User Manual

H-1000XP Fuel Cell System

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Date:20110523 Part Number:H1000XP Version:20110523

Revision History
Release No. Rev. 0 Rev. 0.9 Date 12/13/10 12/24/10 Revised by Tony WRP Revision Description Users Manual draft 1. 2. 3. 4. 5. 1. 2. 3. 4. 1. 1. 2. 1. 1. 2. 1. 1. 2. Modified PART LIST Modified GENERAL INFO Modified SYSTEM SET UP Modified SOFTWARE Added MAINTENENCE Modified SAFETY Modified SOFTWARE Modified MAINTENANCE Added TROUBLESHOOTING Modified Ultra Capacitor Bank Added note to Stack Holder Added note to Hydrogen Sensor Modified Software Installation Added H2 sensor external power Added fuse usage to Step 7 & 11 Fix mistake of supply / purge valve direction arrow. Add note for not too long purge line. Add warning for not to turn off by error protection.

Rev. 0.95

01/13/11

WRP

Rev. 0.96 Rev. 0.97 Rev. 0.98 Rev. 0.99 Rev. 0.99 Rev. 0.10

01/19/11 02/10/11 02/25/11 03/29/11 05/11/11 05/23/11

WRP WRP WRP WRP WRP WRP

OVERVIEW OF THE SYSTEM

Thank you for choosing our fuel cell stack. The Horizon fuel cell stack is an air-cooled, light weight and compact fuel cell stack.
H-1000XP is specially developed for SHELL Eco-marathon event,(please refer to www.shell.com/ecomarathon/ for more details), this system has been designed according to event rules, it only needs a start up battery(12V) to start the system and will be self-sustainable after that, some of the features may not be necessary for other applications, please contact HORIZON for more details Please read all instructions carefully prior to product use and keep this manual for future reference. Further copies can be obtained from Horizon Fuel Cell Technologies or by emailing: [email protected] Please refer to the Horizon website for latest information: www.horizonfuelcell.com Actions that will void the fuel cell and controller warranty: Do not attempt, under any circumstance, to disassemble or inappropriately tamper with the fuel cell. Operate the fuel cell with a controller not designed and built by Horizon for the specific fuel cell. 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 no that is not in the setup and/or specified in the user manual provide for the specific product. IMPORTANT In order for the warranty to come into effect the stack must be registered on the Horizon Warranty Page at: www.horizonfuelcell.com/warranty.htm

Disclaimer
Information contained in this data sheet is considered to be accurate and reliable, to the best of our knowledge, at time of printing. However, we do not guarantee or warrantee its accuracy, reliability or completeness. Information may be subjected to revision and edition at our discretion. It is the Users obligation to use the product safely and within the scope advised in this publication. Information relates only to the specific product/material mentioned and may not be applicable where such product/material is used with any other.

Table of Content

1.0 2.0 3.0 4.0 5.0 6.0 7.0

Safety6 Part list12 General information..18 System set up.27 Software .41 Maintenance...46 Troubleshooting .49

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 what 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 total amount of the hydrogen flow through the fuel cell every minute what the hydrogen supply can be calculated. HFCT: Horizon Fuel Cell Technologies

1.0 SAFETY

1.0 SAFETY
NOTE: 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. 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, or hydrogen leak detection. Do not dismantle the H-1000XP 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 colorless, odorless and flammable substance. It is highly combustible in the presence of oxygen and burns with a colorless 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 asphyxia by displacing the oxygen in the air. There are no warnings before unconsciousness results. When operating the H-1000XP power module in an enclosure: Ensure ventilation slots are clear and unobstructed at all times during operation Operate within the temperatures limits stated on the H-1000XP system nameplate Never operate if an alarm condition exists

1.3 Handling Compressed Gas Cylinders

WARNING! Do not handle compressed hydrogen gas cylinders without training or experience.

 Use a pressure regulator to control the fuel inlet pressure to the system. Do not alter the fitting on a regulator. Ask experienced personnel for help. Do not attempt to force gas cylinder threads. 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. Secure a high-pressure cylinder to a bench, post, or fixed object to avoid accidental contact. Avoid unnecessary contact with On/Off valves. They can easily move to On by accident.

1.4 Hydrogen Leakage

Hydrogen is colorless, odorless and tasteless. Hydrogen is non-toxic but can act as a simple asphyxiated 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, hydrogens 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, H-1000XP must be operated in a well-ventilated area in order to inhibit potential hydrogen accumulation.

WARNING! Always operate H-1000XP 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 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 system.

WARNING! Keep all sources of ignition away. Smoking is not permitted in the vicinity of the H-1000XP

1.6 Oxygen Depletion

Oxygen is a colorless, odorless, 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 asphyxiates. Effects of oxygen deficiency may include: rapid breathing, diminished mental alertness, impaired muscular coordination, faulty judgment, 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, H-1000XP must be operated in a well-ventilated area in order to compensate for the oxygen used within the fuel cells.

WARNING! Always operate H-1000XP in a well-ventilated area.

1.8 Electrical Safety

WARNING! Avoid contact with an exposed fuel cell stack. Electrical shock can cause personal injury or death.
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. Do not wear conductive metallic items when you are close to an exposed fuel cell stack. Minimize static discharge at all times If possible, ground all equipment to your common ground. Minimize conductivity. Avoid contact with surfaces that are in contact with water or gases. Do not operate or store in wet or damp conditions. Never use damaged extension cords. H-1000XP generates up to 48 VDC (open circuit voltage). This voltage decreases as current is drawn from the module. 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 minimize this, ground all equipment in contact with H-1000XP. Never use damaged extension cords. Minimize conductivity by avoiding surfaces in contact with water; hands and clothes must be dry. Do not operate or store H-1000XP in wet or damp conditions.

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WARNING! Minimize static discharge. Ground all equipment.

Residual reactants within the H-1000XP can develop a charge in a matter of minutes when turned off. A reading of zero volts across the entire power module does not guarantee that all fuel cells are uncharged.

NOTE: The cathode has already been connected to the stack shell.
The stack cathode should be connected to common ground of all the equipments.

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 H-1000XP.

1.9 High Temperature

The fuel cell stack is designed to operate above 60C sometimes, At this operating temperature, the air exhaust stream temperature can reach 55C and the cooling air stream can reach 17C 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.

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2.0 PART LIST

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2.0 PART LIST

1. Stack
The H-1000XP fuel cell stack is a cathode-cooled proton exchange membrane (PEM) fuel cell stack designed to provide stable electrical power while operating on air and dry hydrogen. With innovative materials, the H-1000XP achieved 1000W power output with less weight and more compact size compare to standard H1000. Tube size for hydrogen connector 6

2. Stack holder
It helps to fix the fuel cell stack on the place you want. There are 4 in the package. As showed on stack picture above, each side (left or right) can place 2.

NOTE: Please use bolts provided together with spring washer. Do not over tighten. The use of wrong screw length will damage the stack.

4. Hydrogen supply valve

Supply valve 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. Please note the label and the direction of the arrow. Tube size for hydrogen connector 6

3. Hydrogen purging valve

Purging valve: the controller will control the purging time For purging the water and air gas redundant in the fuel cells. Please note the label and the direction of the arrow. Tube size for hydrogen connector 6

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5. SCU switch
It is to turn the SCU on/off. For SCU, Please refer to Terminology.

6. LCD display
It displays the system status, current, voltage, temperature etc. Please refer to trouble shooting section for more details

7. Hydrogen sensor
It triggers at 25% of LFL, which is 1% hydrogen concentration.

NOTE: This sensor has a delayed respond (for about 15 seconds).

8. Start up battery connector

It is the connector which connect startup battery to thecontroller

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9. Ambient temperature sensor

It senses the ambient temperature. The sensor should be place opposite to the blower side of the fuel cell stack. As is showed in system set up section.

10. DC/DC converter

TheDC/DCwillregulatetheoutputvoltageforthe controller.Itcanstepdownthestackvoltage(27.5Vto 48V)to12Vforthefuelcellcontrollerandother peripheralparts.

11. Ultra capacitor bank

Itcansupplypoweroutputduringsystem shortcircuiting(pleaserefertoShortCircuitUnitfor moredetails),whichcouldenablesystemcontinuous operationwithoutexternalpowersupply Ratedvoltage:50V Capacitance:1.25F Ifregenerativebrakingisrequired,pleaseputabigger ultracapacitorbanktostorethisenergy. Ifahighercapacityultracapacitorisused,youcan replacethissetofcapacitors.(Pleasenotethatthe maximumvoltageofthefuelcellis48V,sosizeyour ultracapacitorsaccordingly).

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12. System controller

Hydrogen sensor connector

Status LED LCD display socket

On/OFF switch

RS 232 connector

Emergency stop switch

It controls the stack and all peripheral parts to perform at its optimal condition. It has the following features Control Stack temperature Control Stack purge rate Monitoring stack current and voltage Monitoring H2 concentration(H2 sensor needed) Protect stack from possible failures, like stack low voltage, over current, over temperature Control Hydrogen supply and shut off RS232 Communication with computer

Start up battery connector

DC/DC connector

Ultra capacitor connector

System output connector

Power cord connector

Control signal connector

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Controller Signal Connector from Controller box at the wire side:

Wirecolors Red Grey Red&Black Black Yellow Blue Red&Black Black Black

Connectorpin# #1&#2 #3&#4 #5&#6 #7&#8 #9&#10 #11&#12 #13&#14 #15 #16

Peripheralscontrolled StackTemperatureSensor AmbientTemperatureSensor Blowers(Red#5=+ve,Black#6=ve) HydrogenPurgeValve(Black#7=+ve,Black#8=ve) HydrogenSupplyValve(Yellow#9=+ve,Yellow#10=ve) ShortCircuitSwitch N/A N/A BlowerPWM

Table2.1ControllerConnector

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3.0 GENERAL INFORMATION

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3.0 GENERAL INFORMATION

3.1 Dimensions

3.0 GENERAL INFORMATION

Figure3.1.1ViewsanddimensionsofH1000XPstack

Figure3.1.2Viewsanddimensionsofcontroller

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3.2 General specification

Category Type of fuel cell Number of cells Dimensions Physical Mounting Weight Peak power Performance Rated current DC voltage Reactants Composition Fuel H2 pressure Hydrogen consumption @1000W External temperature Max stack temperature operation Humidification Cooling Relative humidity Start up battery Monitoring RS232 Chart3.2GeneralSpecificationofH1000XP Value PEM 50 264mm x 197mm x 117mm 4 x M6
stack less than 3.6kg

system less than 5.5kg 1100W 0 - 33.5A @ 30V 25V - 48V Hydrogen and Air 99.99% dry H2 7.2 - 9.4 PSI 13.5SLPM 5 - 35C 65C Self-humidified air 10%-95%RH non-condensing 12V System status / Historical data

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3.3 Electric Circuit Diagram

Figure3.3ElectricCircuitDiagramforH1000XP

Please refer to section 2.0 for more details of each part

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3.4 H-1000XP Performance Specifications

The H-1000XP can deliver up to 33A of current. Its operating voltage ranges from 46V (no load) to 30V (full load). The rated operating point of 33A@30V is recommended.

NOTE: All the performances are under lab condition.

3.4.1 Nominal Polarization Characteristics Figure 3.4 below shows the polarization curve for a fully conditioned H-1000XP system operating at nominal conditions and system-to-system variability bands of the fuel cell operating at normal room temperature. Nominal operating conditions are as follows: Steady-state operation( constant voltage mode) Stack oxidant supply (18-24C, 25-35% RH, low levels of common urban pollutants such as nitrogen oxides and sculpture oxides). Anode dead-ended with adequate purge controlled by HORIZON controller 0.5 bar hydrogen inlet pressure

Figure3.4.1PolarizationcurveforH1000XP

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3.4.2 Stack degradation rate and lifetime There are generally two key life-limiting failure modes that will prevent the stack from performing as required in a given application: voltage loss and fuel leakage. Voltage loss is seen as a steady degradation in maximum power. Fuel leakage will lead to both an increase in fuel consumption, and H2 emissions in the coolant air exhaust stream. Testing has demonstrated that the H-1000XP stack has a mean lifetime of approximately 1000 hours and 300 on/off cycles under nominal operating conditions In general, to maximize stack life, avoid the following conditions: Fuel starvation (for example, due to low/high hydrogen pressure, or operating for significant periods of time below optimal ambient temperature) High operating temperatures (operating for significant periods of time above optimal ambient temperature) Contaminants in the coolant/oxidant air Contaminants in the fuel Open storage. Open storage will result in MEA in the stack got dehydrated, which is the most common reason that result in system performance low.

3.4.3 Peak power output The H-1000XP can deliver a peak power output of 1100W* to meet the high power requirements during vehicle climbing hills. This is realized by connecting an ultra capacitor in parallel hybrid configuration. Fuel cell also recharges the capacitor when excess power is available during cruise. Please refer to section 2.0 for more details of ultra capacitor

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3.4.4 System hydrogen consumption rate Figure 3.4.4 presents the fuel consumption rate of the H-1000XP system at different power outputs. The data is recorded in Nominal operating conditions (please refer to 3.4.1 for more details) Please NOTE the fuel consumption will also vary with ambient temperature, since high ambient temperature will require higher fan power consumption and also it will affect the fuel cell stack performance,

Figure3.4.4polarizationcurveforH1000XPsystem 106.6W 1.4L/min 265.2W 3.1 L/min 444W 5 L/min 651W 7.5 L/min 904.2W 10.7 L/min 1081.9W 14 L/min

The following formula is used to calculate the system efficiency

Energy content of 1 kg hydrogen

120.1 MJ (LHV) = 33.3 kWh

(1000/2)x22.4L/molhydrogengenerates33.3kWhenergy 1L/minhydrogengenerate178.361Wpower Take265.2Wpointforexample,thehydrogenconsumptionis3.1L/min Thereforethisamountofhydrogencouldgenerate3.1x178.361=553Wpower Thenthesystemefficiencyis265.2/553=48%

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3.4.5 Airflow requirements Fuel cell system requires airflow for reaction oxidant as well as cooling. Figure 3.4.5 below shows the estimated airflow requirements of the H-1000XP at different power outputs. Slight contaminant level in the operating environment has insignificant effect on the H-1000XP performance over the full product lifetime. Exposure to high level of contamination in the operating environment will lead to a drop in performance drop, which may or may not be recoverable. If the operating environment is expected to be very dusty, filter for the oxidant and cooling air may be required.

Figure3.4.5AirflowcurveforH1000XPsystem

3.4.6 Ambient temperature One factor that affects the H-1000XP performance is ambient temperature. Higher temperature leads to the drying up of the proton exchange membranes inside the fuel cell stack, reducing proton conductivity and consequently the power output of the fuel cell. The H-1000XP can deliver its rated performance when operating at ambient temperature ranging 0-35C* and a relative humidity range of 10-90%. At a given environment temperature, the H-1000XP performance increases with a higher level of relative humidity.

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3.5 Control and Communication

Communication channel: RS232 serial byte format, 9600 bps, 8 data bits, no parity, 1 stop bit; Little-endian format. Message frequency: 1k Hz. Reportable parameters: Name FuelCellStackVoltage FuelCellStackCurrent FuelCellPower FuelCellStackTemperature BatteryVoltage DataRange 2550V 060A 01500W 070 1114V Resolution 0.3V 0.3A 1W 0.5C 0.2V Baudrate 9600 9600 9600 9600 9600 Frequency(Hz) 1k 1k 1k 1k 1k

1.

Table3.5RS232dataandformat

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4.0 SYSTEM SET UP

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4.0 SYSTEM SET UP

To operate H-1000XP, the following items and resource are needed, 12VDC Start up power source Hydrogen source(operating pressure: 0.5bar / flow rate: 15SL/MIN ) H-1000XP is a self-sustainable system once it is started, to start up the system, a 12V power source is required, and it could be a battery (current above 4Ampere) or a 12VDC power supply with current above 4Ampere please follow the steps carefully to set up the systemplease DOT NOT feed the system with hydrogen and DO NOT connect power supply to the controller before all parts are properly connected.

4.1 Setup gas line to the stack

Since H-1000XP stack has two hydrogen inlet port and two outlet port, therefore a proper gas line need to be connected to make the system work as designed, please DO NOT mismatch hydrogen inlet and outlet port, which will result in stack under performance and possible damage!!! Please refer to the label on the stack and pay special attention to the arrow on the solenoid valve.

Step 1 Make gas line for hydrogen inlet, connect two tubes(6 / prefer each tube length Figure4.1 less than 50cm) to the three way, as showed in fig 4.1 and 4.2, Repeat step 1 to make a gas line for hydrogen outlet

Figure4.2

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Step 2 Please place the stack in vertical like this. Then connect the gas line finished in step 1 to stack hydrogen inlet port, as showed in fig 4.3.

WARNING! Do not place anything in front of or back from the stack, which may block off the air flow.
Figure4.3

Step 3 Connect the gas line finished in step 1 to stack hydrogen outlet port, as showed in fig 4.4.

Figure4.4

Step 4 Connect the hydrogen purge valve to the hydrogen outlet gas line; please pay attention to the flow direction on the valve body, as showed from fig 4.5 to 4.8. Figure4.5

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Figure4.6

Figure4.7

Hydrogensupplyvalve/Fromhydrogencanister

Figure4.8

At the air inlet side, since the stack will suck in hydrogen from air side, which could result in permanent damage to the stack!!!

Purgevalve/Toatmosphere

Please keep the hydrogen purge line away from the stack, it is recommended that keep the purge line at the stack fan side, as the air will blow purged hydrogen away. It is strictly prohibited that leave the purge line

Connect your hydrogen supply to the hydrogen supply valve, please DO NOT turn your hydrogen until the system is fully set up. Please make sure hydrogen is 0.5bar/15SLPM at no load and during full load

NOTE: Be sure the purge line is NOT TOO LONG from the purge valve, so that it will not do harm to stack purging easily.
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4.2 Setup controller

Step 5 Connect control signal connector to the stack, as showed in fig 4.9

Figure4.9

Step 6 Connect power cord connector to the stack, as showed in fig 4.10

Figure4.10

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Step 7 Connect ultra capacitor connector to the ultra capacitor bank, as showed in fig 4.11 A fuse is to be installed on the positive side of the capacitor bank (not provided). This fuse rating will varies from team to team and must be according the Chapter 1 Shell Eco Marathon Rules.

Figure4.11

Step 8 Connect DC/DC connector to the DC/DC convertor, as showed in fig 4.12

Figure4.12

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Step 9 Connect hydrogen sensor to the hydrogen sensor connector, as showed in fig 4.13 Please note that some application will not require this component and system will still work without this part

Figure4.13

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Step 10 Connect LCD display to the controller LCD connector; please note system could run without this part, as showed in fig 4.14

Figure4.14

Connect the hydrogen sensor to on-board battery to power the safety circuit, as showed in fig 4.15

Figure4.15

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Step 11 Connect the start up battery (not included in the system); it could be any DC power source with 12VDC, current above 4ampere. First, connect the cable to the start up battery. Then plug the cable connector to the controller, as showed in fig 4.16

Figure4.16

NOTE: It is NOT suggested to plug the battery cable to the controller BEFORE it connects to the battery, as showed in fig 4.17.

WARNING! Remind to plug in the correct polarity. Wrong polarity will fry the controller.

Figure4.17

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Step 12 It is highly recommended to connect rs232 to your computer to record system operation data, as showed in fig 4.18 Please refer to the software section for more details

Figure4.18

Step 13 Please make sure the emergency stop switch is at off position, otherwise the system is unable to start Figure4.19

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Step 13 Figure4.20 To turn on: Push the button, as showed in fig 4.20

To turn off: Wheel the button till it is up, as showed in fig 4.21

Figure4.21

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Figure4.22

Step 14 Connect the load cable to your load, it is suggested that please do not turn on the load before system start up.

Figure4.23

NOTE: The clamp is NOT suggested to use for connecting You may find other tools to make the connection more reliable. This way is only for example.

A fuse is to be installed on the positive side of the fuel cell terminal. This fuse rating will varies from team to team and must be according the Chapter 1 Shell Eco Marathon Rules.

Figure4.24

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4.3 Ready to start up

Step 15 Please find the tube to the Hydrogen supply valve, connect it to the regulator. Then set the regulator value to operating pressure: 0.5bar/15SLPM.

Figure4.25

NOTE: The type of the regulator used for example may be different from yours. WARNING! Be careful to hold on the operating pressure. Too high or too low is harmful to the fuel cell stack.

Figure4.26

Step 16 Please place the ambient temperature sensor opposite to the blower side of the stack. The place where the air comes in

Figure4.27

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Step 17 Check all the connections first, including the gas and the electricity. Be sure there is no problem of disconnecting. Now it is ready to start the system by long press the button (3 seconds)

Figure4.28

Come to booting up phase, system beeps for a short moment, flash the blue LED, display "Horizon /Fuel Cell" on the LCD.

Figure4.29

Come to running phase, the blue LED will light on, the LCD displays: E for ambient temperature; B for battery voltage, T for stack temperature, I for stack current, U for stack voltage.

Figure4.30

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Step 17 If the red LED flashing with the beeps, the system comes to the error protection status. For example, the LCD displays SYSTEM OFF FOR: FCVOLTAGE LOW means the stack open circuit voltage is too low, and the system will shut off for protection. For more, please refer to troubleshooting section.

Figure4.31

4.4 System manual shut off

Step 18 Long press the button (3 seconds) System beeps and LCD displays SYSTEM OFF FOR: MANUAL TURN OFF

Figure4.32

WARNING! Do not attempt to let outside load run out all the energy from fuel cell or other ways may cause system shut down by error protection, if you want to turn off the system.

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5.0 SOFTWARE

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5.0 SOFTWARE
Introduction
ECO-Marathon Serial Port Monitor is software, which is developed to help user to communicate with ECO-Marathon system, monitor and record various information, including: Ambient Temperature, Stack Temperature, Stack Voltage, Stack Current, Stack Power, Battery Voltage and Stack Status.

5.1 Features
1. System Monitoring a) Ambient Temperature Monitoring b) Stack Temperature Monitoring c) Stack Voltage Monitoring d) Stack Current Monitoring e) Stack Power Monitoring 2. Real-time Curves a) Ambient Temperature Curve b) Stack Temperature Curve c) Stack Voltage Curve d) Stack Current Curve e) Stack Power Curve f) Battery Voltage Curve 3. History Display a) Display Result b) Save to File

5.2 Environment
Hardware Environment 1. Desktop or Laptop with Serial Port 2. Serial Cable(RS232) Or 1. Desktop or Laptop with USB 2. USB To RS232 Cable with driver Software Environment 1. Microsoft Windows XP or above (32bit)

5.3 Installation
1. 2.

Put the installation CD into the CD-ROM drive. Run Setup program. 43

NOTE: Better to install the program on a root directory. E.g. C:\

5.4

Usage

Open program 1. Find ECO-Marathon Monitor in START\All Programs. 2. Click the icon to open. Configuration 1. Select I/O Port which is to connect to the ECO-Marathon system. 2. Set Timeout (Default is 100s). 3. Set REC ON/OFF, whether to record data or not. 4. Set recording Period (Default is 1s). Run & Stop 1. After the configuration, press the RUN button on the top left corner to run the program. 2. Press STOP button on the top right corner to stop the program. Figure5.3STOPbutton Monitor Panel 1. Ambient Temperature, Stack Temperature, Voltage, Current, Power will display as meter and number on this panel.

Figure5.1Configuration

Figure5.2RUNbutton

Figure5.4Monitorpanel

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Curves Panel 1. Ambient Temperature, Stack Temperature, Voltage, Current, Power, Battery Voltage will display as real-time curves on this panel.

Figure5.5Curvespanel

History Panel 1. User select the time from the pull down list. Figure5.6Pulldownlist 2. Press the DISPLAY RESULT button, the history data will display in the result records table. Figure5.7DISPLAYRESULTbutton 3. Press SAVE TO FILE button, the results will save in the data directory as an EXCEL file. Figure5.8SAVETOFILEbutton

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Figure5.9Historypanel

5.5 Error Information

1. Connection Timeout Error c) Phenomenon A dialogue window will pop up as follow:

Figure5.10Monitorpanel d) Description ECO-Marathon Serial Port Monitor lost connection to the system.

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6.0 MAINTENANCE

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6.0 MAINTENANCE
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 Input and another one to theH2 Output port. 2. Fill a syringe with pure water (distilled) and connect it to the hose attached to the H2 Input port. 3. Inject pure water into the stack until you see water coming out of the hose connected to the H2 Output port. Keep the water inside the stack. Disconnect the syringe. 4. We strongly recommend you connect a small hose to both H2 Input and H2 Output ports. 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. Connect a short section of hosing to the gas port marked H2 Input and another one to theH2 Output port. 2. Fill a syringe with pure water (distilled) and connect it to the hose attached to the H2 Input port. 3. Inject pure water into the stack until you see water coming out of the hose connected to the H2 Output 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 >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.

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WARNING!
When you turn off the on/off switch connected to the control box at the temperature of the fuel cell stack higher than 45C the stack will not stop working immediately. Only when the stack temperature goes down below 45C, the whole system will stop operation in order to protect the stack. So in order to make it work well, the fuel cell stack must be maintained lower than 45C before operate the on/off switch.

WARNING!
The stack must be standing on the clear plastic feet.

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7.0 TROUBLESHOOTING

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7.0 TROUBLESHOOTING
LCD,LEDandBeepofthestatusduringprocedures
# 1 Procedure Starting up LCD Horizon /Fuel Cell System 2 Starting up off/Battery Low System 3 Starting up off/FC Voltage Low System 4 Starting up off/H2% High E: 5 Running T: I: System 6 Running off/FC Voltage Low System 7 Running off/H2% High System 8 Running off/Current High Red flashing Red flashing Long beep Long beep Hydrogen leaks Stack current is too high Shut down Red flashing Long beep Stack voltage is too low Shut down B: U: Red flashing Green light on Long beep Hydrogen leaks Shut down Red flashing Long beep Stack voltage is too low Shut down LED Green flashing Red flashing Beep Long beep Long beep Status Normal Battery voltage is too low Shut down System Reaction Starting up

NONE

Normal

Running

Shut down Internal load will

Running

System off/T High

Red flashing

Long beep

Stack temperature is too high

switch off until stack temperature is satisfied

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Rehydrating the fuel cell because the stack cannot reach the rated power 1. Make sure the purging valve is disconnected from the hydrogen outlet connector. 2. Add water to fuel cell through the hydrogen inlet connector, and keep filling until water starts to come out of the hydrogen outlet valve. 3. Immediately use the hydrogen supply valve to connect the hydrogen supply the hydrogen inlet connector. Pay attention to the hydrogen supply direction. 4. Make sure the hydrogen supply pressure is not >0.5bar. 5. Open the hydrogen supply. Turn on the on/off switch for purging the water out of the fuel cell. 6. Steps 1-5 should only take 5-10 seconds to do. 7. Setup the fuel cell system again for general operation. 8. With the SCU switch on, start the fuel cell again. Battery voltage is too low Please check if start-up battery connector is ok. Or the battery might not be operating correctly or in the case of a battery may not have any charge left. 1. Disconnect the external power source. 2. Using a multimeter take a reading of the positive and negative connection points on the external power connectors to the controller. 3. If the power is <12V then the power is not coming through to be able to power the controller, blowers and valves. 4. Change or recharge your power supply and check the voltage that it meets the fuel cell voltage before connecting it up to the controller. Stack voltage is too low 1. Please check if supply/purge valve is open. 2. Please check if the blowers are running slowly, or not running at all. Hydrogen leaks Please check if the gas line has no leakage, including gas tubings and gas connectors, etc If the system shuts down by itself check the following details 1. Make sure you have connected all wires according to the diagram. 3. Make sure you have connected the hydrogen supply with the correct pressure. 4. Make sure the load is below the peak power. Overload can trigger the stack protection function to avoid the damage to the stack. 5. Check whether the fuel cell temperature is below 68C, the system will shut off if it is above 68C.

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 Check the SCU 1. During operation with the SCU on, the voltage of the fuel cell will drop. 2. If the fuel cell voltage is not dropping then contact [email protected] with the diagnostic SCU not operational with the controller number.

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