H-100 Fuel Cell Stack
Contents
1. 2 Using the fuel cell stack with water inside can irreparably damage it H IOO Fuel Cell Stack User Manual V4 0 27 O Horizon Fuel Cell Technologies Automatic Shutdown Bleeping interpretation during starting procedure If the system shuts down before finishing the start up procedure then please refer to the following bleeping interpretation If the system stops during the starting No of Bleeps Interpretation Actions 1 Low fuel cell open voltage protection i e the average cell voltage is lt 0 7V 2 High ambient temperature protection the ambient temperature around the system is 45 C 3 Low external power voltage protection i e external power is 12V Automatic Shutdown Bleeping interpretation during running procedure If the system shuts down during operation within the product parameters then please refer to the following bleeping interpretation No of Bleeps Interpretation Action 1 High current protection i e current is too high For H 100 H 300 is 10A For H 500 H 1000 is 30A 2 High temperature fuel cell protection i e fuel cell is running 65 C 3 Low voltage fuel cell protection i e the average voltage per cell is 0 5V Diagnosis Potential for fuel cell damage Fuel cell internal short circuit Yes Controller internal short circuit Yes Controller reading too low voltage No Controller not operational Yes Supply valve not opening No Purge valve is not opening Yes2. Blower s not operational No LCD not operational No High current protection Yes High temperature fuel cell protection Yes Low voltage fuel cell protection Yes High ambient temperature protection Yes Low external power voltage protection No Temperature sensor resistance different Yes Note If you got one of Yes among above mentioned maybe there is something wrong with the stack If the system shuts down by itself check the following details 1 Make sure you have connected all wires according to the diagram 2 Make sure the external voltage is 12V 14V 3 Make sure you have connected the hydrogen supply with the correct pressure 4 Make sure the load is below 100W Overload can trigger the stack protection function to avoid the damage to the stack 5 Check whether the fuel cell temperature is below 65 C the system will shut off if it is above 65 C H IOO Fuel Cell Stack User Manual V4 0 28 O Horizon Fuel Cell Technologies Checking the Fuel Cell System If the fuel cell shuts down you need to check the voltage of the fuel cell by measuring between the FC and FC connectors on the fuel cell There are 3 possible scenarios Voltage 0 O Check the supply valve and purge are open e f not open see Checking Valves in trouble shooting e f open check that the wire FC and FC from the fuel cell controller are connected the right way around to the fuel cell FC and FC connectors red
3. 28 Once the system has started you will hear a 3 seconds long purge from the purging valve this is the initial hydrogen going through the fuel cell to clear any non Hydrogen gas from the system If you do not hear the hissing from the purge valve review Checking the Valve in Troubleshooting Following the purging the fuel cell will short circuit 5 times over a 1 minute period If you cannot hear the 5 short circuits review Check the SCU in Troubleshooting H IOO Fuel Cell Stack User Manual V4 0 22 C Horizon Fuel Cell Technologies RUNNING PROCEDURE After system has started depending on your setup and application you can change your load to get the power you need within the specified power range for this fuel cell Don t connect up a load that will demand more power than the fuel cell is rated at This demand of power from the load can permanently damage the fuel cell During the operation monitor the Hydrogen flow and pressure to consistently supply hydrogen at 0 5 0 6Bar Monitor the voltage of the external power supply to be a providing 12 14V Direct the outlet tubing of the purge valve away the fuel cell Do not let the purged hydrogen go back towards the fuel cell stack it will damage the fuel cell see step 7 in setup Pay attention to the purge take care of the performance during the purge If after each purge the rise of the performance is big it means you need to increase the pressure of hydrogen a
4. Rejuvenate by injecting water into the stack before use 1 Connect a short section of hosing to the gas port marked H2 in and another one to the H2 out port 2 Fill a syringe with pure water distilled and connect it to the hose attached to the H2 in port 3 Inject pure water into the stack until you see water coming out of the hose connected to the H2 out port Keep the water inside the stack for about 5 minutes Now disconnect the syringe and leave the water in the two hoses 4 Purged the water out of the stack thoroughly before use This is done by connecting the H2 supply to the stack without a load attached and purging the stack thoroughly i e letting hydrogen flow through the stack to remove water and other contaminants Make sure the hydrogen supply pressure is not gt 0 5bar WARNING 1 Please make sure you have purged the water out of the stack thoroughly before use 2 Using the fuel cell stack with water inside can irreparably damage it WARNING Disconnect the hydrogen supply completely if the fuel cell is not in operation for more than 30 mins This is to stop hydrogen gas leaking into the fuel cell and destroying some of the parts WARNING When you turn off the on off switch connected to the control box at the temperature of the fuel cell stack higher than 45 C the stack will not stop working immediately Only when the stack temperature goes down below 45 C the whole system will stop operation in order t
5. We highly recommend customer use a hydrogen sensor not provided to detect the hydrogen leakage H IOO Fuel Cell Stack User Manual V4 O l O Horizon Fuel Cell Technologies 1 3 Handling Compressed Gas Cylinders WARNING Do not handle compressed hydrogen gas cylinders without training or experience e Use a pressure regulator to control the fuel inlet pressure to the system e Do not alter the fitting on a regulator Ask experienced personnel for help e Do not attempt to force gas cylinder threads e Never transport a gas cylinder with regulators attached Ensure cylinder caps are in place Always use a cylinder cart with a safety strap or chain e Secure a high pressure cylinder to a bench post or fixed object to avoid accidental contact e Avoid unnecessary contact with On Off valves They can easily move to On by accident 1 4 Hydrogen Leakage Hydrogen is colourless odourless and tasteless Hydrogen is non toxic but can act as a simple asphyxiant by displacing the oxygen in the air There are no warning symptoms before unconsciousness results WARNING Inhaling hydrogen can lead to unconsciousness and asphyxiation Hydrogen molecules are smaller than any other gas making hydrogen more difficult to contain It can diffuse through many materials considered airtight Fuel lines non welded connections and non metal seals such as gaskets O rings pipe thread compounds and packings present potential leakage or permeation s
6. home appliances may not be suitable for this activation process It may cause damaging 3A STEP4 Connect the outside hydrogen supply valve to the stack The hydrogen supply valve will prevent damage to the stack from the hydrogen while the stack is off Notice the direction of the connection of the Hydrogen supply valve The finished connection is shown in 4H 4C 4D H IOO Fuel Cell Stack User Manual V4 0 15 Horizon Fuel Cell Technologies 4F 4H STEPS Connect the stack to the purge valve through the filter for a longer runtime and a better performance 5A 5H If not the gas out of stack may have a negative effect on the purge valve after a long time running Connect the output of the purge valve to a place away from the stack in case of the damage caused by the Hydrogen leakage 5A 5B H IOO Fuel Cell Stack User Manual V4 0 16 Horizon Fuel Cell Technologies H IOO Fuel Cell Stack User Manual V4 0 17 O Horizon Fuel Cell Technologies STEP6 Check all the connection first and connect the load to the system Load is linked to the load at the controller Load links to the FC and load in the stack shown in 6A STEP7 Direct the outlet tubing of the purge valve away the fuel cell Do not let the purged hydrogen go back towards the fuel cell stack this will damage the fuel cell Purged Hydrogen H IOO Fuel Cell Stack User Manual V4 0 18 Horizon Fuel Cell Technolo
7. red and black black e f wiring wrong change it to be correct immediately repetitive attempts at starting the stack with this setup will permanently damage the stack e f wiring correct disconnect the FC and FC from the fuel cell controller and start the fuel cell system again it will shutdown automatically following this measure the fuel cell voltage e f voltage is still O the stack has short circuited internally and needs to be changed Contact support horizonfuelcell com with the diagnostic fuel cell internal short circuit with the fuel cell number e If voltage is gt 0 then the controller has a problem Contact support horizonfuelcell com with the diagnostic Controller internal short circuit with the controller number Voltage lt 0 6 per cell O The fuel cell is dehydrated and needs re hydrating Follow the re hydrating the fuel cell Conditioning the fuel cell steps Voltage gt 0 6 per cell O The fuel cell itself is therefore fine and the fuel cell controller is reading the voltage wrong O Check the various connection points between the fuel cell stack and the controller are firmly in place O Re start the system If the problem continues contact support horizonfuelcell com with the diagnostic controller reading too low voltage with the controller number Checking Valves i With the system completely setup Start the system 2 Once the system has started you will hear a 3 seconds long purge from the purgi
8. small amount The fuel cell is flooding and so you need to use the pressure to push the extra water out e Short circuit will happen every 10 seconds and last for 100ms everytime e f the load does not operate well with the short circuit on we recommend that you run the fuel cell for 10 minutes prior to switching the load on e here will be a slight decrease in the power provided to the load with the short circuit off Make sure the orientation of the fuel cell is kept the same during operation as shown on the fuel cell stack with the sticker This side up We highly recommend you don t move the fuel cell around or shake vigorously during operation If the system shuts down during running procedure listen for how many beeps and review the Bleeping interpretation during running procedure H IOO Fuel Cell Stack User Manual V4 O 23 Horizon Fuel Cell Technologies SHUTDOWN PROCEDURE To shut down the fuel cell system down please follow these steps Turn off the load Hold the ON OFF button down for 2 seconds to stop the system you will hear one long beep which means the system is shutting down Turn the hydrogen supply off and disconnect the hydrogen supply from the supply valve If the fuel cell is not in use for longer than a day please follow these final steps Disconnect the external power supply from the controller Completely disconnect the fuel cell system from the load Completely disconnect the
9. 4V in H 5000 then the power is not coming through to be able to power the controller blowers and valves Change or recharge your power supply and check the voltage that it meets the fuel cell voltage before connecting it up to the controller Check the SCU During operation with the SCU on the voltage of the fuel cell will drop for 100ms every 10 secs If the fuel cell voltage is not dropping then contact support horizonfuelcell com with the diagnostic SCU not operational with the controller number If the stack is un used for a long period of time more than 4 weeks Rejuvenate by injecting water into the stack before use 1 2 3 Connect a short section of hosing to the gas port marked H2 in and another one to the H2 out port Fill a syringe with pure water distilled and connect it to the hose attached to the H2 in port Inject pure water into the stack until you see water coming out of the hose connected to the H2 out port Keep the water inside the stack for about 5 minutes Disconnect the syringe Purged the water out of the stack thoroughly before use This is done by connecting the H2 supply to the stack without a load attached and purging the stack thoroughly i e letting hydrogen flow through the stack to remove water and other contaminants Make sure the hydrogen supply pressure is not gt 0 5bar WARNING 1 Please make sure you have purged the water out of the stack thoroughly before use
10. Cy Horizon Fuel Cell Technologies H IOO Fuel Cell Stack User Manual V4 O Updated 28 DEC eoiO O Horizon Fuel Cell Technologies Disclaimer This manual incorporates safety guidelines and recommendations However it is not intended to cover all situations It is the responsibility of the customer to meet all local safety requirements and to ensure safety during operation maintenance and storage of the H 100W stack Although all efforts have been made to ensure the accuracy and completeness of the information contained in this document Horizon reserves the right to change the information at any time and assumes no liability for its accuracy Actions that will void the fuel cell and controller warranty o Attempt under any circumstance to disassemble or inappropriately tamper with the fuel cell o Operate the fuel cell with a controller not designed and built by Horizon for the specific fuel cell o Operate the fuel cell with valves and blowers that are not provided by Horizon for the specified fuel cell and controller Disassemble the fuel cell Disassemble the controller Operating the fuel cell and controller that is not in the setup and or specified in the user manual provide for the specific product There will be no repair replace or refund should disassembly or tampering occur If you have questions or need help with regards to the fuel cell and its technology please contact IMPORTANT In or
11. der for the warranty to come into effect the stack must be registered on the Horizon Warranty Page at www horizonfuelcell com warranty htm H IOO Fuel Cell Stack User Manual V4 0 O Horizon Fuel Cell Technologies Table of Contents de A E E E 1 VI ele ee a E E E E E 6 3 Stack and System Component Information 10 4 Technical SpeclliCatlOl uusaxccnsixa icis sing oe vasianiiads rua dtr Gd a a iE F V irl ze aci 12 9 System EU a eo RENI 13 6 System Set up DIAOESITI s potui ca cias ai dde eee 20 T Notes for the SSD dass E alea iat adea etica 21 8 Operating PIOGGOUE GS a een sm HEC nn 25 9 Performance Characteristics 25 10 Storage and Re Use eene nennen nnns 26 11 Trouble Shooting amp System Checks 27 12 Fuel Cell DANIEL me sono 34 Ne Oe i E ace 05 H IOO Fuel Cell Stack User Manual V4 O 1 Safety Please read all instructions carefully prior to product use and keep this manual for future reference The safety guidelines included here may not cover every situation Use common sense 1 1 General information For this unit to generate electrical power a supply of hydrogen fuel is necessary It is important for any operator to be aware of understand and follow all local safety requirements related to the handling of hydrogen and compressed gases Ensure that your facility confo
12. fuel cell system from the controller Let the fuel cell cool down before placing it into an air tight container This will help to maintain its performance particularly during long periods of storage H IOO Fuel Cell Stack User Manual V4 0 24 O Horizon Fuel Cell Technologies 9 Performance Characteristics Performance characteristics of the stack are presented All performance data is given for baseline operating conditions defined at sea level and room ambient temperature H 100 U I Curve H 100 H2 flow H 100 P I Curve H IOO Fuel Cell Stack User Manual V4 0 25 O Horizon Fuel Cell Technologies 10 Storage and Re Use When finished operating the stack we highly suggest that inject pure water into the stack before place it back in the supplied air tight container to keep the stack from getting too dry Injecting water into the stack 1 Connect a short section of hosing to the gas port marked H2 in and another one to the H2 out port 2 Fill a syringe with pure water distilled and connect it to the hose attached to the H2 in port 3 Inject pure water into the stack until you see water coming out of the hose connected to the H2 out port Keep the water inside the stack Disconnect the syringe 4 We strongly recommend you connect a small hose to both H2 in and H2 out ports The stack should be stored at room temperature If the stack is un used for a long period of time more than 4 weeks
13. gies STEP8 Connect the controller to a stabilized voltage supply through the 13V DC connectors 8A and the voltage of the power should be between 12V and 14V Connect the 13V external power supply to the controller The voltage should be between 12 14V with the current at o ES H 100 e H 200 a EN H 300 DA ecu DELE H 500 OR H 1000 STEP9 Connect the Hydrogen supply to the hydrogen supply valve and make sure the hydrogen pressure is between 0 5 0 6Bar Make sure the dry Hydrogen gas to be used is gt 99 999 purity and the other gas es within the gas supply are not a Sulphic composition or other gases such as CO or CH4 which can all poison the fuel cell reducing its performance dramatically STEP 10 Check the following steps before starting the system 1 The connection between the hydrogen input valve and the hydrogen source The connection between the hydrogen input valve and the stack intput The connection between the stack outoput and the purging valve The purging valve is kept close to the side of the blower of the stack The 8pin plug connection between the stack and the controller The FC connection between the stack and controller The hydrogen pressure is set at 0 5 0 6Bar The power supply voltage is set at 12 14V The load power is below 100W SoS Se oS TS The System is now setup and ready to be used H IOO Fuel Cell Stack User Manual V4 0 19 O Horizon Fuel Cell Tech
14. ites Furthermore hydrogen s small molecule size results in high buoyancy and diffusivity so leaked hydrogen will rise and become diluted quickly Constant exposure to hydrogen causes hydrogen embrittlement in many materials The mechanisms that cause hydrogen embrittlement effects are not well defined Factors known to influence the rate and severity of hydrogen embrittlement include hydrogen concentration hydrogen pressure temperature hydrogen purity type of impurity stress level stress rate metal composition metal tensile strength grain size microstructure and heat treatment history Moisture content in the hydrogen gas may lead to metal embrittlement through the acceleration of the formation of fatigue cracks Hydrogen embrittlement can lead to leakage or catastrophic failures in metal and non metallic components As a preventative measure the stack must be operated in a well ventilated area in order to inhibit potential hydrogen accumulation WARNING Always operate the stack in a well ventilated area and ensure that ventilation slots are unobstructed H IOO Fuel Cell Stack User Manual V4 0 2 Horizon Fuel Cell Technologies 1 5 Flammability and volatility Hydrogen is flammable over concentrations of 4 75 by volume in air and is explosive over concentrations of 15 59 As a result even small leaks of hydrogen have the potential to burn or explode Leaked hydrogen can concentrate in an enclosed environment
15. nections These low voltages may constitute a shock hazard and can damage electronic components if shorted Therefore do not touch individual fuel cells cell voltage monitoring equipment or electrical components WARNING Do not touch fuel cells cell voltage monitoring equipment or electrical components Electronic components can also be damaged as the result of static discharge To minimise this ground all equipment in contact with the stack Never use damaged extension cords Minimise conductivity by avoiding surfaces in contact with water hands and clothes must be dry Do not operate or store the stack in wet or damp conditions WARNING Minimise static discharge Ground all equipment Residual reactants within the stack can develop a charge in a matter of minutes when turned off A reading of zero volts across the entire stack does not guarantee that all fuel cells are uncharged WARNING Always assume that the fuel cell stack is charged Jewellery such as rings necklaces bracelets and watches may concentrate an electric current when it comes into contact with charged components or when a shock passes through the human body Accordingly no jewellery should be worn near the stack WARNING Do not wear jewellery near the stack H IOO Fuel Cell Stack User Manual V4 0 4 O Horizon Fuel Cell Technologies 1 8 High Temperature The fuel cell stack is designed to operate at 65 C At this operating temperature the air exhau
16. ng prostration and loss of consciousness may result eventually leading to convulsions coma and death At concentrations below 12 immediate unconsciousness may occur with no prior warning symptoms WARNING Lack of oxygen can lead to unconsciousness and asphyxiation As a preventative measure the stack must be operated in a well ventilated area in order to compensate for the oxygen used within the fuel cells WARNING Always operate the stack in a well ventilated area H IOO Fuel Cell Stack User Manual V4 0 3 Horizon Fuel Cell Technologies 1 7 Electrical Safety WARNING Avoid contact with an exposed fuel cell stack Electrical shock can cause personal injury or death e Do not touch fuel cell plates or any electrical components at any time A running fuel cell stack is a potential electrical hazard that can cause burns or electrical shock e Do not wear metallic jewellery rings bracelets watchbands or necklaces when you are close to an exposed fuel cell stack e Minimise static discharge If possible ground all equipment e Minimise conductivity Avoid contact with surfaces that are in contact with water or gases Do not operate or store in wet or damp conditions e Never use damaged extension cords The stack generates up to 24 VDC open circuit voltage This voltage decreases as current is drawn from the stack The stack produces 14 4V at maximum power This voltage is exposed at the output power con
17. ng valve this is the initial hydrogen going through the fuel cell to clear any non Hydrogen gas from the system If you do not hear the hissing from the purge valve a Check the supply valve and purge valve are opening this is can be done by i Holding the valves during the starting up and feeling the clicking motion inside the valves ii Alternatively apply the external power directly to each valve at 12V to feel and hear the clicking of the valves opening iii If either of the valves are not opening then contact support horizonfuelcell com with the diagnostic Supply valve is not opening and or Purge valve is not opening with the fuel cell number 3 If the valves are opening check before starting the system again a The 8pins plug connector is firmly clicked together b The hydrogen supply i ls open ii Open pressure is 0 5 0 6Bar 4 If both valves open system will follow normal start up procedures D If either of the valves still don t open Check the controller section on Valves in Trouble shooting H IOO Fuel Cell Stack User Manual V4 0 29 O Horizon Fuel Cell Technologies Check the Blowers 1 With the system completely setup Start the system 2 Once the system has started after the fuel cell system has been short circuited 5 times as part of the startup procedure the blowers will start to turn pulling air through the fuel cell a If all the blower s are creating non standard noise turning sl
18. nologies 6 System Setup Diagram Blower H2 supply valve To fuel From H2 supply cell H2 IN T sensor Purging valve 13V DC gng power supply From fuel cell L TI o purge H2 OUT H2 WU UV Fuel cell FC controller Load Load Load ro e LOBO Load GN SCU Short Circuit Unit GND Grounding H IOO Fuel Cell Stack User Manual V4 O 20 O Horizon Fuel Cell Technologies 7 Notes for the set up Stack should be placed like this The voltage of external power supply is position between 12V 14V the current range is different based on the different stack gt i 1 0 1524 97 106 TS a The tube should be as short as possible between stack and input amp output valves The tube length between the pressure regulator and the input valve should be less than 0 3M The pressure of the hydrogen is between 0 5 0 6Bar TA E The load connecter load is connected to the load in the controller Connected the load to FC amp Load in the stack H IOO Fuel Cell Stack User Manual V4 0 2l O Horizon Fuel Cell Technologies 8 Operating Procedures STARTUP PROCEDURE Hold the ON OFF button down for 2 seconds to start the system you will hear one beep which means the system has started If at this time the system shuts down in less than 1 second then review the beeping interpretation during starting procedure on page
19. o protect the stack So in order to make it work well the fuel cell stack must be maintained lower than 45 C before operate the on off switch WARNING The stack must be standing on the clear plastic feet H IOO Fuel Cell Stack User Manual V4 O 26 O Horizon Fuel Cell Technologies 11 Trouble Shooting amp system checks Rehydrating the Fuel cell because the stack can not reach the rated power go spo pie Make sure the purging valve is disconnected from the hydrogen outlet connector Add water to fuel cell through the hydrogen inlet connector and keep filling until water starts to come out of the hydrogen outlet valve Immediately use the hydrogen supply valve to connect the hydrogen supply to the hydrogen inlet connector Pay attention to the hydrogen supply direction Make sure the hydrogen supply pressure is not gt 0 5bar Open the hydrogen supply Turn on the on off switch for purging the water out of the fuel cell oteps 1 5 should only take 5 10 secs to do Setup the fuel cell system again for general operation With the SCU switch on start the fuel cell again Check the external power supply The battery might not be operating correctly or in the case of a battery may not have any charge left 1 2 3 4 Disconnect the external power source Using a multimeter take a reading of the positive and negative connection points on the external power connectors to the controller If the power is 12V 2
20. onnector pin Connected Peripherals Voltage supplied Red and Black 3 amp Blowers Red ve Black ve after 3 mE 3V constant iv If any of the pins are not supply the voltage then contact support horizonfuelcell com with the diagnostic Controller not operational with the controller number and the voltage readings you are getting from the connector point d To check the Control chip i The system does not need to be started for this ii Connect the multimeter to the fuel cell stack 8 pin connector pins 4 amp 8 iii The resistance should be 1076ohms at 20 C x3 8ohms for every 1 C of the fuel cell temperature iv If resistance reading is different then contact support horizonfuelcell com with the diagnostic Temperature Sensor resistance different with the fuel cell number and the resistance readings you are getting from the connector point e Check your external power supply to see how much current is being drawn during the starting time it should be more than 0 6A for 3 seconds H IOO Fuel Cell Stack User Manual V4 0 30 12 FUEL CELL DRAWING 3l O Horizon Fuel Cell Technologies 13 FAQ What is the SCU This is the Short Circuit Unit it helps to condition the fuel cell for improving long term performance What is the Hydrogen pressure supplied to the fuel cell stack The pressure is 0 5 0 6Bar H IOO Fuel Cell Stack User Manual V4 0 92
21. or plates between each pair of cells enable the flow of electrons The stack aspect is that they are all placed on top of each other and held together by epoxy endplates 2 H2 Supply Valve It controls the H2 input When the controller turns on also the H2 supply valve does When system turns off it is in the off position for preventing the leakage H2 Purge Valve It purges out the water and air gas redundant in the fuel O A D o Short Circuit Unit It ensures best performance of the fuel cells On Off Switch Hold it for 5 seconds for either on or off operation 6 Blower Supply air to the fuel cells and meanwhile decrease the temperature of the stack H IOO Fuel Cell Stack User Manual V4 0 10 O Horizon Fuel Cell Technologies 7 Controller Connector Connect the stack to the T sensor blower purging valve input valve on the controller 8 Controller Controls the stack temperature blowers hydrogen input purging and short circuiting of the stack 9 H2 Input Output connectors H2 OUT connect the tube shown in 12 below H2 IN connect the tube shown in 11 below 10 Fuel Cell Load Connectors FC is connected to the fuel cell positive pole FC is connected to the fuel cell negative pole 11 Tube for H2 Input The tube with 6mm outer diameter and 3mm inner diameter is connected to the H2 IN as in 9 above and to the input valve of the hydrogen source 12 Tube for H2 Output H2 outpu
22. otal amount of the hydrogen flow through the fuel cell every minute which the hydrogen supply can be calculated HFCT Horizon Fuel Cell Technologies H IOO Fuel Cell Stack User Manual V4 0 6 A H2 inlet connector B Blower C H2 outlet connector D Controller conncetion with the multi connector E H2 supply valve F H2 purge valve G Fuel cell air inlet side H IOO Fuel Cell Stack User Manual V4 0 O Horizon Fuel Cell Technologies O Horizon Fuel Cell Technologies Protection label FC amp load stick FC amp load connector FC connector FC stick Warning labels mo ou H IOO Fuel Cell Stack User Manual V4 0 8 9 Horizon Fuel Cell Technologies torizon WARNING Disassembly will void warranty MARS NO MTO95437 100 No 009 2010 234567 011 2 891011 2 1 A Logo B LED C Product No Label D Connect plug E SCU short circuit units switch F ON OFF button G Connect to FC H Connect to FC I Connect to Load J Controller power supply DC 13V K Controller power supply DC 13V L LCD connector H IOO Fuel Cell Stack User Manual V4 0 9 O Horizon Fuel Cell Technologies 3 Stack and System Component Information Stack Is made up of plate like cells with air channels to allow the flow of air across the membrane The membrane facilitates the flow of Hydrogen creating the release of electrons Electrically conductive separat
23. owly or not turning at all i Check carefully that there are no obstructions in the blower s li Carefully spin the blowers using your finger make sure there is rotation movement without obstructions iii The electrical supply from the controller needs to be checked by applying the 12V 24V external power supply directly to the 8pin plug connector points for the fans and monitoring the performance of the blowers iv If the blowers are not running or running slowly and the current is very high then contact support horizonfuelcell com with the diagnostic Blower s not operational with the fuel cell number v If the blower s are running fine Check the controller section on Blowers in Trouble Shooting Check the controller 1 Make sure the system is shut down and the hydrogen supply is off a Disconnect the Fuel cell stack from the controller b To check that the controller is operating correctly review the pin connector drawing against the pin connector C Using a multimeter you can check the power being supplied to each of the peripherals solenoid valve purging valve blowers of the fuel cell i With the external power supply connected to the controller and the fuel cell not connected to the controller start the system up ii The controller will run through the start up procedure supplying power to the peripherals iii By checking each pair of pins you will get the following power readings Wire colours C
24. rms to all local regulatory requirements including building codes and recommendations The fuel cell system has built in safeguards and is designed to shut down automatically if any out of range operating condition occurs Possible situations include low cell voltage high current high temperature low fuel pressure e Do not operate the stack on a grade of more than 65 C Do not connect or disconnect power cables when the fuel cell stack is energised e Do not dismantle the system Contact Horizon if you have any concerns about operation 1 2 Using Hydrogen WARNING FIRE OR EXPLOSION Keep all sources of ignition away from hydrogen This unit uses hydrogen fuel Hydrogen is a colourless odourless and flammable substance It is highly combustible in the presence of oxygen and burns with a colourless flame Leaking gas may be hot and pose a burn danger Stop the flow of gas if you are not in danger and use water to cool the area If fire occurs do not attempt to extinguish flames allow the fire to burn out Prevent overexposure to hydrogen Hydrogen is non toxic but can act as a simple asphyxiant by displacing the oxygen in the air There are no warnings before unconsciousness results When operating the stack in an enclosure Ensure ventilation slots are clear and unobstructed at all times during operation Operate within the temperatures limits stated in the manual Never operate if an alarm condition exists Note
25. st stream temperature can reach 55 C and the cooling air stream can reach 17 C above ambient conditions These temperatures are sufficient to cause burns or severe discomfort Accordingly avoid contact with the fuel cell stack or components that convey process or cooling air WARNING Avoid contact with the fuel cell stack or components that convey process or cooling air H IOO Fuel Cell Stack User Manual V4 0 5 O Horizon Fuel Cell Technologies 2 Terminology PEM fuel cell a PEM Proton Exchange Membrane fuel cell is a device that converts hydrogen and oxygen into water and electricity A fuel cell stack it includes a plurality of plate like fuel cells arranged along an axis generally parallel to cell thickness with electrically conductive separator plates between each pair of cells Reactants reactant is a material used to start a chemical reaction In the fuel cell the reactants are air and hydrogen by which the electricity will be generated Humidification humidity that the fuel cells need for running Blower supply air to the fuel cells and meanwhile decrease the temperature in the stack Purging valve the controller will control the purging time for purging the water and air gas redundant in the fuel cells SCU short circuit unit the short circuit will be controlled for good performance of the stack Dead ended valve purge valve for the controlling of the gas purging Mass flow per minute the t
26. t tube with 4mm outer diameter and 2mm inner diameter is connected to the purging valve on one end and the H2 OUT the other H IOO Fuel Cell Stack User Manual V4 0 ll Horizon Fuel Cell Technologies 4 Technical Specification The flow rate may change with the power output System electronics need external power supply H IOO Fuel Cell Stack User Manual V4 0 12 O Horizon Fuel Cell Technologies 5 System Set Up Connect the controller to the stack to get the blower the temperature sensor the hydrogen supply valve and the purge valve under control The finished connection is shown in 1B 1A Controller connector Wire colours Connectorpin __Periferals controlled Note EN Eg B ES Only for Red 48 amp 8 Temperature Sensor 100W 300W Blowers signal o Blowers power The blower is PWM control so it needs pins 9 amp 10 to give the signal to the control blowers power STEP2 Connect the controller to the stack as the output power also should be under control The finished connection is shown in 2E H IOO Fuel Cell Stack User Manual V4 0 13 Horizon Fuel Cell Technologies H IOO Fuel Cell Stack User Manual V4 0 14 O Horizon Fuel Cell Technologies STEP3 Keep the SCU Short Circuit Unit switch at the O in usual use Only if the performance of the stack is going down please switch it to the to activate the stack Warning Some
27. thereby increasing the risk of combustion and explosion Hydrogen flames are pale blue and are almost invisible in daylight due to the absence of soot Due to its high buoyancy and diffusivity burning hydrogen rises unlike gasoline which spreads laterally A flammable or explosive hydrogen mixture is easily ignited by a spark or even a hot surface The auto ignition temperature of hydrogen is 500 C 932 F The energy of a hydrogen gas explosion is 2 4 times that of gasoline or methane for an equal volume Hydrogen gas explosions are therefore more destructive and carry further WARNING A mixture of hydrogen and air is potentially flammable and explosive and can be ignited by a spark or a hot surface As in the presence of any fuel all sources of ignition including smoking are not permitted in the vicinity of the stack WARNING Keep all sources of ignition away Smoking is not permitted in the vicinity of the stack 1 6 Oxygen Depletion Oxygen is a colourless odourless non toxic and tasteless gas Oxygen is essential for life in appropriate concentrations Ambient air contains up to 21 oxygen Oxygen levels below 19 5 are biologically inactive and may act as simple asphyxiants Effects of oxygen deficiency may include rapid breathing diminished mental alertness impaired muscular coordination faulty judgement depression of all sensations emotional instability and fatigue As asphyxiation progresses nausea vomiti
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