HydraSafe

CELL VOLTAGE MONITORING FOR ELECTROLYZERS

HydraSafe is a cost-effective and efficient solution for
cell voltage monitoring in electrolyzer stacks,
adaptable to individual requirements.

MODULES

TOPOLOGY

CONTACT

HydraSafe

CELL VOLTAGE MONITORING FOR ELECTROLYZERS

HydraSafe is a cost-effective and efficient solution for
cell voltage monitoring in electrolyzer stacks,
adaptable to individual requirements.

MODULES

TOPOLOGY

CONTACT

Transparency at the cell level:
For long-lasting, high-performance electrolyzers

The better an electrolyzer is understood in detail, the more efficiently and reliably it can be operated. Precise single-cell voltage measurement provides the necessary transparency: it shows in real time how each individual cell is actually performing.

HydraSafe delivers exactly this level of visibility, enabling an optimally tuned operating regime, predictable maintenance, and a high degree of operational safety.

Deviating or aging cells reduce efficiency, shorten the lifetime of the electrolyzer stack, and can lead to safety-critical conditions.

Without HydraSafe, these changes remain undetected for a long time!

Five factors for für maximum electrolyzer performance

HydraSafe creates a deeper understanding of the stack during dynamically controlled operation, making electrolysis more efficient, safer, and more predictable in the long term.

Transparency

Insight into every cell – problems become visible before they cause damage.

– Detect cell damage early
– Understand aging behavior
– Manage operations based on real measurement data
– Basis for optimized maintenance strategies

Smart Monitoring

Precise analysis for rapid deviation detection, taking into account current values and dynamic trends

– Statistical cell mean analysis
– Comparison of each cell with the mean
– Automatic detection of deviations

Effizienz

Precise measurement data helps optimize efficiency and reduce operating costs.

– Avoidance of inefficient operating conditions
– Measurements throughout the entire life cycle
– High accuracy even under extreme conditions
– Increased yield through optimally operated cells

Safety

Early warning system + safety-related shutdown for maximum operational protection.

– Detection of critical cell states
– Real-time response to deviations
– Safety-related shutdown (up to SIL2)

Flexibility

Modular design, open interfaces, easy integration.

– Flexible contact solutions
– Open and diverse data interfaces
– Scalable for different stack sizes

HydraSafe is the result of years of experience
in electrolysis and cell voltage measurement

HydraSafe was developed based on the real-world needs of the electrolysis industry.

For over 20 years, we have worked closely with electrolyzer operators, plant integrators, insulation coordinators, and service teams, and we understand the typical challenges of installation, operation, and maintenance.

This expertise shapes all relevant areas of focus:

Modularity

Connectivity

Commissioning

Measurement accuracy

Diagnosis

OVERVIEW

Electrolyzer

CORE (measuring unit)
BASE (connection unit)
GATE (fiber converter)
OBSERVER (evaluation unit)
VISU (Analysesoftware)

— FiberLink (optical fiber)

— CopperLink (CAT5E patch cable)

— Measurement cable (voltage tap)

OVERVIEW

Electrolyzer

CORE (measuring unit)
BASE (connection unit)
GATE (fiber converter)
OBSERVER (evaluation unit)
VISU (Analysesoftware)

— FiberLink (optical fiber)

— CopperLink (CAT5E patch cable)

— Measurement cable (voltage tap)

1 CORE – cell voltage measurement module

The CORE module provides high-precision measurement of cell voltages for up to 16 cells in a compact and installation-friendly design. Thanks to its easy installation, it is suitable for all common installation variants. Each cell is monitored by an LED that immediately signals cable breaks, while status information is accessible in real time. With an extended operating temperature range of up to 100°C, the CORE module offers reliable performance even under demanding conditions.

It is available in two versions: ECONOMY and SAFETY (with functional safety).

1 CORE – cell voltage measurement module

It is available in two versions: ECONOMY and SAFETY (with functional safety).

2 BASE – Connection Unit

The BASE connection unit serves as the central interface between the electrolyzer and the measurement module. It offers flexible installation and housing variants for both cabinet and field mounting. The number of measurement channels can be individually configured to quickly implement customized solutions for specific customer requirements. The proven CopperLink system is used for wiring, ensuring a reliable and fast connection with a CAT5 cable (or higher).

2 BASE – Connection Unit

3 GATE – Fiber converter

The GATE module extends the data connection to a range of up to 2 km and enables the conversion of HydraLink connections from cable to fiber optic. It is compatible with standard fiber optic cables of type OS1/2. This extension opens up various architectural possibilities, from remote evaluation units to complete fiber optic cabling and the grouping of multiple measurement modules. This enables the realization of a flexible and powerful infrastructure for demanding applications.

3 GATE – Fiber converter

4 OBSERVER – Evaluation unit

The OBSERVER is designed for receiving, monitoring, and exporting cell voltages. The monitoring functions are fully configurable, allowing them to be tailored to specific requirements. The OBSERVER supports the most common communication protocols, including ProfiNET (SAFE), Modbus TCP, and OPC UA. Connectivity can be established either wired via CopperLink with CAT5 cables or optically via FiberLink with fiber optics.

It is available in two versions: ECONOMY and SAFETY (with functional safety).

4 OBSERVER – Evaluation unit

It is available in two versions: ECONOMY and SAFETY (with functional safety).

TOPOLOGIE

Short Distance

Classic

High availability

Key advantages of the HydraSafe CVM-System

Flexible Communication Options – Long/Short Distances:

Supports optical or Ethernet connections.
Selectable cable lengths of up to 2.5 km.
SFP modules for maximum flexibility in connectors and fiber types, ensuring seamless integration into Fast Ethernet infrastructures.

Quick and Easy Maintenance:

Measurement modules can be easily replaced during operation.
Simple configuration after replacement.
Optional test module available for safety checks.

High Availability & Safety:

Combining functional safety and high availability for maximum reliability.
Easily implementable redundancy with minimal effort.
Version with explosion protection and SIL 2 planned.

Integration Options:

Supports OPC UA, Profinet, Modbus, and Profisafe for flexible system integration.

Robust & Heat-Resistant:

Designed for extreme temperatures ranging from -20°C to 100°C.

Key advantages of the HydraSafe CVM-System

Flexible Communication Options – Long/Short Distances:

Supports optical or Ethernet connections.
Selectable cable lengths of up to 2.5 km.
SFP modules for maximum flexibility in connectors and fiber types, ensuring seamless integration into Fast Ethernet infrastructures.

Quick and Easy Maintenance: