H-200 Fuel Cell Stack
Contents
1. SHUTDOWN PROCEDURE To shut down the fuel cell system down please follow these steps 1 Turn off the load 2 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 Note 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 3 Turn the hydrogen supply off 4 Disconnect the hydrogen supply tube from the hydrogen inlet as shown in the picture below WARNING Disconnect the hydrogen tube from the hydrogen inlet immediately after the fuel cell stack is shut down Since hydrogen gas can leak into the fuel cell and destroy the stack If the fuel cell is not in use 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 Manual FCS C200 V2 0 EN 24 O Horizon Fuel Cell Tec2. 4 Disconnect the external power source Using a multimeter take a reading of the positive and negative connection points on the external power connectors to the controller If the power is 12V 24V in H 5000 then the power is not coming through to be able to power the controller blowers and valves 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 During operation with the SCU on the voltage of the fuel cell will drop for 100ms every 10 Secs 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 28 8V after 30 minutes operation 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 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 Connect a short tube
3. 10 Fuel Cell Fuel Cell amp Load Connectors FC of the controller is connected to the fuel cell positive pole FC of the controller is connected to the fuel cell negative pole 11 Tube for H2 Input and Output The tube with 6mm outer diameter and 3mm inner diameter is connected to the H2 IN as in 9 above and to the input valve of the hydrogen source H2 output tube with 4mm outer diameter and 2mm inner diameter is connected to the purging valve on one end and the H2 OUT the other ll 4 Technical Specification Cooling A IAir integrated cooling fan The flow rate may change with the power output System electronics need external power supply The Specification is subject to change without notice Manual FCS C200 V2 0 EN D C 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 Disconnect the hydrogen tube from the hydrogen inlet immediately after the fuel cell stack is shut down Since hydrogen gas can leak into the fuel cell and destroy the stack 3 The stack must be standing on the clear plastic feet 4 Make sure the dry Hydrogen gas to be used must be 299 995 purity 5 Make sure you ha
4. you can shut off the short circuit by switching it to O but it will cause at least 20 performance loss 3A STEP 4 Connect the output of the hydrogen supply valve to the stack pay attention to arrow marked on the valve The hydrogen supply valve will prevent damage to the stack 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 4F Manual FCS C200 V2 0 EN 15 O Horizon Fuel Cell Technologies STEP 5 Connect the stack to the purge valve through the filter for a longer runtime and a better performance 5A 5G 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 5C Manual FCS C200 V2 0 EN 16 O Horizon Fuel Cell Technologies metal point output Note 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 required to be more than 2mm Manual FCS C200 V2 0 EN 17 O Horizon Fuel Cell Technologies STEP 6 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 6A 6A
5. STEP 7 Direct the outlet tubing of the purge valve away from the fuel cell Do not let the purged hydrogen go back towards the fuel cell stack this will damage the fuel cell 7A Note The tube is required to be less than 20cm between stack Purged Hydrogen 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 Manual FCS C200 V2 0 EN 18 Horizon Fuel Cell Technologies STEP 8 Connect the controller to a stabilized external power supply through the 13V DC connectors 8A The external power supply is required to be 13V 1V lt 5A STEP 9 Connect the Hydrogen supply to the hydrogen supply valve and make sure the 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 The inner diameter of this tube is required to be more than 3mm The input pressure to the stack is required to be 0 45 0 55Bar Make sure the dry Hydrogen gas to be used is 299 995 purity and no sulphuric composition or other gases such as CO or CH4 and also no pungent odor paint and perfume are allowed around stack They all can poison the fuel cell reducing its performance dramatically STEP 10 Check the following steps before starting the system 1 The connection between the hydrogen input valve and the hydrog
6. 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 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 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 Manual FCS C200 V2 0 EN 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
7. either of the valves are not opening then contact support Qhorizonfuelcell com with the diagnostic Supply valve is not opening and or Purge valve is not opening with the fuel cell number 3 If the valves are opening check before starting the system again a The 8pins plug connector is firmly clicked together b The hydrogen supply i Is open ii Input pressure is 0 45 0 55Bar 4 If both valves open system will follow normal start up procedures o If either of the valves still don t open Check the controller section on Valves in Trouble shooting Manual FCS C200 V2 0 EN 29 O 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 ii 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 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
8. 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 the stack must be operated in a well ventilated area in order to inhibit potential hydrogen accumulation WARNING Always operate the
9. 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 Ensure ventilation slots are clear and unobstructed at all times during operation Operate within the temperatures limits stated in the manual Never operate if an alarm condition exists Note We highly recommend customer use a hydrogen sensor not provided to detect the hydrogen leakage Manual FCS C200 V2 0 EN l 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 e 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 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 colourless odourless and tasteless Hydrogen is non toxic but can act as a simple asphyxiant by displacing the
10. very high then contact support Mhorizonfuelcell 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 L 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 C 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 Red and Black 3 amp Blowers Red ve Black ve after 3 mE 3V constant iv If any of the pins are 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
11. 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 Jg The load connecter load is connected to the load in the controller The load IS connected to FC amp Load in the stack Manual FCS C200 V2 0 EN 21 O Horizon Fuel Cell Technologies 8 Operating Procedures STARTUP PROCEDURE Make sure both the stack and the ambient temperature are less than 45 C 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 on page 28 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 1 minute period Manual FCS C200 V2 0 EN 22 O 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
12. Cy Horizon Fuel Cell Technologies H 200 Fuel Cell Stack User Manual Updated l4 Aug e01l3 Mode No FCS C200 Manual FCS C200 V2 0 EN C 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 200 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 e 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 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 e Operate the fuel cell stack without the controller produced by Horizon or with the controller not produced by Horizon Do not attempt under any circumstance to disa
13. as not been used for more than 2 months the stack power maybe get a little bit down when you use it again We suggest at the beginning not to have full load to the stack try to have half power for the starting And then step by step increase to full load try to increase 5 every 10 minutes After this activation process the stack can reach the rated power within 1 2 hours 5 If the stack has not been used for more than 2 months and your load could be set to constant voltage try to operate the stack under 0 6V cell Under this operation mode the stack can reach the rated performance within 1 2 hours Manual FCS C200 V2 0 EN 32
14. d 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 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 Do not operate the stack on a grade of more than 65 C Do not connect or disconnect power cables when the fuel cell stack is energised e 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
15. discharge If possible ground all equipment e 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 38VDC open circuit voltage This voltage decreases as current is drawn from the stack The stack produces 24V at maximum power 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 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 concent
16. ee 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 as much as possible before use say it is not coming out of the output 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 to purge the stack as much as possible i e letting hydrogen flow through the stack to remove water and other contaminants Using the fuel cell stack with too much water inside can irreparably damage it Please see picture B below for reference Make sure the hydrogen supply pressure is 0 45 0 55Bar 0 45 0 55Bar WARNING A E 1 Please make sure you have purged the water out of the stack as much as possible before use say it is not coming out of the output if you injected water into the stack Using the fuel cell stack with too much 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 The stack must be standing on the clear plastic feet Manual FCS C200 V2 0 EN 26 Horizon Fuel Cell Technologies 11 Trouble Shooting amp system 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 2 3
17. en 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 the purging valve is kept away from the stack The 8pin plug connections 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 power is providing 12 14V The load is below 200W oe oe 9 49 The System is now setup and ready to be used Manual FCS C200 V2 0 EN 19 O Horizon Fuel Cell Technologies 6 System Setup Diagram Blower H2 supply valve From H2 To fuel supply cell H2 FC IN T sensor Purging val power supply From fuel cell 131 Ti o purge UUU Fuel cell controller SCU Short Circuit Unit GND Grounding Manual FCS C200 V2 0 EN 20 Horizon Fuel Cell Technologies 7 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 is position Stand on the plastic feet different based on the different stack FE DEN ds 2 I A MET iseyi 691 106 Ce 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
18. ent Information Manual FCS C200 V2 0 EN 1 Stack Is 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 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 3 H2 Purge Valve It purges out the water and air gas redundant in the fuel cells Please note that the plastic point is for input and metal point for output 4 Short Circuit Unit It ensures best performance of the fuel cells 5 On Off Switch Hold it for 2 seconds for either on or off operation 6 Blower Supply air to the fuel cells and meanwhile decrease the temperature of the stack 10 Manual FCS C200 V2 0 EN C Horizon Fuel Cell Technologies 7 Controller Connector Connect the stack to the T sensor blower purging valve input valve on the controller 8 Controller Controls the stack temperature blowers hydrogen input purging and short circuiting of the stack 9 H2 Input Output connectors H2 OUT connect the tube shown in 11 below H2 IN connect the tube shown in 11 below
19. for this fuel cell Don t connect up a load that will demand more power than 200W which 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 power is 13V 1V lt 5A 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 Pay attention to the purge take care of the performance during the purge If after each purge the performance is increased about 10 it means you need to increase the pressure of hydrogen a small amount The fuel cell is flooding and so you need to use the pressure to push extra water out e Short circuit will happen every 10 seconds and last for 100ms everytime e If 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 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 during operation If the system shuts down during running procedure review the Bleeping interpretation during running procedure Manual FCS C200 V2 0 EN 23 O Horizon Fuel Cell Technologies
20. hnologies 9 Performance Characteristics Performance characteristics of the stack are presented All performance data is given for baseline operating conditions defined at sea level and room ambient temperature Voltage V N o r3 E E c o 2 Q E 5 N c o oO N I Power W 200W U I Curve 4 0 5 0 6 0 Current A 100 0 Power w 200W Power Curve Current A Manual FCS C200 V2 0 EN 25 9 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 24V after 30 minutes operation 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 s
21. ion 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 65 C 3 Low voltage fuel cell protection i e the average voltage per cell is 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 Diagnosis Potential for fuel cell damage 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 LCD 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 system immediately to avoid potential further damage to the fuel cell and contact support a horizonfuelcell com If the system shuts down by itself check the follo
22. rate 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 No pungent odor paint and perfume are allowed around stack Manual FCS C200 V2 0 EN 4 C Horizon Fuel Cell Technologies 1 8 High Temperature The fuel cell stack is designed to operate at 65 C 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 Manual FCS C200 V2 0 EN 5 O 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 A fuel cell stack It 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 Humidi
23. ssemble or inappropriately tamper with the fuel cell There will be no repair replace or refund should disassembly or 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 Manual FCS C200 V2 0 EN O Table of Contents ES EE EE 1 2 JE MNT 6 3 Stack and System Component Information 10 4 Technical SpecifiCation ccccccceccsecceecceeeceeeceeensecaeecseeeaneeeneeenees 12 D System SEV Diva cecnsantavscscaneccexsezndauseavasennnesgwredsensesndenstersdtonnesdescdventes 13 6 System Set up Diagram anrrnannnnnnennnnnnanennnnnnanennnnnnanennnnnnanennnnennnnen 20 7 Notes for the set up rrarurnrrnrnnnrrnrennrnnvererrnrennevunnnnenuneneernennvenusnnsene 21 8 Operating Procedures raranaranarenanenurenunernnennnennnennnenusnnnsnnuennunenenene 22 9 Performance CharacteristicS rrrrrrarnnrnnnrnnvrrnrnnvernrnnvernrnnnennenuvenenn 25 10 Storage and Re USe rrrnrarananrrnarevnnrrnanrnnarennnennnsennernnanennanennnennnne 26 11 Trouble Shooting amp System Checks eeeeeeseeseess 27 12 Fuel Cell Uem 31 VO 32 Manual FCS C200 V2 0 EN Horizon Fuel Cell Technologies 1 Safety Please rea
24. stack in a well ventilated area and ensure that ventilation slots are unobstructed Manual FCS C200 V2 0 EN 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 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 stack WARNINCG 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
25. t horizonfuelcell com with the diagnostic fuel cell internal short circuit with the fuel cell number e 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 0 6 per cell O 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 per cell O 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 O 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 feeling the clicking motion inside the valves ii Alternatively apply the external power directly to each valve at 12V to feel and hear the clicking of the valves opening ii If
26. the fuel cell stack 8 pin connector pins 4 amp 8 ii The resistance should be 10760hms at 20 C x3 8ohms 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 Manual FCS C200 V2 0 EN 30 O Horizon Fuel Cell Technologies 12 FUEL CELL DRAWING Manual FCS C200 V2 0 EN 3l O 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 What is the maintenance of the stacks 1 When the stack finishes operation disconnect the hydrogen input and output tube from the stack and also disconnect the power output Use a tube to connect the hydrogen input to the hydrogen output of the stack 2 Store the stack in ambient temperature and in a closed space Keep it away from toxic gas such as So2 H2S Co 3 Operate the stack for 2 3 hours every 2 weeks or at least one month in order to maintain the stability of the stack performance 4 If the stack h
27. to the H2 out port And connect the H2 supply 0 45 0 55Bar to the stack without a load attached to purge the stack as much as possible i e letting hydrogen flow through the stack to remove water and other contaminants Using the fuel cell stack with too much water inside can irreparably damage it Make sure the hydrogen supply pressure is 0 45 0 55Bar Please see Storage and Re use WARNING Please make sure you have purged the water out of the stack as much as possible before use say it is not coming out of the output if you injected water into the stack Using the fuel cell stack with too much water inside can irreparably damage it Manual FCS C200 V2 0 EN 27 O 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 Bleeps Interpretation Actions 1 Low fuel cell open voltage protection i e the average cell voltage is lt O 7V 2 High ambient temperature protection the ambient temperature around the system is 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 operation within the product parameters then please refer to the following bleeping interpretation Bleeps Interpretat
28. ty that the fuel cells need for running Blower Supply air to the fuel cells and meanwhile decrease the temperature in the stack Purging valve For purging out the water and air gas redundant in the fuel cells SCU Short circuit unit the short circuit will be controlled for good performance of 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 Manual FCS C200 V2 0 EN 6 C Horizon Fuel Cell Technologies A Warning labels B FC connector C FC amp load connector D H2 supply valve E Controller multi connector F H2 purge valve Note Pictures in the manual are only for reference takes material object as the standard Manual FCS C200 V2 0 EN 7 A Horizon logo B H2 inlet connector C H2 outlet connector D Blower Manual FCS C200 V2 0 EN C Horizon Fuel Cell Technologies T C Horizon Fuel Cell Technologies Lit WARRI i zernbly will wd ETE A Horizon Logo B LED C Product No Label D Connect plug E SCU short circuit units switch F ON OFF button G Connect to FC H Connect to FC I Connect to Load J Controller power supply DC 13V K Controller power supply DC 13V L LCD connector optional LCD not provided Manual FCS C200 V2 0 EN 9 C Horizon Fuel Cell Technologies 3 Stack and System Compon
29. ve purged the water out of the stack as much as possible before use if you injected water into the stack Using the fuel cell stack with too much water inside can irreparably damage it 6 Do not vibrate the stack when it is in operation 7 Keep the stack in ventilation when it is in operation 8 The external power voltage is required to be 12 14V 9 Keep the SCU always on Only when it causes your load operating in difficulty turn off the SCU 10 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 required to be more than 2mm STEP 1 Connect the controller to 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 Wire colours Connector pin Periferals controlled Blowers Red ve Black ve Red 4 amp 8 Temperature Sensor Manual FCS C200 V2 0 EN 13 Horizon Fuel Cell Technologies STEP2 Connect the controller to the stack as the output power also should be under control The finished connection is shown in 2E Manual FCS C200 V2 0 EN 14 O Horizon Fuel Cell Technologies STEP 3 Keep the SCU Short Circuit Unit switch ON at for usual use Warning Some home appliances may not be suitable for this activation process It may cause damaging
30. wing details 1 Make sure you have connected all wires according to the System Setup Diagram 2 Make sure the external voltage is 12V 14V 3 Make sure you have connected the hydrogen supply with the correct pressure 4 Make sure the load is below 200W 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 Manual FCS C200 V2 0 EN 28 Horizon Fuel Cell Technologies Checking the Fuel Cell System If the fuel cell 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 e f not open see Checking Valves in trouble shooting e 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 e f wiring wrong change it to be correct immediately repetitive attempts at starting the stack with this setup will permanently damage the stack e f wiring correct disconnect the FC and FC from the fuel cell controller and start the fuel cell system again it will shutdown automatically following this measure the fuel cell voltage e f voltage is still 0 the stack has short circuited internally and needs to be changed Contact suppor
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