 Shut Down Signal 3 Signal Ground 4

1

4

Relay coil

To ensure proper system operation, the discrete outputs shall remain isolated from external circuitry. Power and Energy recommends the use of Dry Contact Mechanical Relays or Opto-isolated Solid State Relays for switching external equipment.



Alarm Messages

The PE9000W will monitor its performance and display an alarm message should an alarm condition be triggered. The system will also automatically switch to the Alarms screen if an alarm is triggered. While an alarm condition is true, the condition will be highlighted in red. If the condition returns to normal, it will be shown in green. Alarms which are not based on a sensor reading may be cleared using the “Clear Alarms” button located on the Alarms page. The following columns describe the alarm condition, and may be read from left to right by scrolling across the page. Description A description of the variable causing the alarm. Type The following refer to fixed limit alarms, which are triggered when a set value is reached. Only one can be associated with a single variable at any time. LOLO: Extremely low LO : Low HI : High HIHI: Extremely high The following refers to serious system errors. BIT: A bit [Boolean variable] set to 1 when a serious error occurs Value The value of the reading which caused the alarm to be triggered. Temperature will be in ºC, pressure will be in local units. Limit The threshold above or below which an alarm is activated. Date The date when the alarm was triggered. Time The time when the alarm was triggered. Variable The PLC variable which is linked to this alarm .

Any alarm will cause the alarm page to be displayed.



Alarms

Computer error/ failure The PE9000S control system consists of a Programmable Logic Controller (PLC) and its touchscreen interface (HMI). Should a PLC hardware error occur, you will see an alarm of the format: PLC:[error description] BIT On or Interface:[error description] BIT On We suggest that you use the “Clear Alarms” button to reset the alarms. Should the same condition persist, the alarm will reappear within a few seconds. If the problem persists, turn the power off for at least 120 seconds and then back on again. If the problem continues to persist, or indeed if any irregular operation seems to occur, the system may need to be serviced by a Power + Energy field engineer. In this case it is safest to shut down the machine and remove electrical power to the unit. Contact Power + Energy with a detailed description of any error messages you receive, as well as information about the operating conditions under which the incident occurred. NOTE: The PLC hardware errors are built-in GE Fanuc monitoring conditions that are not listed in the ALARM TABLE shown below.

Operating at or above HIHI pressure will void warranty



Shutdown Table AA AB AC AD AE AF Ag AG AH

Inte

rlock

Num

ber

Revi

sion

Service Description P&ID

Inst

rum

ent T

ag

P&ID

- Sh

eet

Refe

renc

e

Proo

f Tes

t Fre

quen

cy

Trip

Set

poin

tE

nglis

h

Eng

Uni

tsE

nglis

h

Trip

Set

poin

tM

etric

Eng

Uni

tsM

etric

Inc

/ Dec

Trip

Typ

e (S

oftw

are

/ Har

dwar

e)

Tim

e De

lay

- Sec

onds

Heat

er C

onta

ctor

H2 V

alve

Sol

enoi

dPL

C O

utpu

t Q00

01

N2 V

alve

Sol

enoi

dPL

C O

utpu

t Q00

02

Lk C

hk V

alve

Sol

enoi

dPL

C O

utpu

t Q00

05

Bypa

ss V

alve

Sol

enoi

dPL

C O

utpu

t Q00

04

UPH

Valv

e So

leno

idPL

C O

utpu

t Q00

03

H2 P

ress

ure-

up V

alve

Sol

enoi

dPL

C O

utpu

t Q00

15

Heat

er S

SR D

igita

lPL

C O

utpu

t Q00

07 a

nd Q

0008

Fina

l PLC

Seq

uenc

e St

ate

CON-143 ECV-415 ECV-416 ECV-419 ECV-418 ECV-417 ECV-420 YIC-1201 1 1 1 1 1 1 1 1

2P 2P 2P 1 1 2P 2P 1 112 MO 12 MO 12 MO 12 MO 12 MO

1 2 Heater Cell Temp Hi-Hi TSHH-302 1 T1:HIHI 430 °C Inc SW 0 ON OFF OFF OFF ON OFF OFF OFF SD2 2 Heater Cell Temp High-High TSHH-146 1 T2 460 °C Inc HW 0 OFF OFF OFF OFF ON OFF OFF OFF SD3 2 Emergency Shutdown HS-001A 1 PB-128 OFF - Dec HW 0 OFF OFF OFF OFF ON OFF OFF OFF SD4 OFF - Dec HW 0 OFF OFF OFF OFF ON OFF OFF OFF SD5 - Inc SW 0 ON OFF OFF OFF ON OFF OFF OFF SD6 2 PLC Failure QY-100 1 OFF - Dec SW 0 ON OFF OFF OFF OFF OFF OFF OFF -7 Input Pressure Low PSL-403 1 P1:LO 55 PSIG Dec SW 0 ON OFF OFF OFF ON OFF OFF OFF SD8 Instrument Air Low PSL-409 1 P3:LO, P3:LOLO 70 PSIG Dec SW 0 ON OFF OFF OFF ON OFF OFF OFF SD9 Delta Pressure High PDSH-410 1 P1P2Diff:HI 200 PSI ∆ Inc SW 0 ON OFF OFF OFF ON OFF OFF OFF SD10 Heater Control Thermocouple broken wire QY-302 1 T1:LOLO -40 °C Dec SW 0 ON OFF OFF OFF ON OFF OFF OFF SD11 Instrument Air High PSH-409 1 P3:HI 98 PSIG Inc SW 0 ON OFF OFF OFF ON OFF OFF OFF SD12 Input Pressure Sensor Fail PSLL-403 1 P1:LOLO -5 PSIA Dec SW 0 ON OFF OFF OFF ON OFF OFF OFF SD13 Input Pressure High PSHH-403 1 P1:HIHI 225 PSIG Inc SW 0 ON OFF OFF OFF ON OFF OFF OFF SD14 Output Pressure Sensor Fail PSLL-406 1 P2:LOLO -5 PSIA Dec SW 0 ON OFF OFF OFF ON OFF OFF OFF SD15 Output Pressure Sensor High PSHH-406 1 P2:HIHI 225 PSIG Inc SW 0 ON OFF OFF OFF ON OFF OFF OFF SD16 Temperature Drop during OPERATE mode TSL-302 1 T1:LO 360 °C Dec SW 0 ON OFF OFF OFF ON OFF OFF OFF SD

Notes1 Final PLC Sequence State will be achieved after a progression through a shutdown sequence

Interlock Letter

P&ID Instrument TagP&ID - SheetSafety Layer

Proof Test Frequency



ALARM TABLE

Seq

No.

Rev

isio

n

Service Description P&ID

- Sh

eet

P&ID

Inst

rum

ent T

ags

P&ID

Ala

rm T

ags

Con

trol

Pan

el D

evic

e Ta

gs

PLC

Inpu

t Typ

e

PLC

Sig

nal T

ype

Zero

Engl

ish

Span

Engl

ish

Eng

Uni

tsEn

glis

h

Nor

mal

Ope

ratio

nEn

glis

h

Zero

Met

ric

Span

Met

ric

Eng

Uni

tsM

etric

Nor

mal

Ope

ratio

nM

etric

Inc

/ Dec

Ala

rm S

etpo

int

Engl

ish

Ala

rm S

etpo

int

Met

ric

HM

I Inp

ut L

imit

Engl

ish

HM

I Inp

ut L

imit

Met

ric

Tim

e D

elay

- Se

cond

s

Latc

h (L

) / N

on-L

atch

(NL)

Safe

ty L

ayer

/ Im

port

ance

Lev

el

Hea

ter C

onta

ctor

H2

Valv

e So

leno

idPL

C O

utpu

t Q00

01

N2

Valv

e So

leno

idPL

C O

utpu

t Q00

02

Lk C

hk V

alve

Sol

enoi

dPL

C O

utpu

t Q00

05

Byp

ass

Valv

e So

leno

idPL

C O

utpu

t Q00

04

UPH

Val

ve S

olen

oid

PLC

Out

put Q

0003

H2

Pres

sure

-up

Valv

e So

leno

idPL

C O

utpu

t Q00

15

Hea

ter S

SR D

igita

lPL

C O

utpu

t Q00

07 a

nd Q

0008

ALA

RM

OU

T PL

C O

utpu

t Q00

014

ATT

ENTI

ON

OU

TPL

C O

utpu

t Q00

013

Ala

rm S

umm

ary

- HM

I

Ala

rm H

isto

ry -

HM

I

Notes1.0 Pressure Sensors

1.1 0 Input Pressure P1 LoLo 1 PT403 AI Voltage 0 500 PSIG 200 -5 - - 0 NL ON OFF ON X X1.2 0 Input Pressure P1 Lo 1 PT403 AI Voltage 0 500 PSIG 200 55 - - 0 NL ON OFF ON X X1.3 0 Input Pressure P1 Hi 1 PT403 AI Voltage 0 500 PSIG 200 220 - - 0 NL ON ON OFF X X1.4 0 Input Pressure P1 HiHi 1 PT403 AI Voltage 0 500 PSIG 200 225 - - 0 NL ON OFF ON X X1.5 0 Output Pressure P2 LoLo 1 PT406 AI Voltage 0 500 PSIG 0-150 -5 - - 0 NL ON OFF ON X X1.6 0 Output Pressure P2 Hi 1 PT406 AI Voltage 0 500 PSIG 0-150 220 - - 0 NL ON ON OFF X X1.7 0 Output Pressure P2 HiHi 1 PT406 AI Voltage 0 500 PSIG 0-150 225 - - 0 NL ON OFF ON X X1.8 0 P1P2Diff Hi N/A N/A 0 500 PSI 180 200 - - 0 NL ON OFF ON X X

2.0 Heating System2.1 0 Heater Temp T1 LoLo 1 TE302 AI Type K T/C -270 1622 °C 0-400 -40 - - 0 NL ON OFF ON X X2.2 0 Heater Temp T1 Lo 1 TE302 AI Type K T/C -270 1622 °C 0-400 360 - - 0 NL ON OFF ON X X2.3 0 Heater Temp T1 Hi 1 TE302 AI Type K T/C -270 1622 °C 0-400 440 - - 0 NL ON ON OFF X X2.4 0 Heater Temp T1 HiHi 1 TE302 AI Type K T/C -270 1622 °C 0-400 460 - - 0 NL ON OFF ON X X2.5 0 Heater Current CT HIHI 1 IT239 AI 4-20mA DC 0 50 A 0-18 21000 - - 0 NL ON ON OFF X X2.6 0 Heater Temp T2 HiHi 1 TE147 N/A Type K T/C -270 1622 °C 0-400 460 - - 0 L OFF OFF ON X X

3.0 General State Transition Error3.1 0 GoToES fault state QY001 N/A SW register 1 - - 0 NL ON OFF OFF OFF ON OFF OFF OFF OFF ON X X

4.0 System Utilities4.1 0 PLC Failure 1 QY001 N/A SW register 1 0 NL ON OFF OFF OFF OFF OFF OFF OFF OFF OFF X X4.2 0 Cabinet Temp T3 LoLo N/A AI Type K T/C -270 1622 °C n/a 0 NL ON ON OFF X X4.3 0 Cabinet Temp T3 Lo N/A AI Type K T/C -270 1622 °C n/a 0 NL ON ON OFF X X4.4 0 Cabinet Temp T3 Hi N/A AI Type K T/C -270 1622 °C n/a 0 NL ON ON OFF X X4.5 0 Cabinet Temp T3 HiHi N/A AI Type K T/C -270 1622 °C n/a 0 NL ON OFF ON X X4.6 0 Cabinet Temp T4 LoLo N/A AI Type K T/C -270 1622 °C n/a 0 NL ON ON OFF X X4.7 0 Cabinet Temp T4 Lo N/A AI Type K T/C -270 1622 °C n/a 0 NL ON ON OFF X X4.8 Cabinet Temp T4 Hi N/A AI Type K T/C -270 1622 °C n/a 0 NL ON ON OFF X X4.9 Cabinet Temp T4 HiHi N/A AI Type K T/C -270 1622 °C n/a 0 NL ON OFF ON X X4.10 Instrument Air P3 LoLo 1 PT409 AI Voltage 0 120 psig 75 -5 -2 ON OFF ON X X4.11 Instrument Air P3 Lo 1 PT409 AI Voltage 0 120 psig 75 72.7 0 NL ON OFF ON X X4.12 Instrument Air P3 Hi 1 PT409 AI Voltage 0 120 psig 75 98 0 NL ON OFF ON X X4.13 Hydrogen Detector In 1 ASHH422 DI DI 0 1 0 1 0 L ON OFF ON X X 1

5.0 Emergency Shutdown5.1 0 Emergency Shutdown 1 HS001A YIC-108 DI On / Off 1 L OFF OFF ON X X5.2 0 Emergency Shutdown - Remote 1 HS001B YIC-108 DI On / Off 1 L OFF OFF ON X X

See interlock 3 - Shutdown TableSee interlock 4 - Shutdown Table

See interlock 8 - Shutdown TableSee interlock11 - Shutdown TableSee interlock 5 - Shutdown Table

See interlock 8 - Shutdown Table

Basis of Setpoint




Notes





The Omron K8-ABTH over-temperature monitor must be reset manually if triggered. The reset button is on the front of the unit and should be depressed with a small instrument such as a pen. The red alarm light will extinguish when the unit is reset. Do not change the dial switch settings on the unit. Doing so may disable the over-temperature protection.



Appendix A: Electrical Schematic Drawings

Electrical Service Connection 200 to 240 VAC, 50~60 Hz, 25 amperes service rating

Wire connection is: HOT, NEUTRAL, GROUND Unit maximum current draw is approximately 16.3 amps at 200VAC .









Appendix B: Chassis Dimensional Drawings



Appendix C : Outlet Flow Curves



Rotameter settings for controlling bleed outlet flow

ROTAMETER FLOW RATES, H2 & N2 ccpm VS BALL

02468

10121416182022

0 5 10 15 20 25 30 35 40 45 50 55 60 65Flow Tube '6G07R3' 1/4" BLACK GLASS - CENTER of BALL

SLP

M

(SLPM HYDROGEN) (SLPM NITROGEN)



Appendix C : Leak Check



Change Log

Date Description Page Initials2009Nov11 Manual revised for Version 4.1.2 software all EP

2009Nov11 Manual revised for hardware rev.6 all EP

2009Nov18 Alarm setpoints table 37 EP

2009Nov18 Schematic 40-42 EP

2009Dec17 Manual revised for Version 4.1.3 software 5-8,11, 12, 19, 30, 36, 37, 40, 43, 45

EP

Documents

PE9000S Series Hydrogen Purifier Operations Manual