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H-1000XP

1. NOTE Please use bolts provided together with spring washer Do not over tighten The use of wrong screw length will damage the stack 3 Hydrogen supply valve Supply valve controls the H2 input The supply valve will open when the system is operational This valve will act as emergency shut down valve in the case of leakage in excess of 1 hydrogen in air when triggered by the hydrogen sensor Please take note of the label and direction of the gas flow 4 Hydrogen purging valve Purging valve the controller will control the purging time For purging the water and air gas redundant in the fuel cells Please note the label and the direction of the arrow Tube size for hydrogen connector 26 13 5 SCU switch It is to turn the SCU on off For SCU Please refer to Terminology 6 LCD display It displays the system status current voltage temperature etc Please refer to trouble shooting section for more details 7 Hydrogen sensor It triggers at 25 of LFL which is 1 hydrogen concentration Power supply for hydrogen sensor Please attached this wire to your on board battery 12V to power the hydrogen sensor NOTE This sensor has a delayed respond for about 15 seconds 8 Start up battery connector It is the connector which connect startup battery to the controller 14 9 Ambient temperature sensor It senses the ambient temperature The sensor should be place opposite to th
2. User Manual H 1000XP Fuel Cell System Date 2013 08 05 Part Number H 1000XP Version 20130805 Revision History Date Revised by Revision Description 12 13 10 User s Manual draft Rev 0 9 12 24 10 WRP Modified PART LIST Modified GENERAL INFO Rev 0 95 01 13 11 WRP Added TROUBLESHOOTING Modified Ultra Capacitor Bank Modified SYSTEM SET UP Rev 0 96 01 19 11 0 Added note to Stack Holder 2 Added note to Hydrogen Sensor Modified SAFETY Modified SOFTWARE Modified MAINTENANCE 2 3 4 5 Added MAINTENENCE 2 3 4 1 1 Modified SOFTWARE Rev 0 97 02 10 11 02 25 11 Rev 0 99 03 29 11 WRP 1 Added H2 sensor external power EA AN A Rev 0 99 0511 11 WRP 1 Fix mistake of supply purge valve Mal direction arrow l WRP 1 Add note for not too long purge Rev 0 10 05 23 11 line Add warning for not to turn off by error protection Rev 0 11 11 11 11 1 Modify H2 sensor related Rev 0 12 05 02 12 Added a blower controller Modified the supply amp purge valves Changed the gas tube Modified the DC DC convertor Rev 0 13 07 12 12 Change the Dimensions value Rev 0 14 03 13 13 1 Change the input amp output valves Rev 0 15 08 05 13 Jason 1 Change the Stack Holder color OVERVIEW OF THE SYSTEM Thank you for choosing our fuel cell stack The Horizon fuel cell stack is an air cooled light weight and compact fuel cell stack H 1
3. 20 Current A Figure 3 4 1 Polarization curve for H 1000XP Power W 02 3 4 2 Stack degradation rate and lifetime There are generally two key life limiting failure modes that will prevent the stack from performing as required in a given application voltage loss and fuel leakage Voltage loss is seen as a steady degradation in maximum power Fuel leakage will lead to both an increase in fuel consumption and H2 emissions in the coolant air exhaust stream Testing has demonstrated that the H 1000XP stack has a mean lifetime of approximately 1000 hours and 300 on off cycles under nominal operating conditions In general to maximize stack life avoid the following conditions e Fuel starvation for example due to low high hydrogen pressure or operating for significant periods of time below optimal ambient temperature e High operating temperatures operating for significant periods of time above optimal ambient temperature e Contaminants in the coolant oxidant air e Contaminants in the fuel e Open storage When the stack is stored over a long period of time in a dry condition in air conditioned room The MEA will be dehydrated and performance of the fuel cell will decrease Please store the stack in an airtight container when not in use 3 4 3 Peak power output The H 1000XP can deliver a peak power output of 1200W to meet the high power requirements during vehicle climbing hills This is realized by connecti
4. Su l gt E ym m TX Pr d l U Bu En I PR PR Y A D m n u Bam T ima su UM ny PA iz PU YN Lam FS AN A y N g a A ia porra as rut la ua fi gt see Y a Ga ra M a Ag y a a ea N DE 1 Vi poise f ava r rv AZ m 7 Aa Y WMA i Q a FP A La WU py AU NU Wa TAJA WW al gf 1 LJ IES ud Us vis i Uy el i A V4 AI WI Y A Z Y w y vV hJ u Goo d I L gt w A ww sf A ra We d ri a y NE y m d gt I a a un Y ws gt Y Y gt L w u zu 5 we E A E y gt Zn sl Zu a e j n a a A PA __ N en ee ug dia ve ee a e Nil de A WA Va QM T h De Y y A i 1AF IN 1 r NN Aa riry 1 Ve Gl f Y 4 A da NO A Q IN A AA WO q AY p Y gi ww Gara ss Ss LJ me 1 io ar TRAD w i al MANS WGA wu uy us amp BLAU WVW wi AI E HUA I BEE LV CIE EN Ww Wi E Ny ww ww UA ww y a ww 4 ae e 30 4 2 Setup controller Step 5 Connect control signal connector to the stack as showed in fig 4 9 Step 6 Connect power cord connector to the stack as showed in fig 4 10 31 Step 7 Connect ultra capacitor connector to the ultra capacitor bank as showed in fig 4 11 A fuse is to be installed on the positive side of the capacitor bank not provided This fuse rating will varies from team to team and must be according the Chapter 1 Shell Eco Marathon Rules Step 8 Connect DC DC connector to the DC DC convertor as showed in fig 4 12
5. on start the fuel cell again Battery voltage is too low Please check if start up battery connector is ok Or 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 3 If the power is lt 12V 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 Stack voltage is too low 1 Please check if supply purge valve is open 2 Please check if the blowers are running slowly or not running at all Hydrogen leaks Please check if the gas line has no leakage including gas tubings and gas connectors etc If the system shuts down by itself check the following details 1 Make sure you have connected all wires according to the diagram 3 Make sure you have connected the hydrogen supply with the correct pressure 4 Make sure the load is below the peak power Overload can trigger the stack protection function to avoid the damage to the stack 5 Check whether the fuel cell temperature is below 68 C the system will shut off if itis above 68 C 52 Check the SCU 1 During operation with the SCU
6. on the voltage of the fuel cell will drop 2 If the fuel cell voltage is not dropping then contact support horizonfuelcell com with the diagnostic SCU not operational with the controller number Check the blower controller Before the load is connected turn on the blower controller Otherwise the load will not run During the operation process do not turn off the blower controller 53
7. 000XP is specially developed for SHELL Eco marathon event please refer to www shell com ecomarathon for more details this system has been designed according to event rules it only needs a start up battery 12V to start the system and will be self sustainable after that some of the features may not be necessary for other applications please contact HORIZON for more details Please read all instructions carefully prior to product use and keep this manual for future reference Further copies can be obtained from Horizon Fuel Cell Technologies or by emailing support horizonfuelcell com Please refer to the Horizon website for latest information www horizonfuelcell com Actions that will void the fuel cell and controller warranty e Do not attempt under any circumstance to disassemble or inappropriately tamper with the fuel cell e Operate the fuel cell with a 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 e Disassemble the fuel cell e Disassemble the controller e Operating the fuel cell and controller that is no that is not in the setup and or specified in the user manual provide for the specific product 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 Disclaimer Information
8. 32 Step 9 Connect hydrogen sensor to the hydrogen sensor connector as showed in fig 4 13 Please note that some application will not require this component and system will still work without this part 33 Step 10 Connect LCD display to the controller LCD connector please note system could run without this part as showed in fig 4 14 Connect the hydrogen sensor to on board battery to power the safety circuit as showed in fig 4 15 34 Step 11 Connect the start up battery not included in the system it could be any DC power source with 12VDC current above 4ampere First connect the cable to the start up battery Then plug the cable connector to the controller as showed in fig 4 16 35 Step 12 It is highly recommended to connect rs232 to your computer to record system operation data as showed in fig 4 18 Please refer to the software section for more details Step 13 Please make sure the emergency stop switch is at off position otherwise the system is unable to start 36 Step 13 To turn on Push the button as showed in fig 4 20 To turn off Wheel the button till it is up as showed in fig 4 21 37 Step 14 Connect the load cable to your load it is suggested that please do not turn on the load before system start up A fuse is to be installed on the positive side of the fuel cell terminal This fuse rat
9. Real time Curves a Ambient Temperature Curve b Stack Temperature Curve c Stack Voltage Curve d Stack Current Curve e Stack Power Curve a Battery Voltage Curve 3 History Display a Display Result b Save to File 5 2 Environment Hardware Environment 1 Desktop or Laptop with Serial Port 2 Serial Cable RS232 1 Desktop or Laptop with USB 2 USB To RS232 Cable with driver Software Environment 1 Microsoft Windows XP or above 32bit 5 3 Installation 1 Put the installation CD into the CD ROM drive 2 Run Setup program NOTE Better to install the program on a root directory E g CA 5 4 Usage Open program 1 Find ECO Marathon Monitor in START AIl Programs 2 Click the icon to open Configuration 1 Select I O Port which is to connect to the ECO Marathon system Wo Port Timeouts con ee 10 2 Set Timeout Default is 100s _ 3 Set REC ON OFF whether to record data or not E 4 Set recording Period Default is 1s Figure 5 1 Configuration Run amp Stop 1 After the configuration press the RUN button on the top left corner to run the program Figure 5 2 RUN button 2 Press STOP button on the top right corner to stop the program Figure 5 3 STOP button Monitor Panel 1 Ambient Temperature Stack Temperature Voltage Current Power will display as meter and number on this panel ECOMARATHON Klei
10. and burns with a colorless 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 asphyxia by displacing the oxygen in the air There are no warnings before unconsciousness results When operating the H 1000XP power module in an enclosure e Ensure ventilation slots are clear and unobstructed at all times during operation e Operate within the temperatures limits stated on the H 1000XP system nameplate e Never operate if an alarm condition exists 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 e Do not alter the fitting on a regulator Ask experienced personnel for help e Do not attempt to force gas cylinder threads 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 e Secure a high pressure cylinder to a bench post or fixed object to avoid accidental contact e Avoid unnecessary contact with On Off valves They can easily move to On by accident 1 4 Hydrogen Leakage Hydrogen is colorless odorless and tast
11. beep low System off FC Red Long Stack voltage 3 Starting up Shut down Voltage flashing beep is too low Low Red Lon Hydrogen 4 Starting up off H2 ae Shut down flashing beep leaks Green pa light on System off FC Red Long Stack voltage Running Shut down Voltage flashing beep is too low Low System Red Long Hydrogen 7 Running off H2 Shut down l flashing beep leaks High System l Red Long Stack current Running off Current l l l Shut down High flashing beep is too high i Internal load will Stack switch off until System Red Long Running l temperature stack off T High flashing beep i i is too high temperature is satisfied 51 Rehydrating the fuel cell because the stack cannot reach the rated power 1 Make sure the purging valve is disconnected from the hydrogen outlet connector 2 Add water to fuel cell through the hydrogen inlet connector and keep filling until water starts to come out of the hydrogen outlet valve 3 Immediately use the hydrogen supply valve to connect the hydrogen supply the hydrogen inlet connector Pay attention to the hydrogen supply direction 4 Make sure the hydrogen supply pressure is not gt 0 5bar 5 Open the hydrogen supply Turn on the on off switch for purging the water out of the fuel cell 6 Steps 1 5 should only take 5 10 seconds to do 7 Setup the fuel cell system again for general operation 8 With the SCU switch
12. contained in this data sheet is considered to be accurate and reliable to the best of our knowledge at time of printing However we do not guarantee or warrantee its accuracy reliability or completeness Information may be subjected to revision and edition at our discretion lt is the User s obligation to use the product safely and within the scope advised in this publication Information relates only to the specific product material mentioned and may not be applicable where such product material is used with any other Table of Content 1 0 2 0 3 0 4 0 9 0 6 0 7 0 SO A eu ee 6 O A 12 General informations aces dnde 18 System SC UD gst tates oo eae 27 SI A A 42 MAME Ce ee ee 47 TFOUDIESNOO UA Usario ee ea 50 Terminology PEM fuel cell A PEM Proton Exchange Membrane fuel cell is a device that converts hydrogen and oxygen into water and electricity A fuel cell stack lt includes a plurality of plate like fuel cells arranged along an axis generally parallel to cell thickness with electrically conductive separator plates between each pair of cells 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 A process to humidify the proton exchange membranes for optimal performance Blower Fans attached to fuel cell stack to supply cooling air and process air Pur
13. e blower side of the fuel cell stack As is showed in system set up section 10 DC DC converter The DC DC will regulate the output voltage for the controller lt can step down the stack voltage 27 5V to 48V to 12V for the fuel cell controller and other peripheral parts 11 Ultra capacitor bank It can supply power output during system short circuiting please refer to Short Circuit Unit for more details which could enable system continuous operation without external power supply Rated voltage 50V Capacitance 1 25F If regenerative braking is required please put a bigger ultra capacitor bank to store this energy If a higher capacity ultra capacitor is used you can replace this set of capacitors Please note that the maximum voltage of the fuel cell is 48V so size your ultra capacitors accordingly 12 Blower controller When no load is connected turn off the blower controller to reduce the power consumption of the stack YOUMS 440 UO J10199UU09 zez SH youms dois ou pawg E lt o O O D ee D un O x Q O D O O J01993uU09 AJayeg dn yes Status LED LCD display socket 13 System controller 101934409 90 00 10199UU09 p109 JOMOd 10 99UU09 eubis O1 U0D J10193UUO9 JONDede9 enim 10198UU09 indino wals s It controls the stack and all peripheral parts to perform at its optimal condition It has the following features Control Stack tempe
14. e the hydrogen supply pressure is not gt 0 5bar 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 WARNING Disconnect the hydrogen supply completely if the fuel cell is not in operation for more than 30 mins This is to stop hydrogen gas leaking into the fuel cell and destroying some of the parts WARNING 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 WARNING The stack must be standing on the clear plastic feet WARNING Before the load is connected turn on the blower controller Otherwise the load will not run During the operation process do not turn off the blower controller 49 7 0 TROUBLESHOOTING 7 0 TROUBLESHOOTING LCD LED and Beep of the status during procedures System Procedure LCD LED Beep Reaction Horizon Green Long l Starting up Normal Starting up Fuel Cell flashing beep Battery Red Long 2 Starting up off Battery voltage is too Shut down flashing
15. eless Hydrogen is non toxic but can act as a simple asphyxiated 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 leakage 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 H 1000XP must be operated in a well ventilated area i
16. ging valve Excess water and hydrogen will be dispelled from the fuel cell flow channels via purge valve SCU Short circuit unit the short circuit will be controlled for good performance of the stack Mass flow per minute The amount of hydrogen consumed to run the fuel cell at a certain power HFCT Horizon Fuel Cell Technologies Blower controller When no load is connected turn off the blower controller to reduce the power consumption of the stack 1 0 SAFETY 1 0 SAFETY NOTE 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 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 or hydrogen leak detection e Do not dismantle the H 1000XP 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 colorless odorless and flammable substance It is highly combustible in the presence of oxygen
17. ground of all the equipments 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 H 1000XP 1 9 High Temperature The fuel cell stack is designed to operate above 60 C sometimes At this operating 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 2 0 PART LIST 2 0 PART LIST 1 Stack The H 1000XP fuel cell stack is a cathode cooled proton exchange membrane PEM fuel cell stack designed to provide stable electrical power while operating on air and dry hydrogen With innovative materials the H 1000XP achieved 1000W power output with more efficiency comparing to standard H1000 Tube size for hydrogen connector 26 2 Stack holder It helps to fix the fuel cell stack on the place you want There are 4 in the package As showed on stack picture above each side left or right can place 2
18. ing will varies from team to team and must be according the Chapter 1 Shell Eco Marathon Rules 38 4 3 Ready to start up Step 15 Please find the tube to the Hydrogen supply valve connect it to the regulator Then set the regulator value to operating pressure 0 5bar 15SLPM AS m Viv A MA una Warning RA _ en u os ou on IV al KA QI re tne press Ol WECAEINW Wu i O UI WiO xy a E aa A es Oe ee a ee A u a ee a QIINnNI VV e malin r ninad 4 i Lk AArA MIA Ie h Bi We gt a er Y y Y er Y Ul SA PS y y i LSS I l G TIL U A l w WAI U a i i te ww td a E Ar Tay ii l Ua A dj Ww a l m HE 3 m eu ACrnar IA A Irn MN In LAN Ll y Y TT Kath Af Gay UWIg Y UUI VA EIN BLO ia o Ca w ww PO Ws WECSEE N d Aa Yi A DRA 25 a E ERS WW i Ol QUAY ds a ad ww ww Step 16 Please place the ambient temperature sensor opposite to the blower side of the stack The place where the air comes in 39 Figure 4 29 Figure 4 30 Step 17 Check all the connections first including the gas and the electricity Be sure there is no problem of disconnecting Now it is ready to start the system by long press the button 3 seconds Come to booting up phase system beeps for a short moment flash the blue LED display Horizon Fuel Cell on the LCD Come to running phase the blue LED will light o
19. me Fuel Cell Stack Voltage Fuel Cell Stack Current Fuel Cell Power Fuel Cell Stack Temperature Battery Voltage Data Range Resolution 25 50V 0 3V 0 60A 0 3A 0 1500W 1W 0 70 0 5C 11 14V 0 2V Table 3 5 RS232 data and format Baud rate 9600 9600 9600 9600 9600 1k 1k 1k 1k 1k Frequency Hz 26 4 0 SYSTEM SET UP 4 0 SYSTEM SET UP To operate H 1000XP the following items and resource are needed O 12VDC Start up power source O Hydrogen source operating pressure 0 5bar flow rate 15SL MIN H 1000XP is a self sustainable system once it is started to start up the system a 12V power source is required and it could be a battery current above 4Ampere or a 12VDC power supply with current above 4Ampere please follow the steps carefully to set up the system please DOT NOT feed the system with hydrogen and DO NOT connect power supply to the controller before all parts are properly connected 4 1 Setup gas line to the stack Since H 1000XP stack has two hydrogen inlet port and two outlet port therefore a proper gas line need to be connected to make the system work as designed please DO NOT mismatch hydrogen inlet and outlet port which will result in stack under performance and possible damage Please refer to the label on the stack and pay special attention to the arrow on the solenoid valve Step 1 Make gas line for hydrogen inlet connect two tubes 6 prefer each tube length les
20. n Fun Cel Trank Figure 5 4 Monitor panel 4 4 Curves Panel 1 Ambient Temperature Stack Temperature Voltage Current Power Battery Voltage will display as real time curves on this panel Ancient TempermuraT Stark Power W i Battery Voltagei Stack T af erature 2 se Stack Currerigay i Hack Voltageft wir Figure 5 5 Curves panel IE Tan BET History Panel 1 User select the time from the pull down list Emin Figure 5 6 Pull down list 2 Press the DISPLAY RESULT button the history data DISPLAY RESULT DISPLAY RESULT will display in the result records table Figure 5 7 DISPLAY RESULT button 3 Press SAVE TO FILE button the results will save in the data directory as an EXCEL file Figure 5 8 SAVE TO FILE button 45 ae MSPLAY RESULT SAVE TO FILE i Er T SET Ta Zu Hehe IE Melt 11 El A E A e de SS Fr Fe a a wi Ta 29 04 17 13041 a Arte UA A Tie 3331313333313 Figure 5 9 History panel 5 5 Error Information 1 Connection Timeout Error c Phenomenon A dialogue window will pop up as follow TO For is timeout Program will STOU Figure 5 10 Monitor panel d Description ECO Marathon Serial Port Monitor lost connection to the system 6 0 MAINTENANCE 6 0 MAINTENANCE When finished operating the stack we highly suggest that inject pure water into the stack before place it back in the su
21. n 12V on board battery ENT LED Emergency Stop Switch Not provided R5232 A N ES ON OFF Switch Short circult Switch Hydrogen Sensor Solid State Relay Optional u ae he Controller 7 Supply Valve Fa bm E Converter is a rE oa A Ambient det 7110004 y 71 Blower T Sytem Output Connector Start up battery Connector Not provided Figure 3 3 Electric Circuit Diagram for H 1000XP Please refer to section 2 0 for more details of each part 21 3 4 H 1000XP Performance Specifications The H 1000XP can deliver up to 33A of current lts operating voltage ranges from 46V no load to 30V full load The rated operating point of 33A 30V is recommended NOTE All the performances are under lab condition 3 4 1 Nominal Polarization Characteristics Figure 3 4 below shows the polarization curve for a fully conditioned H 1000XP system operating at nominal conditions and system to system variability bands of the fuel cell operating at normal room temperature Nominal operating conditions are as follows e Steady state operation constant voltage mode e Stack oxidant supply 18 24 C 25 35 RH low levels of common urban pollutants such as nitrogen oxides and sculpture oxides e Anode dead ended with adequate purge controlled by HORIZON controller 0 5 bar hydrogen inlet pressure v DO O gt ha Voltage Power gt
22. n the LCD displays E for ambient temperature B for battery voltage T for stack temperature for stack current U for stack voltaae 40 SISTER OFF FOR FOVOLIAGE L H Figure 4 31 4 4 System manual shut off SYSTEM OFF FOR MANUAL TURM OFF Figure 4 32 Step 17 lf the red LED flashing with the beeps the system comes to the error protection Status For example the LCD displays SYSTEM OFF FOR FCVOLTAGE LOW means the stack open circuit voltage is too low and the system will shut off for protection For more please refer to troubleshooting section Step 18 Long press the button 3 seconds System beeps and LCD displays SYSTEM OFF FOR MANUAL TURN OFF WARNING Do not attempt to let outside load run out all the energy from fuel cell or other ways may cause system shut down by error protection if you want to turn off the system 41 5 0 SOFTWARE 5 0 SOFTWARE Introduction ECO Marathon Serial Port Monitor is software which is developed to help user to communicate with ECO Marathon system monitor and record various information including Ambient Temperature Stack Temperature Stack Voltage Stack Current Stack Power Battery Voltage and Stack Status 5 1 Features 1 System Monitoring a Ambient Temperature Monitoring b Stack Temperature Monitoring c Stack Voltage Monitoring d Stack Current Monitoring e Stack Power Monitoring 2
23. n order to inhibit potential hydrogen accumulation WARNING Always operate H 1000XP in a well ventilated area and ensure that ventilation slots are unobstructed 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 a result even small leaks of hydrogen have the potential to burn or explode Leaked hydrogen can concentrate in an enclosed 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 system WARNING Keep all sources of ignition away Smoking is not permitted in the vicinity of the H 1000XP 1 6 Oxygen Depleti
24. ng an ultra capacitor in parallel hybrid configuration Fuel cell also recharges the capacitor when excess power is available during cruise Please refer to section 2 0 for more details of ultra capacitor 23 3 4 4 System hydrogen consumption rate Figure 3 4 4 presents the fuel consumption rate of the H 1000XP system at different power outputs The data is recorded in Nominal operating conditions please refer to 3 4 1 for more details Please NOTE the fuel consumption will also vary with ambient temperature since high ambient temperature will require higher fan power consumption and also it will affect the fuel cell stack performance gt c O BD Q 5 Wn c O O Oo 5 LL v 00 0 Su rT gt lt x 200 400 600 800 1000 1200 System Output Power W Figure 3 4 4 System hydrogen consumption rate 0 0L min 3 59L min 4 19L min 6 07L min 8 71L min 11 69L min 15L min The following formula is used to calculate the system efficiency Energy content of 1 kg hydrogen 120 1 MJ LHV 33 3 kWh gt 1000 2 x 22 4 L mol hydrogen generates 33 3kWh energy gt 1L min hydrogen generate 178 361W power Take 211 5W point for example the hydrogen consumption is 3 59L min Therefore this amount of hydrogen could generate 3 59x178 361 640W power Then the system efficiency is 211 5 640 33 24 3 4 5 Airflow requirements Fuel cell system requires airflow for reaction oxidant as
25. on Oxygen is a colorless odorless 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 asphyxiates Effects of oxygen deficiency may include rapid breathing diminished mental alertness impaired muscular coordination faulty judgment depression of all sensations emotional instability and fatigue As asphyxiation progresses 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 H 1000XP must be operated in a well ventilated area in order to compensate for the oxygen used within the fuel cells WARNING Always operate H 1000XP in a well ventilated area 1 8 Electrical Safety WARNING Avoid contact with an exposed fuel cell stack Electrical shock can cause personal injury or death 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 conductive metallic items when you are close to an exposed fuel cell stack e Minimize static discharge at all times If possible g
26. pplied air tight container to keep the stack from getting too dry Injecting water into the stack 1 Connect a short section of hosing to the gas port marked H2 Input and another one to the H2 Output port 2 Fill a syringe with pure water distilled and connect it to the hose attached to the H2 Input port 3 Inject pure water into the stack until you see water coming out of the hose connected to the H2 Output port Keep the water inside the stack Disconnect the syringe 4 We strongly recommend you connect a small hose to both H2 Input and H2 Output ports If the stack is un used for a long period of time more than 4 weeks Rejuvenate by injecting water into the stack before use 1 Connect a short section of hosing to the gas port marked H2 Input and another one to the H2 Output port 2 Fill a syringe with pure water distilled and connect it to the hose attached to the H2 Input port 3 Inject pure water into the stack until you see water coming out of the hose connected to the H2 Output port Keep the water inside the stack for about 5 minutes Now disconnect the syringe and leave the water in the two hoses 4 Purged the water out of the stack thoroughly before use This is done by connecting the H2 supply to the stack without a load attached and purging the stack thoroughly i e letting hydrogen flow through the stack to remove water and other contaminants Make sur
27. rature Control Stack purge rate Monitoring stack current and voltage Monitoring H2 concentration H2 sensor needed Protect stack from possible failures like stack low voltage over current over temperature Control Hydrogen supply and shut off RS232 Communication with computer 16 Controller Signal Connector from Controller box at the wire side Connector pin Peripherals controlled Wire colors Red 1 amp 2 Stack Temperature Sensor Grey 3 4 Ambient Temperature Sensor Red amp Black 5 6 Blowers Red 5 ve Black 6 ve Black 7 8 Hydrogen Purge Valve Black 7 ve Black 8 ve Yellow 9 amp 10 Hydrogen Supply Valve Yellow 9 ve Yellow 10 ve Blue 11 amp 12 Short Circuit Switch Red amp Black 13 14 N A Black 15 N A Black 16 Blower PWM Table 2 1 Controller Connector 17 3 0 GENERAL INFORMATION 3 0 GENERAL INFORMATION 3 1 lesbi Figure3 1 2 Views and dimensions of controller 3 2 General specification MS Numer orale 0 Weight Reactants Hydrogen and Air Hydrogen consumption 12 5SLPM 1000W or flowrate External temperature 5 35 C Max stack temperature Humidification Self humidified Pig ai 10 95 RH non condensing Monitoring S282 Systemstatus Historicaldata Chart 3 2 General Specification of H 1000XP 3 3 Electric Circuit Diagram Hor
28. round all equipment to your common ground e Minimize 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 H 1000XP generates up to 48 VDC open circuit voltage This voltage decreases as current is drawn from the module This voltage is exposed at 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 minimize this ground all equipment in contact with H 1000XP Never use damaged extension cords Minimize conductivity by avoiding surfaces in contact with water hands and clothes must be dry Do not operate or store H 1000XP in wet or damp conditions 10 WARNING Minimize static discharge Ground all equipment Residual reactants within the H 1000XP can develop a charge in a matter of minutes when turned off A reading of zero volts across the entire power module does not guarantee that all fuel cells are uncharged NOTE The cathode has already been connected to the stack shell The stack cathode should be connected to common
29. s than 50cm to the three way port as showed in fig 4 1 and 4 2 Figure 4 1 Repeat step 1 to make a gas line for hydrogen outlet Figure 4 2 28 Step 2 Please place the stack in vertical like this Then connect the gas line finished in step 1 to stack hydrogen inlet port as showed in fig 4 3 Step 3 Connect the gas line finished in step 1 to stack hydrogen outlet port as showed in fig 4 3 amp 4 4 Step 4 Connect the hydrogen purge valve to the hydrogen outlet gas line please pay attention to the flow direction on the valve body as showed from fig 4 5 to 4 8 29 Supply valve From hydrogen To H1000XP canister Purge valve To atmosphere From H1000XP Figure 4 7 Please keep the hydrogen purge line away from the stack it is recommended that keep the purge line at the stack fan side as the air will blow purged hydrogen away It is Strictly prohibited that leave the purge line Please avoid positioning the purge valve near the air inlet side Always position the purge valve on the blow side of the stack If the purged hydrogen is in contact with the stack the MEA will be damaged permanently Hydrogen supply valve From Purge valve To atmosphere Connect your hydrogen supply to the hydrogen supply valve please DO NOT turn your hydrogen until the system is fully set up Please make sure hydrogen is 0 5bar 15SLPM at no load and during full load A E
30. well as cooling Figure 3 4 5 below shows the estimated airflow requirements of the H 1000XP at different power outputs Slight contaminant level in the operating environment has insignificant effect on the H 1000XP performance over the full product lifetime Exposure to high level of contamination in the operating environment will lead to a drop in performance drop which may or may not be recoverable If the operating environment is expected to be very dusty filter for the oxidant and cooling air may be required 0 035 0 03 0 025 002 0 015 Airflow mis 0 01 0 005 O 200 400 600 200 1000 1200 Power VW Figure 3 4 5 Airflow curve for H 1000XP system 3 4 6 Ambient temperature One factor that affects the H 1000XP performance is ambient temperature Higher temperature leads to the drying up of the proton exchange membranes inside the fuel cell stack reducing proton conductivity and consequently the power output of the fuel cell The H 1000XP can deliver its rated performance when operating at ambient temperature ranging 0 35 C and a relative humidity range of 10 90 At a given environment temperature the H 1000XP performance increases with a higher level of relative humidity 3 5 Control and Communication Communication channel RS232 serial byte format 9600 bps 8 data bits no parity 1 stop bit Little endian format Message frequency 1k Hz Reportable parameters Na

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