Summary of Contents for Horizon Fitness T-2.5KW
- Page 1 2.5K EL CEL L UPS S SOLUTI Upda ated Dec 2 26, 2016 T-2.5KW_U U M_V1.5...
- Page 2 Page 1 Discla aimer This man ual incorpo rates safety y guidelines and recom mendations s. However, , it is not int tended to cover all s situations. I It is the resp ponsibility o of the custo mer to mee et all local sa afety requir rements and to en nsure safety y during ope eration, mai ntenance a nd storage of the fuel c cell system. Although all efforts h have been m made to ens sure the acc curacy and c completene ess of the inf formation ...
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Page 3: Table Of Contents
About This Manual ........................8 PEM Technology ......................... 8 The Horizon Solution ........................9 3. The T-2.5KW System ......................10 T-2.5KW Models ........................11 Chassis Features ......................... 12 4. Operation ..........................29 ... -
Page 4: Important Safety Information
Page 3 1. Important Safety Information 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. Although the T‐series systems are designed with simple, easy‐to‐use interfaces, prudent safety measures should be followed. 1.1 General information For this unit to generate electrical power, a supply of hydrogen fuel is necessary. It is important for ... -
Page 5: Handling Compressed Gas Cylinders
Page 4 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 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. ... -
Page 6: Flammability And Volatility
Page 5 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. ... -
Page 7: Electrical Safety
Page 6 1.7 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 metallic jewelry rings, bracelets, watchbands, or necklaces – when you are close to an exposed fuel cell stack. • Minimise static discharge. If possible, ground all equipment. • Minimise 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. 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 ... -
Page 8: Terminology
Page 7 1.9 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 reaction. In the fuel cell the reactants are air and hydrogen by which the electricity will be generated. Humidification: Humidity, 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 through the fuel cell every minute, which the hydrogen supply can be calculated. ... -
Page 9: Introduction
Page 8 2. Introduction Thank you for choosing Horizon’s T‐2.5KW system as your power generating solution. Based on Horizon’s expertise in modular, redundant fuel cell systems, the T‐2.5KW system is the next step in simplicity, scalability, modularity and reliability, providing clean, quiet, and reliable power for backup power applications. 2.1 About This Manual This manual is intended to provide customers with all the information needed to select, install, operate, maintain, and troubleshoot the T‐2.5KW system. 2.2 PEM Technology While there are a number of fuel cell technologies available, the most common and practical technology for standby power is the proton exchange membrane, or PEM, fuel cell. The only inputs to the fuel cell are industrial Grade 3.5 hydrogen (99.995% H2 concentration) and oxygen (air), with the only byproducts being pure water/vapor and heat. As a result, fuel cells are considered a green technology, making them an attractive solution for installations with emissions restrictions. One of the other attributes of a fuel cell that makes it attractive for deployment in many applications is that a fuel cell produces DC power. This makes a fuel cell akin to a standby rectifier source, as the power provided from the fuel cell can be directly connected to the site’s DC power bus. In an outage situation, the fuel cell turns on automatically, providing DC power, which was formerly provided by the rectifiers. DC output also makes the fuel cell ideally suited for hybrid applications with solar (photovoltaic), wind and battery systems. The fuel cell is akin to a generator, in that the fuel cell is sized for the power requirement, and can run indefinitely provided it has a source of fuel. This means fuel cells, when coupled with an appropriately sized fuel storage solution, can function effectively for long reserve times as a standby power source in customer applications. The T‐series system is designed to be a backup power solution for DC power applications within the transportation, security, wire line and wireless telecommunications, utility, and government sectors. ... -
Page 10: The Horizon Solution
Page 9 Figure 2-1. T T-series backup up power syste 2.3 The e Horizon n Solution Horizon’s s T‐series sy stem provid des a single, , fully integr rated system m that fits w within a stan ndard equipmen nt rack. The e chassis inc cludes a refo ormer syste m, a fuel ce ell module, a an integrate ed control and powe er electroni cs for a com mplete syste em in a singl le chassis. -
Page 11: The T-2.5Kw System
Page 10 3. The T-2.5KW System This section describes the operating principles of the T‐2.5KW system. The T‐2.5KW system functions as a fueled DC power source. The unit can be started and stopped manually or automatically. Because its electrical output is DC, the T‐2.5KW system can be installed directly in parallel with other DC equipment. The rated output voltage is 48V. For proper operation, the T‐2.5KW requires airflow. A source of clean air must be supplied. The ... -
Page 12: T-2.5Kw Models
Page 11 3.1 T-2 2.5KW Mo odels The i ntroduction n of the fron nt panel of T T‐2.5KW sys stem, please e see figure e3‐1. Figu ure 3-1. The fr ront panel intro oduction of T- -2.5KW The i ntroduction n of the rea r panel of T ‐2.5KW syst tem, please e see figure3 3‐2. ... -
Page 13: Chassis Features
Page 12 Table 3‐1 1 shows the specificatio on of T‐2.5K W system. F For detailed d specificati ons, please see Appendix x A. Table 3-1 EC COBOX-MR R Specificatio Model Rated P Power Outp put Voltage Detail Inform mation 2.5KW 2500 Appendix In a chas ssis‐only con nfiguration, the T‐2.5K KW ... - Page 14 Page 13 Syste em will shut t down or en nter into er ror mode w when error h happens. 1) R Recoverable e: press ENT TER button f for 3 second ds to restart t the system m.(Refer to T Table 3‐2) Table 3 3-2 Recovera able error splay escription alysis Hydroge en pressure 1. Hy ydrogen sup pply pressur re low. 2. Le eakage occu urred on hyd drogen...
- Page 15 Page 14 1. Fo or current pr recision pro otection. egards to the fuel cell tech hnology Set curre ent fail ntact: pport@horiz zonfuelcell.co egards to 1. Fo or system pr rotection. e fuel cell tec chnology con ntact: EEPROM M memory fa ail pport@horiz zonfuelcell.co 3.2.1.2 LE ED Indicato Green: ...
- Page 16 Page 15 3.2.2 LC CD display informatio Syste em operatio on status dis splay Syste em error dis splay Stack k and batter ry paramete er display 3.2.2.1 Se et Output Vo oltage Press the e ON/OFF s switch to st tart the sys stem, then the ...
- Page 17 Page 16 3.2.2.2 Se et System Mo Mode and Con ndition After sta rting, custo omer can se et the syste em mode d during oper ation. T‐2.5 5KW system m has three e modes, w which is Prim mary Mode , Manual M Mode and Lo ow Volt Mo ode. Use dir rection keys s to choose...
- Page 18 Page 17 When the system starts in manual mode, the system will never return to Standby. The front panel ON/OFF switch allows the user to manually turn the system on to generate power. And the only method to stop the unit is by pressing the switch again. When choose Primary Mode or Manual Mode, press enter to the next interface, then press enter again to start the system or press up key to reset the system mode. 3) Low Volt Mode When the system starts in low volt mode, the unit will attempt to achieve an output voltage which is the value set in the Float Volt field. Once the system has achieved and held float voltage for a period of time (set in the Float Timer field), the unit will return to Standby. This mode functions as a battery charge mode, charging up an external battery to the float voltage, and then returning to Standby. When the batteries discharge to the low voltage threshold, the system will start again. This charge/discharge method is useful for very small loads, where the battery is properly sized to support the small load, and is recharged by the fuel cell. The fuel cell system will operate “thermostatically”, turning on at the low voltage threshold, and turning off after holding the output at the float volt setting until the float timer expires. When primary power is restored to the ...
- Page 19 Page 18 Fuel cell need regula ar operation n to keep m membrane h hydrated to maintain th he perform ance. If the e backup p power syste m is not fre equently us sed, it will b be needed t to operate t the stack fo or about 30 0 minutes a a month. During th he normal st tandby mod de, the syste em will star rt to operate e, when sta ndby time r reaches the e value wh ich is set as s “Condition n Cycle”. An nd system w will back to ...
- Page 20 Page 19 3.2.2.4 Op Operation Inf formation Table 3-4 4 Operation i information System Displ Note Solutions phase System sta arting proce Spend 40 s seconds artup Startup ok k, system going to n ormal operation Operation System op peration time System mo ode setting interface, p...
- Page 21 Page 20 if you h have question ns or To display y GRID need h elp with rega ards Power ON N/OFF alarm to the f fuel cell and message. I It will not techno logy contact shut down n the system suppor rt@horizonfu uelcell...
- Page 22 Page 21 3.2.3.2 Ventilation System The ventilation system should be inspected annually and maintained free of obstruction for proper venting. An indoor rack installation should include room ventilation with sufficient filtered make‐up air to provide adequate airflow to the unit. And the air exhaust area should be always keeping fluent. Either in an indoor rack installation, or a closed cabinet (indoor or outdoor), the air exhaust must be ducted outside to prevent the accumulation of humid air, which can condense on cooler surfaces. 3.2.4 FC+/- The positive and negative outputs are provided on the back panel connector. The T‐2.5KW stack is connected to the T‐2.5KW controller at the fence type connector on the rear panel. WARNING DC terminals should always be considered electrified when connected to a DC bus. Observe proper polarity when connecting the power leads. 3.2.5 Output+/- The ECOBOX‐MR system is connected to the user’s DC power bus at the fence type connector on ...
- Page 23 Page 22 3.2.7 RS S 232 RS232 Da atabase outp put port First, , we need to o connect th hese ports a and do the s setup. Conn nect the Ua rt1 port on the hardw ware to the relevant PC C serial port ts. Use the RS232 data a line to connect t the Uart1 1 with the RS232 con nnector on the ...
- Page 24 Page 23 Selec ct COM por rt when con nnect them . In some P PCs, there m might be 2 ports. Such h as COM1, , M2… Please make sure e the port connecting to the pla atform is se elected ...
- Page 25 Page 24 Then n press Conf firm to start t showing th he system in nformation. COM M port Setup p. Setting u up ASCII: Fil le – Proper rties – Setti ngs, check the box “A Append line e feeds s to incomin ng line ends s” as shown in Figure 3‐ ‐11 and 3‐1 2. ...
- Page 26 Page 25 On th he Menu ba ar, Click Tran nsfer ‐> Cap pture Text, a and select a save path t t o save it. C Click Start to o start recording t the data. Figure 3- -13, Data savi ing interface Figu ure 3-14, Save e Data Copyright t Horizon Fue el Cell Techno ologies – T‐2. .5KW_UM_V1 Page 25...
- Page 27 Page 26 Figur re 3‐15 plea se find the data instruc ctions. Figure 3-15, Data in structions Table 3-5 RS232 Data a Instructions No. Instruc ctions Comment t 1 Stack vo oltage 2 Stack cu urrent 3 Stack tem perature 4 Ambient tem mperature 5 ...
- Page 28 Page 27 3.2.8 Inp put signal A user inp put signal co onnector is provided o n the rear p panel of con ntroller. The e connector r has clamp‐ ‐ type term minals that a are engaged d with a scre ewdriver. The inpu t signal con nnector pla aces an ent ry in the co ontroller w when the tw wo ...
- Page 29 Page 28 2. U Unrecovera ble: H2 leak age Stack cu urrent too h high Stack te emperature too high Output short circui it Set volt tage fail Set curr rent fail EPPROM M memory f fail Syste em Operati on Status: ...
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Page 30: Operation
Page 29 4. Operation WARNING To avoid property damage, personal injury or loss of life, DO NOT attempt to operate the T‐2.5KW system until all directions have been read and understood. When running, the unit will operate similar to a power‐limited voltage source. The unit will supply power, attempting to achieve the output voltage. If the power limit of the unit is reached before the output voltage is achieved, the system will sustain its maximum power output. This maximum power output may be less than the unit’s rating due to temperature, altitude, reduced airflow (due to restrictions of intake or exhaust flow), reduced fuel flow (due to regulator pressure or hydrogen bleed obstruction), or fuel cell aging. From start‐up, a properly maintained T‐2.5KW system will achieve 60% power in approximately one minute, and peak power in approximately 10 minutes at 20°C and sea level. This warm‐up period is required for the fuel cell to heat itself sufficiently to evaporate the water created during ... -
Page 31: Hydrogen Connection
Page 30 4.1 Hyd drogen Co onnection Follow th he figure 4‐1 1 to connec ct the hydro ogen input t tube and th he hydrogen n output tub be with the e T‐2.5KW system. Ho orizon sugge ests to keep ping the hyd drogen inpu ut high pres ssure aroun d 1.2Bar to o 2Bar. And d use the p ressure reg ulator to ad djust the hy ydrogen inp ut low pres ssure betwe een 0.55Bar r and 0.75B Bar. Figure 4 4-1. -
Page 32: Wire Connection
Page 31 4.2 Wir re Connec ction A fuel ce ll system w ith multiple e chassis ca n be config ured as a si ingle bus sy ystem, or as s a multiple e bus syste em. Figure 4 4‐4 illustrat tes the deta ailed wiring g connection ns for an in ndoor T‐2.5 KW system m installatio on. ... -
Page 33: Grounding
Page 32 4.3 Grounding Using acceptable practices, as specified by NFPA 70 and National Electrical Code 250.166, connect a chassis ground wire to the chassis ground terminal provided on the T‐2.5KW system front and rear panel The ground wire size shall be a minimum of 10 AWG. 5. Applications Engineering This section provides information to assist with the selection of the best‐suited T‐2.5KW system configuration for the desired application. It also outlines site considerations for optimal fuel cell performance. 5.1 Storage Requirements The T‐2.5KW system requires placement into service and periodic operation or exercise in order to ... -
Page 34: Appendix A: T-2.5Kw Specifications
Page 33 Appendix A: T-2.5KW Specifications T‐2.5KW Technical Specifications SPECIFICATION VALUE Power Rating 0 to 2,500 W @ 20°C and 101.3 kPa Current Rating 0 to 47A @54V Voltage Adjustable 43.2 to 57.6 V DC Voltage ripple ±1V Controller Dimension(WxDxH) 430mm x 550mm x 88mm Stack Dimension(WxDxH) 430mm x 550mm x 356mm Controller Weight 13.5 kg Stack Weight 40.3 kg ﹣10⁰C to +45⁰C Standard (additional heating needed when Ambient temperature temperature less than 0⁰C, during operation) Recommended cold start temp More than 5⁰C Relative Humidity 0‐95% Non‐Condensing Communications RS232 Reactants Hydrogen and Air Cooling Air (integrated cooling fan) H2 inlet pressure ... -
Page 35: Appendix B: System Error And Alarm Information
Page 34 Appendix B: System error and alarm information Appendix B-1: Last ALM: XXXX First no. no alarm Second no. no alarm no alarm Third no. FC temperature high 1：GRID Power OFF 1:door open 0：GRID Power ON 0:door close Forth no. Appendix B-2: Last ERR: XX Error information Description... -
Page 36: Appendix C: Circuit Diagram Of Signal Output Connector
Page 35 Appen ndix C: Circuit t Diagra am of S ignal O O utput C C onnect Copyright t Horizon Fue el Cell Techno ologies – T‐2. .5KW_UM_V1 Page 35... -
Page 37: Appendix D: Circuit Diagram Of Signal Input Connector
Page 36 Appen ndix D: Circuit t Diagra am of S Signal In n put Co o nnecto Copyright t Horizon Fue el Cell Techno ologies – T‐2. .5KW_UM_V1 Page 36... -
Page 38: Appendix E: T-2.5Kw Drawing
Page 37 Appe endix E: : T-2.5K KW Dra awing: Copyright t Horizon Fue el Cell Techno ologies – T‐2. .5KW_UM_V1 Page 37... - Page 39 Page 38 Copyright t Horizon Fue e l Cell Techno o logies – T‐2. . 5KW_UM_V1 1 .5 Page 38...