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FC20/FC40 - User Manual

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1. 6 4 4 Recorder function After selecting the menu item Tools gt recorder the window for the graphical presentation of the measured values opens up in the lower half of the screen common settings 20 00 18 00 oood1 00 _ooodt10 oood1 20 ooodiao ooodtso ooodiso oooizoo oooi210 oontz20 onoizao oooizso oooi2so 14 63 A stack current time hhhemm ss Fig 9 Recorder window The preset length of the timeline 3 is two minutes After the start the previously selected measured values are shown as coloured curves going from left to right in a unit diagram When the right margin of the indicating range is reached the display changes into rolling mode Now the oldest values are displaced outside the display on the left margin The measured values are not stored beyond the 2 minutes dur ing which they are displayed This function only serves for real time monitoring of the operation of the fuel cell unit In order to record the measured values for rea Phocos AG 27 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software Phocos AG phocos son of subsequent evaluation even for longer periods of time the logging function must be used The time data on the x coordinate are continuously adapted to the actual time The y axis of the diagram 1 can be
2. So tevel 3 send SMS and eMail contact closed Fig 16 Event control for GSM module In case of certain events the fuel cell unit offers the opportunity to submit a re spective message to the user For each individual event that can be activated in the menu 1 it can be additionally determined whether it has to be transmitted by SMS to a mobile phone or by e mail to a PC or both 2 If for example the first entry in the menu is activated end of a charging cycle a message in the following form will be submitted to the respective receiver as soon as the charging process is finished Each individual sedecimal number within a message corresponds to certain measured values or states that have been detected during the charging cycle The procedure to convert this rather cryptic message in plain text is the same as described under History charging cycles From 015114730703 t mobile sms de To receiver xyz com This message has been submitted to you by T Mobile Please consider for your answer that only the first 160 signs of the subject line and of the content of the message will be transmitted If the hydrogen accumulator cylinder is equipped with a manometric switch and the second entry of the menu is activated the receiver will receive a message with the following content in the case that the manometric switch has been triggered From 015114730703 t mobile sms de To receiver xyz com Th
3. tun hrs z stack curren13 52 A AAA ERA Ba A manometric manometric purge 13 00 AJ ironment 6 9 c Degi este cooling system accu al E stack 330 c f E 5 temp Asie accu 13 28 accu 33 9 C temperature 60 Samples min logging analog inputs o oo userl vlij F2 Fig 8 Schematic overview 6 4 3 File types file denominations The software offers numerous possibilities for data storage The data are stored in 4 different file types With exception of the data stored in a special format into kfg files all data are stored in ASCII format Phocos AG 26 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and parameterisation software ___ POCOS File extension Stored information a new ope be i e A aralng ccs no yes 2 eee ee yes yes IEA no yes EA eo no no Tab 1 Overview file types For the automatically generated and proposed standard file names the following has been specified independent of whether the names can be modified afterwards or not Current count of the operating hours meter TY peer Serial number from digital type plate Seen eee Year of construction ik ee Week of construction eed eo eet Nominal output voltage here 12 0V aaa eee Nominal power of the device stack s here 45W oe a Device type Fuel Cell Unit
4. cc scssssssssssssssseseseeees 20 5 4 Messages FC CIES aac dicoacinaindaatdindaduanicudaaesaca sb dasiausiibuabaaatdwaacuatcnanduabieamnaubea 21 6 Description of the Visualisation and Parameterisation Software 0 000 22 6 1 Preliminary FEMANKS iocsccccisssiataccdcnsdededinadiaisensdidsdeeisMdaidedaieentdesassasdincsanias 22 6 2 Installation eeemeeennte emma nate nee ener mee mn mtr mr enn ee eenere ree eer arene 22 6 3 Uninstall process ssn acide dead loaded ond dd enedabd dad cdecanidvopdaloadeiies 22 6 4 Structure of the Software vecciasccnstedesdcctacsacacsaiesdesiactnenaaadeiqeedectadeanasancaiaen 22 6 4 1 Basic SET ENS vaeciesstoatbecioatiecicactototactbiaisauterulecaviateashoutiuavbeleatvonsoebbieteaoncesne 22 6 4 2 Schematic Overview satiescttpadincnisaciiciaieabitinassiaruosa sendestunan Soaucieihardsicealdanudadaindtidunndannahdaes 26 6 4 3 File types file CENOMINATIONS ccccccccessessssssssseeeeeeeeessssssseseeeeeeseeseeees 26 6 4 4 Recorder function saicicrssnannernmnscrdanmnacenasonneteinenauineniaatnanaamedaameties 27 6 4 5 Logging function sssssssennnnnessseeeennrnnnneseneerrnrnnnrnssnrnrrrrnnnnssneenenrnnnnnnnneeeenrnn nnn 29 Phocos AG 3 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Table of Contents 6 4 6 History Ce ANNI ay geet aa deers ancenres oun ee uaa esau ceo ceaituoaioese naam auaraunes 31 6 4 7 GSM TNO CNG stata tars acetcadc cncste
5. FC20 FC40 Hybrid Solar Power Fuel Cell Unit User Manual 2007 08 16 Hybrid Solar Power Fuel Cell Unit FC20 FC40 amp Preface Preface Phocos AG phocos This user manual informs about the appropriate operation of the hybrid solar power fuel cell unit FC20 FC40 The fuel cell unit serves for charging 12 V 24 V lead ac cumulators The user manual has to be stored It is not allowed to copy or to manifold texts plans and tables or to make them available to third persons without our formal approval We point to the fact that this manual is not part of any existing previous agreement or consent or any part of a legal relationship All obligations arise from the sales contract which also exclusively contains the warranty regulation The user manual does not affect the stipulations The documentations and user manuals of the suppliers of the purchased parts and components used are also valid in the context of this manufacturer s user manual In addition to the user manual all general legal and other binding rules for accident prevention and environmental protection have to be considered and applied 2 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Table of Contents P h OCOS Table of Contents DMEF OCU CUO creaeicsesvecavnen ti cisntcancvesentecranerecchuacadaceoarcducvsncecucvamteaccvnntvancvexcwancvincsnnsensbansa 5 2 Identification cise caeicse ieee tet ces dees
6. signals at the connection M messages This signal is set when the fuel cell unit is in operation and charges the accumula tor Connection M digital out pin 2 open collector maximum 10 mA Additionally the green LED is flashing This signal is set when the accumulator voltage drops below the preset value This can only occur in case of failure Connection M digital out pin 3 open collector maximum 10 mA This signal is set when the pressure in the hydrogen accumulator drops below a preset value e g 20 bar The precondition for this signal is that a manometric switch is connected with connection S H2 accumulator pin 8 Connection M digital out pin 4 open collector maximum 10 mA Additionally the red LED is flashing Additionally to the signalling of messages by setting digital outputs of the connec tion M relevant information are signalised by flashing patterns of both LED of the control panel too LED green LED red STATUS OF DEVICE t t INITIALIZATION GSM FUNCTION 1s 1s 1s 1s INITIALIZATION 1s 1s 0 28 0 2s READY FOR START UP 2s 1s 1s J DEVICE CHARGES ACCUMULATOR 2s 0 2s 0 2s l l LOW PRESSURE OF H2 BOTTLE 1s 1s 1s FAULT H2 SUPPLY 1s Fig 6 Flashing patterns of the LED 21 Phocos AG www phocos com Subject to Change without notice Hybrid Solar P
7. After the adaptation of the accumulator voltage the device will be restarted 5 2 2 initialisation of the FC20 FC40 After the automatic accumulator voltage recognition the actual initialisation of the device takes place During initialisation several hardware tests and basic adjust ments are carried out The initialisation takes about 2 to 3 seconds and the process is signalized by the LED Fig 6 5 2 3 initialisation of the GSM module If the fuel cell unit is equipped with the optional GSM module this module will be initialised too The initialisation takes about 10 to 15 seconds and it is signalized by the LED Fig 6 5 2 4 Charging process The device works automatically and the charging process starts and ends respec tively after the adjustable minimum voltage or final charging voltage for the ac cumulator respectively are reached Fig 6 Phocos AG 18 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 phocos Operation Manual Shutdown criteria With respect to possible shutdown criteria see description of the data of the proto col file Tab 2 Purging PEM fuel cells operated with hydrogen show discontinuous behaviour during their Operation Even at constant external conditions such as temperature quantity of the supplied air and hydrogen and their constant quality the operation characteris tics can change These changes often cause a reduction of the
8. Depend ing on whether a digital or an analog input has been chosen a corresponding event can be selected now 4 In case of an analog input on which a voltage between 0 V and 10 V can be applied this event can be that the voltage falls below or exceeds a voltage level defined in the next input field 5 For the first digital inputs the cor responding event can be the detection of a 0 level or 1 level Since these in puts are evaluated with the polling procedure in the least favourable case a dura tion of 125 ms is required for the detection of the significant level Each previously defined event can be defined in the next selection field as condi tion for the submittal of a message As already described for the system events it can be chosen between SMS e mail or both communication ways 6 If the choice has been made to send a message in case of the next occurrence of the respective event the content of the message can be formulated at will and be entered into the following input field 7 Independent of whether a message has to be transmitted or not the states of the two available digital outputs can be event dependently influenced By respective selection in the last field 8 the digital output 1 or 2 can be set to 0 level or to 1 level in case of the occurrence of the related event A possible variant is the logical negation of the actual state By clicking the OK button 10 the chosen settings a
9. quality In case of val ues below 10 it should be checked whether another installation location would pro vide better results Often small displacements can already lead to distinct im provements With the next field below which has a red background 8 the PIN of the SIM of the GSM module can be read out and modified if necessary Each time when the con troller in the fuel cell unit switches on the GSM module the PIN is requested just like in case of a mobile phone This action is carried out in the background by the controller and the PIN stored in its EPROM is used for it Only when this PIN is the same as it has been stored in the SIM card of the GSM module the log on takes place and the device becomes ready to send and to receive In order to change the PIN in any case the read out button must be clicked before A change will only be suc cessful when the PIN read out from the controller is correct for the connected GSM module If the SIM card in the GSM module is replaced or a wrong PIN has been entered it is possible that the controller tries to start the GSM module with an incorrect PIN Af ter three erroneous PIN requests in the field state the message PUK expected appears 9 In this case the SIM card must be removed from the GSM module and inserted into a mobile phone After switching on the mobile phone the PUK will be requested too This eight digit number required now can be found in the docu ments h
10. 1 5V on p 2 TEMPERATURE ACCUMULATOR INPUT o2 Av 3 GND o3 4 N C 5 12V 6 NC 7 N C 8 PRESSURE SWITCH H2 STORAGE INPUT O8 9 GND i p 10 5V 010 STORAGE e VIEW AT DEVICE 12 N C Phocos AG 10 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Product description o hoos Fig 5 Connection external hydrogen storage Scope of supply e Hybrid solar power fuel cell unit FC20 FC40 e Plug for connection of accumulator e Special connector for hydrogen connection e PC software for Windows 2000 XP for visualisation and parameterisation e User manual Optionally e Temperature sensor for accumulator e Internal GSM module for data transfer e IN OUT interface 2 x digital out 2 x digital in 2 x analog in comprised in GSM option e Implementation of user specific program tools for user IN OUT e Pressure control fittings for gas cylinders 200 bar on 0 10 bar and connecting hose 2 5m e Solar accumulator 12V 6 6 Ah other capacities on request e Steel casing IP 64 e Putting into operation at customer s premises 3 3 Emissions and environmental compatibility During the operation of the fuel cell unitFC20 FC40 low amounts of hydrogen are emitted flushing of the anode Furthermore during power generation water wa ter vapour is generated escaping together with the hydrogen on the bottom part of the device 3 4 Safety information The fuel cell u
11. all components and their functions In particular the topic of safety must be taken into account The present user manual contains important indications as to the appropriate and economical use of the fuel cell unit The observance of these instructions helps to avoid risks to reduce costs due to repair and downtimes and to extend the service life of the device In the individual chapters on the margin of the text occasionally symbols are printed indicating the function of the respective paragraph These indications are important for the operation or the maintenance or they indicate important de scriptions or remarks respectively Danger All paragraphs in the user manual that contain indications to possible endanger ments are marked with the alongside symbol Non observance might implicate severe injuries The instructions have to be strictly adhered to Attention All paragraphs marked with this symbol provide indications for the avoidance of damages to the installation Hint Paragraphs with this symbol give important hints for effective work The working steps that are described in logical order adjacent to this symbol specify the most ergonomic way of operation Phocos AG 5 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 iensen o ows 2 Identification 2 1 Product brand and type designation Phocos FC20 FC40 2 2 Product ver
12. are not re quested explicitly by the present manual For all these reasons our customers should always contact our customer service 44 WWW phocos com Subject to Change without notice
13. charging voltage according to the tem perature The correct value for the influence of the temperature on the rated val Phocos AG www phocos com 23 Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos ues of the accumulator voltages must be taken from the manufacturer s data of the accumulator A x A x N N 4 Danger If values are entered which are within the permitted range for the data field but not permitted for the accumulator see data sheet of the accumulator the accu mulator can be destroyed or the device can be damaged respectively Phocos AG Purging current When the current drops below the purging current set in 5 the process of purging will be started If the time between two purgings is in average about 2 minutes op timum setting can be assumed Longer pauses between the purgings would be of advantage but the average output power would be lower than in case of more fre quent purgings However if in the case of a relatively lowly set purging current the output power seems to be sufficient for the actual application and the device is running stable for a considerable time the lowest possible value should be chosen This will lead not only to a minimum hydrogen consumption but also for a longer service life of the stack Operating voltages In 3 the operating voltages of the stac
14. part of the generated electrical energy is temporarily used for an internal heating element The corresponding amount of energy will be derived from its normal purpose the charging of the accumulator In this case full cooling down due to long charging pauses should be avoided in order to avoid full length heating periods Conditions for which charging pauses in case of tempera tures distinctly below 0 C do not take longer than 24 hours can be considered as energetically favourable For the determination of the optimum accumulator capacity the essential influenc ing factors are the temperatures to be expected and the average power consump tion of the application Appropriate recommendations will be provided in the con text of the initial putting into operation or on request 14 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Product peseription hows 4 4 2 Connection of the hydrogen accumulator For hydrogen supply the parameters mentioned above are relevant For a safe con nection or exchange respectively of the pressure vessel the following sequence has to be followed L 2 0 SL p e w 10 11 I2 13 14 Switch off the fuel cell unit FC20 FC40 red key Pull the accumulator plug The power supply by the fuel cell unit will be inter rupted Close the hydrogen cylinder Close pressure line at the pressure control fittings of the gas cylinde
15. settings only become effective after the present active settings have run out In the yellow bordered field a button for explicitly switching on the GSM module can be found Unlike in the case of a voice communication the data of an SMS e mail are first transmitted to a provider or network dependent service number respectively in order to be transferred then to the real receiver The service number for the SMS communication is stored in the mobile phone in this case in the GSM module With the read out button the number stored in the GSM module 5 can be dis played it is also possible to submit a changed number to the GSM module with the store button next to it 36 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software Phocos AG phocos With the read out button in the field below time and date 6 of the GSM module can be displayed If necessary in the window tools gt clock it is possible to set this clock However this will not influence the function or the contents of the mes sage The on site received field strength can be detected with the button detect in fol lowing field below 7 This function should be executed several times during the setting up of the fuel cell unit The detected values should be commented with re marks enabling the assessment of the reception reliability
16. the opportunity for the user to pro vide the fuel cell unit with additional information about the connected hydrogen accumulator optional manometric switch or the accumulator to be charged 1 wire temperature sensor The manometric switch can be used to signalise the state hydrogen accumulator almost empty The temperature measurement on the ac cumulator serves for the determination of the exact final charging voltage of the accumulator temperature dependent adaptation of the final charging voltage Phocos AG 16 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Product peseription hows Attention The length of the connecting lines on the installation location must not exceed 3 m because otherwise problems with EMC interference signals may occur For lengths above 3 m screened signal cables have to be used The laying of the required electric cables must be carried out by a professional electrician 4 4 4 Putting the device into operation After it has been checked that the lead accumulator and the hydrogen supply have been connected to the device that the accumulator voltage is within the specified range of the charging voltage and that the hydrogen supply is ensured the device is operational Now the charging process can be started manually by pressing the green key on the device or it starts automatically when the supply voltage drops below the preset voltag
17. 0 Xxxx Reset the event control on the user inputs Con dition for a new recognition of an event 11 xXxxx Set digital user output 1 to 0 12 Xxxx Set digital user output 1 to 1 13 XxXxX Negate digital user output 1 14 xXxxx Set digital user output 2 to 0 15 XXxx Set digital user output 2 to 1 16 XXxx Negate digital user output 2 18 XXxxx The logged data of the last executed or of the present charging process will be sent by SMS to the mobile phone designated in the fuel cell unit 19 XXxxx The logged data of the last executed or of the present charging process will be sent by e mail to the e mail address designated in the fuel cell unit The format of the message in case of commands 18 and 19 corresponds to that which is used in the comparable system event 48XXXX The basic device settings will be send by SMS to the mobile phone designated in the fuel cell unit 49XXXX The basic device settings will be send by e mail to the e mail address designated in the fuel cell unit Similar to the logging data for a charging cycle commands 48 and 49 provide sedecimal numbers which cannot be understood by simply regarding them Like in the case of the charging cycle messages the operating software of the fuel cell unit offers the opportunity to convert these numbers in plain text format For this pur pose in the corresponding fields of the basic settings window the necessary changes must be carr
18. 111 switch on the fan at above 53 C onstack rated temperature continued run even though exceeding turn off device type voltage until temperature exceeds at least D 5 C means heater ON accu charge Forced start of charging although no under i S p voltage on Accu risk of frost at below E 5 C produced in cold start behaviour until stack temperature o above J 30 c from to file i from eml file aa into device transmit load save as eml file _send Fig 7 Basic settings digital device label far week iol x stack dig User inputs for external switching on or off power 45 Watt 2006 serial number voltage 12 0 Volt Ea 3 device close With respect to a temperature of 25 C it can be assumed that an accumulator as shown in the example above is discharged when its voltage has dropped below 11 5 V In the contrary a voltage of about 14 4 V indicates that it is fully charged If beyond this voltage level the charging process continues the water in the accumu lator begins to decompose in its gaseous components If the corresponding loss of water will not be compensated the accumulator will be permanently damaged That means that overcharging has to be avoided For the final charging voltage de pends on the accumulator temperature an additional parameter can be set that adapts the effective recognition of the final
19. 450 C e Soil and dust resisting packaging which is however permeable to air e Vibrations strong shocks impacts and blows have to be avoided Packaging Generally for the transport or the shipment of the device respectively packaging that is suitable for the destination and for the object and that is environmental friendly has to be used As the device itself has a degree of protection of IP54 a packaging type has to be selected for transport that prevents penetration of water soil and dust The use of conventional dehumidifiers is recommended Storage It is only allowed to store the device after it has passed through a complete phase of cooling down This phase of cooling down is realised in the automatic charging operation mode after the final charging voltage has been reached or after a shut down by the device due to the characteristics of the system Additionally the fol lowing has to be considered e Storage exclusively in upright position e Temperature range during storage 5 50 C e Soil and dust resisting packaging which is however permeable to air Putting into operation Before putting the device into operation the following conditions have to be en sured and to be checked e Professional installation and layout of all required connecting lines and conduits electricity and media and their correct connection to the fuel cell unit and the other system components respectively e The availabilit
20. Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos happening can be dedected the active Level have to take back use the digital userinput number two in the same way to switch off Hint Speciation settings for the digital userinputs by using GSM functions must be deactivated Be carful that at the digital user inputs never have an active level at the same time a Loading saving the set of parameters The set of parameters actually shown can be transferred by the transmit button in the menu item to device to the FC20 FC40 By load and save in the menu item from to file the actual set of parameters can be stored on the data carrier or a stored set can be loaded from there Furthermore with load and save it is possible to load a set of parameters that has been sent by e mail or to transmit the actual set as e mail optional GMS module required The procedure of loading and converting a set of parameters from an e mail is described in 6 4 6 by Error Refer ence source not found 6 4 2 Schematic overview After selection of the menu item Window gt schematic overview an animated scheme will be presented It shows the device together with its connected compo nents Additionally the graphical presentation and the corresponding captions indi cate the state of the components
21. Remaining endangerments The described product complies with the state of the art and the generally ac cepted safety related rules However the occurrence of dangers cannot be ex cluded The remaining endangerments in connection with the use of the device are due to e The use of hydrogen accumulators and the associated fittings including the con necting pipes to the device e The use of lead accumulators and their possible improper use In this context the regulations applying to these components have to be considered and observed according to the installation location 3 4 3 Qualification of the operating staff Only persons with technical preferably electrotechnical training who are able to realise the connections in a professional manner are allowed to put the fuel cell unit into operation and to connect it For the operation of the PC user interface belonging to the scope of supply basic knowledge on the current WINDOWS system software is required The respective details can be found in the attached detailed program description Phocos AG 12 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Product Description 4 4 1 4 2 4 3 4 4 Phocos AG phocos Preparation for the Use of the Product Transport For the transport of the device the following must be taken into account e Transport exclusively in upright position e Temperature range during transport 5
22. anded over to the client with purchase of a SIM card or with contract con clusion respectively The yellow bordered area 10 serves for explicitly switching on or off the GSM module by the controller of the fuel cell unit Preferably for switching off the soft method should be used In this way the GSM module receives a command for shutdown and for automatic switching off So it will be ensured that the modifi cations made will be stored in the GSM module If due to communication distur bances or other malfunctions this method is not applicable the only way out is the hard switching off In this case the power supply of the GSM module will be in terrupted Clicking on the configure button opens up the following window 37 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos GE for gsm modul ioxi event reaction end of one charging cycle Ssend a SMS pressure key switched on H2 bottle Isend eMail accu voltage under allowable value device faul send SMS and etal pressure key switched low pressure send a SMS watchdog responded escape x save and close events on user inputs wie event threshold kind of message content of message Sofortreaktion janalog input 4 Sfthreshold value a E dig Outt to 1 analog input 2
23. changed without interrupting the display of the measured data The easiest way to do so is to bring the curser to the respective curve and to click on it Then on the left margin of the display a scale with the colour of the selected curve and with the corresponding values appears Addition ally on the lower margin the value and the unit of the most recent measured value will be displayed corresponding to the point of the curve in the right end of the curve If as it is shown in figure 9 two curves superpose each other the selec tive list 4 can be opened and the scale to be displayed can be determined explic itly Without further selection in the bottom margin of the diagram a curve is displayed which does not refer to a scale This curve only makes visible interventive measures of the controller during operation e g purging decrease or increase of air etc The menu item settings opens up a window where measured values 1 to be dis played can be selected E3 settings for data recorder loj x Eecteesssesencenconnsetsnssnsecassnsensenseed v voltage stack voltage stack2 voltage stack1 2 output voltage output current env temperature stack temperature accu temperature hydr storage temp 60 samples per minute OK Fig 10 Selection for display The colours of the curve to be displayed are assigned automatically The topmost measured value of the list selected and marked with a che
24. ckmark will be displayed in red The following curves will be displayed in blue green yellow and magenta Finally the brightness of the mentioned colours will be changed for reasons of distinguishability In field 2 time resolution can be determined The preset value is 60 samples per minute This value can be varied between 12 corresponding to 5 seconds for each 28 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos value and 300 corresponding to 5 values per second However only certain set tings are really practicable or reasonable respectively In any case the preset value of 2 minutes for the display time will remain constant but the number of the individual measurements per unit of time that will be displayed will change 6 4 5 Logging function Pressing the start button logging in the window with the schematic overview starts the logging process for all measured values and status information Automati cally a ASCII file with the extension prt is generated in which the data are stored in form of a table with 28 columns The first row of each file states the sampling frequency for the data The columns are separated by a tab stop Deliberately decimal separators have not been used in order to avoid data import problems with PC programs in different language versions Independent of th
25. ds carbon monox ide ammonia chlorine compounds solvents and dust Casing Dimensions 415 mm x 335 mm x 235 mm Material Plastic material Mass About 9 5 kg Connections GSM MODULE optional CONTROL PANEL and USB PORT CONNECTIONS EXHAUST GAS CONTROL PANEL and USB PORT LED green On OO is BUTTON ON 5 BUTTON OFF USB PORT CONNECTOR PANEL USER IN OUT MESSAGES 3 H2 HYDROGEN IN D FUSE 4A fast STORAGE 12 polig ACCUMULATOR Phocos AG 9 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 Product Description 6 phocos Fig 2 Situation of the connections and the control elements ANALOG INPUT 1 ANALOG INPUT 1 ANALOG INPUT 2 o 10v A sid 4 ANALOG INPUT 2 DIGITAL OUTPUT 1 open collector max 30 mA 6 GND DIGITAL OUTPUT 1 2 max 30 mA 8 5 30V E 9 5 30V 10 USER IN OUT gt DIGITAL OUTPUT 2 open collector DIGITAL INPUT 1 GND DIGITAL INPUT 1 2 DIGITAL INPUT 2 N C OPTOCOUPLER o6 GND USER alp O 8 10 OPTOCOUPLER O9 GND USER VIEW AT DEVICE a 12 N C Fig 3 Disposable connections e 2 DEVICE IN OPERATION open collector max 10 mA 5 2 3 FAULT DEVICE open collector 5 30V 4 LOW PRESSURE H2 STORAGE R 7 open collector 2 3 4 6 D 5 NC 6 5V gad 7 NC GND mee 3 GND user MESSAGES 1 VIEW AT DEVICE Fig 4 Connection signalling
26. e button store 3 Unlike the file that contains the whole table this file has the extension hss and it is a pure text file too For this file too an automatically generated file name will be proposed unless in the popup that has been opened before the option attach has been selected In this case an already existing file of the same type can be chosen to which the present data set will be attached If this type of storage is used a table whose structure is identical with that described above will be generated This variant is particularly useful when the GSM functions will be applied see be low Clicking on the button import data allows to display values in the fields within the green frame that do not come from a connected fuel cell unit but from the con tent of a received e mail The window that opens up open file preferably allows the file type eml which is used by the e mail program Outlook Express for the export of e mails However other file extensions are possible too When the chosen file has been opened a window of the following type appears dis playing the full content of the e mail lolx input help panel Delivered To armold flexiva de Received from mail flexiva info ltby localhost with POP3 fetchmail 5 9 0 ifor arnold localhost single drop Tue 02 May 2006 11 11 20 0200 CEST Received by mail flexiva into Postfix from userid 0 lid AATB8518E0 Tue 2 Ma
27. e level The initialisation and all operating states will be signalised by different flashing patterns of the two LED on the device see 5 4 Phocos AG 17 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 phocos Operation Manual 5 Operating Manual 5 1 General functional description The fuel cell unit FC20 FC40 serves for charging 12 V 24 V lead accumulators used for optional applications Pure gaseous hydrogen is the primary energy source 5 2 Operating modes 5 2 1 Accumulator voltage recognition FC20 FC40 disposes of automatic accumulator voltage recognition For each new connection of an accumulator corresponding to cold start of the device the ac cumulator voltage is measured several times and the measured values are com pared with the parameterised accumulator voltage If this comparison shows a dis crepancy the device will be automatically adapted to the determined accumulator voltage and for all relevant parameters the default values for the respective accu mulator voltage will be selected If the measured voltage is Attention 1 greater than 17V for the parameterised 12 V accumulator type gt Adapta A tion to 24 V accumulator type 2 lower than 18V for the parameterised 24 V accumulator type gt Adapta tion to 12 V accumulator type The whole process takes about 1 second and it is accompanied by simultaneous flickering of both LED
28. e sender of an e mail from the device is a PC 0 Hint It is generally assumed that the receiver of the e mail is a PC Phocos AG In order to receive messages of the fuel cell unit with a mobile phone its telephone number must be entered into the next field 2 If the fuel cell unit and the receiv ing mobile phone are in different countries it is necessary to use the international code of the telephone number That means that the leading zero must be replaced by the international dialling code 49 for Germany A message sent by the GSM module that is to be received as e mail must be submit ted to a provider dependent special service number 3 The given example is 8000 for the D1 network The four digit PIN 4 ensures that unauthorised or accidental transmission of a message a command will not cause malfunction or disturbances This PIN must not be confounded with the PIN of the GSM module inhibiting abusive use of the SIM card Requests or inputs modifications respectively in the orange bordered fields re quire a data connection between fuel cell unit controller and the GSM module The window with the schematic overview of the fuel cell unit shows whether such a connection exists or not no connection gt dimmed presentation of the symbol of a mobile phone In the menu sub item tools gt clock it is possible to determine the duration of the on and off conditions of the GSM module The new
29. e set time period sampling rates between 300 min and 1 min are possible after 1 hour a new file with running numbering in the automatically gen erated file name is generated Attention If the highest rate is selected the file size after 1 h of recording is about 1 7 MB Phocos AG The contents of the individual columns have the following meaning Column Meaning Time in 0 1s with respect to the start time 1 For example the entry 36076 means that the following columns contain values that have been measured after 1h 0m 7 6s since start Output current of the DC DC transformer in 0 01A For this value it must be taken into account that it does not represent the cur rent available for charging the accumulator because the own consumption of the 2 device must be subtracted from it In case of starting at low temperatures own consumption can mean a considerable amount because for reasons of optimising the operating conditions for the fuel cell most of the available energy will be used for heating the system Stack current in 0 01A This value is strongly connected with the before mentioned output current of the transformer because its calculation within the controller implies the output volt age and the efficiency Actual purging current in 0 01A This column represents the stack current that has been preset for the stack cur rent in the basic device settings and which varies in dependence of interventive 4 measures suc
30. ects rci cecaes ence aaeisaanus iene n nannan nenna nnn 6 2 1 Product brand and type designation cccic cedacadacaccrncntancescacecoraderaconndessereicnas 6 2 2 Product version release no software document issu 0006 6 3 Product Description nssnnsssnnnnnnnennnnnnnnnnnnnnnnnnnnnnnnnn nn nnnnnnnnnnnn nenn nnnnnnnnn nenne nnana nnen 7 3 1 General functions and areas of application appropriate use 7 3 2 Technical information and data c ccccecsesssssscceessecseesseesssscoeenes 8 3 3 Emissions and environmental Compatibility cccesssceeeeeseesssseteees 11 3 4 Safety information stats secetscietecreadatsietathad Dhadtic al vcard cuba bndeadsloandadndcsadaiodebasrsedasubesase 11 3 4 1 Safety measures on the installation lOCAtION ccccccseeceeeeeeseeseteeeeeeeeeeeeees 12 3 4 2 Remaining endangerment ccccccsssssssseccceeeeesssssssseeseeceeeeessessssseeeeeeeeseesseees 12 3 4 3 Qualification of the operating Staff 0 0 cccesssssssseeeeeeeeesssssssseeseeeeeseesseses 12 4 Preparation for the Use of the Product cccsesseeeeeseeeeeeeeeeeneeeeeeeenneeeeeeneeees 13 4 1 Transport iesteecisccpicenctenadetittiiecit vicsuMeeicctpayigu tess viele ae aE iia 13 4 2 Pt AO INO EAEE EEE E E EE AE E 13 4 3 ON BOG wo AE E EEEE E E 13 4 4 Putting into OBST ON siscisnssnactnniayadicvssaesenndays discus titsnias dic asesniwuderwsisise 13 4 4 1 Choice of the accumulator sw
31. electrical power out put Such effects are mostly due to the reduction of the reactive catalyst surface by accumulation of inert gas components to inhomogeneous distribution of humidity over the whole surface of the membrane and to inhomogeneous current density distribution A simple measure to reduce this effect is the so cold purging of the hydrogen containing component of the device For this reason the valve situated at the stack exit H2 side which is closed during normal operation will be opened for a short time A small quantity of unused hydrogen will be blown off but the stack can now be operated stably with distinctly higher power for a considerable time An indica tor for the necessity of purging is for example the output current of the stack at constant stack voltage see 6 4 1 5 2 5 Cooling phase Independent of the reason of the end of the charging process the cooling phase sets in after the process has stopped For each decrease of stack temperature of 5 Kelvin the pump will be switched on for about 1 s in order to remove condensed humidity from the stack This phase is time independent and the only criterion for its end is the difference between stack temperature and ambient temperature If this difference is lower than 2 K the cooling phase stops The cooling phase can be aborted by shortly pressing the red key 5 2 6 Stand by mode After the cooling phase the device is in stand by mode Temperature and accumu lator
32. ete ee men ner ee 31 Fig 13 E mail import WINdOWs sses aeo a e e E aera baad uacaees 33 Fig 14 Mistry data3 iseci a E E EE 34 Fig 15 Information window GSM module eesti ds ceccccee reteset aeaniedecieeceeiedndscel anes 35 Fig 16 Event control for GSM MOdUe sc5jc cco sseteeaenetendsteuaanaletadatiaesianeheasiaiacamasaunnns 38 Fig 17 Configuration real time ClOCK eccccesseeeeeceeeeseceeeeeceeeseceteseeeesneceneeneeesnenenenneees 42 List of Tables Tab 1 Overview file COS a ccd sas cscs cones cans cade vans ica ds ead aceneed ean enrereaeaeeceemecades 27 Tab 2 Column overview of log file prt oisrectstectessecciamececrsderracdtartaranidtediasel imaceseattate 30 Tab 3 Column overview history RSt sssssssssssenssreessrnrerneetrerresrtensrrnnstnnnrtnnsrnnern nene 32 Phocos AG 4 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Introduction phocos 1 Introduction Before using the device or the installation connected with it for the first time it must be categorically ensured that this user manual has been completely read in order to guarantee the safety of the operator and to avoid possible damages to the fuel cell unit The present user manual is aimed to support a better knowledge of the fuel cell unit and its use according to the appropriate working conditions Before putting the fuel cell unit into operation the operating staff must become acquainted with
33. g 0 off 1 on Bit 4 cooling phase 0 no failure 1 failure occurred Bit 5 reserved Bit 6 7 Shutdown due to 00 Final charging voltage has been reached or manual shutdown 01 Accumulator had already been fully charged but minimum temperature has been reached only later Temperature of the device above permitted maximum cooling failure or ambient temperature to high 11 Stack voltage of the device was below the permitted minimum transformer failure or other failure 10 Bit 8 emergency shutdown due to action of manometric switch at too low pres sure 0 not triggered 1 triggered Bit 9 device with 2 stacks has determined that the stack voltage difference was too high Bit 10 either a permanent device failure or the accumulator has been discon nected Bit 11 manometric switch at MHS or at H2 cylinder has been triggered Bit 12 temperature sensor at stack defective Bit 13 1 sufficient number of correct temperature measurements has been determined Bit 14 1 purging valve rusted in or frozen anyway purging without effect Bit 15 1 Interruption due to too frequent purging for internal use for internal use for internal use for internal use for internal use for internal use for internal use for internal use for internal use Tab 2 Column overview of log file prt 30 Subject to Change without notice Hybrid Solar Power Fuel Cell U
34. ge of the charging voltage USB connection connector panel The USB connector connects the fuel cell unit with a computer The visualisation and parameterisation software contained in the scope of supply enables easy access to all functions of the fuel cell unit Besides the possibilities of parameterising data acquisition data storage and visualisation complete access to the optional GSM module is assured see 6 4 7 Connection U user specific connection connector panel If a GSM module optional is available the user can use the connector U Besides 2 analog inputs it has 2 disposable digital inputs and 2 disposable digital outputs pin assignment see 3 2 The inputs and outputs can be logically connected with each other As a result of these logical connections respective messages can be trans mitted by SMS and or e mail For example the level of a digital output can change and or an SMS and or e mail can be transmitted when a threshold value has been exceeded for an analog output Inversely level changes for digital outputs can be triggered by command sequences transmitted by SMS or e mail Connection M monitored information connector panel By level changes of certain pins of this connector pin assignment see 3 2 the fuel cell unit provides external status signals These signals can be processed by the user if required Connection S H2 accumulator connector panel This connection pin assignment see 3 2 offers
35. h an e mail can be very different because the numerous additional information of the e mail header 1 are influenced by many factors Providers too use to add information For this reason the user must Phocos AG 33 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos mark the actual message transmitted by the fuel cell unit 2 in order to point out to the operating program the real data to be imported If the data are marked the button ready 3 is clicked and the fields within the green frame will be filled by the data from the e mail HistListAmong from device center 72 data from file read out no error or hint M environment temperatur stack temperature accutemperature MHS temperature start time stop time minimum maximum minimum maximum minimum maximum minimum maximum number Purges 02 05 2006 10 33 39 02 05 2006 10 55 59 23 5 S 24 6 EEE 29 2 E 36 9 SEE OE oE 24 5 26 5 ee 34 era ints outp current voltage stack1 voltage stack2 voltage accu charge period previous charge pause minimum maximum minimum maximum minimum maximum minimum maximum longest purge 00000d 00h 21m 13s 100000d 00h 00m 39s 0 12 A 311 A 1 57 MAJ 1 96 MEJ 1 29 MEJ 1 65 12 93 MEG 13 46 W 70s Fig 14 History data 3 After that this individual data set can be stored to a file or be attached to an exist ing file as descr
36. h as purging or short term air decrease increase etc influencing the operation of the device During operation of the device at temperatures be low the specified operating temperature the values in this columns vary be cause during this phase this parameter is adjusted dynamically Voltage of stack 1 in 0 01V Voltage of stack 2 in 0 01V Output voltage identical with voltage on accumulator in 0 01V Voltage at analog input 1 of the user interface in 0 01V Voltage at analog input 2 of the user interface in 0 01V WO CO MI J UT 29 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos for internal use for internal use Temperature at purging valve or air exit respectively in 0 1 C Temperature at accumulator in 0 1 C Temperature in stack container in 0 1 C Ambient temperature in 0 1 C measured in the interior of the device 19 Phocos AG www phocos com for internal use for internal use for internal use Decimal in the range 0 32767 The bits represent recognised failures or indications Bit 0 open circuit voltage during start 0 reached l not reached Bit 1 start phase 0 successfully terminated 1 with failure or manually terminated Bit 2 normal run 0 no failure 1 failure occurred Bit 3 Intervention due to drop in power e g purgin
37. ibed above 6 4 7 GSM module If the fuel cell unit is equipped with a GSM module and the corresponding entries in the basic devices settings have been made each start of the device will begin with an initialisation procedure During this phase both LED will shine together for several seconds The exact duration cannot be predicted precisely because the re ceiving conditions have a certain influence on it After a program start with correct functioning communication the PC application will determine whether the device disposes of a GSM module or not In case of an available GSM module in the menu item tools the sub item GSM settings will be activated If this menu item is selected the following can be seen Phocos AG 34 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos E3 GSM settings and informations 1 e x receiver xyz com eMail address 01755052604 mobile number of SMS receiver national format D 3400 provider number for eMail service national format 3333 User PIN GSM modul read out store fesponsed correct PIN entered successful Hummern ohne f hrende Null Erste beiden Ziffern k nnen Landesvorwahl sein SCA number 491722270333 read out store international format clock in GSM modul 01 01 2002 00 02 06 read out To set date and or
38. ice equipment and configuration When the history has been read out completely the content of the whole table can be stored in a file for reasons of further processing or storage For this the button store 5 must be clicked The proposed file name can be changed at will The preset file extension is hst It cannot be modified by the user In order to export the data to other applications it must be considered that no spe cial separators are used All spaces are blank characters For the separation of decimals points are used if the basic settings are not taken into account Excel would for example interpret the data as dates After the table has been read out possibly in the column failure indication an entry in hexadecimal format can be found in which each bit position corresponds to a particular meaning If one clicks on one of these fields with the left mouse button the plain text form of the meaning of the entry will be displayed in the right lower area of the window The contents of the individual columns have the following meaning Column Meaning 1 Cycle number counted continuously during the entire service life of the device 2 Start time in real time date and time 3 Stop time in real time date and time 4 Charging period in days hours minutes seconds 5 Previous charging pause in days hours minutes seconds 6 Ambient temperature minimum in C 7 Ambient temperature maximum in C 8 Stack te
39. ied out 6 4 8 Real time clock If the menu item tools gt clock is selected the following window opens up if no modifications are entered the window closes automatically after 2 minutes Phocos AG 41 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 Description of the Visualisation and Parameterisation Software phocos x __fake over _ Joa 22 J51 Jor Jor 2008 dfiroay transfer to charge device al v transfer to GSM modul ore minutes Fig 17 Configuration real time clock The fuel cell unit is equipped with a battery buffered real time clock which is read out when the window shown above is opened In the fields for time 1 and date 2 the actual time and date of the fuel cell unit are shown provided that a FC20 FC40 is connected and that the communication functions In order to set the clock there are several possibilities With the small arrows in the left margin of each field the value can be changed in both directions Hint Impossible entries such as the 13 month or the 25t hour will be refused for this method of setting the clock However the date will not be checked with respect to calendrical rules o The easiest and safest way to set the fuel cell unit clock is to click on the import button 3 So the system time of the computer will be displayed in the input fields When the button transfer to fuel cell un
40. is a significant leakage in the system there is a risk that the stacks would be damaged due to undersupply Operation with insufficient hydrogen supply must be absolutely avoided The built in manometric switch is triggered at a pressure that usually is sufficiently above the risk zone for the stacks If the device recognises the trigger ing of this switch during operation immediately load disconnection and shutdown take place If the corresponding entry in the menu 1 has been activated the de vice sends the following message From 015114730703 t mobile sms de To receiver xyz com This message has been submitted to you by T Mobile Please consider for your answer that only the first 160 signs of the subject line and of the content of the message will be transmitted Hint If the above messages are sent by SMS to a mobile phone only the parts of the example messages with yellow background will be displayed im o The blue bordered area offers convenient and flexible possibilities for the user of Phocos AG 39 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos the FC20 FC40 to install remote control and survey functions corresponding to his concrete problem reaching well beyond the normal functions of a fuel cell unit In the first selection box 3 the object to be surveyed can be determined
41. is message has been submitted to you by T Mobile Please consider for your answer that only the first 160 signs of the subject line and of the content of the message will be transmitted Phocos AG 38 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos In dependence of the set value of the manometric switch it can be determined how long the hydrogen supply can still be maintained and when the gas cylinder has to be replaced by a full one at the latest When the voltage of the connected accumulator falls below the voltage level of the basic device settings the fuel cell unit automatically starts the stacks and the charging process That means that in case of a correct function the voltage level can never be significantly lower than the set threshold value If this case occurs nevertheless it indicates a failure which can probably not be remedied without re pair The corresponding message is as follows From 015114730703 t mobile sms de To receiver xyz com This message has been submitted to you by T Mobile Please consider for your answer that only the first 160 signs of the subject line and of the content of the message will be transmitted The fuel cell unit disposes of a built in manometric switch fulfilling an important safety function If the hydrogen supply will not be replaced in time or if there
42. it 5 is clicked all values displayed in the time and date fields will be transferred to the fuel cell unit and stored there In order to determine whether the setting process has been successfully carried out the button read 4 can be used If it is clicked time and date of the fuel cell unit are requested and displayed anew The elements 6 and 7 appear on opening the window only in the case that the operating program has detected that the fuel cell unit is equipped with a GSM mod Phocos AG 42 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos ule The GSM module contains like any other mobile phone a real time clock If the fuel cell unit is disconnected from the accumulator for a longer period of time the GSM module loses the correct time and date values With the button transfer to GSM module this clock can be set too with the values displayed in the input fields m o Hint The content of the GSM module clock is insignificant of the functions and for the contents of the messages Phocos AG The orange bordered fields serve for the preset of on and off times of the GSM module The controller in the fuel cell unit switches the GSM module on and off ac cording to the values entered here If the GSM module is to be switched on con tinuously in the field unit for i
43. ks are set The total value will be used by the built in DC DC transformer to dynamically adjust the electrical power required from the stacks so that this total voltage is always exactly reached constant volt age operation As standard a single stack as it has been used for the FC20 FC40 consisting of three cells is operated with 1 8 V corresponding to 0 6 V per cell This voltage is a good compromise between efficiency power operation characteristics and ser vice life According to the concrete stack properties values that are slightly differ ent of the values mentioned above can be preset or set If the FC20 FC40 is provided with 2 stacks slightly different operating voltages for the stacks are possible or reasonable respectively The voltage stabilisation men tioned above refers to the sum of both stack voltages For this reason it is possible that the voltages that are measured during operation and the actual monitored voltages for example in the diagrams or in the general chart can differ from the rated voltage levels preset here If the voltage difference between the two rated voltages of the stacks exceeds a critical value purging takes place If purging is not successful the device will be shut down Open circuit voltages The rated open circuit voltages to be entered in 4 are significant only for the start of a charging cycle The comparison between the actual open circuit voltages and 24 www phocos com Subjec
44. low temperatures to layer formation and thus to an unfavourable temperature distribution For this reason a pump that has been built in the container makes circulate the liquid For reasons of energy saving this pump is not operated continuously In the topmost input field for the different temperature settings 8 within the range between 2 K and 10 K it can be deter mined for which increase of temperature in K the circulation pump will be switched on In the moment of switching on the pump the corresponding tempera ture sensor will measure a temperature drop For the stack will continue to heat the container after a certain period of time the temperature at which the pump has been switched on will be reached again and now the pump will be switched off This leads to a step by step march of the stack temperature The individual steps are denominated here as temperature plateaus The other temperature settings are described by their denominations Switch on off with external signals There is an other option as switch on and off the fuel cell unit depended on the voltage by the accumulator This is an option for external switching with separate ports Is the Dot at 9 in the basic setting are set the fuel cell unit switches on when a 1 Level is detected at the digital user input number one To dedect this happen ing safely the level must be active at least for 0 2 seconds Before the inverted 25 www phocos com Subject to
45. mperature minimum in C 9 Stack temperature maximum in C 10 Accumulator temperature minimum in C 11 Accumulator temperature maximum in C 12 MHS temperature minimum in C 13 MHS temperature maximum in C 14 Output current minimum in A 15 Output current maximum in A 16 Stack voltage minimum at stack1 in V 17 Stack voltage maximum at stack1 in V 18 Stack voltage minimum at stack2 in V 19 Stack voltage maximum at stack2 in V 20 Accumulator output voltage minimum in V 21 Accumulator output voltage maximum in V 22 Indications or disturbances respectively during the charging cycle 23 Longest distance between two purgings in seconds 24 Number of purgings during the entire charging process Tab 3 Column overview history hst In the green bordered area of the window history the respective last charging Phocos AG 32 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos process can be loaded from the memory of the fuel cell unit by clicking on the read out button 1 It will then be displayed in the respective fields If an entry has been made in the field failure indication its meaning will be shown in plain text form without the necessity of clicking on the corresponding field The last charging process displayed in this way can be stored to a file too by clicking on th
46. nactive time the option none must be se lected in the opposite case the procedure is analogous If for both times inactive and active in the field unit the option none is used the inactivity of the GSM module is prioritary the module remains permanently switched off With the abort button 8 the window can be closed 43 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 amp Maintenance Service and Repair by the Customer Service phocos 7 Maintenance Service and Repair by the Customer Service According to the general sales terms and conditions for the device supplied by the manufacturer a GUARANTEE is issued If during the guarantee period malfunctions or damages to the devise should occur for which according to the guarantee condi tions a guarantee has been issued the manufacturer will after previous examina tion repair or replace the faulty components The manufacturer is responsible for the device in its original configuration All interventions concerning the device its structure the software or the operating cycle of the device shall only be carried out by the manufacturer or by his express authorisation Attention The stipulated environmental conditions must be kept to Phocos AG The manufacturer is not liable for damages due to improper or inappropriate use of the device and for damages due to interventions in the device that
47. nbcdadalcndatetusedatetadodesndetebeindedptabosstadevedededecatdbudebadesedaondvencs 34 6 4 8 Real time Clock sim tarcctnasn nace tonneau neaninemaienneaataaiuieaieaanendends 41 7 Maintenance Service and Repair by the Customer Service ccsssseeceesseeees 44 List of Figures Fig 1 B si circuit diagr OI caactanerestarecnqestneysScgten a E a a ai 7 Fig 2 Situation of the connections and the control elements ssssseeeesreereeeeeen 10 Fig 3 Disposable COMME C LIONS scc0r3s ke crsetncce nests cassactacctnennnceoreiaxctcnatal cectacaotadalsaeaceasseanagers 10 Fig 4 Connection SUING aso dae seaerisctenscecentcacadeas gonecnaucaacaauyecsnueactuauiersduedsansisseansiedaduentes 10 Fig 5 Connection external hydrogen Storage ccscecceeceesseceteseeeeeseceteeeeenseeeeeeneees 11 Fig 6 Flashing patterns of the LED sssreersscariarn nanena e a 21 Fig 7 Basic settings gach eect areca clenat sence sce wleen ae ecenes yoncn nara ocacemccausacsnueneeusacctawatstaedececen 23 Fig 8 Schematic OVervieW cacictatcacag ances Garces ductannderataaeceacatands Ae attimiannmaatinianidesauiriatentades 26 Fig 9 Recorder WINdOW 21 5222 cccatsesscccrstiencebneciicegtadeaacintmucs dnabaycetpareeauepindeiarennicieaasaanagen 27 Fig 10 Selection for display ssc Sacasauscansccens necneacants veinsnnanpnensenedsunensynattensdandseuiscaniacieasdnenten 28 Fig 11 Mist ry data 1 sce cceraisaccnsconeees anne EA 31 Fig 12 History data 2 areca m
48. nit FC20 FC40 Description of the Visualisation and Parameterisation Software P h OCOS 6 4 6 History charging cycles After selecting the menu item window gt read out history it is possible to read out relevant data with respect to the previous charging processes from the device to visualise and to store them E history alta xi histary aja i ae i pa p rT ear R A sore thes ror erae of tol vof oo 1s eae eae needa fie oo oe E ag a N M B K E N ER E EE a aie ae nn iet eee pfo E T BENT CT TT ENT CY IT GE T AT WT T ECEE eal a ee ee E E E E E SS a ee ree sla i a a VC A ET a i gt i 3 7 tint modot noe arsta arm crvtormert temperos itacktempeanae accutempertse MHG tampershre Miana aiie m ramer Purges oc Comey o ma hts voag accu W mi moi ongen purge Jka m Fig 11 History data 1 Below the still dimmed table there is a read out button If this button is clicked the data are read line by line from the fuel cell unit and entered into the list The maximum total number of stored charging processes is 50 After the 50 charging process the respective oldest entry will be deleted However cycle numbering will continue history mele AEA stop time charge period prev charge pause Some Clute zonm zan eeu accutemp Rie ee IMHS T r
49. nit was developed and produced according to state of the art tech nology and it was subject to a safety inspection before delivery However faulty operation or misuse can cause danger for persons and for the fuel cell unit Every person involved in setting up operating or maintaining the fuel cell unit must 1 read this user manual and adhere strictly to its instructions 2 be trained and appropriately instructed for his her activity Phocos AG 11 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Product vescrition SS hoos 3 4 1 Safety measures on the installation location Danger When hydrogen is used as energy source fire and explosion hazards are gener ally increased The use of open fire as well as smoking is strictly forbidden in this area The rooms in which the fuel cell unit will be operated must dispose of the following e Local removal by suction for hydrogen on the installation location or e a room air suction or aerating installation on the room ceiling enabling safe ex hausting of the rising hydrogen out of the room The installation location has to be chosen in a way that product water escaping from the bottom of the fuel cell unit in the course of operation cannot cause dam ages or endangerments Attention A No electrical or electronic components or other components sensitive to water are permitted below the fuel cell unit 3 4 2
50. ower Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos 6 Description of the Visualisation and Parameterisation Software 6 1 Preliminary remarks Together with the device a parameterisation and monitoring software for PC is supplied In the following details as to function and handling of this software are given System requirements Hardware Customary medium performance PC with USB interface System software MS Windows 2000 XP 6 2 Installation The software is installed like any common Windows software 1 Insert data carrier 2 Begin installation by running setup exe 3 Follow the commands of the installation program enter path etc a Installation step back by clicking on back b Abort installation by clicking on abort 4 Finish installation by clicking on finish 6 3 Uninstall process If the software is to be removed from the hard disk proceed as follows 1 Open the Windows Start Menu 2 Open the Control Panel 3 Inthe control panel click on the Software symbol A list of the existing programs is shown 4 From this list select the symbol for FC20 FC40 5 Click on Remove The software will now be uninstalled 6 4 Structure of the Software 6 4 1 Basic settings After selecting the menu item Window gt basic device settings the dialogue win dow for the basic device settings opens up Here all significant settings for the running operation of
51. r Screw off fittings from the hydrogen cylinder attention left handed thread Exchange hydrogen cylinders Screw the fittings on the new cylinder Only in case of initial putting into operation detach snap closing of the hy drogen supply from the fuel cell unit Turn on hydrogen cylinder Open the pressure line at the pressure control fittings of the gas cylinder Only in case of initial putting into operation deaerate the supply pipe to the fuel cell unit filling it with hydrogen Only in case of initial putting into operation connect the snap closing to the fuel cell unit Connect the accumulator plug to the fuel cell unit Carry out a leak test with a gas leak spray The hydrogen pressure on the device must be between at least 1 bar and at most 10 bars 4 4 3 Connections on the device Connection H2 connector panel To this connector the hydrogen supply line is connected The supply of the fuel cell unit with hydrogen is necessary for its operation Connection A accumulator connector panel This connector is used for the connection of the lead accumulator to be charged A connected accumulator is necessary for the operation of the fuel cell unit pin as Phocos AG 15 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Product Description phocos signment 1 1 whereas the accumulator voltage must be within the limits of the specified ran
52. r 1 For e205 2008 roe Aza 05208 110978 E E si T ET ET zs ze ET E z 2 23 05 2006 16 49 52 00000d 00h im 415 00000d 09h 41m 16 25 2 254 2a 254 a na n 3 IEEE C7 EELEE 223 zag 235 21 231 235 nal n 4 004 24 05 2006 08 59 18 24 05 2006 09 03 24 000004 00h 03m 55s 000004 00h O4m 48 230 231 of 299 234 235 na n 5 ER Ss TC S n 6 08 24 06 06 0817 624 05 2008 09 2 4 3 00000d 00h 06m 03s 00000d 00h 00m 53 23a 234 as see z235 238 na n 7 0 000004 00h 03m 39s 00000dO0hO4m IIs 23 234 wA sA 235 e naf n 8 008 24 05 2006 09 35 03 24 05 2006 09 43 11 000004 00h 07m 47s 000004 00h O4m oz 232 234 sea go 23s 236 na n 9 003 01 06 2005 12 58 40 01 06 2006 14 09 10 000004 01h O7m 26s 000004 13h 08m ons 24 4 25o 23 6 sof 246 naf n 10 00000d 00h 00m 57s 00000d 18h 58m O7 24 5 249 ao 2s 234 235 na n 11 011 02 06 2008 14 31 34 02 06 2006 14 38 57 000004 00h O7m O0s oooood 00h 34m 16 243 24 A soif zs so nal n wfoof T o S S o o o oof oof oof oof o joof f oof ood oo od 0 0 og od C 16 000 oof ood oo oof oo oo 0 0 c 2 pe oo oo oof od 0 0 o c 0 9 000 oof ood oo oo oo oo 0 0 c Bo O oo oo oof od oof od o o 000 oof ood oo oo oo oo 0 0 c Fig 12 History data 2 Phocos AG 31 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos The real entries depend on the respective dev
53. re transferred to the control ler of the fuel cell unit If the transfer is not desired the window can be closed by clicking on the abort button 9 For all events on the user inputs the following applies If an event to be monitored by the controller did occur the corresponding reactions will be carried out only once Therefore it is insignificant how long the event con tinues But it also means that the new occurrence of the significant event even af ter the previous event relevant state has already ended does not lead to a new re action In order to arm the event control anew a special message must be sent to the fuel cell unit or its GSM module respectively explanations in the respective paragraph l Hint Reactions to USER events are carried out only once The event control must be reset explicitly by sending a special message Phocos AG 40 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos The FC20 FC40 is not only capable to send messages but also to receive messages and to react in the way described in the following The special content of the SMS or e mail to be sent to the fuel cell unit has been summarised in a table Content of the SMS or e mail Action of the receiving fuel cell unit 7 XXXX yyyy user PIN xxxx old valid PIN yyyy new 1
54. sion release no software document issue Product version FC20 FC40 Software version V01 00 Build109 Issue 10 2006 Phocos AG 6 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 phocos Product Description 3 Product Description 3 1 General functions and areas of application appropriate use The fuel cell unit FC20 FC40 is assigned for charging lead accumulators with rated voltages of 12 V 24 V in the allowed temperature range It must be considered that the user or the manufacturer must input the application related voltage levels of the automatic charge control before putting the fuel cell unit into operation On delivery factory settings are parameterised ensuring an automatic cyclic charg ing mode e Accumulator type Lead accumulator e Final charging voltage 14 4V 425 C e Switch on voltage 11 5V e Temperature correction value for accumulator 34 8 mV K e Stack voltage 1 8 V stack QUTDOOR CHARGERIGut2 E i USB EE e User speciric 4 P PARAMETRIZATION ACCUMULATOR CONTROLILER HANDLIN S SAEFTY CONTROL HYDROGEN STORAGE DC DC CONVERTER BUFFER USER SPECIFIC PERIPHERY APPLICATION FUEL CELL with PERIPHERY CHARGING ELECTRONICS A LEAD ACCUMULATOR AUXILIARY POWER SUPPL 12 24V Fig 1 Basic circuit diagram Phocos AG 7 WWW phocos com Subject to Change witho
55. sstiincssnccesannssdeariuucseniced asurdennisdielidexeieaddaimeledeasdeenes 14 4 4 2 Connection of the hydrogen acCUMULALOL ccceceesssssssssceeeeeeeessssssseaseeeeeess 15 4 4 3 Connections on the device sssssssssssnnssnnnsnnnnneeeenneennnnrnrnrerrrrrrrrererereeerrereerene 15 4 4 4 Putting the device into Operation cccsssssccccccesssssssssssseececeseesssssssssseeeeeess 17 5 Operating Man al sissies secs cy ainnssaseantednacawetbsndewadiegdeenttend cndeeaaueiaanaendbnademetieianenaesd 18 5 1 General functional description nicuimminimuteimminietudimniaimmtacenan 18 5 2 Operating MOUS siaiscsnsssdnicnosanpatesaceseaessdegusdsuvssntasigniivdnssomincisejudrssiesuadentest 18 5 2 1 Accumulator voltage recognition scccccccccsssssssssssseeceeseesssssssseseeeeeeseeseeses 18 5 2 2 Initialisation OF the FC20 FCA irciccciescisiecusricacveindeseseledenedatedcvedassiduesieiedecedainseisas 18 5 2 3 Initialisation of the GSM module dnnisecmenaneninandamnkoerkuminsvavankennmancinauicanduenmimmnnsiak 18 Bi eI NOG Soe tcantecrionsteonstcactnnebacuihaissubanchooasbialeassonbuarbleionkontpesbtetenrenillet 18 5 2 5 Cooling phase acticin i cecindticeaaldgee aise adireaitn dnacindiuearaaldinesainawduduamaaninseedatiiuiien 19 5 2 6 Stand by mode sec ccerateccasnctigechaiiiattiniiaciusdlealdtnRiadteniieasdranhaddsnieaiduadtiaiteniieaebeiads 19 5 2 7 Heating ModE seseina AEE E AE A 19 5 3 Operation with GSM module optional
56. t to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos Phocos AG the rated open circuit voltages before the start of the device provides a first indi cation for the operatability of the stacks If the supply with hydrogen and air are ensured the measured voltage for each stack should be 2 4 V 0 8 V per cell or higher when no current is drained In this case the stacks are operational and by successively increasing the drained current the electrical output power can be in creased The stack voltages will consequently decrease gradually After the operat ing voltage is reached this value will be kept constant The operating stack voltage in particular has a far reaching influence on the opera tion characteristics and the service life of the stacks In extreme cases permanent damages can occur within short time if a too low value has been set for the voltage Therefore only staff with special knowledge in the field of fuel cells should be al lowed to modify the settings Temperatures The stacks are situated in a container with coolant On the one hand this coolant will cool the stacks efficiently in case of high ambient temperatures and on the other hand its great thermal capacity will expand the cooling phase in case of low ambient temperatures The heat emission of the stacks to the surrounding liquid leads especially in case of a start at
57. the device can be carried out Phocos AG 22 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 Description of the Visualisation and Parameterisation Software phocos l float 0 0 17 0 15 0 Indication Data Type Min Value Max Value If an invalid value is entered in a data field value out side of the permitted range for this data field an indi cation appears Default Value Accumulator settings In 7 a preselection is possible between a 12V and a 24V accumulator If the exist ing setting is modified the corresponding default voltage levels for the begin and the end of the charging processes will be set For this a customary lead acid accu mulator is assumed as it is commonly used as starter battery for motor vehicles EJ device basic settings number of stacks in device one stack amp two stacks Operating voltage open circuit voltage GSM exists D stacki A 1 80 total stack1 3240 total icy 5 stack2 27 80 v 3 60 H sack2 ajz v 480 v purging below S 1404 exists temperature sensors 7 S start of charging end of charging M abient aunt below above I onstack tated voltage of 2 Wee connected Accu C 24V 311 5 v on accu 314 4 vonaccu at 25 C t lt 25 C V MHS aS 25 C s 334 8 mY per Kelvin coolant pump inside on E on stack above previous plateau in F at difference above 5K temperature course version o 00 build
58. time use in menu tools the panel clack Feldstarke 17 findout entspricht etwa 79 dBm gut D device PIN state and counter state tcodot _ PIN already accepted on GSM modul switch events for send hard off of SMS or eMail soft _off 2 configure te Fig 15 Information window GSM module The input data in the blue bordered fields are used exclusively by the controller and therefore only stored by it they do not require a direct connection with the GSM module which can be switched off at that time The e mail address 1 designates the receiver of the messages which will be sent by the fuel cell unit on request or in event dependently The remote communica tion by e mail offers certain advantages with respect to SMS communication as to further data processing Several mobile network providers are limiting this kind of data transmission with respect to number and or scope Further information on this Phocos AG 35 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Description of the Visualisation and Parameterisation Software phocos topic must be requested from the contractual partner of the respective network Although it is possible that a mobile phone receives e mails in form of SMS this op tion is not supported because all advantages of e mail communication would be lost in this way For this reason it will be generally assumed that th
59. ut notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 Product Description 3 2 Performance data Power FC20 FC40 Charging voltage 12 V 24 V Maximum charging current FC20 FC40 Hydrogen consumption Technical information and data phocos 20W 40W 10 5 14 7 V 21 0 29 4 V 2 0A 1 0A 4 0A 2 0A approx for the above given power FC20 FC40 Cooling Permitted accumulators Interfaces Inputs Outputs Data exchange Analog inputs Digital inputs Digital outputs Signal output Gas supply Hydrogen CO content Operation pressure hydrogen Connection Process air Environmental conditions Ambient temperature range Storage temperature Phocos AG www phocos com 20NI h 40NI h Water Lead accumulator lead gel accumulator 12 V 24V USB interface GSM module optional 2 x 0 10 V in connection with GSM option 2 x 0 5 V in connection with GSM option 2 x 0 5 V in connection with GSM option 3x0 5V Purity 3 0 99 9 or better lt 20 ppm Minimum 1 bar maximum 10 bar Self sealing snap closing Clean ambient air good aeration 25 450 C if the device is operationally con nected Minimum 5 C system temperature 8 Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 Product peseription hows Degree of protection IP 54 Pollutants The ambient air must not contain increased con centrations of sulphur compoun
60. voltage are still surveyed and the possibility to communicate through the USB interface is maintained The stand by mode is signalised by the LED Fig 6 5 2 7 Heating mode If the stack temperature becomes lower than the set minimum value e g in case of frost in outdoor use the device switches into heating mode In this mode a part of the generated electrical power is used for charging the accumulator and the remaining part is used for heating the relevant components If during the heating Phocos AG 19 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Operation Manual phocos mode the accumulator voltage reaches the value of the final charging voltage the whole electrical power generated by the fuel cells is used for heating 5 3 Operation with GSM module optional The optional GSM module enables the communication with the fuel cell unit through mobile network On the one hand the device can send system information or user specific information e g events at the user inputs or information derived from them respectively by SMS and or e mails On the other hand the fuel cell unit can receive and process command sequences by SMS and or e mail Phocos AG 20 www phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 phocos Operation Manual 5 4 Messages signals The fuel cell unit generates the following messages and provides them as electric
61. y 2006 11 00 28 0200 CEST IX Envelope From lt 015114730703 t mobile sms de gt X Envelope T o lt matthias armold flexiva de gt lt Delivery Time 1146560152 Received from post strato de 192 67 198 62 ltby localhost with POPS fetchmail 6 2 1 Ifor root localhost single drop Tue 02 May 2006 11 00 25 0200 CEST Received from thor ic3s de thor ic3s de 62 159 211 165 by mailin webmailer de 8 13 6 8 13 6 with ESMTP id k428tpf0025068 Ifor lt matthias amold flexiva de gt Tue 2 May 2006 10 55 51 0200 MEST Received by thor ic3s de Sendmail 8 12 9 via SMTP for lt matthias amold flexiva de gt from t mobile sms de id k428tpJC004495 Tue 2 May 2006 10 55 51 0200 CEST Date Tue 2 May 2006 10 55 51 0200 CEST From 015114730703 t mobile sms de To matthias amold flexiva de Message ID lt D1T6C06050208554348396 t mabile sms de gt Received by D1SMH6 as D176C06050208554348396 by 3 105 17 12 2004 BVO Revision 1 31 Subject T Mobile SMS E Mail MIME Version 1 0 Content Type text plain charset 1 0 8859 15 Content Transfer Encading 8bit UIDL Sall3m 2E 1Q4 2 60 20bd00b1c0ca00bb40bffffffff7 71 Diese Nachricht wurde Ihnen durch T Mobile zugestellt Bitte beachten Sie bei Ihrer Antwort dass nur die ersten 160 Zeichen der Betreffzeile und des Nachrichteninhalts weitergeleitet werden Fig 13 E mail import window The concrete structure and content of suc
62. y and correct functioning of the room aeration for fresh air supply and for the exhaustion of the hydrogen escaping due to normal operation mode e The minimum temperature of the device is 45 C e The indications and instructions of this user manual must be known 13 WWW phocos com Subject to Change without notice Hybrid Solar Power Fuel Cell Unit FC20 FC40 8 Product Description phocos 4 4 1 Choice of the accumulator Phocos AG The fuel cell unit is designed for cyclic operation That means that the power sup ply system must be dimensioned in a way that the average power taken from the accumulator is less than the power supplied by the fuel cell unit Special attention must be paid to the capacity of the chosen accumulator In dependence of the en ergy demand of the installation to be supplied with power the capacity of the ac cumulator determines the frequency and the duration of the charging cycles If the fuel cell unit is used in areas where outside temperatures only slightly above or even below 0 C can be expected the duration of the charging cycles should be op timised in order to reach high energy efficiency During their operation the fuel cells provide enough heat to ensure optimum temperature conditions in the interior of the device However in case of the above mentioned low outside temperatures this requires several hours of operation of the device In order to keep the heating period as short as possible a

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