Test Equipment Maintenance Tips

The ion exchange resin cartridge plays a vital role in maintaining high-purity water for electrolyzer operation. As the resin becomes exhausted, conductivity of the circulating water gradually increases, which can affect cell performance and accelerate degradation.

It is recommended to replace the cartridge every six months, or after 2,000 hours of operation, whichever comes first. In addition, if the conductivity reading rises above the baseline level, the cartridge should be replaced immediately, regardless of the elapsed time.

Operators should note that the actual replacement interval depends strongly on the inlet deionized (DI) water quality. Facilities with consistently high-purity feed water may extend cartridge life, while environments with lower-quality inlet water will require more frequent changes. Monitoring conductivity trends on a routine basis is the most reliable way to establish the correct replacement schedule for a given installation.

The cathode separator bottle serves to collect water and hydrogen exiting the cathode side of the electrolyzer. Over time, this bottle may accumulate carbon fiber debris originating from cell hardware, in addition to condensed water carried by the gas stream. If left unattended, these particulates can build up, leading to contamination, reduced gas–liquid separation efficiency, and in some cases flow blockages.

• Inspect the bottle at scheduled intervals for debris accumulation or discoloration.
• Replenish the water level as needed to ensure consistent separation function.
• Empty and clean the bottle thoroughly using DI water and mild detergents, ensuring all carbon fiber debris and residues are removed.

Establishing a routine inspection—such as weekly during continuous operation—will help maintain reliable gas management and minimize the risk of contamination in downstream components.

The liquid circulation pump is tuned to maintain stable flow and pressure conditions across the electrolyzer cell. Different cell hardware designs, however, exhibit varying pressure drop characteristics due to differences in flow fields, gasket compression, and active area.

• Re-calibrate the pump whenever a new cell hardware configuration is installed.
• Use updated pump performance curves to reflect the expected flow and pressure drop.
• Verify calibration by running the system at typical operating conditions and confirming stable readings from pressure and flow sensors.

Proper calibration ensures that the pump delivers the required coolant or water circulation without introducing excessive mechanical or thermal stresses to the system.

Adhering to these preventive maintenance practices will help ensure that electrolyzer test stands operate safely, consistently, and with high data fidelity. Regular replacement of the ion exchange resin cartridge, routine inspection and cleaning of the cathode separator bottle, and recalibration of pumps when changing hardware are straightforward steps that have significant impact on long-term reliability. By institutionalizing these practices into operating procedures, laboratories and industrial users alike can maximize the value of their test stand investments and support the generation of reproducible, high-quality results.