Operating Instructions

Solar Hydrogen Technology

Science Kit

heliocentris Energiesysteme GmbH, Rudower Chaussee 29, D-12489 Berlin, Germany


hydro-Genius Solar Hydrogen Technology Science Kit

Operating Instructions Solar Hydrogen Technology Science Kit

October 99 model or later.
st
1 edition, 1 October 1999

heliocentris Energiesysteme GmbH, Rudower Chaussee 29, D-12489 Berlin, Germany

All rights reserved. These operating instructions and each separate part thereof are
protected by copyright. All exploitation, duplication or photocopying is prohibited except in cases
permitted by law.

Components of the hydro-Genius Solar Hydrogen Technology Science Kit are protected by patent
applications and/or utility models.

hydro-Genius is a trademark of heliocentris Energiesysteme GmbH, Germany. In some countries it

is a registered trademark.

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hydro-Genius Solar Hydrogen Technology Science Kit

Contents
1. Notes for the User ............................................................................................................. 1

2. Safety................................................................................................................................. 1
2.1. Introduction and Safety Information ...........................................................................1
2.2. Correct Use ................................................................................................................2
2.3. Sources of Danger .....................................................................................................3
2.4. Authorised Operators .................................................................................................4
2.5. Workplace .................................................................................................................. 4
2.6. Protective Equipment .................................................................................................4

3. Technical Information and Data ........................................................................................ 5

3.1. Contents of the package ............................................................................................5
3.2. Necessary Expendables.............................................................................................5
3.3. Available Additional Accessories................................................................................5
3.4. Basic Functions ..........................................................................................................6
3.5. Overview ....................................................................................................................7
3.6. Technical Data .........................................................................................................10

4. Transport and Storage..................................................................................................... 11

5. Installation and Assembly................................................................................................ 11

5.1. Solar Module ............................................................................................................11
5.2. Electrolyser............................................................................................................... 12
5.3. Fuel Cell ................................................................................................................... 13
5.4. Load Measurement Box ...........................................................................................13
5.5 Assembling and Starting up the Solar Hydrogen Plant ............................................13

6. Operation of the hydro-Genius Solar Hydrogen Technology Science Kit ..................... 14
6.1. Using the right Operation Media...............................................................................14
6.2. Operating the Stop Watch........................................................................................15
6.3. Safety Precautions for Operation .............................................................................16
6.4. Recommended Modes of Operation ........................................................................16
6.5. Improper Modes of Operation ..................................................................................17
6.6. Possible Malfunctions...............................................................................................18
6.7. Closing Down Operation ..........................................................................................19
6.8. Closing down operation in an emergency ................................................................19

7. Maintenance and Servicing ............................................................................................. 20

7.1. Safety Precautions ...................................................................................................20
7.2. Cleaning ................................................................................................................... 20
7.3. Maintenance.............................................................................................................20

8. Warranty and Complaints................................................................................................ 21

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hydro-Genius Solar Hydrogen Technology Science Kit

1. Notes for the User

The following symbols are used in the operating instructions to indicate dangers and references:

Dangerous situation
(serious injuries User tips
possible)

Danger from heat No open fire

Danger of explosion Smoking prohibited

Do not touch

2. Safety

2.1. Introduction and Safety Information

hydro-Genius Solar Hydrogen Technology Science Kit is equipped with safety devices.

Nevertheless, improper operation or abuse can lead to dangers for

- the health of the operator
- the unit itself and other items of property.

All persons involved in the setting up, operation and maintenance of the unit must
- read and precisely follow these operating instructions

- be fully trained for/instructed in their work.

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hydro-Genius Solar Hydrogen Technology Science Kit

The following symbols and signal words are used in these operating instructions:

Warning!
Draws attention to a potentially dangerous situation.
Serious injuries can occur if this reference is ignored.

Important!
Draws attention to application tips and other useful pieces of information. This
is not a reference to dangerous situations. A risk of damage to the product or
to the environment might be involved, however.

2.2. Correct Use

hydro-Genius Solar Hydrogen Technology Science Kit is an experimentation and demonstration
model on hydrogen technology and its components. It may only be used for experimentation and
demonstration purposes and must be operated in accordance with these operating instructions.

The enclosed experiment instructions describe in the detail the procedure to be followed in the
experiments and contain additional safety information. They should be treated as part of these
operating instructions.

hydro-Genius Science Kit may not be used for:

1. generating electricity for general use, e.g. for operating electrical devices or equipment,

2. generating hydrogen for any other purposes than those described in the experiment
instructions,

3. storing or collecting more than minimal amounts of hydrogen (approx. 20 ml).

4. The load measurement box must not be used to measure voltage and current with other

than components from the hydro-Genius program, particularly no voltage of more than
3V must be connected to the terminals.

For the experiments use only the components of the Science Kit unless otherwise stated in the
attached experiment descriptions.

Unauthorised modifications or changes to the components are prohibited for safety reasons. The
operating and maintenance conditions laid down in these operating instructions must be observed.

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hydro-Genius Solar Hydrogen Technology Science Kit

2.3. Sources of Danger

Source of danger

Precautions
Possible consequences
Use of hydrogen Avoid handling open fire in the vicinity of the model.

Danger of explosion Smoking is strictly prohibited.

Hot light source

Do not touch the lamp when in operation or immediately

after operation
Danger of burning
Overheating of system Keep the stipulated distance between the lamp and all
surfaces

Under very intense illumination the Touch the solar module only on the sides not exposed
surface of the solar module may to the light source.
become very hot

Remove the light source and wait for the solar module
to cool down before touching it
Danger of skin burns if touched

Using the load measurement box with Never operate the load measurement box with others
foreign components than hydro-Genius components.

The connected voltage must never exceed 3V.

electric shock

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hydro-Genius Solar Hydrogen Technology Science Kit

2.4. Authorised Operators

You may only work with the unit if you

- have read the operating instructions,
- have been instructed on proper handling by the operator,
- have been informed about the potential dangers involved in connection with the
unit.

The hydro-Genius Solar Hydrogen Technology Science Kit may only be used by trained teaching
staff or by pupils and students under the supervision of teaching staff. As the teacher you must
ensure proper handling. You are obliged to draw attention to potential dangers. Before starting an
experiment, hand out the experiment instructions provided in order to prevent pupils and students
from "playing around" with the model.
Take measures to prevent unauthorised persons from installing, using or maintaining the unit. If the

hydro-Genius Solar Hydrogen Technology Science Kit is passed on to a third party, you must also
pass on the operating instructions.

2.5. Workplace

The components of the hydro-Genius Solar Hydrogen Technology Science Kit must be assembled
and operated on an even, horizontal, stable and solid base.

A working height of 75 - 85 cm is recommended for experimentation purposes.

The model needs approx. 1.0 m x 0.5 m of space.

The ambient temperature should be between 10C and 35C. We therefore recommend that you
only operate the model inside the building in order to protect it from the weather.

2.6. Protective Equipment

All people present during experiments must wear protective goggles.

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hydro-Genius Solar Hydrogen Technology Science Kit

3. Technical Information and Data

3.1. Contents of the package

Solar module, mounted in plastic housing

PEM-Electrolyser with storage cylinders, 2 overflow pipe for storage cylinders

PEM Fuel Cell

Load Measurement Box

2 red cables, 2 black cables

2 silicone tubes 4-6 mm, approx. 40 cm length

2 silicone tubes 4-6 mm, approx. 20 cm length

3 Tubing stoppers

Stop watch

1 replacement bulb

Documentation: Operation Instruction

Experiment instructions

Illustrated set-up/packaging instructions

Scale of angles/connection diagram for Load Measurement Box

For transport reasons, heliocentris delivers the hydro-Genius Science Kit in partially dismantled
form. For repacking after operation see the drawing in section 3.5 and inside the box.

3.2. Necessary Expendables

Distilled water.

The load measurement box requires two 9 V 6LR61-batteries as power supply.

The stop watch requires a round cell battery AG 3, LR 41 or L 736 as power supply.

Both batteries are included in the initial delivery

3.3. Available Additional Accessories

Dismountable Fuel Cell Extension Kit (heliocentris order No. 353),

With 2 different oxygen/air inlets and 2 membranes with different catalyst surfaces, plug-in
resistance.
Allows experiments that give a detailed insight into fuel cells process parameters and how they
work.

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hydro-Genius Solar Hydrogen Technology Science Kit

3.4. Basic Functions

This Science Kit is a miniature solar-hydrogen plant which has been specially designed for teaching
purposes. The components are identical to those used in solar-hydrogen off-grid power-supply
plants.

And this is how the hydro-Genius Solar Hydrogen Science Kit works:

1. The solar module converts light into current.

2. This current splits water into hydrogen and oxygen in the electrolyser.

3. The gases may be stored in the storage cylinders of the electrolyser.

4. The hydrogen and oxygen are fed into the fuel cell, where they are converted directly into current.

5. The current drives the electric motor or the bulb.

Solar Module with Solar Cells Electric load

Sun
M

- + Oxygen
Oxygen Hydrogen

+ -

Hydrogen
Electrolyser
Oxygen storage Hydrogen storage
Fuel Cell

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hydro-Genius Solar Hydrogen Technology Science Kit

3.5. Overview

2c
1a
2f

1b 2d

2g

2j
2k
2b
1d 2h

1c
2e
2a

1 Solar Module 2 Electrolyser

1a Housing 2a Electrolysis cell
1b Solar cells 2b Hydrogen storage cylinder
1c Tip jack: positive terminal 2c Hydrogen storage overflow pipe
1d Tip jack: negative terminal 2d Hydrogen gas outlet
2e Oxygen storage cylinder
2f Oxygen storage overflow pipe
2g Oxygen gas outlet
2h Tip jack: positive terminal
2j Tip jack: negative terminal
2k Protective diode

3g

3b 3 Fuel Cell
3f
3a Housing
3b Hydrogen gas inlet
3c Hydrogen gas outlet
3c 3d Oxygen gas inlet
3d
3e Oxygen gas outlet
3f Tip jack: positive terminal
3e 3g Tip jack: negative terminal
3a

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hydro-Genius Solar Hydrogen Technology Science Kit

4 Load Measurement Box

4h 4j 4k

4b 4c 4d 4e 4f 4g 4a
4a ON/OFF switch 4f Tip jack: positive terminal for Voltmeter
4b Ammeter display 4g Tip jack: negative terminal for Voltmeter
4c Tip jack: positive terminal for 4h Rotary switch Resistances/Loads
Load/Am-meter
4d Tip jack: negative terminal for 4j Lamp
Load/Am-meter
4e Voltmeter display 4k Coloured Disk for Motor

Circuit Diagram for Load Measurement Box

   

   
 

 


 
 

 

I


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hydro-Genius Solar Hydrogen Technology Science Kit

Repacking the Science Kit after operation

Fuel cell
Load measure-
ment box Electrolyser Brennstoff-
Stopwatch zelle

Elektrolyseur
Verbraucher-
Messbox 3 red cables
2 black cables
Stoppuhr 3 rote Kabel
2 schwarze
Kabel
Overflow pipes

Solar module
Extension kit
dismantable fuel cell

Solarmodul Ergnzungssatz
zerlegbare
Brennstoffzelle

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hydro-Genius Solar Hydrogen Technology Science Kit

3.6. Technical Data

Solar module
Dimensions (length x width x height) 70 mm x 120 mm x 52 mm
Terminal voltage 3.0 V
Short circuit current 245 mA
Maximum Power Point:
Voltage 2.4 V
Current 200 mA
Power 0.48 Watt
2
Output data under standard conditions (all data at 1000 W/m and 25C)

Electrolyser
Dimensions (length x width x height) 85 mm x 190 mm x 90 mm
Consumption of distilled water 1 ml/10 h at 300 mA electrolysis
current
Amount of water carried from oxygen to 1 ml/ h at 500 mA electrolysis
hydrogen side current
Storage volume of hydrogen and oxygen 10 ml each
Normal/Operating voltage 1.4 1.8 V
Current 0 - 500 mA
Hydrogen production max. 3.5 ml / min

Fuel cell
Dimensions (length x width x height) 85 mm x 70 mm x 70 mm
Voltage 0.4 1.0 V
Current max. 1000 mA
Consumption of hydrogen max 7 ml/ min at 1000 mA
current

Load measurement box

Dimensions (length x width x height) 190 mm x 110 mm x 85 mm
Operation voltage of motor 0.2 3 V
Current drain of motor with coloured disk 10 15 mA
Operating voltage of lamp 0.6 1.5 V
Current drain of lamp 0 80 mA
Operating voltage of display units 9V

Climatic conditions
Ambient temperature 10 - 35 C
Transport and storage temperature 10 - 35 C protect against frost!

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hydro-Genius Solar Hydrogen Technology Science Kit

4. Transport and Storage

The Solar Hydrogen Technology Science Kit is delivered partially dismantled in a plastic storage
container. The container protects the components from damage.

Please contact the manufacturer in the event of any transport damage.

Use only the storage container for transporting the Science Kit. The electrolyser must never be filled
with water during transport.

Protect the storage container against falling, vibrations and the influence of weather.

Store the components in their designated compartments in the original container. The electrolyser
must be emptied of water before storage.

The electrolyser must be refilled with distilled water before the unit is restarted.

5. Installation and Assembly

The hydro-Genius Solar Hydrogen Technology Science Kit is supplied complete with illustrated
assembly instructions for starting up. Please hand these out to the pupils to ensure that they set the
unit up properly.

The following sections contain written assembly instructions.

Some of the experiment instructions contain further of set-up advice. Please follow these
instructions.

5.1. Solar Module

The solar module is set up perpendicular/at right angles to the workplace surface. The light source
should illuminate the solar module perpendicularly.

Enclosed with the Science Kit is a printed scale of angles, which you can use to set up the solar
module at specific angles to the light source.

See experiment instructions for further information.

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hydro-Genius Solar Hydrogen Technology Science Kit

5.2. Electrolyser

Assembling the gas storage cylinders

Insert the overflow pipes (2c and 2f) into the stoppers at the top of the
storage cylinders (2b and 2e) and press them in tightly.

Tip: 0

Moistening the pipe ends with distilled water 4

makes them easier to insert. 6

Push the two 40 cm tubes onto the gas outlets (2d and 2g) of the 10

storage cylinders. These tubes conduct the gases from the electrolyser
to the fuel cell.

Filling with distilled water

Before the Science Kit can be started up, the electrolyser must be filled
with approx. 50 ml of distilled water.

Caution: the PEM electrolyser may only be filled with distilled water. If
you use any other liquids (e.g. containing electrolytes), this could destroy
the electrolyser.

Use a wash bottle to simplify this operation.

Pour distilled water through the bore-holes in

both stoppers.

For normal use in class and for operation up

to a maximum of 1 hour, fill both storage
0

cylinders up to the 0 ml marks (see Fig. a)). 2

4
Since a small amount of water is transported
6

from the oxygen to the hydrogen side during 8

electrolysis (approx. 1 ml/h at an electrolysis 10

current of 500 mA), for longer use

(continuous operation) the two storage
cylinders must be filled to different levels (see
Fig. b)).

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hydro-Genius Solar Hydrogen Technology Science Kit

O2 H2 O2 H2
0 0 0 0

2 2 2 2

4 4 4 4

6 6 6 6

8 8 8 8

10 10 10 10

a) Storage mode b) Continuous operation

5.3. Fuel Cell

The fuel cell is delivered ready assembled.

5.4. Load Measurement Box

The load measurement box is delivered ready assembled.

5.5. Assembling and Starting up the Solar Hydrogen plant

1. Make sure that all components of the Science Kit are standing on a horizontal and stable base.

2. Use laboratory cables ("banana plugs") to make the connection between the power source
(solar module or power-supply unit) and the electrolyser:

Positive terminal of the solar module (1c) to the positive terminal of the electrolyser (2h)
Negative terminal of the solar module (1d) to the negative terminal of the electrolyser (2j)

3. Connect the hydrogen gas outlet (2d) of the electrolyser and the hydrogen gas inlet of the fuel
cell (3b) using one of the enclosed tubes. Repeat for the oxygen side.

4. Illuminate the solar module sufficiently or use the power-supply to set a current of between 150
mA and 350 mA.

5. You should now observe a distinct development of gas in the electrolyser. Oxygen forms in
one of the half-cells, hydrogen in the other.

6. Use laboratory cables ("banana plugs") to make the following connection:

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hydro-Genius Solar Hydrogen Technology Science Kit
Positive terminal of the fuel cell (3f) to the positive terminal of the load measurement box (4c)
Negative terminal of the fuel cell (3g) to the negative terminal of the load measurement box
(4d).

7. Turn the ON/OFF switch of the load measurement box to the ON position. Adjust the rotary
switch (4h) to the MOTOR position.

8. After a maximum of 10 20 minutes the fuel cell should be sufficiently supplied with gas to be
able drive the electric motor.

The hydro-Genius Science Kit is supplied with illustrated assembly instruction to guide you when
starting up the system and making the necessary cable and tubing connections.

The enclosed experiment instructions contain further instructions for experiments using the Science
Kit. Follow these instructions to carry out your experiments safely and reliably.

6. Operation of the hydro-Genius Solar Hydrogen Technology Science Kit

6.1. Using the right Operation Media

The solar module can be operated using various light sources:

1. Sunlight

2. Halogen lamp with reflector, up to 150 watts

3. Filament lamp with reflector, up to 150 watts

The light source must ensure that the surface of the solar cells is evenly illuminated. For safe and
reliable experiments, we recommend the heliocentris 120 W accessory filament lamp.

The electrolyser can be operated with the following power sources:

1. Solar Module: The enclosed solar module is perfectly adjusted to the electrolyser and offers the
greatest operational safety.

2. Power-supply unit: The current must be limited to a maximum of 0.5 amps. Otherwise the
electrolyser will be destroyed.

Caution: The electrolyser current must never exceed 0.5 amps.

Otherwise the electrolyser may be destroyed.

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hydro-Genius Solar Hydrogen Technology Science Kit
Make sure that the power sources are connected correctly, i.e. connect the positive terminal of the
power source to the positive terminal of the electrolyser and the negative terminal of the power
source to the negative terminal of the electrolyser.

The electrolyser is equipped with a protective diode which short-circuits the power source if polarity
is reversed. At currents above 0.5 amps, reversed polarity can lead to the destruction of the
protective diode.

Use only the enclosed electrolyser as the source of hydrogen and oxygen for the fuel cell.

The fuel cell will supply its full output of electrical energy approx. 10 minutes after the electrolyser is
started up.

For further information see the enclosed experiment instructions.

6.2. Operating the Stop Watch

Tear out the white insulation strip before first use of the stop watch.

1. Press the H and M keys simultaneously; the display shows 0:00. An alarm tone also
sounds until you release the keys.

2. Press the S/S key to start the stop watch. Press S/S again to stop.

The stop watch can also be used as timer. It counts down to zero from a preselected time and
sounds an alarm to indicate that the time has expired:

1. Press the H and M keys simultaneously; the display shows 0:00. An alarm tone also
sounds until you release the keys.

2. Press H to set the hours and M to set the minutes.

3. Press S/S to start. The colon starts flashing. The alarm sounds when the preselected time
has expired. Press S/S to stop the alarm.

If the numbers on the display are no longer properly visible, the round cell battery must be replaced.
Proceed according to section 7.3.

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hydro-Genius Solar Hydrogen Technology Science Kit

6.3. Safety Precautions for Operation

1. The teacher is responsible for ensuring that pupils and other persons only operate the model
under supervision and after receiving instruction.

2. When carrying out experiments with the hydro-Genius Solar Hydrogen Technology Science
Kit, be sure to follow the enclosed experiment instructions.

3. If the light source heats up the solar module too much, remove the light source and do not
touch the solar module until it has cooled down sufficiently.

4. If appropriate follow the safety instructions in the operation manual of the light source. It is
especially important to keep the stipulate minimum distance from the lamp.

6.4. Recommended Modes of Operation

Make sure that the electrolyser does not dry out during operation.

Regular operation is good for the fuel cell. If possible, the equipment should be used for several
hours every 3-4 weeks. The more frequently the fuel cell is used, the more efficient it is. The
membrane can dry out if it not used for a long time. The model will then take longer to start up.

In order to ensure that measured data of the fuel cell (e.g. for the characteristic curve) correspond
to the data indicated in the experimental operating instructions, the fuel cell should be in operation
for some time before the measurements are made

The electrolyser allows in principle two different modes of operation:

1. Storage mode

2. Continuous operation

In storage mode make sure that both gas storage cylinders are filled with distilled water up to
exactly the 0 ml mark before the experiment is started.

In continuous operation, the oxygen side should be filled to the 0 ml mark, but the hydrogen side
only to the 10 ml mark, a small measurable volume of water is transported from the oxygen to the
hydrogen side since during electrolysis. When the water-level on the hydrogen side approaches the
0 ml mark, the surplus water must be siphoned out with a pipette or syringe after removing the
stopper. About the same volume must be added on the oxygen side.

For operation using oxygen from the ambient air, disconnect the oxygen tube from the fuel cell.

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hydro-Genius Solar Hydrogen Technology Science Kit

6.5. Improper Modes of Operation

1. The solar module must not be heated above 60C by the radiation/light source.

2. The solar module must not be illuminated with focused (directed) light.

3. Avoid pinching the rubber gas tubing, because this can lead to positive pressure, causing the
rubber tubes to jump off and leading to an acute risk of injury.

4. The gas outlets of the fuel cell and all other tubes may only be sealed when strictly following the
experiment instructions.

5. The gas storage cylinders of the electrolyser must be filled with distilled water at least to the top
of the electrolyser.

6. The maximum operating voltage indicated in section 3.6 must never be exceeded.

7. Do not under any circumstances connect the fuel cell to an external power source (e.g.
laboratory power-supply unit or solar module). A forced current flow from outside can
immediately lead to the destruction of the fuel cell.

8. If other objects than the installed disk are connected to the motor axle on the load
measurement box, heliocentris assumes no liability for any damage thus caused.

9. The bulb of the lamp in the load measurement box must not be operated at voltages exceeding
1.5 V and especially not using the enclosed solar module.

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hydro-Genius Solar Hydrogen Technology Science Kit

6.6. Possible Malfunctions

(Minor faults which you can remedy yourself)

Electrolyser is not producing any gas Is the electric connection between the solar module
and the electrolyser correct (see section 5.5)?

Electrolyser is producing too little gas Illuminate the solar module better with the lamp
(less than one gas bubble every 4 (Caution, danger of burning!)
seconds)

The Ammeter is indicating no current Check that the fuel cell and the electrical load are
connected correctly (see section 5.5)
Is the ON/OFF switch of the load measurement box
set to ON?
Is the rotary switch of the load measurement box set
to one of the positions LAMP, MOTOR, SHORT
CIRCUIT or a resistance smaller than 50 ?
Check that the stoppers at the electrolyser and the
rubber tubes leading to the fuel cell are tight and
impervious
If gas bubbles can be observed in the electrolyser, a
rubber tube to the fuel cell might be leaky.
The fuel cell might have dried up if the Science Kit
has not been in operation for more than 2 months. In
this case, use a wash bottle to introduce a few drops
of distilled water into the oxygen inlet.

Continuous operation may lead to surplus water in

the fuel cell. It can be poured out through the gas
nozzles on request.

All other faults and irregularities can only be remedied by heliocentris.

Please notify your dealer in such an event by telephone or by fax.

Many questions can be clarified by phone. A decision can then be still taken on whether the Science
Kit or individual parts of it need to be sent in for repair.

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hydro-Genius Solar Hydrogen Technology Science Kit

6.7. Closing Down Operation

1. Switch off the light source (if in operation) and allow the light source and the solar module to
cool down sufficiently.

2. Switch the load-measurement box OFF.

3. Remove all cables and tubes.

4. Pour the distilled water out of the electrolyser. To do this you must first disconnect the tubes
from the outlets. You can now pour the water out through the gas outlets.

5. Store all the components in their designated compartments in the storage container. Check the
packaging instruction on the storage container.

6. Store the hydro-Genius Solar Hydrogen Technology Science Kit in a safe place that it is
protected against unauthorised access.

6.8. Closing down operation in an emergency

Proceed as follows in the event of unexpected operating conditions:

Plastic parts deform because the Switch off the lamp.
minimum distance of the lamp has Allow the model to cool down before you or anyone
not been adhered to. else touches it.
Proceed as indicated in section 6.7.

Leaking hydrogen ignites Immediately remove the current-supply cable from

the electrolyser to stop hydrogen production.
Initiate all necessary fire fighting measures.
Immediately ensure that everyone keeps a safety
distance of at least 10 m from the model.
After a waiting period of at least 10 minutes,
approach the model with suitable protective clothing
(protective goggles!), and close down operation of the
model according to section 6.7.

In all the cases specified here, send hydro-Genius Science Kit in to the manufacturer to be
checked before starting up again.

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hydro-Genius Solar Hydrogen Technology Science Kit

7. Maintenance and Servicing

7.1. Safety Precautions

Make sure that all rubber tubes and cables are correctly fitted after maintenance work.

Follow the security advice in section 2.

7.2. Cleaning

Use only clear water or a special acrylic glass cleaner to clean the components of the Science Kit.
No liquid must be allowed to enter the components.

Be sure to avoid all contact with solvents.

When cleaning, be careful to not damage the components by using too much force.

7.3. Maintenance

Refilling the Electrolyser with distilled water

If the filling level on the oxygen side of the PEM electrolyser falls below the 10 ml mark, it has to be
refilled with distilled water. Proceed as described in section 5.2. If necessary, the filling level on the
hydrogen side must be reduced to the 10 ml mark by pouring out water.

Replacement of the batteries inside the Load Measurement Box

If the numbers on the LCD displays are no longer properly visible, the batteries of the load
measurement box must be replaced.

Proceed as follows: Remove the four screws on the front cover of the housing. Carefully raise the
front cover. Remove the batteries from their compartments.

Place batteries of the same type (9 V energy bar, see section 3.2) into the compartments.

Tighten the four screws to secure the front cover.

Replacement of the battery inside the Stop Watch

If the numbers on the stop watch display are no longer properly visible, the round cell batteries must
be replaced. You will find the battery compartment on the back of the stop watch.

Open the cover by pushing in the direction indicated by the arrow and remove the round cell
batteries. Insert round cell batteries of the same type (see asection3.2) into the battery
compartment, checking correct polarity. The positive terminal + should be on top.

Dispose your used batteries in an ecologically responsible way.

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hydro-Genius Solar Hydrogen Technology Science Kit

8. Warranty and Complaints

The guarantee period for the hydro-Genius Solar Hydrogen Technology Science Kit is 6 months.

The guarantee period begins on the day of delivery and only covers faults that occur in the context
of proper use through no fault of the operator.

Warranty claims shall be deemed invalid if:

1. the customer caused the damage by maloperation.

2. the equipment has been arbitrarily repaired or manipulated.

3. the customer has neglected his/her duty of supervision, and damage has been caused by third
parties.

Your dealer shall be liable for damage caused during delivery to the customer and shall ensure
replacement in the event of damage.

The customer shall bear the risk and costs in the event of complaint and the return of the Science
Kit for repair, and must ensure proper and safe packaging.

In all cases of questions, please contact your dealer.

Manufacturer:

heliocentris Energiesysteme GmbH, Rudower Chaussee 29,

D-12489 Berlin, Germany
Tel.: +49 30 63 92 63 26
Fax: +49 30 63 92 63 29
e-mail: [email protected]

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 Operating Instructions

Solar Hydrogen Technology

Science Kit

heliocentris Energiesysteme GmbH, Rudower Chaussee 29, D-12489 Berlin, Germany


hydro-Genius Solar Hydrogen Technology Science Kit

Operating Instructions Solar Hydrogen Technology Science Kit

October 99 model or later.
st
1 edition, 1 October 1999

heliocentris Energiesysteme GmbH, Rudower Chaussee 29, D-12489 Berlin, Germany

All rights reserved. These operating instructions and each separate part thereof are
protected by copyright. All exploitation, duplication or photocopying is prohibited except in cases
permitted by law.

Components of the hydro-Genius Solar Hydrogen Technology Science Kit are protected by patent
applications and/or utility models.

hydro-Genius is a trademark of heliocentris Energiesysteme GmbH, Germany. In some countries it

is a registered trademark.

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hydro-Genius Solar Hydrogen Technology Science Kit

Contents
1. Notes for the User ............................................................................................................. 1

2. Safety................................................................................................................................. 1
2.1. Introduction and Safety Information ...........................................................................1
2.2. Correct Use ................................................................................................................2
2.3. Sources of Danger .....................................................................................................3
2.4. Authorised Operators .................................................................................................4
2.5. Workplace .................................................................................................................. 4
2.6. Protective Equipment .................................................................................................4

3. Technical Information and Data ........................................................................................ 5

3.1. Contents of the package ............................................................................................5
3.2. Necessary Expendables.............................................................................................5
3.3. Available Additional Accessories................................................................................5
3.4. Basic Functions ..........................................................................................................6
3.5. Overview ....................................................................................................................7
3.6. Technical Data .........................................................................................................10

4. Transport and Storage..................................................................................................... 11

5. Installation and Assembly................................................................................................ 11

5.1. Solar Module ............................................................................................................11
5.2. Electrolyser............................................................................................................... 12
5.3. Fuel Cell ................................................................................................................... 13
5.4. Load Measurement Box ...........................................................................................13
5.5 Assembling and Starting up the Solar Hydrogen Plant ............................................13

6. Operation of the hydro-Genius Solar Hydrogen Technology Science Kit ..................... 14
6.1. Using the right Operation Media...............................................................................14
6.2. Operating the Stop Watch........................................................................................15
6.3. Safety Precautions for Operation .............................................................................16
6.4. Recommended Modes of Operation ........................................................................16
6.5. Improper Modes of Operation ..................................................................................17
6.6. Possible Malfunctions...............................................................................................18
6.7. Closing Down Operation ..........................................................................................19
6.8. Closing down operation in an emergency ................................................................19

7. Maintenance and Servicing ............................................................................................. 20

7.1. Safety Precautions ...................................................................................................20
7.2. Cleaning ................................................................................................................... 20
7.3. Maintenance.............................................................................................................20

8. Warranty and Complaints................................................................................................ 21

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hydro-Genius Solar Hydrogen Technology Science Kit

1. Notes for the User

The following symbols are used in the operating instructions to indicate dangers and references:

Dangerous situation
(serious injuries User tips
possible)

Danger from heat No open fire

Danger of explosion Smoking prohibited

Do not touch

2. Safety

2.1. Introduction and Safety Information

hydro-Genius Solar Hydrogen Technology Science Kit is equipped with safety devices.

Nevertheless, improper operation or abuse can lead to dangers for

- the health of the operator
- the unit itself and other items of property.

All persons involved in the setting up, operation and maintenance of the unit must
- read and precisely follow these operating instructions

- be fully trained for/instructed in their work.

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hydro-Genius Solar Hydrogen Technology Science Kit

The following symbols and signal words are used in these operating instructions:

Warning!
Draws attention to a potentially dangerous situation.
Serious injuries can occur if this reference is ignored.

Important!
Draws attention to application tips and other useful pieces of information. This
is not a reference to dangerous situations. A risk of damage to the product or
to the environment might be involved, however.

2.2. Correct Use

hydro-Genius Solar Hydrogen Technology Science Kit is an experimentation and demonstration
model on hydrogen technology and its components. It may only be used for experimentation and
demonstration purposes and must be operated in accordance with these operating instructions.

The enclosed experiment instructions describe in the detail the procedure to be followed in the
experiments and contain additional safety information. They should be treated as part of these
operating instructions.

hydro-Genius Science Kit may not be used for:

1. generating electricity for general use, e.g. for operating electrical devices or equipment,

2. generating hydrogen for any other purposes than those described in the experiment
instructions,

3. storing or collecting more than minimal amounts of hydrogen (approx. 20 ml).

4. The load measurement box must not be used to measure voltage and current with other

than components from the hydro-Genius program, particularly no voltage of more than
3V must be connected to the terminals.

For the experiments use only the components of the Science Kit unless otherwise stated in the
attached experiment descriptions.

Unauthorised modifications or changes to the components are prohibited for safety reasons. The
operating and maintenance conditions laid down in these operating instructions must be observed.

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hydro-Genius Solar Hydrogen Technology Science Kit

2.3. Sources of Danger

Source of danger

Precautions
Possible consequences
Use of hydrogen Avoid handling open fire in the vicinity of the model.

Danger of explosion Smoking is strictly prohibited.

Hot light source

Do not touch the lamp when in operation or immediately

after operation
Danger of burning
Overheating of system Keep the stipulated distance between the lamp and all
surfaces

Under very intense illumination the Touch the solar module only on the sides not exposed
surface of the solar module may to the light source.
become very hot

Remove the light source and wait for the solar module
to cool down before touching it
Danger of skin burns if touched

Using the load measurement box with Never operate the load measurement box with others
foreign components than hydro-Genius components.

The connected voltage must never exceed 3V.

electric shock

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hydro-Genius Solar Hydrogen Technology Science Kit

2.4. Authorised Operators

You may only work with the unit if you

- have read the operating instructions,
- have been instructed on proper handling by the operator,
- have been informed about the potential dangers involved in connection with the
unit.

The hydro-Genius Solar Hydrogen Technology Science Kit may only be used by trained teaching
staff or by pupils and students under the supervision of teaching staff. As the teacher you must
ensure proper handling. You are obliged to draw attention to potential dangers. Before starting an
experiment, hand out the experiment instructions provided in order to prevent pupils and students
from "playing around" with the model.
Take measures to prevent unauthorised persons from installing, using or maintaining the unit. If the

hydro-Genius Solar Hydrogen Technology Science Kit is passed on to a third party, you must also
pass on the operating instructions.

2.5. Workplace

The components of the hydro-Genius Solar Hydrogen Technology Science Kit must be assembled
and operated on an even, horizontal, stable and solid base.

A working height of 75 - 85 cm is recommended for experimentation purposes.

The model needs approx. 1.0 m x 0.5 m of space.

The ambient temperature should be between 10C and 35C. We therefore recommend that you
only operate the model inside the building in order to protect it from the weather.

2.6. Protective Equipment

All people present during experiments must wear protective goggles.

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hydro-Genius Solar Hydrogen Technology Science Kit

3. Technical Information and Data

3.1. Contents of the package

Solar module, mounted in plastic housing

PEM-Electrolyser with storage cylinders, 2 overflow pipe for storage cylinders

PEM Fuel Cell

Load Measurement Box

2 red cables, 2 black cables

2 silicone tubes 4-6 mm, approx. 40 cm length

2 silicone tubes 4-6 mm, approx. 20 cm length

3 Tubing stoppers

Stop watch

1 replacement bulb

Documentation: Operation Instruction

Experiment instructions

Illustrated set-up/packaging instructions

Scale of angles/connection diagram for Load Measurement Box

For transport reasons, heliocentris delivers the hydro-Genius Science Kit in partially dismantled
form. For repacking after operation see the drawing in section 3.5 and inside the box.

3.2. Necessary Expendables

Distilled water.

The load measurement box requires two 9 V 6LR61-batteries as power supply.

The stop watch requires a round cell battery AG 3, LR 41 or L 736 as power supply.

Both batteries are included in the initial delivery

3.3. Available Additional Accessories

Dismountable Fuel Cell Extension Kit (heliocentris order No. 353),

With 2 different oxygen/air inlets and 2 membranes with different catalyst surfaces, plug-in
resistance.
Allows experiments that give a detailed insight into fuel cells process parameters and how they
work.

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hydro-Genius Solar Hydrogen Technology Science Kit

3.4. Basic Functions

This Science Kit is a miniature solar-hydrogen plant which has been specially designed for teaching
purposes. The components are identical to those used in solar-hydrogen off-grid power-supply
plants.

And this is how the hydro-Genius Solar Hydrogen Science Kit works:

1. The solar module converts light into current.

2. This current splits water into hydrogen and oxygen in the electrolyser.

3. The gases may be stored in the storage cylinders of the electrolyser.

4. The hydrogen and oxygen are fed into the fuel cell, where they are converted directly into current.

5. The current drives the electric motor or the bulb.

Solar Module with Solar Cells Electric load

Sun
M

- + Oxygen
Oxygen Hydrogen

+ -

Hydrogen
Electrolyser
Oxygen storage Hydrogen storage
Fuel Cell

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hydro-Genius Solar Hydrogen Technology Science Kit

3.5. Overview

2c
1a
2f

1b 2d

2g

2j
2k
2b
1d 2h

1c
2e
2a

1 Solar Module 2 Electrolyser

1a Housing 2a Electrolysis cell
1b Solar cells 2b Hydrogen storage cylinder
1c Tip jack: positive terminal 2c Hydrogen storage overflow pipe
1d Tip jack: negative terminal 2d Hydrogen gas outlet
2e Oxygen storage cylinder
2f Oxygen storage overflow pipe
2g Oxygen gas outlet
2h Tip jack: positive terminal
2j Tip jack: negative terminal
2k Protective diode

3g

3b 3 Fuel Cell
3f
3a Housing
3b Hydrogen gas inlet
3c Hydrogen gas outlet
3c 3d Oxygen gas inlet
3d
3e Oxygen gas outlet
3f Tip jack: positive terminal
3e 3g Tip jack: negative terminal
3a

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hydro-Genius Solar Hydrogen Technology Science Kit

4 Load Measurement Box

4h 4j 4k

4b 4c 4d 4e 4f 4g 4a
4a ON/OFF switch 4f Tip jack: positive terminal for Voltmeter
4b Ammeter display 4g Tip jack: negative terminal for Voltmeter
4c Tip jack: positive terminal for 4h Rotary switch Resistances/Loads
Load/Am-meter
4d Tip jack: negative terminal for 4j Lamp
Load/Am-meter
4e Voltmeter display 4k Coloured Disk for Motor

Circuit Diagram for Load Measurement Box

   

   
 

 


 
 

 

I


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hydro-Genius Solar Hydrogen Technology Science Kit

Repacking the Science Kit after operation

Fuel cell
Load measure-
ment box Electrolyser Brennstoff-
Stopwatch zelle

Elektrolyseur
Verbraucher-
Messbox 3 red cables
2 black cables
Stoppuhr 3 rote Kabel
2 schwarze
Kabel
Overflow pipes

Solar module
Extension kit
dismantable fuel cell

Solarmodul Ergnzungssatz
zerlegbare
Brennstoffzelle

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hydro-Genius Solar Hydrogen Technology Science Kit

3.6. Technical Data

Solar module
Dimensions (length x width x height) 70 mm x 120 mm x 52 mm
Terminal voltage 3.0 V
Short circuit current 245 mA
Maximum Power Point:
Voltage 2.4 V
Current 200 mA
Power 0.48 Watt
2
Output data under standard conditions (all data at 1000 W/m and 25C)

Electrolyser
Dimensions (length x width x height) 85 mm x 190 mm x 90 mm
Consumption of distilled water 1 ml/10 h at 300 mA electrolysis
current
Amount of water carried from oxygen to 1 ml/ h at 500 mA electrolysis
hydrogen side current
Storage volume of hydrogen and oxygen 10 ml each
Normal/Operating voltage 1.4 1.8 V
Current 0 - 500 mA
Hydrogen production max. 3.5 ml / min

Fuel cell
Dimensions (length x width x height) 85 mm x 70 mm x 70 mm
Voltage 0.4 1.0 V
Current max. 1000 mA
Consumption of hydrogen max 7 ml/ min at 1000 mA
current

Load measurement box

Dimensions (length x width x height) 190 mm x 110 mm x 85 mm
Operation voltage of motor 0.2 3 V
Current drain of motor with coloured disk 10 15 mA
Operating voltage of lamp 0.6 1.5 V
Current drain of lamp 0 80 mA
Operating voltage of display units 9V

Climatic conditions
Ambient temperature 10 - 35 C
Transport and storage temperature 10 - 35 C protect against frost!

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hydro-Genius Solar Hydrogen Technology Science Kit

4. Transport and Storage

The Solar Hydrogen Technology Science Kit is delivered partially dismantled in a plastic storage
container. The container protects the components from damage.

Please contact the manufacturer in the event of any transport damage.

Use only the storage container for transporting the Science Kit. The electrolyser must never be filled
with water during transport.

Protect the storage container against falling, vibrations and the influence of weather.

Store the components in their designated compartments in the original container. The electrolyser
must be emptied of water before storage.

The electrolyser must be refilled with distilled water before the unit is restarted.

5. Installation and Assembly

The hydro-Genius Solar Hydrogen Technology Science Kit is supplied complete with illustrated
assembly instructions for starting up. Please hand these out to the pupils to ensure that they set the
unit up properly.

The following sections contain written assembly instructions.

Some of the experiment instructions contain further of set-up advice. Please follow these
instructions.

5.1. Solar Module

The solar module is set up perpendicular/at right angles to the workplace surface. The light source
should illuminate the solar module perpendicularly.

Enclosed with the Science Kit is a printed scale of angles, which you can use to set up the solar
module at specific angles to the light source.

See experiment instructions for further information.

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hydro-Genius Solar Hydrogen Technology Science Kit

5.2. Electrolyser

Assembling the gas storage cylinders

Insert the overflow pipes (2c and 2f) into the stoppers at the top of the
storage cylinders (2b and 2e) and press them in tightly.

Tip: 0

Moistening the pipe ends with distilled water 4

makes them easier to insert. 6

Push the two 40 cm tubes onto the gas outlets (2d and 2g) of the 10

storage cylinders. These tubes conduct the gases from the electrolyser
to the fuel cell.

Filling with distilled water

Before the Science Kit can be started up, the electrolyser must be filled
with approx. 50 ml of distilled water.

Caution: the PEM electrolyser may only be filled with distilled water. If
you use any other liquids (e.g. containing electrolytes), this could destroy
the electrolyser.

Use a wash bottle to simplify this operation.

Pour distilled water through the bore-holes in

both stoppers.

For normal use in class and for operation up

to a maximum of 1 hour, fill both storage
0

cylinders up to the 0 ml marks (see Fig. a)). 2

4
Since a small amount of water is transported
6

from the oxygen to the hydrogen side during 8

electrolysis (approx. 1 ml/h at an electrolysis 10

current of 500 mA), for longer use

(continuous operation) the two storage
cylinders must be filled to different levels (see
Fig. b)).

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hydro-Genius Solar Hydrogen Technology Science Kit

O2 H2 O2 H2
0 0 0 0

2 2 2 2

4 4 4 4

6 6 6 6

8 8 8 8

10 10 10 10

a) Storage mode b) Continuous operation

5.3. Fuel Cell

The fuel cell is delivered ready assembled.

5.4. Load Measurement Box

The load measurement box is delivered ready assembled.

5.5. Assembling and Starting up the Solar Hydrogen plant

1. Make sure that all components of the Science Kit are standing on a horizontal and stable base.

2. Use laboratory cables ("banana plugs") to make the connection between the power source
(solar module or power-supply unit) and the electrolyser:

Positive terminal of the solar module (1c) to the positive terminal of the electrolyser (2h)
Negative terminal of the solar module (1d) to the negative terminal of the electrolyser (2j)

3. Connect the hydrogen gas outlet (2d) of the electrolyser and the hydrogen gas inlet of the fuel
cell (3b) using one of the enclosed tubes. Repeat for the oxygen side.

4. Illuminate the solar module sufficiently or use the power-supply to set a current of between 150
mA and 350 mA.

5. You should now observe a distinct development of gas in the electrolyser. Oxygen forms in
one of the half-cells, hydrogen in the other.

6. Use laboratory cables ("banana plugs") to make the following connection:

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hydro-Genius Solar Hydrogen Technology Science Kit
Positive terminal of the fuel cell (3f) to the positive terminal of the load measurement box (4c)
Negative terminal of the fuel cell (3g) to the negative terminal of the load measurement box
(4d).

7. Turn the ON/OFF switch of the load measurement box to the ON position. Adjust the rotary
switch (4h) to the MOTOR position.

8. After a maximum of 10 20 minutes the fuel cell should be sufficiently supplied with gas to be
able drive the electric motor.

The hydro-Genius Science Kit is supplied with illustrated assembly instruction to guide you when
starting up the system and making the necessary cable and tubing connections.

The enclosed experiment instructions contain further instructions for experiments using the Science
Kit. Follow these instructions to carry out your experiments safely and reliably.

6. Operation of the hydro-Genius Solar Hydrogen Technology Science Kit

6.1. Using the right Operation Media

The solar module can be operated using various light sources:

1. Sunlight

2. Halogen lamp with reflector, up to 150 watts

3. Filament lamp with reflector, up to 150 watts

The light source must ensure that the surface of the solar cells is evenly illuminated. For safe and
reliable experiments, we recommend the heliocentris 120 W accessory filament lamp.

The electrolyser can be operated with the following power sources:

1. Solar Module: The enclosed solar module is perfectly adjusted to the electrolyser and offers the
greatest operational safety.

2. Power-supply unit: The current must be limited to a maximum of 0.5 amps. Otherwise the
electrolyser will be destroyed.

Caution: The electrolyser current must never exceed 0.5 amps.

Otherwise the electrolyser may be destroyed.

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hydro-Genius Solar Hydrogen Technology Science Kit
Make sure that the power sources are connected correctly, i.e. connect the positive terminal of the
power source to the positive terminal of the electrolyser and the negative terminal of the power
source to the negative terminal of the electrolyser.

The electrolyser is equipped with a protective diode which short-circuits the power source if polarity
is reversed. At currents above 0.5 amps, reversed polarity can lead to the destruction of the
protective diode.

Use only the enclosed electrolyser as the source of hydrogen and oxygen for the fuel cell.

The fuel cell will supply its full output of electrical energy approx. 10 minutes after the electrolyser is
started up.

For further information see the enclosed experiment instructions.

6.2. Operating the Stop Watch

Tear out the white insulation strip before first use of the stop watch.

1. Press the H and M keys simultaneously; the display shows 0:00. An alarm tone also
sounds until you release the keys.

2. Press the S/S key to start the stop watch. Press S/S again to stop.

The stop watch can also be used as timer. It counts down to zero from a preselected time and
sounds an alarm to indicate that the time has expired:

1. Press the H and M keys simultaneously; the display shows 0:00. An alarm tone also
sounds until you release the keys.

2. Press H to set the hours and M to set the minutes.

3. Press S/S to start. The colon starts flashing. The alarm sounds when the preselected time
has expired. Press S/S to stop the alarm.

If the numbers on the display are no longer properly visible, the round cell battery must be replaced.
Proceed according to section 7.3.

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hydro-Genius Solar Hydrogen Technology Science Kit

6.3. Safety Precautions for Operation

1. The teacher is responsible for ensuring that pupils and other persons only operate the model
under supervision and after receiving instruction.

2. When carrying out experiments with the hydro-Genius Solar Hydrogen Technology Science
Kit, be sure to follow the enclosed experiment instructions.

3. If the light source heats up the solar module too much, remove the light source and do not
touch the solar module until it has cooled down sufficiently.

4. If appropriate follow the safety instructions in the operation manual of the light source. It is
especially important to keep the stipulate minimum distance from the lamp.

6.4. Recommended Modes of Operation

Make sure that the electrolyser does not dry out during operation.

Regular operation is good for the fuel cell. If possible, the equipment should be used for several
hours every 3-4 weeks. The more frequently the fuel cell is used, the more efficient it is. The
membrane can dry out if it not used for a long time. The model will then take longer to start up.

In order to ensure that measured data of the fuel cell (e.g. for the characteristic curve) correspond
to the data indicated in the experimental operating instructions, the fuel cell should be in operation
for some time before the measurements are made

The electrolyser allows in principle two different modes of operation:

1. Storage mode

2. Continuous operation

In storage mode make sure that both gas storage cylinders are filled with distilled water up to
exactly the 0 ml mark before the experiment is started.

In continuous operation, the oxygen side should be filled to the 0 ml mark, but the hydrogen side
only to the 10 ml mark, a small measurable volume of water is transported from the oxygen to the
hydrogen side since during electrolysis. When the water-level on the hydrogen side approaches the
0 ml mark, the surplus water must be siphoned out with a pipette or syringe after removing the
stopper. About the same volume must be added on the oxygen side.

For operation using oxygen from the ambient air, disconnect the oxygen tube from the fuel cell.

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hydro-Genius Solar Hydrogen Technology Science Kit

6.5. Improper Modes of Operation

1. The solar module must not be heated above 60C by the radiation/light source.

2. The solar module must not be illuminated with focused (directed) light.

3. Avoid pinching the rubber gas tubing, because this can lead to positive pressure, causing the
rubber tubes to jump off and leading to an acute risk of injury.

4. The gas outlets of the fuel cell and all other tubes may only be sealed when strictly following the
experiment instructions.

5. The gas storage cylinders of the electrolyser must be filled with distilled water at least to the top
of the electrolyser.

6. The maximum operating voltage indicated in section 3.6 must never be exceeded.

7. Do not under any circumstances connect the fuel cell to an external power source (e.g.
laboratory power-supply unit or solar module). A forced current flow from outside can
immediately lead to the destruction of the fuel cell.

8. If other objects than the installed disk are connected to the motor axle on the load
measurement box, heliocentris assumes no liability for any damage thus caused.

9. The bulb of the lamp in the load measurement box must not be operated at voltages exceeding
1.5 V and especially not using the enclosed solar module.

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hydro-Genius Solar Hydrogen Technology Science Kit

6.6. Possible Malfunctions

(Minor faults which you can remedy yourself)

Electrolyser is not producing any gas Is the electric connection between the solar module
and the electrolyser correct (see section 5.5)?

Electrolyser is producing too little gas Illuminate the solar module better with the lamp
(less than one gas bubble every 4 (Caution, danger of burning!)
seconds)

The Ammeter is indicating no current Check that the fuel cell and the electrical load are
connected correctly (see section 5.5)
Is the ON/OFF switch of the load measurement box
set to ON?
Is the rotary switch of the load measurement box set
to one of the positions LAMP, MOTOR, SHORT
CIRCUIT or a resistance smaller than 50 ?
Check that the stoppers at the electrolyser and the
rubber tubes leading to the fuel cell are tight and
impervious
If gas bubbles can be observed in the electrolyser, a
rubber tube to the fuel cell might be leaky.
The fuel cell might have dried up if the Science Kit
has not been in operation for more than 2 months. In
this case, use a wash bottle to introduce a few drops
of distilled water into the oxygen inlet.

Continuous operation may lead to surplus water in

the fuel cell. It can be poured out through the gas
nozzles on request.

All other faults and irregularities can only be remedied by heliocentris.

Please notify your dealer in such an event by telephone or by fax.

Many questions can be clarified by phone. A decision can then be still taken on whether the Science
Kit or individual parts of it need to be sent in for repair.

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hydro-Genius Solar Hydrogen Technology Science Kit

6.7. Closing Down Operation

1. Switch off the light source (if in operation) and allow the light source and the solar module to
cool down sufficiently.

2. Switch the load-measurement box OFF.

3. Remove all cables and tubes.

4. Pour the distilled water out of the electrolyser. To do this you must first disconnect the tubes
from the outlets. You can now pour the water out through the gas outlets.

5. Store all the components in their designated compartments in the storage container. Check the
packaging instruction on the storage container.

6. Store the hydro-Genius Solar Hydrogen Technology Science Kit in a safe place that it is
protected against unauthorised access.

6.8. Closing down operation in an emergency

Proceed as follows in the event of unexpected operating conditions:

Plastic parts deform because the Switch off the lamp.
minimum distance of the lamp has Allow the model to cool down before you or anyone
not been adhered to. else touches it.
Proceed as indicated in section 6.7.

Leaking hydrogen ignites Immediately remove the current-supply cable from

the electrolyser to stop hydrogen production.
Initiate all necessary fire fighting measures.
Immediately ensure that everyone keeps a safety
distance of at least 10 m from the model.
After a waiting period of at least 10 minutes,
approach the model with suitable protective clothing
(protective goggles!), and close down operation of the
model according to section 6.7.

In all the cases specified here, send hydro-Genius Science Kit in to the manufacturer to be
checked before starting up again.

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hydro-Genius Solar Hydrogen Technology Science Kit

7. Maintenance and Servicing

7.1. Safety Precautions

Make sure that all rubber tubes and cables are correctly fitted after maintenance work.

Follow the security advice in section 2.

7.2. Cleaning

Use only clear water or a special acrylic glass cleaner to clean the components of the Science Kit.
No liquid must be allowed to enter the components.

Be sure to avoid all contact with solvents.

When cleaning, be careful to not damage the components by using too much force.

7.3. Maintenance

Refilling the Electrolyser with distilled water

If the filling level on the oxygen side of the PEM electrolyser falls below the 10 ml mark, it has to be
refilled with distilled water. Proceed as described in section 5.2. If necessary, the filling level on the
hydrogen side must be reduced to the 10 ml mark by pouring out water.

Replacement of the batteries inside the Load Measurement Box

If the numbers on the LCD displays are no longer properly visible, the batteries of the load
measurement box must be replaced.

Proceed as follows: Remove the four screws on the front cover of the housing. Carefully raise the
front cover. Remove the batteries from their compartments.

Place batteries of the same type (9 V energy bar, see section 3.2) into the compartments.

Tighten the four screws to secure the front cover.

Replacement of the battery inside the Stop Watch

If the numbers on the stop watch display are no longer properly visible, the round cell batteries must
be replaced. You will find the battery compartment on the back of the stop watch.

Open the cover by pushing in the direction indicated by the arrow and remove the round cell
batteries. Insert round cell batteries of the same type (see asection3.2) into the battery
compartment, checking correct polarity. The positive terminal + should be on top.

Dispose your used batteries in an ecologically responsible way.

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hydro-Genius Solar Hydrogen Technology Science Kit

8. Warranty and Complaints

The guarantee period for the hydro-Genius Solar Hydrogen Technology Science Kit is 6 months.

The guarantee period begins on the day of delivery and only covers faults that occur in the context
of proper use through no fault of the operator.

Warranty claims shall be deemed invalid if:

1. the customer caused the damage by maloperation.

2. the equipment has been arbitrarily repaired or manipulated.

3. the customer has neglected his/her duty of supervision, and damage has been caused by third
parties.

Your dealer shall be liable for damage caused during delivery to the customer and shall ensure
replacement in the event of damage.

The customer shall bear the risk and costs in the event of complaint and the return of the Science
Kit for repair, and must ensure proper and safe packaging.

In all cases of questions, please contact your dealer.

Manufacturer:

heliocentris Energiesysteme GmbH, Rudower Chaussee 29,

D-12489 Berlin, Germany
Tel.: +49 30 63 92 63 26
Fax: +49 30 63 92 63 29
e-mail: [email protected]

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