The HXB-V1 makes hydrogen and oxygen, runs on mains power with high direct current, and circulates a corrosive electrolyte. Three hazards live in one machine, so the safety rules come in three strands.
This chapter covers immediate safety actions only. Diagnosis is in the troubleshooting chapter, and that work happens after the area is secure and only by qualified people.
- HazardsHydrogen · electricity · electrolyte
- PPEDepends on the task
- When to readAll of it, once, before installing
How to read this chapter
First timeThere is no section here to skip. Read it through once before installing, and keep the emergency response section next to the system.
Done this beforeRe-read the signal words and the emergency response. Use the rest when checking against your own site safety rules.
On this pageSignal words
Signal words
This handbook and the manual use the same signal words. They differ in severity, so read them as such.
| Signal word | Meaning |
|---|---|
| DANGER | A situation that will cause serious injury or death if not avoided |
| WARNING | A situation that could cause serious injury or death if not avoided |
| CAUTION | A situation that may cause minor or moderate injury if not avoided |
| NOTICE | Information that is not about personal injury but prevents equipment damage or loss of performance |
Hydrogen
Ventilation and detection
- Operate only in a well-ventilated area, or connect the vents to an engineered exhaust system.
- Do not operate in a sealed or poorly ventilated room.
- HXB-V1 is not certified for explosive atmospheres. Do not install it in an area classified as hazardous (an ATEX or equivalent zone). Place it in a non-hazardous area kept free of explosion risk by ventilation.
- For indoor installation we strongly recommend a hydrogen detection system with an appropriate safety circuit.
Ignition control
- Keep smoking, open flames, welding, grinding and any spark-producing work away from the system and the vent outlets.
- Use electrical equipment suited to the area classification wherever hydrogen may be present.
Checking for leaks
- Use an approved method: a hydrogen detector or leak detection solution.
- Never use an open flame to check for a leak.
Vent lines
- Vent lines must stay open. Do not fit valves or devices that could inadvertently close one.
- Do not restrict the lines or create backpressure.
- Keep them free of obstructions, kinks, debris and trapped liquid.
- Condensate can freeze. Use slope, drain points, insulation or heat tracing as your site conditions require.
- Provide a drain point or water trap at the low point so liquid cannot block the line.
- Route the outlets away from ignition sources and follow local codes and site safety rules.
- Do not place objects in front of the vent outlets.
- If you connect the hydrogen outlet to downstream equipment or storage, provide overpressure protection as the code and your system design require.
Electrical
- Electrical installation must be done by qualified personnel.
- Provide overcurrent protection and a disconnecting device to local code.
- Earth the system and everything connected to it correctly.
- Never connect or disconnect power cables under load.
- Voltage can remain after shutdown because of stored energy. Switch off, isolate, wait for it to discharge, and measure the terminal voltage before handling anything.
- Do not short the terminals with a tool.
- Get the polarity right and make the terminations tight. A loose connection causes overheating and arc faults.
- Keep electrical parts dry and away from electrolyte.
- Do not remove covers while powered. Do not touch terminals, busbars or wiring until power is isolated and verified dead.
Electrolyte
- Handle it according to the SDS and your site procedures.
- Use only KOH-compatible materials: containers, tubing and fittings alike.
- Avoid splashing when filling or draining tanks, hoses or filters.
- For a spill, contain and clean it by your site procedure and dispose of the waste to regulation.
- On contact, flush with water immediately and seek medical attention if needed.
- An eyewash station and a safety shower must be available near where KOH is handled.
PPE
Safety glasses
Sealed goggles
Alkali-resistant gloves
Closed-toe shoes
- Routine operation and monitoring
- Safety glasses, closed-toe shoes and suitable work clothing
- Handling electrolyte
- Splash-proof goggles or a face shield, KOH-resistant gloves, and a chemical apron or lab coat
- Working directly on the stack
- Safety glasses and work gloves, plus whatever the task needs. Near power cables or terminals, add electrical protection
Emergency shutdown and response
The common sequence
For a visible gas or electrolyte leak, an unusual noise, smoke, fire nearby, or visible damage.
- If it is safe to approach, stop the system and leave it off.
- Activate the E-stop if there is one.
- Isolate power at the external mains disconnect.
- Warn people nearby, evacuate anyone not needed, and restrict access to the area.
- Follow the site emergency plan and notify the responsible safety officer.
- Do not resume until qualified personnel have found and corrected the cause.
What each situation adds
- Suspected hydrogen leak
- Do not operate switches or equipment that could spark in that area. Keep ignition sources away and increase ventilation by your site procedure. Do not re-enter until authorised personnel declare it safe.
- Suspected vent blockage or icing
- Keep people away from the discharge point. Do not try to clear the blockage until the piping is fully depressurised and isolated. Only qualified personnel do this work.
- Electrolyte spill or exposure
- Avoid skin and eye contact with the spill. Follow your site spill response. If a person is exposed, rinse with water immediately, follow the first aid in the SDS, and seek medical attention if needed.
What this chapter is based on
- HXB-V1 datasheetPDF · 2.1 MB
- HXB-V1 outline drawingPDF · 1.9 MB
- HXB-V1 user manualOn request
Ask the engineer who built it
If your case is not covered here, send us the operating condition and what you observed. The engineer who designed the system answers directly.