H-1000 Fuel Cell Stack - Horizon Fuel Cell/Brasil H2
Contents
1. 5A 1000 10A STEP10 Connect the Hydrogen supply to the hydrogen supply valve and make sure the closed hydrogen pressure is between 0 45 0 55Bar Warning The tube between the hydrogen pressure regulator and the fuel cell gas input is required to be less than 30cm Make sure the Hydrogen gas to be used is 299 995 purity and the other gas es within the gas supply are not a Sulphic composition or other gases such as CO or CH4 which can all poison the fuel cell reducing its performance dramatically STEP 11 Check the following steps before starting the system 1 The connection between the hydrogen input valve and the hydrogen source The connection between the hydrogen input valve and the stack intput The connection between the stack outoput and the purging valve The output tube of purging valve is kept away from the stack The 8pin plug connection between the stack and the controller The FC connection between the stack and controller The input hydrogen pressure is 0 45 0 55Bar The external battery is providing 12 14V The load is below 1000W E EE The System is now setup and ready to be used H IOOO Fuel Cell Stack User Manual V4 4 19 Horizon Fuel Cell Technologies 6 Notes for the set up Note The pictures below are only for reference The voltage of external power supply is Stack should be placed like this between 12V 14V the current range is2. Horizon Fuel Cell Technologies H IOOO Fuel Cell Stack User Manual Updated 18 May eoll 1000 UM V4 4 EN Horizon Fuel Cell Technologies Disclaimer This manual incorporates safety guidelines and recommendations However it is not intended to cover all situations It is the responsibility of the customer to meet all local safety requirements and to ensure safety during operation maintenance and storage of the H 1000 stack Although all efforts have been made to ensure the accuracy and completeness of the information contained in this document Horizon reserves the right to change the information at any time and assumes no liability for its accuracy Actions that will void the fuel cell and controller warranty Attempt under any circumstance to disassemble or inappropriately tamper with the fuel cell Operate the fuel cell with controller not designed and built by Horizon for the specific fuel cell e Operate the fuel cell with valves and blowers that are not provided by Horizon for the specified fuel cell and controller Disassemble the fuel cell Disassemble the controller Operating the fuel cell and controller that is not in the setup and or specified in the user manual provide for the specific product Operate the fuel cell stack without the controller produced by Horizon or with the controller not produced by Horizon There will be no repair replace or refund should disassembly or
3. _ __ Red 48 amp 8 Temperature Sensor The blower is PWM control so it needs pins 9 amp 10 to give the signal to the control blowers power Blowers signal H IOOO Fuel Cell Stack User Manual V4 4 12 Horizon Fuel Cell Technologies 5 System Set Up N PLEASE READ CAREFULLY BEFORE STARTING WARNINGS 1 The tube between the hydrogen pressure regulator and the fuel cell gas input is required to be less than 30cm The inner diameter of the hydrogen supply tube is required to be more than 3mm The input pressure to the stack is required to be 0 45 0 55Bar 2 Using the fuel cell stack with water inside can irreparably damage it 3 Disconnect the hydrogen supply completely within 5 minutes after the fuel cell stack is shut down Since hydrogen gas can leak into the fuel cell and destroy the stack 4 The stack must be standing on the clear plastic feet 5 Make sure the dry Hydrogen gas to be used must be 299 995 purity 6 Make sure you have purged the water out of the stack thoroughly if you injected water into the stack 7 Do not vibrate the stack when it IS in operation 8 Keep the stack in ventilation when it is in operation 9 The external battery voltage is required to be 12 14V 10 Keep the SCU always on Only when it causes your load operating in difficulty turn off the SCU 11 The tube between stack output and purging valve is required to be less than 20cm The tube connected to the
4. 12V 24V external power supply directly to the 8pin plug connector points for the fans and monitoring the performance of the blowers iv If the blowers are not running or running slowly and the current is very high then contact support horizonfuelcell com with the diagnostic Blower s not operational with the fuel cell number v If the blower s are running fine Check the controller section on Blowers in Trouble Shooting Check the controller 1 Make sure the system is shut down and the hydrogen supply is off a Disconnect the Fuel cell stack from the controller b To check that the controller is operating correctly review the pin connector drawing against the pin connector Using a multimeter you can check the power being supplied to each of the peripherals solenoid valve purging valve blowers of the fuel cell i With the external power supply connected to the controller and the fuel cell not connected to the controller start the system up ii The controller will run through the start up procedure supplying power to the peripherals iii By checking each pair of pins you will get the following power readings Wire colours Connector pin Connected Peripherals Voltage supplied 1 amp 5 Hydrogen purge valve 12V for 3 seconds 2 amp 6 Hydrogen supply valve 12V constant Red 4 amp HB Temperature Sensor DN Red and Black 3 amp 7 Blowers Red ve Black ve after 3 seconds 3V constant
5. conforms to all local regulatory requirements including building codes and recommendations The fuel cell system has built in safeguards and is designed to shut down automatically if any out of range operating condition occurs Possible situations include low cell voltage high current high temperature low fuel pressure e Do not operate the stack on a grade of more than 65 Do not connect or disconnect power cables when the fuel cell stack is energised Do not dismantle the system Contact Horizon if you have any concerns about operation 1 2 Using Hydrogen WARNING FIRE OR EXPLOSION Keep all sources of ignition away from hydrogen This unit uses hydrogen fuel Hydrogen is a colourless odourless and flammable substance It is highly combustible in the presence of oxygen and burns with a colourless flame Leaking gas may be hot and pose a burn danger Stop the flow of gas if you are not in danger and use water to cool the area If fire occurs do not attempt to extinguish flames allow the fire to burn out Prevent overexposure to hydrogen Hydrogen is non toxic but can act as a simple asphyxiant by displacing the oxygen in the air There are no warnings before unconsciousness results When operating the stack in an enclosure e Ensure ventilation slots are clear and unobstructed at all times during operation Operate within the temperatures limits stated in the manual e Never operate if an alarm condition exist
6. curve H1000 H2 flow 400 600 W H1000 H2 flow H1000 P I Curve 1000 P Curve H IOOO Fuel Cell Stack User Manual V4 4 26 Horizon Fuel Cell Technologies 10 Storage and Re Use When finished operating the stack place it in an enclosed area for storage to keep the stack from getting too dry The stack should be stored at room temperature If the stack is un used for a long period of time more than 4 weeks and it s performance goes down 50 to the rated power at 43 2V we recommend do the following steps Note Generally injecting water into the stack it is not recommended Only if the performance of the stack decreases 50 is it recommended to inject water into the stack to activate the stack before operation Rejuvenate by injecting water into the stack 1 Connect a short section of hosing to the gas port marked H2 in 2 Fill a syringe not provided with water distilled or purified Make sure there is no air in the syringe And then connect it to the hose attached to the H2 in port 3 Inject distilled or purified water into the stack until you see water coming out of the H2 out port see picture A below for reference Keep the water inside the stack for about 2 minutes Now disconnect the syringe with the tube and leave the water in the stack 4 Purged the water out of the stack thoroughly before use Connect a short tube to the H2 out port And connect the H2 supply 0 45 0 55Ba
7. iv If any of the pins not supply the voltage then contact support horizonfuelcell com with the diagnostic Controller not operational with the controller number and the voltage readings you are getting from the connector point d To check the Control chip i The system does not need to be started for this ii Connect the multimeter to the fuel cell stack 8 pin connector pins 4 amp 8 iii The resistance should be 10760hms at 20 C 3 80hms for every 1 C of the fuel cell temperature iv If resistance reading is different then contact support horizonfuelcell com with the diagnostic Temperature Sensor resistance different with the fuel cell number and the resistance readings you are getting from the connector point e Check your external power supply to see how much current is being drawn during the starting time it should be more than 0 6A for 3 seconds H IOOO Fuel Cell Stack User Manual V4 4 31 12 Fuel Cell Drawing Ce Kg Pig 7 Ki d gt Pr Misc K es 39 7 H 1 1000 Fuel Cel A tack User Manual V4 4 1000 Horizon Fuel Cell Technologies 32 Horizon Fuel Cell Technologies 13 FAQ What is the SCU This is the Short Circuit Unit it helps to condition the fuel cell for long term good performance What is the Hydrogen pressure supplied to the fuel cell stack The pressure is required to be 0 45 0 55Bar H IOOO Fuel Cel
8. position Stand on the plastic feet different based on the different stack D SEI fal TL 691 106 The tube is required to be less than 20cm between stack output and purging valve The tube connected to the purging valve output is required to be less than 30cm The inner diameter of the tube is required to be more than 2mm Warning The tube between the hydrogen pressure regulator and the fuel cell gas input is required to be less than 30cm The pressure of the hydrogen is between 0 45 0 55Bar ET 4 5 a TA The load connecter load is connected to the load in the controller Connected the load to FC amp Load in the stack 20 H IOOO Fuel Cell Stack User Manual V4 4 Horizon Fuel Cell Technologies The outlet of the purge valve should be far away from the stack Don let the hydrogen from purge valve back to the stack otherwise it would damage the stack Note The tube between stack output and purging valve is required to be less than 20cm The tube connected to the purging valve output is required to be less than 30cm The inner diameter of the tube is required to be more than 2mm Fuel Cell Stack User Manual V4 4 21 Horizon Fuel Cell Technologies 7 System setup diagram Blower H2 supply valve From H2 JA To fuel supply SE cell H2 IN T sensor Purging valve 13V DC gng power supply From fuel cell T gt
9. purge H2 OUT H2 u IK Fuel cell FC controller Load Load Load GND SCU Short Circuit Unit GND Grounding H IOOO Fuel Cell Stack User Manual V4 4 22 Horizon Fuel Cell Technologies 8 Operating Procedures STARTUP PROCEDURE Make sure both the stack and the ambient temperature are less than 45 Otherwise the system will not start up successfully Hold the ON OFF button down for 2 seconds to start the system you will hear one beep which means the system has started If at this time the system shuts down in less than 1 second then review the beeping interpretation during starting procedure Once the system has started you will hear a 3 seconds long purge from the purging valve this is the initial hydrogen going through the fuel cell to clear any non Hydrogen gas from the system If you do not hear the hissing from the purge valve review Checking the Valve in Troubleshooting Following the purging the fuel cell will short circuit 5 times over a 10 seconds period If you cannot hear the 5 short circuits review Check the SCU in Troubleshooting H IOOO Fuel Cell Stack User Manual V4 4 23 Horizon Fuel Cell Technologies RUNNING PROCEDURE After system has started depending on your setup and application you can change your load to get the power you need within the specified power range for this fuel cell Don t connect up a load that
10. purging valve output is required to be less than 30cm The inner diameter of the tube 15 required to be more than 2mm Connect the connectors of the controller and the stack to get the blower the temperature sensor the hydrogen supply valve and the purge valve under control The finished connection is shown in 1B H IOOO Fuel Cell Stack User Manual V4 4 13 Horizon Fuel Cell Technologies STEP2 Connect the controller and the stack as the output power also should be under control The finished connection is shown in 2E H IOOO Fuel Cell Stack User Manual V4 4 14 Horizon Fuel Cell Technologies STEP3 Connect the stack to a stabilized voltage supply through the 13V DC connectors and the voltage of the power should be between 12V and 14V STEP4 Keep the SCU Short Circuit Unit switch at for usual use Warning Some home appliances may not be suitable for this activation process It may cause damaging you can shut off the short circuit by switching it to O but it will cause at least 20 performance loss 4A STEPS Connect the output of the hydrogen supply valve to the stack see the arrow on the valve The hydrogen supply valve will prevent damage from the hydrogen while the stack is off Pay attention to the direction of the connection of the Hydrogen supply valve The finished connection is shown in 5H H IOOO Fuel Cell Stack User Manual V4
11. tampering occur If you have questions or need help with regards to the fuel cell and its technology please contact IMPORTANT In order for the warranty to come into effect the stack must be registered on the Horizon Warranty Page at www horizonfuelcell com warranty htm H IOOO Fuel Cell Stack User Manual V4 4 Horizon Fuel Cell Technologies Table of Contents EE eege 1 DZ EN 6 Stack and System Component 10 4 Technical 42 9 NN 13 6 Notes for the set up 20 T System Setup Diagram 92 8 Operating Procedure 23 PR NENNE 26 10 Storage and Heuse ss 27 11 Troubleshooting amp System 28 12 Fuel Cell Drawing 32 Fe ET 33 H IOOO Fuel Cell Stack User Manual V4 4 Horizon Fuel Cell Technologies 1 Safety Please read all instructions carefully prior to product use and keep this manual for future reference The safety guidelines included here may not cover every situation Use common sense 1 1 General information For this unit to generate electrical power a supply of hydrogen fuel is necessary It is important for any operator to be aware of understand and follow all local safety requirements related to the handling of hydrogen and compressed gases Ensure that your facility
12. 4 15 Horizon Fuel Cell Technologies SF 5H H IOOO Fuel Cell Stack User Manual V4 4 16 Horizon Fuel Cell Technologies STEP6 Connect the stack to the purge valve through the filter for a longer running time and a better performance 6A 6F If not the gas out of stack may have a negative effect on the purge valve after a long time running Connect the output of the purge valve to a place away from the stack in case of the damage caused by the hydrogen leakage 6F Note The tube between stack output and purging valve is required to be less than 20cm The tube connected to the purging valve output is required to be less than 30cm The inner diameter of the tube is required to be more than 2mm H IOOO Fuel Cell Stack User Manual V4 4 17 Horizon Fuel Cell Technologies STEP7 Check all the connection first and connect the load to the system Load is linked to the load at the controller Load links to the FC and load in the stack shown in 7A STEP8 Provide hydrogen and stabilized voltage first and then press the ON OFF switch to start the system H IOOO Fuel Cell Stack User Manual V4 4 18 Horizon Fuel Cell Technologies STEP9 Connect the 13V external power supply to the controller 1 The voltage should be between 12 14V with the current at OO 1 5A 200 300 4 5A 500
13. ad connecter FC connecter D Lable FC E Warning Labels H IOOO Fuel Cell Stack User Manual V4 4 8 Horizon Fuel Cell Technologies Horizon WARNING Disassembly will void warranty eebe NO MTO95437 100 mu gt 891011 I No 009 2010 234567 2 1 Logo LED Product No Label D Connect plug E SCU short circuit units switch ON OFF button G Connect to FC H Connect to FC Connect to Load J Controller power supply DC 13V K Controller power supply DC 13V H IOOO Fuel Cell Stack User Manual V4 4 9 Horizon Fuel Cell Technologies 3 Stack and System Component Information Stack 5 made up of plate like cells with air channels to allow the flow of air across the membrane The membrane facilitates the flow of Hydrogen creating the release of electrons Electrically conductive separator plates between each pair of cells enable the flow of electrons The stack aspect is that they are all placed on top of each other and held together by epoxy endplates 2 H2 Supply Valve and purge It controls the H2 input When the controller turns on also the H2 supply valve does When system turns off it is in the off position for preventing hydrogen leakage Short Circuit Unit The short circuit unit can be turned on or off depending on what application the stack is to be used in It ensures enhanced performance of the fuel cells in applications where the sta
14. age or permeation sites Furthermore hydrogen s small molecule size results in high buoyancy and diffusivity so leaked hydrogen will rise and become diluted quickly Constant exposure to hydrogen causes hydrogen embrittlement in many materials The mechanisms that cause hydrogen embrittlement effects are not well defined Factors known to influence the rate and severity of hydrogen embrittlement include hydrogen concentration hydrogen pressure temperature hydrogen purity type of impurity stress level stress rate metal composition metal tensile strength grain size microstructure and heat treatment history Moisture content in the hydrogen gas may lead to metal embrittlement through the acceleration of the formation of fatigue cracks Hydrogen embrittlement can lead to leakage or catastrophic failures in metal and non metallic components As a preventative measure the stack must be operated in a well ventilated area in order to inhibit potential hydrogen accumulation WARNING Always operate the stack in a well ventilated area and ensure that ventilation slots are unobstructed H IOOO Fuel Cell Stack User Manual V4 4 2 Horizon Fuel Cell Technologies 1 5 Flammability and volatility Hydrogen is flammable over concentrations of 4 75 by volume in air and is explosive over concentrations of 15 59 As result even small leaks of hydrogen have the potential to burn or explode Leaked hydrogen can concentrate in an en
15. ally following this measure the fuel cell voltage If voltage is still 0 the stack has short circuited internally and needs to be changed Contact support horizonfuelcell com with the diagnostic fuel cell internal short circuit with the fuel cell number If voltage is gt 0 then the controller has a problem Contact support horizonfuelcell com with the diagnostic Controller internal short circuit with the controller number Voltage lt 0 6 per cell The fuel cell is dehydrated and needs re hydrating Follow the re hydrating the fuel cell Conditioning the fuel cell steps Voltage gt 0 6 cell The fuel cell itself is therefore fine and the fuel cell controller is reading the voltage wrong O Check the various connection points between the fuel cell stack and the controller are firmly in place Re start the system If the problem continues contact support horizonfuelcell com with the diagnostic controller reading too low voltage with the controller number Checking Valves 1 With the system completely setup Start the system 2 Once the system has started you will hear a 3 seconds long purge from the purging valve this is the initial hydrogen going through the fuel cell to clear any non Hydrogen gas from the system If you do not hear the hissing from the purge valve a Check the supply valve and purge valve are opening this is can be done by i Holding the valves during the starting up and fe
16. ck is turned off for prolonged periods On Off Switch It is the switch of the controller Hold it for 2 seconds for either on or off Blower Supply air to the fuel cells and meanwhile decrease the temperature in the stack H IOOO Fuel Cell Stack User Manual V4 4 10 Horizon Fuel Cell Technologies 6 Controller Connector Connect the stack cables to the lead wires of the T sensor blower purging valve input valve on the controller 7 Controller Controls the stack temperature blowers hydrogen input purging and short circuiting of the stack H2 out amp H2 In connect tube in 10 below H2 OUT connect tube shown in 10 below H2 IN connect tube shown in 10 below 9 Fuel Cell Load Connectors FC is connected to the fuel cell positive pole FC is connected to the fuel cell negative pole 10 Tube for H2 Input amp Output The tube with 6mm outer diameter and 3mm inner diameter is connected to the H2 Inlet and outlet as in 9 above and to the input valve and output valve of the hydrogen source 11 Fittings For connecting the load H IOOO Fuel Cell Stack User Manual V4 4 CH Horizon Fuel Cell Technologies 4 Technical Specification the flow rate may change with the power output system electronics need external power supply The Specification is subject to change without notice Controller connector Wire colours Connector pin l Periferals controlled
17. closed environment thereby increasing the risk of combustion and explosion Hydrogen flames are pale blue and are almost invisible in daylight due to the absence of soot Due to its high buoyancy and diffusivity burning hydrogen rises unlike gasoline which spreads laterally A flammable or explosive hydrogen mixture is easily ignited by a spark or even a hot surface The auto ignition temperature of hydrogen is 500 C 932 F The energy of a hydrogen gas explosion is 2 4 times that of gasoline or methane for an equal volume Hydrogen gas explosions are therefore more destructive and carry further WARNING A mixture of hydrogen and air is potentially flammable and explosive and can be ignited by a spark or a hot surface As in the presence of any fuel all sources of ignition including smoking are not permitted in the vicinity of the stack WARNING Keep all sources of ignition away Smoking is not permitted in the vicinity of the stack 1 6 Oxygen Depletion Oxygen is a colourless odourless non toxic and tasteless gas Oxygen is essential for life in appropriate concentrations Ambient air contains up to 21 oxygen Oxygen levels below 19 5 are biologically inactive and may act as simple asphyxiants Effects of oxygen deficiency may include rapid breathing diminished mental alertness impaired muscular coordination faulty judgement depression of all sensations emotional instability and fatigue As asphyxiation progre
18. eling the clicking motion inside the valves li Alternatively apply the external power directly to each valve at 12V to feel and hear the clicking of the valves opening iii If either of the valves are not opening then contact support horizonfuelcell com with the diagnostic Supply valve is not opening and or Purge valve is not opening with the fuel cell number G If the valves are opening check before starting the system again a The 8pins plug connector is firmly clicked together b The hydrogen supply 15 open ii Input pressure is 0 45 0 55Bar 4 If both valves open system will follow normal start up procedures 5 If either of the valves still don t open Check the controller section on Valves in Trouble shooting H IOOO Fuel Cell Stack User Manual V4 4 30 Horizon Fuel Cell Technologies Check the Blowers 1 With the system completely setup Start the system 2 Once the system has started after the fuel cell system has been short circuited 5 times as part of the startup procedure the blowers will start to turn pulling air through the fuel cell a If all the blower s are creating non standard noise turning slowly or not turning at all i Check carefully that there are no obstructions in the blower s li Carefully spin the blowers using your finger make sure there is rotation movement without obstructions iii The electrical supply from the controller needs to be checked by applying the
19. em immediately to avoid potential further damage to the fuel cell and contact support horizonfuelcell com If the system shuts down by itself check the following details 1 Make sure you have connected all wires according to the diagram 2 Make sure the external battery is providing 12V 14V 3 Make sure the input hydrogen pressure is 0 45 0 55Bar 4 Make sure the load is below 1000W Overload can trigger the stack protection function to avoid the damage to the stack 5 Check whether the fuel cell temperature is below 65 C the system will shut off if it is above 65 C H IOOO Fuel Cell Stack User Manual V4 4 29 Horizon Fuel Cell Technologies Checking the Fuel Cell System If the fuel shuts down you need to check the voltage of the fuel cell by measuring between the FC and FC connectors on the fuel cell There are 3 possible scenarios Voltage 0 O Check the supply valve and purge are open If not open see Checking Valves in trouble shooting f open check that the wire FC and FC from the fuel cell controller are connected the right way around to the fuel cell FC and FC connectors red red and black black f wiring wrong change it to be correct immediately repetitive attempts at starting the stack with this setup will permanently damage the stack f wiring correct disconnect the FC and FC from the fuel cell controller and start the fuel cell system again it will shutdown automatic
20. l Stack User Manual V4 4 33
21. ng operation If the system shuts down during running procedure review the Bleeping interpretation during running procedure H IOOO Fuel Cell Stack User Manual V4 4 24 Horizon Fuel Cell Technologies SHUTDOWN PROCEDURE To shut down the fuel cell system down please follow these steps Turn off the load Hold the ON OFF button down for 2 seconds to stop the system you will hear one long beep which means the system is shutting down Turn the hydrogen supply off and disconnect the hydrogen supply from the supply valve WARNING Disconnect the hydrogen supply completely within 5 minutes after the fuel cell stack is shut down Since hydrogen gas can leak into the fuel cell and destroy the stack If will not be using the fuel cell please follow these final steps Disconnect the external power supply from the controller Completely disconnect the fuel cell system from the load Completely disconnect the fuel cell system from the controller Let the fuel cell cool down before placing it into an air tight container This will help to maintain its performance particularly during long periods of storage H IOOO Fuel Cell Stack User Manual V4 4 25 Horizon Fuel Cell Technologies 9 Polarization curves Performance characteristics of the stack are presented All performance data is given for baseline operating conditions defined at sea level and room ambient temperature H1000 U I curve 1000 U I
22. or about 2 minutes Now disconnect the syringe with the tube and leave the water in the stack 4 Purged the water out of the stack thoroughly before use Connect a short tube to the H2 out port And connect the H2 supply 0 45 0 55Bar to the stack without a load attached and purge the stack thoroughly i e letting hydrogen flow through the stack to remove water and other contaminants Using the fuel cell stack with water inside can irreparably damage it Please see the pictures at page 27 for reference Make sure the hydrogen supply pressure is 0 45 0 55Bar WARNING 1 Please make sure you have purged the water out of the stack thoroughly before use 2 Using the fuel cell stack with water inside can irreparably damage it H IOOO Fuel Cell Stack User Manual V4 4 28 Horizon Fuel Cell Technologies Automatic Shutdown Bleeping interpretation during starting procedure If the system shuts down before finishing the start up procedure then please refer to the following bleeping interpretation If the system stops during the starting No of Bleeps Interpretation Actions 1 Low fuel cell open voltage protection i e the average cell voltage is lt 0 7V 2 High ambient temperature protection the ambient temperature around the system is gt 45 C 3 Low external power voltage protection i e external power is lt 12V Automatic Shutdown Bleeping interpretation during running procedure If the system shuts down during opera
23. r to the stack without a load attached and purge the stack thoroughly i e letting hydrogen flow through the stack to remove water and other contaminants Using the fuel cell stack with water inside can irreparably damage it Please see picture B below for reference Make sure the hydrogen supply pressure is 0 45 0 55Bar lt gt e WW PRE 0 45 0 55Bar WARNING A B 1 Please make sure you have purged the water out of the stack thoroughly before use if you injected water the stack Using the fuel cell stack with water inside can irreparably damage it 2 The tube between the hydrogen pressure regulator and the fuel cell gas input is required to be less than 30cm 3 Disconnect the hydrogen supply completely within 5 minutes after the fuel cell stack is shut down Since hydrogen gas can leak into the fuel cell and destroy the stack 4 When you turn off the on off switch connected to the control box at the temperature of the fuel cell Stack higher than 45 C the stack will not stop working immediately Only when the stack temperature goes down below 45 C the whole system will stop operation in order to protect the stack So in order to make it work well the fuel cell stack must be maintained lower than 45 C before operate the on off switch 5 The stack must be standing on the clear plastic feet H IOOO Fuel Cell Stack User Manual V4 4 27 Horizon Fuel Cell Technologies 11 Trouble Shooting amp s
24. s Note We highly recommend customer use a hydrogen sensor not provided to detect the hydrogen leakage H IOOO Fuel Cell Stack User Manual V4 4 1 Horizon Fuel Cell Technologies 1 3 Handling Compressed Gas Cylinders WARNING Do not handle compressed hydrogen gas cylinders without training or experience e Use a pressure regulator to control the fuel inlet pressure to the system Do not alter the fitting on a regulator Ask experienced personnel for help e Do not attempt to force gas cylinder threads e Never transport a gas cylinder with regulators attached Ensure cylinder caps are in place Always use a cylinder cart with a safety strap or chain Secure a high pressure cylinder to a bench post or fixed object to avoid accidental contact Avoid unnecessary contact with On Off valves They can easily move to On by accident 1 4 Hydrogen Leakage Hydrogen is colourless odourless and tasteless Hydrogen is non toxic but can act as a simple asphyxiant by displacing the oxygen in the air There are no warning symptoms before unconsciousness results WARNING Inhaling hydrogen can lead to unconsciousness and asphyxiation Hydrogen molecules are smaller than any other gas making hydrogen more difficult to contain It can diffuse through many materials considered airtight Fuel lines non welded connections and non metal seals such as gaskets O rings pipe thread compounds and packings present potential leak
25. sses nausea vomiting prostration and loss of consciousness may result eventually leading to convulsions coma and death At concentrations below 12 immediate unconsciousness may occur with no prior warning symptoms WARNING Lack of oxygen can lead to unconsciousness and asphyxiation As a preventative measure the stack must be operated in a well ventilated area in order to compensate for the oxygen used within the fuel cells WARNING Always operate the stack in a well ventilated area H IOOO Fuel Cell Stack User Manual V4 4 3 Horizon Fuel Cell Technologies 1 7 Electrical Safety WARNING Avoid contact with an exposed fuel cell stack Electrical shock can cause personal injury or death e Do not touch fuel cell plates or any electrical components at any time A running fuel cell stack is a potential electrical hazard that can cause burns or electrical shock e Do not wear metallic jewellery rings bracelets watchbands or necklaces when you are close to an exposed fuel cell stack e Minimise static discharge If possible ground all equipment Minimise conductivity Avoid contact with surfaces that are in contact with water or gases Do not operate or store in wet or damp conditions e Never use damaged extension cords The stack generates up to 72 VDC open circuit voltage This voltage decreases as current is drawn from the stack The stack produces 43 2V at maximum power This voltage is exposed a
26. t the output power connections These low voltages may constitute a shock hazard and can damage electronic components if shorted Therefore do not touch individual fuel cells cell voltage monitoring equipment or electrical components WARNING Do not touch fuel cells cell voltage monitoring equipment or electrical components Electronic components can also be damaged as the result of static discharge To minimise this ground all equipment in contact with the stack Never use damaged extension cords Minimise conductivity by avoiding surfaces in contact with water hands and clothes must be dry Do not operate or store the stack in wet or damp conditions WARNING Minimise static discharge Ground all equipment Residual reactants within the stack can develop a charge in a matter of minutes when turned off A reading of zero volts across the entire stack does not guarantee that all fuel cells are uncharged WARNING Always assume that the fuel cell stack is charged Jewellery Such as rings necklaces bracelets and watches may concentrate an electric current when it comes into contact with charged components or when a shock passes through the human body Accordingly no jewellery should be worn near the stack WARNING Do not wear jewellery near the stack H IOOO Fuel Cell Stack User Manual V4 4 4 Horizon Fuel Cell Technologies 1 8 High Temperature The fuel cell stack is designed to operate at 65 C At this operating
27. temperature the air exhaust stream temperature can reach 55 C and the cooling air stream can reach 17 C above ambient conditions These temperatures are sufficient to cause burns or severe discomfort Accordingly avoid contact with the fuel cell stack or components that convey process or cooling air WARNING Avoid contact with the fuel cell stack or components that convey process or cooling air H 1000 Fuel Cell Stack User Manual V4 4 5 Horizon Fuel Cell Technologies 2 Terminology PEM fuel cell a PEM Proton Exchange Membrane fuel cell is a device that converts hydrogen and oxygen into water and electricity Reactants reactant is a material used to start a chemical reaction In the fuel cell the reactants are air and hydrogen by which the electricity will be generated Humidification humidity that the fuel cells need for running Blower supply air to the fuel cells and meanwhile decrease the temperature in the stack Mass flow per minute the total amount of the hydrogen flow through the fuel cell every minute which the hydrogen supply can be calculated HFCT Horizon Fuel Cell Technologies H IOOO Fuel Cell Stack User Manual V4 4 6 O A Hydrogen Inlet connector B Blower C Hydrogen Outlet connector D Supply valve E Purge valve H IOOO Fuel Cell Stack User Manual V4 4 Horizon Fuel Cell Technologies Horizon Fuel Cell Technologies A Lable FC and Load B FC and Lo
28. tion within the product parameters then please refer to the following bleeping interpretation No of Bleeps Interpretation Action 1 High current protection i e current is too high For H 100 H 300 is gt 12A set by the controller For H 500 H 1000 is gt 30A set by the controller 2 High temperature fuel cell protection i e fuel cell is running gt 65 C 3 Low voltage fuel cell protection i e the average voltage per cell is lt 0 5V Note If one of the above situations occurs the stack will disconnect the load and make an alarm Reduce the demand of the load on the fuel cell The system will re connect the load every 10 seconds If the situation causes the initial disconnection is the same the system will again disconnect the load Potential for fuel cell Fuel cell internal short circuit Yes Controller internal short circuit Yes Controller reading too low voltage No Controller not operational Yes Supply valve not opening No Purge valve is not opening Yes Blower s not operational No High current protection Yes High temperature fuel cell protection Yes Low voltage fuel cell protection Yes High ambient temperature protection Yes Low external power voltage protection No Temperature sensor resistance different Yes Note If the diagnosis refers to a Yes from the above list shut down the syst
29. will demand more power than the fuel cell is rated at This demand of power from the load can permanently damage the fuel cell During the operation monitor the Hydrogen flow and pressure to consistently supply hydrogen at 0 45 0 55Bar Monitor the external battery is providing 12 14V Direct the outlet tubing of the purge valve away the fuel cell Do not let the purged hydrogen go back towards the fuel cell stack it will damage the fuel cell see step 8 in setup Pay attention to the purge take care of the performance during the purge If after each purge the rise of the performance is big it means you need to increase a the pressure of hydrogen a small amount The fuel cell is flooding and so you need to use the pressure to push teh extra water out During the operation you need to keep the SCU ON at it will condition the fuel cell for rated power and keep it conditioned for long performance lifetimes e Short circuit will happen every 10 seconds and last for 100ms everytime the load does not operate well with the short circuit on we recommend that you run the fuel cell for 10 minutes prior to switching the load on e There will be a slight decrease in the power provided to the load with the short circuit off Make sure you the orientation of the fuel cell is kept the same during operation as shown on the fuel cell stack with the sticker This side up Do not move the fuel cell around or shake vigorously duri
30. ystem checks Check the external power supply The battery might not be operating correctly or in the case of a battery may not have any charge left 1 Disconnect the external power source 2 Using a multimeter take a reading of the positive and negative connection points on the external power connectors to the controller d If the power is lt 12V lt 24V in 5000 then the power is not coming through to be able to power the controller blowers and valves 4 Change or recharge your power supply and check the voltage that it meets the fuel cell voltage before connecting it up to the controller Check the SCU 1 During operation with the SCU the voltage of the fuel cell will drop for 100ms every 10 SECS 2 If the fuel cell voltage is not dropping then contact support horizonfuelcell com with the diagnostic SCU not operational with the controller number If the stack is un used for a long period of time more than 4 weeks and performance goes down 50 to the rated power at 43 2V Rejuvenate by injecting water into the stack before use 1 Connect a short section of hosing to the gas port marked H2 in 2 Fill a syringe with water distilled or purified Make sure there is no air in the syringe And then connect it to the hose attached to the H2 in port 3 Inject distilled or purified water into the stack until you see water coming out of the H2 out port Keep the water inside the stack f
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