Fuel Cell Power System Operating Manual
Contents
1. cartridge detected Change fuel cartridge Bad connection of fuel cartridge solve error cause t ir leak internal fuel sensor connector air leak then press RESET Dirty fuel cartridge connector Please contact service Please refill Operation at high ambient service fluid temperatures or insufficient cooling Add service fluid air solve potential error causes then press RESET Interruption r fluid level below 409 p services Nud level below 40 Ambient temperature to high avoid Surroundings too warm Wait direct sunlight A Temparature to high internal until temperature has dropped Poor air ventilation in installation sensor space Interruption Temperature too low Defrost unit Anti freeze protection did not w ork Please defrost stack temperature sensor lt 3 C ca 24 h at room temperature due to an error device slow ly Low service fluid level error 30 lt 20 error 31 lt 5 Fluid level measurement defect Please check Battery voltage too low Battery voltage lt 10 5 21 V gt battery voltage sense line charge with battery charger Battery voltage too high Battery voltage gt 16 5 33 V gt sense line Solve error cause check external battery charger and check battery and connections disconnect if necessary Batttery voltage too low Check connection to battery power line Check battery cables Battery voltage too high Check battery fuses power line Please cont2. ensol M1012 REV 0 SYSTEMS Fuel Cell Power System Operating Manual Unit 2 5550 Panorama Drive Surrey BC Canada V3S 1B7 Tel 604 576 8333 Fax 604 576 8233 www ensolsystems com ensol Fuel Cell Power System Operating Manual SYSTEMS Forward Thank you for purchasing Ensol System s Fuel Cell Power System Please read through this reference guide before operating the unit as it contains particular start up shut down and disconnection procedures If you have any questions or concerns contact Ensol at Ensol Systems Inc Unit 2 5550 Panorama Drive Surrey BC Canada V3S 1B7 Tel 604 576 8333 Fax 604 576 8233 Email admin ensolsystems com www ensolsystems com M1012 REV O 2 enso SYSTEMS M1012 REV O Fuel Cell Power System Operating Manual Table of Contents Contents Section 1 Quick Startup PIO CONG an Bean 4 SECHOM 2 General To aka ubi 5 CPOO in ae ea se 5 LE Produce Sa en 5 Section 3 System Insta At Ost mesen E beat RE RR GA Tan lusa aak bae eat men ema naa 6 3 1 FS CAM AUTOR OW CIEE scctoacrvssyracrsmaracieta ov hEN aba unde EEE wi nl OEE E an sisi 6 S BOOS na eee Ne eee es se ae an An An eee us An Aa 6 3 3 Methanol FUCTC lll ek aa Kanan 7 SOCIO System CE Na nee aa aa eta 7 BG SEPA SS On era NO Nee NN RaR nana aan 7 4 CWS UCT O en Ba ea eta 8 4 3 UN Certified Methanol Fuel Cartridges oooooooWoooooocooooomm 10 ME Operaona State aa an an Ge Hen aa E 11 4 5 Def
3. required p 7 Error 72 was once ignored a information no display Self test equipment no action required information successfully Firmw are corrupt sdn te i dat update required transfer defective firmware repeate firmware update No connect or Remote control has no Check connection load battery if Remote control is connected to Check battery connection to fuel cell necessary wrong port Data Interface Batter voltage lt 8 5 V na No communication defect M1012 REV O 20
4. to facilitate ease of use and transport e The methanol fuel cartridges are UN certified containers certified for transport on cargo planes e The containers are spill resistant and designed to withstand significant impact force e Ensol Systems will recycle empty plastic cartridges and dispose of any residual methanol if necessary e 28Lcartridges are the largest available size and a cartridge adapter is required to use this cartridge with the EFOY Pro fuel cell DO NOT THROW AWAY THE CARTRIDGE ADAPTER e The fuel cell methanol is ultrapure Do not puncture the cartridge To avoid contamination do not transfer residual methanol from an old cartridge to a new cartridge DO NOT USE ANY OTHER METHANOL SOURCE TO FUEL THE EFOY PRO Impure contaminated methanol will severely degrade the performance and life of the EFOY and will VOID WARRANTY EFOY QUALITY CONTROL M1012 REV O 10 en sol Fuel Cell Power System Operating Manual SYSTEMS 4 4 Operational States Charging mode MISS oFF a Battery voltage gt 14 2 V and charging current lt 2 Ja IO A Automatic charging battery voltage lt 12 3 V Manually ON battery voltage max 13 2 V Temperature below 5 C anti freeze mode Manually OFF Device successfully warmed itself Battery protection mode at 12 8 V Actual output energy gt defined output energy After 24 hours of charging Ambient temper
5. act Battery voltage measurement a the error persists a repair is Circuit Board defect service defect required 700 R Error fuel reservoir sensors P T SOP internalfuel sensor defect 75 Reservoir error emptying time a Pm an Aa mawas tolerance a sr R DC DC Transformer defect Error 70 or error 72 Serious reservoir error Permanent error repair required reoccurred 3 times M1012 REV O 19 Press RESET max 3 attempts repair required if error reoccurs ensol Fuel Cell Power System Operating Manual SYSTEMS Please check fuel Reservoir error refilling time Solve potential error cause Firmware problem FW lt 9 11 Firmw are update cartridge too long then press RESET max 3 attempts Bad connection of fuel cartridge recommended fixed with connector connector pumps air FW 9 11 or higher Dirty fuel cartridge connector Pease install Filter EFOY XT is removed a EFOY 2200 XT LL bie Please contact Filter Circuit Board EFOY XT not Press RESET max 3 attempts only EFOY 2200 XT esr res no display Filter change confirmed no action required only EFOY 2200 XT information no display Antifreezemode successfully no action required information Update DO NOT Firmware update is performed Inot interrupt firmware update UNPLUG BATTERY no displa another error is blocking the p y Antifreezemode not possible fix other error g information antifreezemode no displa 172 no action
6. ature gt 45 C 113 F ow ad Automatic standby or OFF automatic charging deactivated anti freeze protection and battery protection mode active e Note that a minimal battery voltage of 9 0V or 18 5 V is required for the EFOY Pro to start Battery protection at 11 2 V M1012 REV O 11 A enso Fuel Cell Power System Operating Manual SYSTEMS 4 5 Default Parameters of cutoff threshold New charging strategy firmware 9 20 since mid of August 2010 e Switch on voltage 12 3 V 11 0 13 0 V e Switch off voltage 14 2 V 13 5 14 7 e Switch off current 2 A 4 A EFOY Pro 2200 0 5 10 A e Switch off time 3 hours 0 5 hours e This ensures full battery charging and maximizes battery life Voltage EFOY 14 2 V tl LAN EFOY On Tana ime M1012 REV O 12 en sol Fuel Cell Power System Operating Manual SYSTEMS 4 6 Startup and Shutdown Phases Current ul Note Regular stack shutdowns regeneration cycle every 20 minutes for a few seconds during charging Time Device needs a Start up phase of 10 20 min to achieve full power During start up phase several starts until full power is achieved Output I EFOY Pro charges with continuous power gt decreasing charging current with increasing battery voltage Upon reaching the switch off threshold voltage Vox in the Automatic mode the charge current I is reduced Vott Battery voltage V End
7. ault Parameters of cutoff threshold Wo oo Woo Wo Ja 12 4 6 Startup and Shutdown Phase Su o oco ooo oocooooomoomodomkoti antam nana 13 4T Ani Freeze Proteccion MOUE asa 14 Ae Operation ane Dee T E ee ee 15 A oare FIU eison e An A A A 16 NO Beater C ON en aan 17 ATON S Er Me en na 18 sM Bgas AEE 8 A E oho E E E E E EE EA A EEEE T 18 DEO O E EEEE E 18 5 3 Most Common Error Messages oococooooooo oooooooo naa 18 enso SYSTEMS Fuel Cell Power System Operating Manual Section 1 Quick Startup Procedure So Fae ae ee e e e O 12 13 14 Ensure all fuses and or circuit breakers are open or set to Off Connect the battery leads to the batteries if required Plug the remote into the RJ45 port labeled Remote on the fuel cell Connect fuel line to methanol cartridge Insert the exhaust tube from the fuel cell to the water collection tank port Ensure the 2 exhaust port from the water collection tank is connected Plug the power connector into the fuel cell Close all fuses and or circuits breakers Turn the system on using the power button the remote or the button on the fuel cell If the display of remote control shows Automatic device is ready Functionality check Switch on device manually check if charging starts this is only possible if battery voltage lt 13 2 V Ensure the thermostat is set at an appropriate temperature less than 45 C Remove any too
8. cted water should be changed out at the point in time that the fuel cartridge is replaced Cathode Carbone Water dioxide Exhaust Methanol Ai Water r Membrane Electrolyte Methanol Oxygen gt Carbon dioxide Water vapor 2 CHOH 30 gt 2 CO 4 HO Figure 2 Since the EFOY Pro fuel cell is a smart fuel cell charging and monitoring to the batteries is handled automatically example in Figure 3 With the remote which is included the user can view the charging mode battery voltage charging current system operating hours and firmware version and can also change the charging mode By pressing the power button on the remote the user can turn the system off put itin automatic or turn the system on for one charge cycle M1012 REV O A enso Fuel Cell Power System Operating Manual SYSTEMS 14 2 V with EFOY Pro optimum charge 12 3 V Fuel cell Fuel cell on on 11 0 V Battery voltage 0 V time Figure 3 Ensol Systems has pre programmed the fuel cell s parameters for the installation location If charging voltage set points need to be altered please contact Ensol Systems For a full description of the EFOY Pro fuel cell s operation please see the manual provided by SFC s document 101123 UM EFOY Pro GB v02 M1012 REV O A enso Fuel Cell Power System Operating Manual SYSTEMS 4 3 UN Certified Methanol Fuel Cartridges The EFOY Pro uses special plastic fuel cartridges
9. emedied e M Manual user intervention required e F Anti freeze protection is possible from this error if the error cause currently no longer exists e P Permanent error not resettable e R Reset required to restart system e W Warning 5 3 Most Common Error Messages e 12 13 14 Failure due to blocking of exhaust or circulation pump defect e 32 31 30 41 Failure due to high surrounding temperature Check installation and ensure air circulation is adequate e 52 54 Check battery voltage too low and or battery connection problem e 72 76 Failure in Methanol dosing or internal sensors Possible issues in Methanol cartridge because of fuel line M1012 REV O 18 ensol Fuel Cell Power System Operating Manual SYSTEMS Error description Remedial measure Potential error causes fo a a Men aa Basara Please contact A 1x 30s Stack power output too low Hardware defect service R F A 1x 30s Fluid level sensor defect Press RESET max 3 attempts R repair required if error reoccurs F 17 Abnormal power difference between stack and output Please check A 1x 30s exhaust hose R F ae ee oe Solve potential error cause Exhaust hose blocked Test disconnect exhaust 18 TA 3x1300s Hp PE then press RESET max 3 attempts not sufficient fresh air hose and press Reset if R fuel cell is now running the F exhaust hose is blocked Please change Error causes if fuel cartridge not fuel cartridge empty Empty fuel
10. ensure appropriate PPE is utilized e First isolate the batteries from the electrical system by disconnecting all fuses and or circuit breakers e Disconnect the leads from the batteries first beginning with the positive leads then continue to disconnect the remaining batteries from one another e When reconnecting the batteries please ensure that they are wired appropriately for 12 or 24VDC as your electrical system requires Wiring the batteries incorrectly can result in an over voltage condition and damage process equipment wired to the power package e Once the battery bank is connected check that the voltage going to the system is within the range dependent upon a 12 or 24VDC electrical system If the wiring is correct and the voltage is still not within the correct range test each battery individually to see if any are defective or damaged e If the voltage is within the range reconnect all the loads via the fuses and or circuit breakers M1012 REV O 6 A enso Fuel Cell Power System Operating Manual SYSTEMS 3 3 Methanol Fuel Cell The EFOY Pro Fuel Cell will already be mounted but all its accessories still may need to be connected Connect all accessories in the following order e First connect the methanol fuel cartridge s Screw the M28 cartridge adapter to the cartridge s if not already done so Then connect the fuel line to the cartridge s If there is only one cartridge in the system screw the fuel line from the fue
11. l cell to the top of the M28 adapter If there are two cartridges screw the fuel line into the Duo Cart switch then connect the two fuel lines coming from the duo cart switch to each cartridge e Second connect the exhaust tubing line to the EFOY Pro fuel cell s exhaust port This is a small tube stub protruding just next to the fuel line e Third connect the wiring harness and remote to their respective ports Ensure that the remote is plugged into the Remote RJ45 port and not the Data port Section 4 System Operation 4 1 General System Operation The fuel cell power system is a simple package consisting of a methanol fuel cell to charge a bank of sealed lead acid batteries This stored electrical power is then used to run measurement and control equipment and whatever other loads may be involved A typical hybrid application where the fuel cell is connected in parallel with a solar system is illustrated in Figure 1 70 Solar cell Voltage regulator Battery Load M10 L EFOY Fuel Cartridge EFOY Pro Series Figure 1 Hybrid System M1012 REV O 7 enso Fuel Cell Power System Operating Manual SYSTEMS 4 2 Fuel Cell Operation The SFC EFOY Pro fuel cell uses a catalytic process to directly convert methanol into electricity see Figure 2 The byproduct of this reaction is water small amounts of CO and heat To eliminate freezing the water must be collected internally The colle
12. ls from the enclosure store service fluid and user manual Close the enclosure and ensure that it is properly sealed M1012 REV O A enso Fuel Cell Power System Operating Manual SYSTEMS Section 2 General Information 2 1 Product Introduction The Ensol Systems Fuel Cell Power System can be used to provide reliable power for measurement and control eguipment air compressors chemical injection communications surveillance and a broad range of other applications Powered by a DMFC Direct Methanol Fuel Cell these packages are reliable even in the most remote and harsh environments These systems can be used in conjunction with other power systems Typically Ensol ties the fuel cell packages into existing solar systems The design philosophy then is to use solar energy when you have it with a methanol fuel cell as a back up when you don t This will provide you with 100 reliable power even in the darker months of winter 2 2 Product Specifications EFOY Pro EFOY Pro EFOY Pro 600 1600 2200 Max Energy Output 600 Wh day 1 560 Wh day 2 160 Wh day Nominal Power 25W 65 W 90 W Cascading multiple EFOY Pro units and integrating them Hybrid Power Solutions Into hybrid solar or wind packages provide significantly higher power Nominal Current 12V 24V 21A 1 05 A 5 4A 2 7A 7 5A 3 75A Operating Temperature 20 to 45 C Rated to 40C in Ensol Systems Hybrid Packages Methanol Consumption 0 9 L kWh 0 24 US gal kWh Dimensi
13. n at 40 C e Startup temperature when the Anti Freeze Mode has not been activated is 5 C M1012 REV O 14 e nsol Fuel Cell Power System Operating Manual SYSTEMS 4 8 Operation at the Device Push button green yellow red Push shortly lt 0 5s Reset Push longer gt 3s On Off Push button LED state Ready Add service fluid Error Blinking Shutting down Cartridge empty Interruption Off Off or error No error Remote Control Display of operating condition and system information Info key for language selection Reset key On Off key Automatic operation key Signal lamp Signal lamp yellow Please red Error change cartridge M1012 REV O 15 A enso Fuel Cell Power System Operating Manual SYSTEMS 4 9 Service Fluid e If service fluid is low the yellow light will turn on at the EFOY Pro and the message Please refill service fluid will appear at the control panel display e Normally there is no need to add service fluid prior to the initial start up e Note that the fuel cell produces its own service fluid during operation This is critical to the function of the device If the EFOY Pro is operated continuously at temperatures above the acceptable operating range 45 C the service fluid will be expelled faster than it can be regenerated and cause a failure For this reason it is critical that the thermostat and fan provided with the Fuel Cell Power Package are maintained in working
14. of charging The switch off process allows a controlled disconnection of the EFOY Pro Fuel Cell The switch off process may take up to 30 minutes Avoid interrupting the switch off process M1012 REV O 13 ensol Fuel Cell Power System Operating Manual SYSTEMS 4 7 Anti Freeze Protection Mode e Note that the standard Ensol Systems Fuel Cell Power Packages are rated to 40C operation e THE ANTI FREEZE PROTECTION MODE WILL NOT WORK WITHOUT FUEL Please ensure that the fuel cell does not run out of methanol in freezing temperatures If the fuel cell freezes 24 hours will be required for the fuel cell to warm back up and be returned to service e The Anti Freeze Mode will keep the EFOY Pro warm while the temperature is below 5 C This will work even when the unit is OFF e Anti Freeze Mode requires the connection to a faultless adequately charged battery and fuel cartridge e Fuel consumption will be dependent upon external temperature differential Weather insufficient insulation ambient temperature and operating mode can have an impact on fuel consumption e The EFOY Pro does not give the produced energy to a fully charged battery in Anti Freeze Mode Rather the stack burns methanol and supplies the peripheries pumps etc to heat up the system The batteries will not be overcharged e The EFOY Pro can operate in 20 C temperature Proper heat management and insulation is required to ensure reliable operatio
15. ons L x W x H 433 x 188 x 278 mm 17 x 8 x 11 in EFOY Pro Weight ca 8 kg 18 Ibs M1012 REV O 5 ensol Fuel Cell Power System Operating Manual SYSTEMS Section 3 System Installation 3 1 Installation Overview The Fuel Cell Power System s electrical rating is General Purpose and shall therefore be installed outside the Hazardous location Typically the system will be mounted 3 meters away from any source of gas and 0 6 meters off the ground The Fuel Cell Power System also has an exhaust port located on the bottom of the unit In order for the unit to operate this port shall not be blocked and needs at least a 300cm space left open below it 3 2 Batteries Sealed Lead Acid batteries may be provided to store the fuel cell energy Battery cables provide the link between the batteries equipment and charging system Faulty connections can lead to poor performance and terminal damage meltdown or fire Batteries Inspection e Examine the outside appearance of the battery The tops of the batteries and terminal connections should be clean free of dirt and corrosion and dry e If fluid is on the top of a gel or AGM battery this means that the battery is being overcharged and the performance and life will be reduced e Check battery cables and connections Replace any damaged cables with a min 12 AWG Tighten any loose connections Changing or Disconnecting Batteries e Use extreme caution while working on the batteries and
16. order and set at an appropriate temperature e Service fluid can be added by removing the exhaust line as pictured below EFOY Service Fluid M1012 REV O 16 ensol Fuel Cell Power System Operating Manual SYSTEMS 4 10 Battery Connection Power lead Carries current from the fuel cell to the battery Sense lead Measures battery voltage Connection as close to the battery as possible Note Power and sense lines must contain fuses 8 m extension sense line and power lines available Connecting line to fuel cell 1 m Extension sense line 8 m optional Extension power line optional Battery fuse sense 1 m 4A Battery fuse in power line 1 m 15A Battery M1012 REV O tam feom POWER LEAD 17 ensol Fuel Cell Power System Operating Manual SYSTEMS Section 5 Error Messages 5 1 Error Classifications Ranges e 10 Internal hardware or firmware issue Contact Ensol Systems e 20 Fuel Change the cartridge and reset e 30 Service Fluid Add service fluid and reset Check thermostat and fan function e 40 Environmental Issue Temperature too high or too low to maintain function e 50 Battery Battery voltage too high or low Check connections Check solar charge controller e 70 Reservoir Internal fuel problem Check fuel connections and reset e 80 System Internal voltage or system error Reset 5 2 Error Types e A Automatic reset after error cause is r
Download Pdf Manuals
Related Search