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Summary of Contents for Horizon Fitness H-500
- Page 1 H-500 Fuel Cell Stack User Manual Updated 14 Aug. 2013 Model No.: FCS-C500 Manual_FCS-C500_V1.1_EN...
- Page 2 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-500 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.
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Page 3: Table Of Contents
Table of Contents 1. Safety....................2. Terminology..................3. Stack and System Component Information........4. Technical Specifications..............5. System Set Up.................. 6. Notes for the set up ................7. System Setup Diagram ..............8. Operating Procedure................ 9. Polarization Curves................10. Storage and Re-use................11. Troubleshooting&System Checks............12. Fuel Cell Drawing................13. FAQ....................Manual_FCS-C500_V1.1_EN... -
Page 4: Safety
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. - Page 5 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 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).
- Page 7 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 jewellery – 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. The stack generates up to 36 VDC (open circuit voltage). This voltage decreases as current is drawn from the stack. The stack produces 21.6V at maximum power. This voltage is exposed at the output power connections.
- Page 8 1.8 High Temperature The fuel cell stack is designed to operate at 65ºC. At this operating temperature, the air exhaust stream temperature can reach 55ºC and the cooling air stream can reach 17ºC 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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Page 9: Terminology
2. Terminology PEM fuel cell: A PEM (Proton Exchange Membrane) fuel cell is a device that converts hydrogen and oxygen into water and electricity. A fuel cell stack: It includes a plurality of plate-like fuel cells arranged along an axis generally parallel to cell thickness with electrically conductive separator plates between each pair of cells. - Page 10 A: Warning lable B: Blower C: Controller connector D: FC- connector E: FC+ connector F: Grounding cable G: Hydrogen supply valve H: Hydrogen purging valve Manual_FCS-C500_V1.1_EN...
- Page 11 A: Hydrogen input connector B: Hydrogen output connector C: This side up label D: Silicon tube Note: The silicon tube connected between the hydrogen input and hydrogen output is to keep the membrane humidity to maintain the fuel cell stack in best performance.
- Page 12 A: Logo B: SCU(short circuit units) switch C: ON/OFF button D: Controller connector E: Controller power supply DC 13V- F: Controller power supply DC 13V+ G: Connect to Load+ H: Connect to FC+ I: Connect to FC- Manual_FCS-C500_V1.1_EN...
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Page 13: Stack And System Component Information
3. Stack and System Component Information 1. Stack Is made up of plate-like cells with air channels to allow the flow of air across the membrane. The membrane facilitates the flow of Hydrogen creating the release of electrons. Electrically conductive separator plates between each pair of cells enable the flow of electrons. - Page 14 7. Controller Connector Connect the stack cables to the lead wires of the T-sensor/ blower/purging valve/input valve on the controller. 8. Controller Controls the stack temperature, blowers, hydrogen input, purging and short circuiting of the stack. 9. H2 output & H2 Input H2 output: connect the tube shown in 11 below. H2 input: connect the tube shown in 11 below with the hydrogen pressure between 0.45-0.55Bar.
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Page 15: Technical Specifications
4. Technical Specification Type of fuel cell Number of cells Rated Power 500W Performance 14.4V @35A H2 Supply valve voltage Purging valve voltage Blower voltage Reactants Hydrogen and Air External temperature 5 to 30ºC Max stack temperature 65ºC H2 Pressure 0.45-0.55bar Hydrogen purity ≧... -
Page 16: System Set Up
5. System Set-Up 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 3mm. The input pressure to the stack is required to be 0.45-0.55Bar . - Page 17 STEP 2: Connect controller "FC+" to the stack "FC+" and controller "FC-" to stack "FC-&Load-". The finished connection is shown in 2B. STEP 3: Connect the controller to a stabilized power supply through the “13V DC” connectors (3A), and the external power supply should be 13V(±1V), ＜5A. Manual_FCS-C500_V1.1_EN...
- Page 18 STEP 4: Keep the SCU (Short Circuit Unit) switch ON at “-” for usual use. Warning: Some home appliances may not be suitable for this activation process. It may cause damaging. you can shut off the short circuit by switching it to "O", but it will cause at least 20% performance loss. STEP 5: Connect the output of the hydrogen supply valve to the stack (pay attention to the arrow direction on the valve).
- Page 19 Warning:The tube between the hydrogen pressure regulator and the fuel cell gas input is required to be less than 30cm. STEP 6: Connect the stack to the purge valve through the filter for a longer running time and a better performance (6A-6D). If not, the gas out of stack may have a negative effect on the purge valve after a long time running.
- Page 20 Note: The tube between stack output and purging valve is required to be less than 20cm. The tube connected to the purging valve output is required to be less than 30cm. The inner diameter of the tube is required to be more than 2mm. STEP 7: Use the M4 (7mm) sleeve to unscrew the nut and then connect the grounding cable (7A-7B).
- Page 21 STEP 8: Check all the connection first and connect the load to the system, Load+ is linked to the "load+" at the controller, Load- links to the "FC- and load-" in the stack shown in 8A STEP 9: Check the following steps before starting the system: The connection between the hydrogen input valve and the hydrogen source. The connection between the hydrogen input valve and the stack intput. The connection between the stack outoput and the purging valve. The output tube of the purging valve is kept away from the stack.
- Page 22 STEP 10: Provide hydrogen and stabilized voltage first and then press the ON/OFF switch to start the system. Note: Make sure the hydrogen pressure is between 0.45-0.55Bar. Make sure the dry Hydrogen gas to be used is ≥99.995% purity and no sulphuric composition or other gases such as CO or CH4, and also no pungent odor, paint and perfume are allowed around stack.
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Page 23: Notes For The Set Up
6. Notes for the set-up Note: The pictures below are only for reference. The voltage of external power supply is Stack should be placed like this between 12V-14V, the current range is position. Stand on the plastic feet. different based on the different stack. The tube between stack output and purging valve is required to be less than 20cm. - Page 24 The outlet of the purge valve should be far away from the stack. Don't let the hydrogen from purge valve back to the stack, otherwise it would damage the stack. Note: The tube between stack output and purging valve is required to be less than 20cm.
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Page 25: System Setup Diagram
7. System setup diagram SCU: Short Circuit Unit GND: Grounding Manual_FCS-C500_V1.1_EN... -
Page 26: Operating Procedure
8. Operating Procedures STARTUP PROCEDURE Make sure both the stack and the ambient temperature are less than 45℃. Otherwise the system will not start up successfully. Hold the ON/OFF button down for 2 seconds to start the system; you will hear one beep, which means the system has started. If at this time the system shuts down in less than 1 second, then review the "beeping interpretation during starting procedure". - Page 27 RUNNING PROCEDURE After system has started, depending on your setup and application you can change your load to get the power you need within the specified power range for this fuel cell. Don’t connect up a load that will demand more power than 500W which can permanently damage the fuel cell. During the operation, monitor the Hydrogen flow and pressure to consistently supply hydrogen at 0.45-0.55Bar. Monitor the external power is providing 12-14V. Direct the outlet tubing of the purge valve away the fuel cell. Do not let the purged hydrogen go back towards the fuel cell stack, it will damage the fuel cell. Pay attention to the purge, take care of the performance during the purge, If after each purge, the performance is increased about 10%, it means you need to increase the pressure of hydrogen a small amount. The fuel cell is flooding and so you need to use the pressure to push extra water out.
- Page 28 SHUTDOWN PROCEDURE To shut down the fuel cell system down, please follow these steps: 1. Turn off the load. 2. Hold the ON/OFF button down for 2 seconds to stop the system, you will hear one long beep, which means the system is shutting down. Note: When you turn off the on/off switch connected to the control box at the temperature of the fuel cell stack higher than 45˚C the stack will not stop working immediately.
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Page 29: Polarization Curves
9. Polarization curves Performance characteristics of the stack are presented. All performance data is given for baseline operating conditions, defined at sea-level and room ambient temperature. 500W U-I Curve Current(A) H2 consumption(ml/min) 7000 6000 5000 4000 3000 2000 1000 100.0 200.0 300.0 400.0 500.0 600.0 Power(w) 500W Power Curve 600.0 500.0 400.0 300.0... -
Page 30: Storage And Re-Use
10. Storage and Re-Use When finished operating the stack, place 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 it's performance goes down 50% to the rated power at 21.6V 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. -
Page 31: Troubleshooting&System Checks
11. Trouble Shooting & system checks Check the external power supply The battery might not be operating correctly or in the case of a battery may not have any charge left. Disconnect the external power source. Using a multimeter take a reading of the positive and negative connection points on the external power connectors to the controller. - Page 32 Bleeps Interpretation Action High current protection i.e. current is too high - For H-100 - H-300 is > 12A set by the controller. - For H-500 - H-1000 is > 30A set by the controller. High temperature fuel cell protection i.e. fuel cell is running >65˚C. Low voltage fuel cell protection i.e. the average voltage per cell is <0.5V Note: If one of the above situations occurs, the stack will disconnect the load and make an alarm.
- Page 33 Checking the Fuel Cell System If the fuel cell shuts down you need to check the voltage of the fuel cell by measuring between the FC+ and FC- connectors on the fuel cell. There are 3 possible scenarios: Voltage = 0 Check the supply valve and purge are open.
- Page 34 Check the Blowers With the system completely setup, Start the system. Once the system has started, after the fuel cell system has been short circuited 5 times as part of the startup procedure the blowers will start to turn, pulling air through the fuel cell. If all the blower(s) are creating non-standard noise, turning slowly, or not turning at all. i.
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Page 35: Fuel Cell Drawing
12. Fuel Cell Drawing Manual_FCS-C500_V1.1_EN... -
Page 36: Faq
13. FAQ What is the SCU? This is the Short Circuit Unit, it helps to condition the fuel cell for long term good performance. What is the Hydrogen pressure supplied to the fuel cell stack? The pressure is required to be 0.45-0.55Bar. What is the maintenance of the stacks? 1. When the stack finishes operation, disconnect the hydrogen input and output tube from the stack and also disconnect the power output.