Product Training EFOY-Fuel Cells
Contents
1. Avoid exposure to sunlight and other sources of heat Off heat and exhaust gas are discharged from the installation space Supply air Off heat Installation of the Unit EFOY 1 Belt for fastening the unit 2 Screws to fasten the mounting plate screws are not included in the standard equipment 3 Place the unit onto the mounting plate 4 Strap the unit tightly to the mounting plate Note The unit should be mounted on a substrate thick enough to sustain the weight and absorb operational vibrations EFOY Supply and Exhaust Air Duct ENERGY FOR YOU 1 Supply Air Provide the installation space with an air inlet i opening of at least 40 sq cm in open cross section Supply air jes n i Heavily structured openings fine grid small gaps need to be wider To ensure proper ventilation of the installation Space the sucking side of the cooling fan should not Exhaust air Warm cooling air be ducted Minimum distance from the side wall 3 cm Off Heat e The off heat must be removed from the installation Supply air i I i eee Space via a 100 mm tube The outlet opening must SISI have an open cross section of at least 40 cm Heavily structured openings fine grids small gaps need to be wider EFOY Installation of the Off Heat Duct NERS FORNON Note All hoses should be installed the shortest possible way In as few bows as possible Avoid all possible f2. 7 Store the service kit and the User Manual inside the vehicle EFOY When does the EFOY Fuel Cell start operating ENERGY FOR YOU Automatic Manual Antifreeze Ps C Battery voltage On 12 3 V Manual start will only Regardless of the battery be possible at a voltage A Lan q maximum of 13 2 V Note The system requires a minimum voltage of 10 5 V i Start up Phase of the EFOY Fuel Cell EFOY Output J The stack is regularly deactivated for several seconds during charging regeneration cycle A VA Time Start up Phase up to 30 minutes Note The EFOY Fuel Cell cannot be manually turned off during the start up phase EFOY Switch Off Cycle in the Automatic Mode EAD FOR SEL Upon reaching the switch off threshold voltage V in the Automatic mode the charge current I is reduced The unit automatically enters the standby mode when reaching the switch off threshold voltage Battery voltage V EFOY Switch off Cycle in the Manual Mode EN REV FOR SEL Current U Switch off process Note The switch off process allows a controlled disconnection of the EFOY Fuel Cell The switch off process may take up to 30 minutes in the manual mode Avoid interrupting the switch off process Service Fluid EFOY ENERGY FOR YOU Service Fluid is needed when the unit is operated for extended periods of time at high temperatures When the service f
3. 0 98 in ca 215 8 46 in 140 5 51 in EFOY ENERGY FOR YOU Dimensioned Drawing of the Fuel Cartridge Holder M5 M10 ti ul I h voncdstarke d E EFOY Dimensioned Drawing of the Fuel Cartridge ENERGY FOR YOU M5 M10 231 AUF in 318 1252 in 185 17 28 in
4. 45 Ah 100 Ah J15Ah 150Ah 20Ah 200 Ah 25 Ah 250 Ah R f ecommended type of battery 12 V Lead accumulators lead acid lead gel or AGM The above listed minimum capacities must be observed In any case If the runtime of the EFOY fuel cell is often less than one hour the switch on threshold should be lowered or a higher capacity battery should be used Fewer long charge cycles are better than many short ones because consumption and wear of the unit rise during the start up process EFOY Battery Knowledge ENERGY FOR YOU Battery voltage depends among other things on Charge condition Load current charge current Temperature Suitable types of battery Lead gel recommended type of battery Lead acid liquid AGM Note Please follow the recommendations of the battery manufacturer and if the occasion arises adjust the settings of the switch on and switch off thresholds by means of the interface adapter EFOY Electrical Connection via a Central Electrical Box ENE REV FOR SO When using parallel connected batteries attach to the first battery and to the last one Fuse 2A sense line EFOY Electrical Connection Directly to the Battery ENERGY FOR YOU When using parallel connected batteries attach to the first battery and to the last one Fuse 2A sense line power line Fuse 7 5A EFOY Mounting the Remote Control
5. ENERGY FOR YOU Connection Description SS New Connection Enter a name and choose an icon for the connection SFC gt CONFIG Mame switch on voltage actual 12500mV min 12000mV max 12800mMV 2 ecu Unit switch off voltage actual 14200mV min 13600mV max 14600mV x switch off current actual 2000mA min 500mA max 10000mA leon reaction time actual 10s min 1s max 300s 20 Note For a detailed description see the Interface Adapter User Manual I Customer Service EFOY ENERGY FOR YOU Our customer service representatives will gladly assist you with any questions concerning installation and start up SFC Smart Fuel Cell AG Eugen Sanger Ring 4 D 85649 Brunnthal Nord Germany Phone 49 89 673 592 0 Fax 49 89 673 592 369 Email salesldsic com www sfc com EFOY Contents ENE REV FORO oe e o Design and Operation of the EFOY Fuel Cell EFOY Fuel Cells Standard Equipment and Accessories Installation of the EFOY Fuel Cell Start up of the EFOY Fuel Cell Configuration of the ON and OFF Parameters Hybrid Control System Annex CV Hybrid Control System Installation EFOY EFOY Please read the EFOY Fuel Cell User Manual or the above instructions carefully Solar module Please read the installation instructions of the solar charge controller or the battery computer respectively For further information please contact Buttner Elektronik Please connect t
6. ENERGY FOR YOU Plug the remote control into the socket marked Remote Control Note If the supplied DL1 data cable is not long enough or too long it may be replaced by a longer or shorter commercial network cable Type Category 5 patch cable Surface mounting I Remote Control of the EFOY Fuel Cells EFOY Information and language selection button EFOY ENERGY FOR YOU I aa Reset button On OFF button SYellovy warning light Please change fuel Automatic operation cartridae button Red warning light Error 9 EFOY Contents ENE REV FORO 1 Design and Operation of the EFOY Fuel Cell 2 EFOY Fuel Cells Standard Equipment and Accessories 3 Installation of the EFOY Fuel Cell 4 Start up of the EFOY Fuel Cell o Configuration of the ON and OFF Parameters 6 Hybrid Control System 7 Annex Start Up EFOY ENERGY FOR YOU 1 Clean the installation space Check all electrical contacts and the fastenings of fuel cartridge holder and unit Connect the fuel cartridge to the unit and check for secure fastening Auto appears on the display of the remote control The unit is ready for operation and automatically starts operating at a battery voltage of 12 3 V Tse S a Switch on the unit manually to check its functionality This may be done up to a battery voltage of 13 2 V If necessary reduce the battery voltage by switching on electrical consumers
7. e AA pe Product Training EFOY Fuel Cells Installation and Setting of the Operating Parameters CFOY ENERGY FOR YCU EFOY Contents ENE REV PORNO ee ee eS Design and Operation of the EFOY Fuel Cell EFOY Fuel Cells Standard Equipment and Accessories Installation of the EFOY Fuel Cell Start up of the EFOY Fuel Cell Configuration of the ON and OFF Parameters Hybrid Control System Annex I Cross Sectional View of the EFOY Fuel Cell EFOY Charge cable and Heat exchanger Fan Intermediate tank remote control connectors HPHNH gigi gegigigigsgigigegigigigligi 1 FH ee H HEHH H HAUT lee Bi elia x T Ami lt 0 iil LEJ 11 oar dij TI HIT TTT ii d nH TI I B af di i TT Peery KI Ll NE N E I LI I nmr FF Po p a Pump Stack ENERGY FOR YOU Cross Sectional View of the EFOY Fuel Cell Intermediate tank Heat exchanger I KI 1 EN GSS r i E A aaa l nm A i N yy u E i ir i ii qi Mi r rt i ij E ni Hi Li i i A a n 4 pi I di if 2 le E TC l A l i vi lt a Pump unit Control and connector charge cable remote control i Operational Principle of the EFOY Fuel Cell EFOY ENERGY FOR YOU Off heat Battery m Exhaust gas Water vapor CO Methanol EFOY Electrical Consumers Device
8. he control line of the charge controller or the battery computer to the Data Interface socket of the EFOY Fuel Cell Note Make sure a solar module is connected before connecting the control line of the charge controller EFOY Contents ENE REV FORO O Design and Operation of the EFOY Fuel Cell EFOY Fuel Cells Standard Equipment and Accessories Installation of the EFOY Fuel Cell Start up of the EFOY Fuel Cell Configuration of the ON and OFF Parameters Hybrid Control System Annex i Operational Principle of the Fuel Cell EFOY ENERGY FOR YOU Operating principle Devices Anode Cathode Carbon dioxide Ga Water vapour 101 E OOO 19 Methanol Water gt Membrane Electrolyte SFC s patented water recirculation Diagram of a direct methanol fuel cell EFOY Dimensioned Drawing of the Main Unit ENERGY FOR YOU IN EFOY Dimensioned Drawing of the Remote Control ENERGY FOR YOU ca 28 1 10 in Note The standard equipment includes a drill template for flush mounting ca 78 3 07 in EFOY Dimensioned Drawing of the Off Heat Bow ENERGY FOR YOU EFOY Dimensioned Drawing of the Off Heat Flange ENERGY FOR YOU EFOY Dimensioned Drawing of the Orifice ENERGY FOR YOU EFOY Dimensioned Drawing of the Mounting Plate ENERGY FOR YOU ca 445 17 52 in 350 13 78 in 70 2 76 in ca 25
9. low obstacles squeeze kink offset EFOY Installation of the Exhaust Gas Hose EN ER N FORNON Exhaust Gas Hose Exhaust gas Water vapor and CO Only use the exhaust gas tube supplied to route down Avoid siphoning the exhaust gas from the installation space to the outside Make sure the liquid components do not gather in the hose and may drop freely from the end of the hose Make sure all hoses are installed the shortest possible way In as few bows as possible Avoid all possible flow obstacles squeeze kink offset During winter operation at a constant ambient temperature of less than 6 C the exhaust gas hose should be shortened to a maximum of 50 cm The end of the hose should be cut diagonally if the hose ends vertically EFOY Installation of the Fuel Cartridge Holder ENERGY FOR YOU 1 Off heat flow 2 3 Electrical Connections Power line Sense line EFOY ENERGY FOR YOU Power line This line supplies electrical power from the fuel cell to the battery Note In the presence of a central electrical box the power line should be connected to the outlet of the additional charging unit Sense line This line is used to measure the battery voltage Note Make sure the sense line is directly connected to the battery EFOY Recommended Battery Capacities ENERGY FOR YOU EFOY 600 EFOY 900 EFOY 1200 EFOY 1600 ecommended battery capacity
10. luid is low the red light turns on and the message Please refill the service fluid appears on the display of the remote control There is no need to add service fluid when starting the unit for the first time Make sure no dirt and no foreign matter enters the filler hole Slowly pour the entire contents of the bottle into the filler hole with the unit slightly tilted It is recommended to keep the service fluid together with the User Manual close to the unit Peale Service Fluid EFOY Contents EERE PORNO Design and Operation of the EFOY Fuel Cell EFOY Fuel Cells Standard Equipment and Accessories Installation of the EFOY Fuel Cell Start up of the EFOY Fuel Cell pys Configuration of the ON and OFF Parameters Hybrid Control System i i n 6 7 Annex EFOY Configuration of the ON and OFF Parameters using ENERGY FOR YOU an Interface Adapter i EFOY EFOY off off v u 142V E 5 optimum with EFOY 5 123V charge status E i TV i i time t without EFOY Configuration on a PC using Automatic operation of the EFOY Fuel Cells an interface adapter EFOY Control and Monitoring of the Operating Parameters ENERGY FOR YOU Components required Interface Adapter IA1 Data cable Cat 5 PC using a terminal interface e g Windows HyperTerminal USB RS232 adapter if applicable EFOY Programming using a Terminal Software
11. s in a Mobile Home CER EOR SO Entertainment amp communication Electrical devices f EFOY Contents EERE FOR SON e Se oe Design and Operation of the EFOY Fuel Cell EFOY Fuel Cells Standard Equipment and Accessories Installation of the EFOY Fuel Cell Start up of the EFOY Fuel Cell Configuration of the ON and OFF Parameters Hybrid Control System Annex Standard Equipment EFOY Fuel Cell EFOY Beecher pass rihn a User Manual EFOY Service Fluid Service Kit Set of cables ESS 20 Off heat duct set EFOY ENERGY FOR YOU Mounting plate with belt Fuel cartridge holder with belt EFOY Accessories ENE REV FORO Extension sense line Extension povver line Length 8 m Length 8 m M5 Fuel cartridge M10 Fuel cartridge EFOY Contents ENE REV FORO 1 Design and Operation of the EFOY Fuel Cell D 4 9 6 7 EFOY Fuel Cells Standard Equipment and Accessories Installation of the EFOY Fuel Cell Start up of the EFOY Fuel Cell Configuration of the ON and OFF Parameters Hybrid Control System Annex EFOY Notes on Choosing the Location ENERGY FOR YOU Operating temperature range 20 C to 40 C max 30 cm Maximum distance between fuel cartridge and fuel cell 30 cm _ en re aT ie sore Se Minimum lateral distance from the walls 3 cm Make sure the supply air opening is big enough
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