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Horizon Educational FCDK-1.5 User Manual

1.5-3w fuel cell developer kit
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1. Overview
2. What is included
3. What you will need
4. Setup instructions
5. Connect H2 regulator and purge valve
7. Electrical connections to Arduino shield
8. Prepare Arduino and fuel cell control shield
9. Connect HYDROSTIK PRO and load
10. Operation
11. Status LEDs
12. Purge
13. Waste water
14. Output power
15. Overload protection
16. Fuel cell maintenance and use
17. Software downloads
18. Monitoring fuel cell status
19. Power output & conditioning
2
20. Software description
2
21. Setup and defines
2
22. Arduino Pinouts
3
23. Available Functions
3
24. Storage
3
25. Reconditioning
4
26. Hydrogen supply
4
27. Safety
5
28. FAQ
5
29. License
5
30. Appendix
5
31. Included in the power extender module
5
32. Setup instructions using power extender
5
module (2 stacks) 3
3. Connect H2 regulator & purge valve
5
34. Solder wires to fuel cell stack
5
5
Control system for Horizon fuel cell stack
Refillable metal hydride hydrogen storage
with
pressure regulators
Complete component kit to build and create
your own hydrogen fuel cell power plant
Development board "shield" for popular
Arduino platform with stack control
software
Monitoring and data-logging via USB
(voltage &
current)
Open source hardware and software
Regulated 5V output
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Summary of Contents for Horizon Educational FCDK-1.5

  • Page 1 Control system for Horizon fuel cell stack Refillable metal hydride hydrogen storage with pressure regulators Complete component kit to build and create your own hydrogen fuel cell power plant Development board "shield" for popular Arduino platform with stack control software Monitoring and data-logging via USB (voltage &...

  • Page 2: What Is Included

    The Developer kit enables the user to easily design and build fuel cell systems using the Horizon 1.5W PEM fuel cell stack. Output power can be upgraded to 3W total, using the extender module sold separately (see Appendix). An open source platform supported by an online developer forum encourages rapid customisation of systems, control and user interface for a wide range of applications from model trains, planes and automobiles, to remote monitoring systems.

  • Page 3: Connect H2 Regulator And Purge Valve

    IMPORTANT: Only run the kit in a well ventilated room. Connect H2 regulator and purge valve 1. Cut a short length of silicone tube (approx 3cm) 2. Push one end of the short length onto the white nozzle of the purge valve 3.

  • Page 4: Connect Hydrostik Pro And Load

    If you do not already have the Arduino environment and drivers installed on your computer, follow these instructions, relating to your operating system (http://arduino.cc/en/Guide/HomePage) Before proceeding, make sure you can open an example Arduino sketch (e.g. blink), compile it and upload. If so; then proceed. Plug the Fuel Cell Shield into the Arduino Uno taking care that all the pins on the underside of the shield slot into the holes in the Arduino Uno stackable header Connect your Arduino to your computer using a standard USB cable...

  • Page 5: Status Leds

    Status LEDs There are 3 LEDs: After reset, the status LED flashes twice in 200ms, and then every 400ms until the capacitors have charged. When the system is operating normally the LED will flash every second the short LED shows when the fuel cell is shorted. This maintains proper temperature and humidity inside the stack the purge LED shows when the purge valve operates Purge Every minute, you will hear a short "hiss"...

  • Page 6: Setup And Defines

    Setup and defines The _stacksize setting defines the size of the fuel cell stack and can be one of V1_5W, V3W, V12W V30W The _shield setting defines the version of the shield. This is printed on the reverse of your shield and currently can be one of V1_0, V1_2, V1_3 Available Functions void poll() This function must be called at least every 100ms to keep the stack running.

  • Page 7: Reconditioning

    Important The fuel cell stacks will degrade if they are allowed to dry out. Therefore whenever the fuel cell stack is not be used for more than one hour, it should be stored in the sealed airtight bag. Reconditioning If the fuel cell is not used for several days or is not working at the rated power, it can be reconditioned as follows: 1.

  • Page 8: License

    I get less power than I expect, why? Things to check include: Getting enough hydrogen? perhaps you need an extra HYDROSTIK PRO. The fuel cell may not be getting enough oxygen; check the vents are clear. Remember the Arduino will draw about 0.25W, so for the lower power systems this can be a sizable percentage of available output power.

  • Page 9: Included In The Power Extender Module

    Included in the power extender module 1.5W stack 2 x T-splitter Silicon tubing (30cm) Figure 6. What is included in the extender module Setup instructions using power extender module (2 stacks) The instructions for using 2 stacks differ only in the hydrogen and electrical connections. These are detailed below. Follow all the other instructions detailed in the single stack setup.
  • Page 10 Solder wires to fuel cell stack Important Fuel cell stacks must be connected with correct polarity otherwise components will be damaged. Please check that the red and black wires are soldered to the correct terminals as outlined below. 1. Cut the wires into two 15cm lengths: 1 x red. 1 x black, and 1 x black 5cm length 2.

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