User Manual
Contents
1. 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 13 VDC open circuit voltage This voltage decreases as current is drawn from the stack The stack produces 7 8V at maximum power This voltage is exposed at the output power connections These low voltages may constitute a shock hazard and can damage electronic components if shorted Therefore do not touch individual fuel cells cell voltage monitoring equipment or electrical components WARNING Do not touch fuel cells cell voltage monitoring equipment or electrical components Electronic components can also be damaged as the result of static discharge To minimise this ground all equipment in contact with the stack Never use damaged extension cords Minimise conductivity by avoiding surfaces in contact with water hands and clothes2. 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 sites Furthermore hydrogen s small molecule size results in high buoyancy and diffusivity so leaked hydrogen will rise and become diluted quickly Constant exposure to hydrogen causes hydrogen embrittlement in many materials The mechanisms that cause hydrogen embrittlement effects are not well defined Factors known to influence the rate and severity of hydrogen embrittlement include hydrog
3. stack see Storage and re use for details And then re test open voltage Note Make sure you have purged the water out of the stack as much as possible before use Connect a load 5 6W to the stack And then note the voltage and current to check if they comply with our power curve If not inject water see Storage and re use for details and then run the stack again If the voltage and current from the 5 6W load comply with the power curve increase the load to 12W If the voltage and current from the high power load does not comply with the power curve check the hydrogen pressure to the stack and the flow rate Meanwhile purge the stack and then observe the stack Run the stack at 7 8V for 30minutes If the performance does not go up Contact Horizon Fuel Cell Technologies for support 17
4. to be 0 45 0 55Bar 2 Disconnect the hydrogen tube from the hydrogen input immediately after the fuel cell stack is shut down Since hydrogen gas can leak into the fuel cell and destroy the stack 3 Make sure the dry Hydrogen gas to be used must be 99 995 purity 4 Do not vibrate the stack when it is in operation 5 Keep the stack in ventilation when it is in operation Hydrogen input Step 1 Use the tube to connect the hydrogen supply 0 45 0 55 Bar to the fuel cell hyrogen input port Warning The tube between the hydrogen pressure regulator and the fuel cell gas input is required to 12W Fuel Cell Stack be less than 30cm Step 2 To obtain higher Hydrogen input efficiency you can connect a pin to the H2 gas output Warning before connecting the pin let the hydrogen flow through the whole stack 12W Fue Cell Stack 13 12W Fuel Cell Stack 12W Fuel Cell Stack Step 3 Now the fuel cell system is ready to use Please connect the load to the fuel cell system and enjoy the experience with clean energy Hydrogen input WARNING Disconnect the hydrogen tube from the hydrogen input immediately after the fuel cell stack is shut down Since hydrogen gas can leak into the fuel cell and destroy the stack Step 4 Disconnect the red pin from the stack output for 1 second to purge a little amount of water out of the stack It is suggested every 10 minutes to purge the stack one time Hydrogen
5. O Horizon Fuel Cell Technologies H 12 Fuel Cell Stack User Manual Updated 08 Dec 2011 H 12 UM_ V2 4 EN 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 12 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 warranty o Attempt under any circumstance to disassemble or inappropriately tamper with the fuel cell e Operate the fuel cell with valves and blowers that are not provided by Horizon for the specified fuel cell and controller Disassemble the fuel cell Operate the fuel cell that is not in the setup and or specified in the user manual provide for the specific product Do not attempt under any circumstance to disassemble or inappropriately tamper with the fuel cell There will be no returns refunds or exchanges should disassembly or tampering occur If you have questions or need help with regards to the fuel cell and its technology contact support horizontuelcell com IMPORTANT In order for the warranty to come into effect the stack must be registered
6. Set the H2 supply to 0 45 0 55Bar and connect it to the hydrogen input port of the stack without a load attached and purge the stack as much as possible i e letting hydrogen flow through the stack to remove water and other contaminants Please see picture B below for reference Using a fuel cell stack with too much water inside can irreparably damage it Make sure the hydrogen supply pressure is 0 45 0 55Bar WARNING Make sure you have purged the water out of the stack as much as possible before use Using the fuel cell stack with too much water inside can irreparably damage it 16 8 Trouble Shooting Make sure the dry Hydrogen gas to be used must be 99 995 purity The tube between the hydrogen pressure regulator and the fuel cell gas input is required to be less than 30cm The inner diameter of the hydrogen supply tube is required to be more than 2mm The input pressure to the stack is required to be 0 45 0 55Bar If the system shuts down by itself check the following details 1 Make sure you have connected all wires according to the diagram on page 15 2 Make sure you have a hydrogen input supply at 0 45 0 55Bar to the stack 3 Make sure the load is below 12W The blower does not run after the stack was connected and supplies with hydrogen according to the System set up Contact Horizon Fuel Cell Technologies for support The open voltage no load stack voltage is less than 9 1V 1 Inject water into the
7. en 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 1 5 Flammability and volatility Hydrogen is flammable over concentrations of 4 75 by volume in air and is explosive over concentrations of 15 59 As a result even small leaks of hydrogen have the potential to burn or explode Leaked hydrogen can concentrate in an enclosed environment thereby increasing the risk of combustion and explosion Hydrogen flames are pale blue and are almost invisible in daylight due to the absence of soot Due to its high buoyancy and diffusivity burning hydrogen rises unlike gasoline which spreads laterally A flammable or explosive hydrogen mixture is easily ignited by a spark or even a hot surface The auto ignition temperature of hydrogen is 500 C 932 F The energy of a hydrogen gas explosion is 2 4 times that of ga
8. input 14 6 2 Simplified Drawings of HFCT Measurement Stand Hydrogen input L P Power V x A 12W Fuel Cell Stack 7 Storage and Re Use When finished operating the stack place it back in the air tight container and keep it in an enclosed area for storage to keep the stack from getting too dry The stack should be stored at room temperature If the stack is un used for a long period of time more than 4 weeks and the performance goes down 50 to the rated power at 7 8V after 30 minutes operation we recommend do the following steps Note Generally injecting water into the stack it is not recommended Only if the performance of the stack decreases 50 is it recommended to inject water into the stack to activate the stack before operation Rejuvenate by injecting water into the stack 1 2 Connect a short section of hosing to the hydrogen input port on the stack Fill a syringe with water distilled or purified Make sure there is no air in the syringe And then connect it to the hose attached to the stack Inject distilled or purified water into the stack until you see water coming out of another port see picture A below for reference Keep the water inside the stack for about 2 minutes Now disconnect the syringe with the tube and leave the water in the stack Purge the water out of the stack as much as much before use say it is not coming out of the stack output Connect a tube to the hydrogen output port
9. 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 No pungent odor paint and perfume are allowed around stack 1 8 High Temperature The fuel cell stack is designed to operate at 65 C At this operating temperature the air exhaust stream temperature can reach 55 C and the cooling air stream can reach 17 C above ambient conditions These temperatures are sufficient to cause burns or severe discomfort Accordingly avoid contact with the fuel cell stack or components that convey process or cooling air WARNING Avoid contact with the fuel cell stack or components that convey process or cooling air 2 Terminology PEM fuel cell a PEM Proton Exchange Membrane fuel cell is a device that converts hydrogen and oxygen into water and electricity Reactants reactant is a material used to start a chemical
10. on the Horizon Warranty Page at www horizonfuelcell com warranty htm Table of Contents SAVE nanas same nana come se A 4 2 Terminology ssaa a e EE 9 3 Stack and System Component Information mmmmmemsmmenenensnns 10 4 Technical Specification cccccescececenceeeceneueeceneueueeneeeneneeneneneenes 11 5 System Performance CurveS cscccccesecceeeecccececceseceeeeeueaeeeeeaeenseeeeeas 12 6 System Set Do RU Ta 13 Gel Pel Al EE a A E E E EE nt 13 6 2 Simplified Drawings of HFCT Measurement Stand sssssssseccccssscececoossssececssosssesee 15 7 Storsgeand Re SG EEE REEERE 16 8 Trouble SROOINO 15 200 2eme enea e e dde 17 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 conforms to all local regulatory requirements including building codes and recommendations The fuel cell system has built in safeguards and is designed to shut down automatically if any out of range operating condition occurs Possible situations include low cell voltage high current high temperature low fuel pressu
11. re e Do not operate the stack on a grade of more than 65 C e 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 e Ensure ventilation slots are clear and unobstructed at all times during operation e Operate within the temperatures limits stated in the manual e Never operate if an alarm condition exists Note We highly recommend customer use a hydrogen sensor not provided to detect the hydrogen leakage 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
12. 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 Mass flow per minute the total amount of the hydrogen flow to the fuel cell every minute which the hydrogen supply can be calculated HFCT Horizon Fuel Cell Technologies 1 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 3 Tube It is used for connecting the pressure regulator to the stack 3 Stack and System Component Information 2 Plug It provides higher hydrogen efficiency in lower stack power situations 4 Technical Specifications CE Purging valve voltage 6V Blower voltage External temperature The flow rate may change with the power output The Specification is subject to change without notice 11 5 Standard System Performance Curves H 12 U I Curve 12 6 System Set Up 6 1 Operating Instructions PLEASE READ CAREFULLY BEFORE STARTING WARNINGS 1 The tube between the hydrogen pressure regulator and the fuel cell gas input is required to be less than 30cm The inner diameter of the hydrogen supply tube is required to be more than 2mm The input pressure to the stack is required
13. soline 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 vomiting prostration and loss of consciousness may result eventually leading to convulsions coma and death At concentrations below 12 immediate unconsciousness may occur with no prior warning symptoms WARNING Lack of oxygen can lead to unconsciousness and asphyxiation As a preventative measure the stack must be operated in a well ventilated area in order to compensate for the oxygen used within the fuel cells WARNING Always operate the stack in a well ventilated area
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