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Contents
1. 1 cluster controller 2 interface adapter 3 computer connection 4 tofuel cartridge sensor Automatic P Charging mode Cluster Controller CC1 The cluster controller CC1 provides 3 functions E Interface splitter provide 2 sockets Parallel operation of up to 5 EFOY Pro s E Remote control of one EFOY Pro remote on pin Interface splitter The cluster controller splits the data interface and provides two sockets to connect the interface adapter IA1 and the fuel cartridge sensor FS1 together Parallel operation It is possible to parallel up to 5 EFOY Pro s to provide a higher power output The cluster controller C1 is used to synchronize the units so that they switch on and off together and act like one bigger fuel cell Units running in parallel must all be in the same operating mode For a detailed description please see the cluster controller user manual A P for Parallel will appear in the first line when the unit is operating In parallel 42 7 Data Interface and Accessories Automatic R Charging mode Automatic Ra Charging mode 7 6 Remote control remote on The EFOY Pro can be activated via a switching contact at the CC1 which means that the charging mode can be activated The same function can be activated via the computer interface An R2. National regulations Waterhazard class Water hazard class 1 Assessment by list slightly hazardous for water 16 Other information This information is based on our present knowledge However this shall not constitute a guarantee for any specific product features and shall not establish a legally valid contractual relationship EU
3. Storage Requirements to be met by storerooms and receptacles Store in a cool location Store only in the original receptacle Information about storage in one common storage facility Store away from foodstuffs Further information about storage conditions Keep receptacle tightly sealed Store under lock and key and with access restricted to technical experts or their assistants only Store under lock and key and out of the reach of children Protect from heat and direct sunlight 8 Exposure controls personal protection Additional information about design of technical facilities No further data see item 7 Contd on page 3 EU Page 3 5 Safety Data Sheet according to 1907 2006 EC Article 31 Printing date 15 11 2007 Revision 15 11 2007 Trade name METHANOL Contd of page 2 Ingredients with limit values that require monitoring at the workplace 67 56 1 methanol AGW Germany 270 mg m 200 ppm 4 II DFG EU H Y IOELV European Union 260 mg m 200 ppm Skin WEL Great Britain Short term value 333 mg m 250 ppm Long term value 266 mg m 200 ppm Sk Additional information The lists valid during the making were used as basis Personal protective equipment General protective and hygienic measures Keep away from foodstuffs beverages and feed Immediately remove all soiled and contaminated clothing Avoid contact with the eyes and skin Respiratory protection Use sui
4. Off Off or error No error 11 No error 3 Operation Automatic Please change fuel cartridge Automatic Voltage 13 6 V Remote Control The optional remote control displays the current status and is used to control the EFOY Pro Remote control connection Connect the remote control with the included data line DL1 Then insert the plug Into the left socket on the EFOY Pro marked Remote Control If the included data line DL1 Is not long enough you can replace it with a commercially available network cable Cat 5 patch cable 1 Display 2 Information button and language selection button gt gt 3 On Off button 4 Button for automatic operation auto 5 Yellow warning light Please change fuel cartridge 6 Red error warning light 7 Reset button reset The first line indicates the operating mode selected such as Automatic The second line of the display provides information about normal operation errors or malfunctions see Chapter 5 Troubleshooting Press gt gt to obtain the following information E Battery voltage 3 Operation Automatic Current 4 6 A Automatic V03 9 06112V 24V QB Automatic 100200 0808 0002 Operating hours 500 h Automatic Standby Automatic g Charging mode Charging current Please no
5. for remote will appear in the first line when the unit is operating in remote mode You can lock or unlock the unit s software from a remote location by pressing auto and gt gt simultaneously This will deactivate the function and the unit cannot be started by a remote signal If you have locked the software a padlock W will appear in the first line of the display EFOY ProCube The EFOY ProCube is a modular plug amp play solution for outdoor operation of the EFOY Pro The unit includes preinstalled electronics air ventilation and all mounting materials The integrated solar charge controller allows the easy combination with solar panels The EFOY ProCube allows the installation of 1x EFOY Pro 600 1200 1600 1x Fuel cartridge M5 M10 or M28 1x Battery 40 60 or 90 Ah 1x Fuel cartridge sensor FS1 1x GSM modem GSM 2 43 8 Accessories and Spare Parts Category A Use only original equipment Use of unauthorized parts compromise safety and void the warranty Description Item number Fuel cartridges Accessories Spare parts Fuel cartridge M5 2 pieces Fuel cartridge M10 Fuel cartridge M28 M28 adapter Fuel level sensor FS1 Cluster Controller CC1 Interface adapter IA USB adapter GSM modem GSM 2 EFOY ProCube Mounting plate EFOY Pro Fuel cartridge holder with belt FH1 Belt for fuel cartridge holder Remote control with surface mount
6. ENERGY FOR YOU To q yt t at av mit VUUUURETR NEEL ATT WERENT NM WWunnunnus D gt x S 5 a D lt LLLTITITITITTTTN Ty TTY NENUNG MEUANYNUL gt gt mmni VUVUUUALNN NANI TUTTI TTT ETE LUT TT TELE TL gt Operation and Installation Manual 1 Introduction User Manual iF Introduction 1 1 Foreword 1 2 Safety Information 1 3 Normal Operation 1 4 Declaration of Conformity 1 5 Seals of Approval 1 6 Disposal Configuration 2 1 Standard Equipment 2 2 System Overview 2 3 Specifications Operation 3 1 Integrated user interface 3 2 Remote Control 3 3 Select Language 3 4 Remote Control with Computer 3 9 Connecting the Fuel Cartridge 3 6 Automatic Operation 3 7 Switching On manually 3 8 Switching Off manually 3 9 Automatic Antifreeze Feature 3 10 Storage Maintenance 4 1 Service 4 2 Cleaning Troubleshooting 9 1 Safety 9 2 Problems and Solution 9 3 Problems without Error Messages 0 4 Replacing Service Fluid Oo SO OonNN oo fF BK A 3 OD O 12 1 Introduction Installation System integration 6 Installation 6 1 6 2 6 3 6 4 6 9 6 6 6 7 6 8 Installation Space Requirements Mounting of the Fuel Cell Connecting the Off Heat Duct Connecting the Exhaust Hose Installing the Fuel Cartridge Holder Electrical Connection to the Battery Combination with other energy sou
7. Hazard label 3 6 1 Contd on page 5 EU Page 5 5 Safety Data Sheet according to 1907 2006 EC Article 31 Printing date 15 11 2007 Revision 15 11 2007 Trade name METHANOL Contd of page 4 Description of goods 12350 METHANOL Limited quantities LQ LOO Transport category 2 Tunnel restriction code DIE Maritime transport IMDG IMDG Class 3 UN Number 1230 Label 3 6 1 Packaging group IT EMS Number F E S D Proper shipping name METHANOL Air transport ICAO TI and ATA DGR ICAOJIATA Class 3 UND Number 1230 Label 3 6 1 Packaging group IT Proper shipping name METHANOL 15 Regulatory information Labelling according to EU guidelines The product has been classified and marked in accordance with EU Directives Ordinance on Hazardous Materials Code letter and hazard designation of product T Toxic F Highly flammable Risk phrases ll Highly flammable 23 24 25 Toxic by inhalation in contact with skin and if swallowed 39 23 24 25 Toxic danger of very serious irreversible effects through inhalation in contact with skin and if swallowed Safety phrases 1 2 Keep locked up and out of the reach of children 7 Keep container tightly closed 16 Keep away from sources of ignition No smoking 36 37 Wear suitable protective clothing and gloves 45 In case of accident or if you feel unwell seek medical advice immediately show the label where possible
8. in contact with skin and if swallowed 3 Composition Anformation on ingredients Chemical characterization CAS No Description 67 56 1 methanol Identification number s EINECS Number 200 659 6 EU Number 603 001 00 X 4 First aid measures General information Immediately remove any clothing soiled by the product Remove breathing equipment only after contaminated clothing have been completely removed In case of irregular breathing or respiratory arrest provide artificial respiration After inhalation Supply fresh air or oxygen call for doctor In case of unconsciousness place patient stably in side position for transportation After skin contact After contact with skin wash immediately with plenty of soap and water If skin irritation continues consult a doctor After eye contact In case of contact with eyes rinse immediately with plenty of water and seek medical advice After swallowing Fresh air Induce vomiting Make victim drink ethanol e g 1 drinking glass of a 40 alcoholic beverage Call in physician mentioning methanol ingestion EU Contd on page 2 Page 2 5 Safety Data Sheet according to 1907 2006 EC Article 31 Printing date 15 11 2007 Revision 15 11 2007 Trade name METHANOL Contd of page 1 5 Fire fighting measures Suitable extinguishing agents CO2 powder or water spray Fight larger fires with water spray or alcohol resistant foam Special hazards caused by
9. D Connecting the Fuel Cartridge For safety s sake use only original EFOY fuel cartridges Do not smoke while changing the cartridge and avoid open flames Do not expose fuel cartridges to temperatures above 45 C Do not place the fuel cartridge in front of the air intake or outlet Original equipment EFOY fuel cartridges contain EFOY approved methanol Even slight impurities in commercially available methanol may cause permanent damage to the unit and may void the warranty Note When the cartridge is empty Please change fuel cartridge will appear on the remote control and the yellow light at the EFOY Pro and the remote control will blink The cartridge may be changed while the system IS running mM Unscrew the empty fuel cartridge and remove M Close each cartridge tightly with the cap after use m EFOY fuel cartridges are intended for one way use only They may not be refilled E Sort empty fuel cartridges with plastics Dispose of partly filled fuel cartridges in the same manner as solvents or paint 15 3 Operation 1 an 2 ves 3 E t D m Place anew sealed original equipment EFOY fuel cartridge in the system 1 Make sure the cartridge is fixed properly for mobile applications 2 Only remove the childproof cap when the new fuel cartridge has been placed into the fuel cartridge holder 3 Screw the connector onto the new fuel cart
10. a warm place for approximately 24 hours before operating Please note that the unit s performance may diminish if it freezes repeatedly Running in straight antifreeze mode the unit will consume approximately 10 liters of methanol in the course of a five month Central European winter 19 3 Operation 3 10 Off Antifreeze mode gt gt D Storage E Press on the remote control to switch off the unit m Wait until the unit has shut down and the display has disappeared approx 30 min E Unplug the charging line and the data line for the remote control mM Store the plugs and lines in a cool dry place mM Do not smoke when handling unit and fuel cartridge Keep away from open flame m Unscrew the fuel cartridge and close it with a cap Keep all elements clean mM Keep unit and fuel cartridges even empty or partially empty cartridges away from children Mm Remove the exhaust hose Keep it clean and place a cap over the exhaust outlet mM Remove the off heat tube and the off heat bow If necessary and remove the EFOY Pro from the mounting plate m Store unit in a cool place however the temperature should exceed 1 C because the automatic antifreeze feature will only work if a fuel cartridge is attached along with a sufficiently charged battery See Chapter 3 9 m Use a proper box such as the original carton to ship the unit Use padding to prevent shocks Transport the unit in
11. is low the yellow light will turn on at the EFOY Pro and the message Please refill service fluid will appear at the control panel display There is no need to add service fluid prior to the initial Start up Use EFOY brand service fluid only Switch off the unit before refilling fluid Unplug the charge line Always keep the device s service fluid nozzle clean Use a clean pair of scissors to cut off the tip of the Cap The service fluid bottle is for one time use only Remove the exhaust hose from the device s service fluid nozzle Insert the tip Into nozzle and gently squeeze the entire contents into the nozzle Never refill more than one bottle of Service Fluid at a time Wipe off any spilled service fluid with a cloth Replace the exhaust hose Reconnect the charge line Order a spare bottle service fluid at your local dealer 26 6 Installation 45 C 20 C 6 1 Installation Space Requirements Securely fasten unit and fuel cartridges when using on board motor vehicles Do not operate unit if there is danger of explosion Unit is not watertight Make sure that no water can enter Keep unit and fuel cartridges away from children temperatures in excess of 45 C and direct sunlight Make sure when choosing an installation space that the temperature ranges between 20 C and 45 C The unit requires air from the outside and generates off heat that needs to be conducted t
12. socket on the unit marked Remote Control If the DL 1 data line is not long enough you can replace it with a commercially available network line that is longer or shorter Category 5 patch cable 39 7 Data Interface and Accessories bree g cle nl 1 data line 2 interface adapter 3 PC COM interface 7 2 Data Interface Functionality The EFOY Pro data interface enables the connection of E Computer or Modem with the interface adapter IA1 mM Fuel cartridge sensor FS1 Cluster Controller CC1 Important the data interface cannot be connected directly to a computer the interface adapter is required for this Pin configuration of data Interface Pin 1 Output reserved Pin 2 RS232 RxD Receive Pin 3 RS232 TxD Transmit Pin 4 Ground Pin 9 Battery voltage Pin 6 Input fuel cartridge sensor FS1 Pin 7 Input Remote on contact CC1 Pin 8 Master slave parallel operation control CC1 Computer Interface Adapter With a computer It is possible to communicate with the EFOY Pro via a serial COM interface By using a modem this can also be done remotely This enables to check the current system status change parameter or remote control the EFOY Pro For a detailed description please see the computer interface adapter user manual The Interface Adapter IA1 is used to connect the EFOY Pro to a computer COM interface The USB Adapter is use
13. the substance its products of combustion or resulting gases Can form explosive gas air mixtures Formation of toxic gases is possible during heating or in case of fire Protective equipment Wear self contained respiratory protective device Do not inhale explosion gases or combustion gases Additional information Cool endangered receptacles with water spray Dispose of fire debris and contaminated fire fighting water in accordance with official regulations O CATAE KANATLI EA Person related safety precautions Wear protective equipment Keep unprotected persons away Ensure adequate ventilation Keep away from ignition sources Measures for environmental protection Prevent seepage into sewage system workpits and cellars Inform respective authorities in case of seepage into water course or sewage system Measures for cleaning collecting Ensure adequate ventilation Absorb with liquid binding material sand diatomite acid binders universal binders sawdust Dispose of the material collected according to regulations Additional information Fumes can combine with air to form an explosive mixture 7 Handling and storage Handling Information for safe handling Keep receptacles tightly sealed Ensure good interior ventilation especially at floor level Fumes are heavier than air Information about fire and explosion protection Keep ignition sources away Do not smoke Protect against electrostatic charges
14. 0 ft 433 x 188 x 278 mm 17x 8x 11 in Permanent max 35 temporary 10 min max 45 8 4 kg 18 5 lbs Permanent max 20 At the unit or via Remote Control with text display RJ 45 plug for accessories e g Interface adapter MNL plug 4 pins e g Tyco Electronics Universal Mate N Lok Nr 350779 Depends on battery type and application bigger batteries possible if charging current sufficient e g solar battery Factory Setting can be modified with Interface Adapter and PC Effective consumption depends on operating conditions Fuel Cartridges M5 M10 M28 requires M28 adapter Volume 5 1 32 gallons 10 L 2 64 gallons 28 7 4 gallons Weight 4 3 kg 9 5 lbs 8 4 kg 18 5 lbs 22 kg 48 5 lbs Nominal capacity 5 9 kWh 11 1 kWh 31 1 kWh Dimensions Lx Wx H 190 x 145 x 283 mm 230 x 193 x 318 mm 420 x 280 x 360 mm 10 3 Operation 3 1 Integrated user interface Push button Green LED Yellow LED Red LED BS WN Remote Data Control Interface Le power o The LED s indicate the EFOY Pro system status The push button is used to control the unit Push button action Result Starting state Resulting state Push shortly lt 0 5s Reset On Off or Automatic Automatic Push longer gt 3s Switch On off On or Automatic Off Off On LED state Green LED Yellow LED Red LED On Ready Add service fluid Error Blinking Shutting down Fuel empty Interruption
15. an upright position only 20 4 Maintenance 4 1 4 2 Service Do not open unit Unauthorized tampering may jeopardize safe operation and void any warranty The unit does not contain any components that you can service or repair yourself The unit is maintenance free under normal operating conditions Cleaning Switch off device before cleaning and unplug the battery charging cable The device is not watertight Make sure that moisture cannot get inside Clean only with a soft cloth dampened with a mild detergent Reconnect the battery charging cable after cleaning so that the antifreeze feature remains activated See Chapter 3 9 21 o Troubleshooting 0 1 Safety Do not open unit It contains no components that you can repair yourself Please contact our sales partner where you have bought the product if you are unable to fix a malfunction by using these instructions Manufacturer s address SFC Smart Fuel Cell AG Eugen Sanger Ring 4 D 85649 Brunnthal Nord Phone 49 89 673 5920 Fax 49 89 673 592 369 Email hotline efoy com Web www efoy com 22 o Troubleshooting 5 2 Message Problems and Solution At the EFOY Pro and at the remote control the red and yellow light indicate a system error The remote control additionally shows a detailed error message The messages will assist you in solving the problem quickly and easily Press the reset b
16. and data line Frame for remote control Surface mount for remote control Data line DL1 5 m Exhaust hose EH1 1 5 m Service fluid Charge line CL1 Set incl connecting line battery fuse lines sense and power Connecting line to fuel cell Battery fuse in sense line 2 A BF1 Battery fuse in power line 7 5 A BF2 Extension sense line 8 m 44 150 905 006 190 905 008 150 905 040 151 905 012 151 905 006 151 076 058 151 075 001 151 906 018 151 906 019 153 002 001 151 908 012 150 905 002 150 905 007 151 077 029 151 077 007 151 077 006 151 075 003 150 904 004 151 903 001 151 906 009 151 906 004 151 906 007 151 906 008 151 906 005 8 Accessories and Spare Parts Category Description Item number Extension power line 8m Off heat duct EFOY Pro set incl flange bow tube face plate and screws Off heat flange EFOY Pro Off heat bow External face plate heat duct Off heat tube Screw for fastening off heat flange 4 pcs Packaging EFOY Pro User manual EFOY Pro 45 151 906 006 151 903 021 151 903 020 151 903 014 151 903 013 151 904 001 000 992 629 151 902 015 151 901 070 9 Output characteristic U I and U P characteristic as per CE test EFOY 600 U I and U P Characteristic D ea eit niin Seater kk ee 3 0 25 M p O h MEESE al Current aa Output Current A Output Voltage V EFOY 1200 U I and U P Characteristic Le
17. arging power of 0 0 A is displayed then The second line of the display will indicate charging mode as long as the unit is providing voltage to the electrical system The device goes through a cold start phase of about 20 minutes before reaching Its full rated output If the battery is sufficiently charged and the unit is not providing input the unit will remain in the standby mode Should the device detect a malfunction such as an empty fuel cartridge it will shut down and advise you how to correct the situation Please change fuel cartridge Resume automatic operation using the reset button after the error has been corrected See Chapter 5 17 Operation 3 7 On Charging mode 3 8 Off Shutting down Switching On manually If desired you can switch on the unit manually regard less of the battery voltage The unit will then be in the charging mode This function is only possible when the battery voltage is below 13 2V 26 4 V Press on the control panel once if the unit has been switched off and twice If it is operating In automatic mode The unit will start up regardless of the battery voltage and will continue charging until it reaches the Sswitch off point The device will then switch to automatic mode by itself and will only charge If the battery or the demand for power requires it Switching Off manually Press on the remote control
18. b ice l Output Current A Output Voltage V EFOY 1600 U I and U P Characteristic Output Current A Output Voltage V 46 Output Power W Output Power W Output Power W 10 Material Safety Data Sheet Methanol We deliver methanol in the form of secure and certified fuel cartridges that protect you In normal operation from direct contact with methanol In case of accident or nausea immediately seek medical assistance and present this safety data sheet 47 Page 1 5 Safety Data Sheet according to 1907 2006 EC Article 31 Printing date 15 11 2007 Revision 15 11 2007 1 Identification of the substance preparation and of the company undertaking Product details Trade name METHANOL Application of the substance the preparation Solvents Manufacturer Supplier SFC Smart Fuel Cell AG Eugen Saenger Ring 4 85649 Brunnthal Tel 49 0 89 673 592 0 Fax 49 0 89 673 592 169 Further information obtainable from Safety Department Department issuing MSDS info chemiel de Information in case of emergency Giftnotruf M nchen 49 89 19 240 2 Hazards identification Hazard description T Toxic F Highly flammable Information concerning to particular hazards to man and environment R1l Highly flammable R 235 24 25 Toxic by inhalation in contact with skin and if swallowed R 39 23 24 25 Toxic danger of very serious irreversible effects through inhalation
19. cartridge on tightly Check cartridge hose for kinks Check hose and connection for dirt Please refill service fluid Error 30 31 Add service fluid see Chapter 5 4 Check that exhaust can escape and that ambient temperature is below 45 C Please check battery voltage Error 50 51 52 53 Error 50 Battery voltage is too low sense line Error 51 Battery voltage is too high sense line Error 52 Battery voltage is too low power line Error 53 Battery voltage is too high power line Check connections Check whether the battery Is the proper type Check battery voltage If too low use an external battery charger to recharge Check other charging devices such as generators or regulators for defects Automatic restart Unit is restarting automatically please wait 24 o Troubleshooting 5 3 Cause Problems without Error Messages Please check the following if the device doesn t respond and nothing Is displayed on the remote control If problem recurs please contact the SFC partner where you have bought the product Solution Remote control has no or wrong connection Check remote control connection No battery connected wrong battery or undercharged Check contacts polarity cables and battery fuses Connect a charged battery to start device 29 o Troubleshooting 0 4 Replacing Service Fluid If service fluid
20. d to connect the interface adapter to a computer USB interface if no COM interface is available 40 7 Data Interface and Accessories 7 3 7 4 GSM Modem GSM 2 The optional GSM modem allows to control and configure the EFOY Pro remotely It is recommended to use such a solution if the EFOY Pro is installed remotely Functions Notification if errors occur Notification if fuel cartridge goes low with optional fuel cartridge sensor FS1 E Remote diagnostics E Remote control mM Remote programming For further details see GSM modem user manual Fuel Level Sensor FS1 The EFOY Pro by default does not supervise the fuel cartridge level The EFOY Pro will go in an error as soon as the fuel cartridge is empty The optional fuel cartridge sensor FS1 monitors the level of the fuel cartridge and Indicates if the fuel level drops below the position where the fuel cartridge sensor Is positioned at the fuel cartridge This early warning gives the user time to change the cartridge before it is completely empty and the fuel cell stops This sensor should be combined with a remote management system e g the GSM modem GSM 2 The FS1 is mounted with two screws at the fuel cartridge holder There are two different levels available to mount the FS1 The FS1 sensor is connected to the EFOY Pro data interface 41 7 Data Interface and Accessories 7 9
21. e Sink the screws for the off heat flange into the holes provided Use the bow to conduct warm air to the side If you do not need the off heat bow you can connect the off heat tube directly to the flange Then pass the off heat tube to the exterior You will need an opening with a 100 mm diameter Make sure the off heat tube has no kinks Pass the off heat tube through the opening any excess may be shortened It may be necessary to use an external face plate to protect the outlet Use a suitable sealant to prevent moisture from penetrating Into the body or into the interior 30 6 Installation 6 4 Connecting the Exhaust Hose Within the fuel cell methanol and oxygen are converted into water and carbon dioxide This chemical reaction generates off heat which needs to be conducted together with water vapour and carbon dioxide to the outside Connect the included exhaust hose and conduct the exhaust to the outside Exhaust gasses contain moisture and may exceed 60 C causing scalding Exhaust by products may contain injurious substances Avoid inhaling exhaust directly or for long periods of time It is possible to collect the generated water ina Separate water cartridge But make sure that there is a hose that allows the gasses including the carbon dioxide to evaporate from the water cartridge to the outside mM Remove the cap from the exhaust port Retain the cap for winter storag
22. e or for possible returns m Attach the exhaust hose included to the exhaust port mM Route the hose to the exterior and use a Suitable sealant to seal the opening The hose may be shortened as needed The opening must be10 mm in diameter m Make sure the exhaust hose has no kinks or blockage and that exhaust can escape freely 31 6 Installation Routing the exhaust hose At no time may siphoning occur in the hose Make sure that the hose is neither clogged nor blocked The exhaust hose may not be longer than 50 cm in order to prevent freezing in winter The hose may be up to 150 cm long for summer operation and during transitional seasons Up Down Avoid siphoning 32 6 Installation COOLING AIR WARM AIR wep ft ELECTRICAL CONNECTION Installing the Fuel Cartridge Holder Keep fuel cartridge and all reserve cartridges away from children Keep cartridges away from heat and out of direct sunshine Secure fuel cartridge and all reserve cartridges so that they can not shift Make sure that the fuel cartridge connecting hose is neither crushed nor kinked Do not place fuel cartridges or reserve cartridges in front of the air intake or outlet Do not place objects such as reserve fuel cartridges in front of the air intake or outlet Place fuel cartridges next to or in front of the unit as illustrated Secure the f
23. mm 5 10m 4 mm 10 15 m 6 mm Accessories Extension sense line 8 m Art No 151 906 005 Extension Power line 8 m Art No 151 906 006 Notes mM The EFOY Pro is charging the connected battery and the battery supplies the power for the application m The EFOY Pro can only be used to charge lead batteries which conform to the technical specification see chapter 2 3 mM The EFOY Pro can charge 12 V and 24 V batteries and automatically detects the voltage of the connected battery E The charging parameters for the automatic mode can be adjusted with a standard PC see user manual of computer interface adapter E To protect the battery against deep discharging It Is recommended to install a low voltage load disconnector that disconnects the load from the battery 35 6 Installation Connection diagram EFOY fuel cartridge EFOY Pro Series Battery Load FUSE 2A FUSE 7 5A EFOY Pro Series connecting line to fuel cell extension sense line optional battery fuse 2A battery extension power line optional battery fuse in power line 7 9 A NO OF WN gt 36 6 Installation 6 7 Combination with other energy sources The EFOY Pro can be combined with other energy sources which then load the battery together A widely used combination is together with solar cells In this case it is recommended to adjust the charging parameter of the EFOY Pro so that it only s
24. o the outside Please take this into account when considering possible locations 1 Air intake for installation space 2 Air intake for heat exchange and for stack 3 Off heat from heat exchanger see chapter 6 3 4 Exhaust from stack see chapter 6 4 9 Off heat from installation space 27 6 Installation COOLING AIR _ 40 cm min Me max 70 cm The installation space should have a minimum size of 510 x 350 x 300 mm LxWxH In closed chambers please provide an opening with an opening cross section of at least 10 cm or 40 cm for the air intake at structured openings fine grid narrow gap accordingly more Use the off heat duct to conduct the off heat out of the installation space The air openings of the installation space need to be protected against the penetration of water and particles A forced ventilation of the installation space is required to prevent heat accumulation This can be done with additional openings or an additional temperature controlled ventilator Install only in upright position Make sure that the device does not exceed the maximum inclination Inclination along the direct axis 35 temporary 45 Inclination along the quadrature axis 20 max All electrical connections the fill opening for service fluid and the fuel cartridge should be easily accessible Make sure that the fuel cartridge is located within reach of the connec
25. quipment Do not store unit and fuel cartridges at temperatures above 45 C Do not operate at temperatures above 45 C Keep away from heat and direct sunlight Store the unit where there is no danger of freezing or use the automatic antifreeze feature see Chapter 3 9 Do not smoke when handling the unit or the fuel cartridges Keep away from heat and open flame There is a danger of fire if methanol leaks out i e following an accident or if the unit or the fuel cartridge has been damaged Keep away from open fire and make sure area is well ventilated Small amounts of methanol which may leak out will evaporate without leaving any residue Keep unit and fuel cartridges including empty or partially filled cartridges out of children s reach Operate the unit only in accordance with instructions and keep operating area well ventilated Do not block exhaust Avoid inhaling exhaust fumes directly or for prolonged periods of time 1 Introduction There is no risk of coming into contact with methanol provided that you handle the unit and fuel cartridges in accordance with instructions We are required by law to print the following notice Methanol is toxic if inhaled ingested or if it comes into contact with skin Irreparable damage may occur If inhaled ingested or If it comes into contact with skin In the event of an accident or if nausea occurs consult a physician immediately Be sure to bring the fuel car
26. rces Connecting the Remote Control 7 Data Interface and Accessories 7 1 Ved 7 3 7 4 7 9 7 6 Data Interface Functionality Computer Interface Adapter GSM Modem GSM 2 Fuel Level Sensor FS1 Cluster Controller CC1 EFOY ProCube Appendix 8 Accessories and Spare Parts 9 Output characteristic 10 Material Safety Data Sheet Methanol 27 27 27 29 30 31 33 34 37 38 40 40 40 41 41 42 43 44 44 46 47 I Introduction 1 1 Foreword Thank you for purchasing an EFOY product We hope that you will enjoy your new unit Please read these Instructions first before using and follow the installation instructions Please contact our sales partner where you have bought the product in case you have questions about installation or operation Manufacturers address SFC Smart Fuel Cell AG Eugen Sanger Ring 4 D 85649 Brunnthal Nord Phone 49 89 673 5920 Fax 49 89 673 592 369 Email hotline efoy com web www efoy com UM EN 080904 User Manual EFOY Pro Copyright by SFC Smart Fuel Cell AG 2008 1 Introduction 1 2 Safety Information Read the instructions before operating and keep them nearby Be sure to follow all directions in the manual Do not open unit or fuel cartridges Do not use force to open cartridges and do not refill them Any modifications to the unit may affect safe operation will lead to a loss of license and will void the warranty Use only original EFOY e
27. ridge Press reset jon the control panel to extinguish the yellow warning light and the maintenance message Notes E For mobile applications the fuel cartridge needs to be properly fixed with a fuel cartridge holder E The optional M28 adaptor is required to connect the M28 cartridge to the EFOY Pro Connect the M28 fuel cartridge Connect the EFOY Pro fuel cartridge connector 1 with the M28 adaptor 2 Screw the M28 adaptor 2 onto the M28 fuel cartridge 3 3 Operation 3 6 Automatic Operation A Automatic Charging mode Automatic Start phase Automatic Standby Automatic Please change fuel cartridge Before connecting to the electrical system make sure the unit has been positioned properly and that the electrical system is protected by fuses as described in Chapter 6 6 As soon as you connect the unit to the battery and after every reset the unit will start the automatic operation mode The unit monitors the battery voltage and starts charging as soon as the battery voltage drops bellow a defined threshold It will stop charging as soon as the battery voltage exceeds the defined switch off threshold The thresholds for automatic charging can be modified with a computer see Computer interface user manual Please note that the device interrupts power generation briefly several times an hour during normal operation and a ch
28. ropean Community s 89 336 EWG guidelines for electro magnetic compatibility The following norms apply DIN EN 61000 6 1 DIN EN 61000 6 3 1 Introduction Packaging Fuel Cartridges Old Units 1 6 Seals of Approval These units have been tested in accordance with ECE Regulation No 10 for electro magnetic compatibility Operation in motor vehicles is permitted These units have undergone voluntary testing by TUV SUD for conformity with the basic requirements of IEC 62282 5 and have been awarded the seal of approval for product safety Disposal Packaging protects your unit during shipping All materials used are environmentally compatible and recyclable We recommend saving the packaging for eventual winter storage Danger of Suffocation Keep packaging away from children Plastic wrapping and cartons may cause suffocation Sort empty fuel cartridges with plastics Dispose of partly filled fuel cartridges in the same manner as solvents or paint Old units are still valuable Proper disposal can yield valuable raw materials while protecting the environment Your supplier can advise you about returning old units 2 Configuration 2 1 Standard Equipment The following is included in the standard delivery package EFOY Pro fuel cell Remote control with data line Fuel cartridge holder with belt Mounting plate for EFOY Pro Exhaust hose Charge line Service Fluid User manual 2 2 Sy
29. rticle 31 Printing date 15 11 2007 Revision 15 11 2007 Trade name METHANOL Contd of page 3 10 Stability and reactivity Thermal decomposition conditions to be avoided Protect from heat and direct sunlight Dangerous reactions Forms explosive gas mixture with air Dangerous decomposition products No dangerous products of decomposition if used and stored according to specifications e e e e 11 Toxicological information Acute toxicity LD LC50 values relevant for classification 67 56 1 methanol LD50 13000 mg kg rat Primary irritant effect on the skin No irritant effect on the eye No irritating effect Sensitization No sensitizing effects known e e e 12 Ecological information General notes Water hazard class I German Regulation Assessment by list slightly hazardous for water Do not allow undiluted product or large quantities of it to reach ground water water course or sewage System 13 Disposal considerations Product Recommendation Disposal must be made according to official regulations Uncleaned packaging Recommendation Disposal must be made according to official regulations Recommended cleansing agents Water if necessary together with cleansing agents e e 14 Transport information Land transport ADR RID cross border ADR RID class 3 FT1 Flammable liquids Danger code Kemler 336 UN Number 1230 Packaging group IT
30. stem Overview Charge line connection Remote control connection Data interface Push button LEDs Connection for EH 1 exhaust hose and nozzle for service fluid Fuel cartridge connection Cooling inlet reverse 9 Warm air outlet and connection for off heat duct oor O N CO N 2 Configuration 2 3 Specifications Fuel cells EFOY Pro 600 EFOY Pro 1200 EFOY Pro 1600 Max charging power per day Nominal power Nominal voltage Nominal charging current 12 V 24 V Recommended battery capacity 12 V 24 V Weight Switching threshold for automatic battery charging 12 V 24 V Required start up voltage 12 V 24 V Noise level at 1m 7m Nominal consumption Quiescent current draw Operating temperature Start up temperature Storage temperature Recommended altitude Dimensions Lx Wx H Inclination along the roll axis Inclination along the lateral axis User interface Data interface Electrical interface 600 Wh day 1200 Wh day 1560 Wh day 25 W 50 W 65 W 12V 24V 12V 24V 12V 24V 2 1A 1 05A 4 2A 21A 5 4A 2 7A 10 to 100 Ah 20 to 200 Ah 25 to 250 Ah 5 to 50 Ah 10 to 100 Ah 12 to 120 Ah 7 8 kg 17 2 lbs 8 2 kg 18 1 lbs On lt 12 3 V lt 24 6 V Off gt 14 2 V gt 28 4 V gt 10 5 V gt 21 0 V 39 23 dB A 0 9 L kWh 15 mA 20 C to 45 C 2 F to 113 F 5 C to 45 C 41 F to 113 F 1 C to 45 C 34 F to 113 F Up to 1500 m 492
31. table respiratory protective device in case of insufficient ventilation Protection of hands Protective gloves EN 374 The glove material has to be impermeable and resistant to the product the substance the preparation Due to missing tests no recommendation to the glove material can be given for the product the preparation the chemical mixture Selection of the glove material on consideration of the penetration times rates of diffusion and the degradation Material of gloves The selection of the suitable gloves does not only depend on the material but also on further marks of quality and varies from manufacturer to manufacturer Penetration time of glove material The exact break trough time has to be found out by the manufacturer of the protective gloves and has to be observed Eye protection Tightly sealed goggles Body protection Use protective suit 9 Physical and chemical properties General Information Fluid Colourless Alcohol like Change in condition Melting point Melting range 98 C Boiling point Boiling range 64 C Flash point 11 C Ignition temperature 455 C Danger of explosion Product is not explosive However formation of explosive air vapour mixtures are possible Explosion limits Lower 5 5 Vol Upper 44 Vol Vapour pressure at 20 C 128 hPa Density at 20 C 0 79 g cm Contd on page 4 EU Page 4 5 Safety Data Sheet according to 1907 2006 EC A
32. te that the device interrupts power generation briefly several times an hour during normal operation and a charging power of 0 0 A is displayed then Firmware version Serial number Total operating hours Standard display The standard display will be restored after about 30 seconds Alternatively you can return to the standard display by pressing gt gt again If you have connected the optional cartridge sensor to your unit a fuel cartridge will appear in the display as soon as a predetermined amount is reached Always keep a reserve fuel cartridge at the ready The cartridge need only be changed when the message Please change cartridge appears in the display 13 Operation 3 3 Select Language mM Press gt gt on the control panel for two seconds The control panel will display the language currently selected mM The following languages are available German factory setting Deutsch English French Italian Dutch Spanish E Continue pressing gt gt until the desired language appears E Then hold gt gt 2 more seconds in order to set your language choice 3 4 Remote Control with Computer It is also possible to remote control the EFOY Pro with a computer By using a modem this can also be done remotely he computer interface enables the same functions as the remote control see chapter 7 3 Operation gt gt
33. ting hose 70 cm and that the hose is neither kinked nor crushed 28 Installation 6 2 Mounting of the Fuel Cell Select a suitable location as described in Chapter 6 1 paying attention to the dimensions in Chapter 2 3 1 Secure the mounting plate tightly to the desired location Use proper screws and dowels If necessary so that the mounting plate cannot shake loose In case of an accident 2 Place the unit onto the mounting plate It is possible to mount the unit in 2 possible directions 3 Put the mounting bar at the screws of the mounting plate 4 Move the mounting bar to the fuel cell and then to the right hand side Adjust the mounting bar in this position with the two mounting nuts ua HHHH HHHH HHHH 29 6 Installation 6 3 COOLING AIR 40 cm min COOLING AIR 40 cm min D J eo ta ta Connecting the Off Heat Duct The off heat duct included extracts warm air so that the unit can also be operated in close quarters The off heat of the heat exchanger needs to be conducted to the outside with a 100 mm duct The cross section of the opening should be at least 35 cm at structured openings fine grid narrow gap accordingly more The air intake side should not be guided by a duct to enable forced ventilation within the installation spac
34. to switch off the device The unit will gradually shut down performing various function checks as it does so To protect components the unit must run at least 30 minutes before shutting down If the unit is shut off beforehand it will continue running until 30 minutes have elapsed The message Shutting down will appear in the display Leave the fuel cartridge and the battery connected during this time Please note that the fuel cell will not charge the battery automatically if it is switched off The unit needs to be switched on manually and can only start up if it is connected to an intact battery 3 Operation Off Antifreeze mode 3 9 Automatic Antifreeze Feature This unit features an intelligent antifreeze feature If the temperature drops close to the freezing point then the EFOY Pro starts automatically the charging mode to prevent freezing As soon as the unit has warmed up enough it stops the antifreeze mode The antifreeze mode works also If the unit is switched off If the unit is in antifreeze mode the message Antifreeze mode will appear on the second line The first line will indicate the current operating mode for example Off The antifreeze function works only as long as a fuel cartridge and a sufficiently intact battery are connected Please observe the following maintenance tips for Storage and winter operation If despite precautions the unit does freeze let it thaw in
35. tridge label or these instructions to the consultation A caution concerning methanol can be found in the appendix System exhaust may contain harmful components Avoid inhaling exhaust directly or for prolonged periods of time Use the exhaust hose to conduct exhaust gases to the exterior Improper use or improper connection to other electrical devices may result in damage In addition to these safety instructions please observe the passages in bold type Otherwise you may endanger yourself and others 1 Introduction 1 3 1 4 CE Normal Operation The EFOY Pro fuel cells are automatic charging devices for 12V and 24V lead batteries The unit may be used only to charge lead batteries that conform to the specifications in Chapter 2 3 The unit can be used according the specification in Chapter 2 3 for stationary and mobile operation in vehicles Operate only with original equipment EFOY fuel cartridges The unit is not intended for emergency medical power generation or for powering life sustaining or agricultural devices The parallel operation of units to increase the charging current Is possible The serial operation of units to increase the voltage output is not permitted Do not operate unit if housing is damaged Declaration of Conformity SFC Smart Fuel Cell AG Eugen Saenger Ring 4 85649 Brunnthal Nord declares that the EFOY Pro 600 EFOY Pro 1200 and the EFOY Pro 1600 conform to the Eu
36. uel cartridge holder with four suitable screws and dowels if necessary so that it will not shake loose in the case of an accident 33 6 Installation POWER LEAD Cc GOA C SENSE LEAD 6 6 Electrical Connection to the Battery All work should be carried out by qualified technicians in accordance with technical regulations Improper connections or the use of wrong gauge wires could result in fire All wires must be properly insulated and have adequate voltage rating All connections must be tight The use of uninsulated wires and contacts is not permitted Use the wire harness included to connect the unit The circuit connecting the battery must contain a fuse Check the polarity see illustration before connecting the unit Both sensor and power lines must always be connected Always use separate lines for charging power and for voltage metering sensor to the battery Otherwise the flow of current will cause false readings The charging lines consists of four leads that must be connected to the battery as follows Power lead This lead carries current from the fuel cell to the battery Sense lead This lead measures battery voltage 34 6 Installation To minimize current loss in the leads the following cross section is recommended should the battery charging cable be Insufficient Length m min cross section lt 5m 2 5
37. utton on the control panel AFTER the problem has been solved Solution Check connection or Check battery Check remote control connection proper socket on the EFOY Pro is marked Remote Control Check battery voltage If under 10 5 V use an external battery charger to recharge Interruption Please defrost device slowly Error 40 The unit is frozen Let stand at room temperature for approx 24 hours before operating Interruption Surroundings too warm Error 32 41 Ambient temperature is too high The unit starts again as soon as It has cooled down Please contact service Error 1 10 13 14 15 17 70 73 75 76 80 System periphery error Please contact the SFC partner where you have bought the product If the problem remains after a restart Please check exhaust hose Error 11 18 Stack does not reach expected voltage Check that the exhaust hose has been properly connected and arrange It so that condensation cannot form Check for kinks Clean hose if necessary and keep opening Clear Please change fuel cartridge Error 20 22 Insert a new fuel cartridge as described in Chapter 3 5 Check connection and screw cartridge on tightly Check cartridge hose for kinks Check hose and connection for dirt 23 o Troubleshooting Message Solution Please check fuel cartridge connector Error 72 Check fuel cartridge connection and screw
38. witches on if solar alone can not provide enough energy e g in winter times Connection diagram EFOY fuel cartridge EFOY Pro Series 37 6 Installation Flush mounting 1 2 3 4 remote control opening frame screws Connecting the Remote Control Surface mounting 1 2 3 4 remote control surface mount frame screws The remote control 1 displays the current status and is used to control the device Mount the panel where it is easily accessible Flush mounting If installing the panel flush with the surface of the unit make sure that there is a sufficient opening for the electronic components behind the opening Use templates for drilling and sawing when flush or surface mounting 2 Use a drill to start the opening and then cut out the rest of the opening with a keyhole or compass Saw Connect the remote control with the DL 1 data line included Then secure the control panel 1 with four suitable screws 4 and place the frame 3 over the control panel Surface mounting Secure the surface mount with two screws Connect the remote control with the DL 1 data line included Then secure the control panel 1 with four suitable screws 4 and place the frame 3 over the control panel 38 6 Installation Connect the remote control with the DL data line included Then insert the plug into the left
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