Table of Contents
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Table of Contents
Related Manuals for Intelligent Energy FCM-802
Summary of Contents for Intelligent Energy FCM-802
- Page 1 FCM-802/804 User Manual Retain for future reference...
- Page 2 Intelligent Energy Limited. Intelligent Energy has made every effort to ensure that this User Manual is accurate and disclaims liability for any inaccuracies or omissions that may have occurred.
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Page 3: Table Of Contents
Contents 1 Safety and warnings 2 Product specification 3 Parts of the FCM-802/804 4 Product interface 5 FCM-802/804 overview 6 Connections Electrical configuration Electrical isolation and over-current protection Air supply Hydrogen fuel Hydrogen connection Communication connection CAN connection Potential free contacts... -
Page 4: Safety And Warnings
Where the intended use is outside that assessed by Intelligent Energy, the customer must assess and design their system appropriately with regard to this limitation. - Page 5 Drawing excessive load may lead to a shutdown of the fuel cell and load not being supported · When the FCM-802/804 is running it will stay live if the power cables are disconnected · EVEN when the FCM802/804 is NOT running the cables may still be powered from the load side battery or external power source ·...
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Page 6: Product Specification
Rated power from 30%. Power de-rate commences below 30% CAN interface can be provided, see section 6.5 Please contact Intelligent Energy to discuss your requirements For details see Declaration of Conformity Allow space for power cables and hydrogen connection to rear... -
Page 7: Parts Of The Fcm-802/804
Parts of the FCM-802/804 The key components of the FCM-802/804 are: Display screen Rating plate Unit serial number label Exhaust air Air filter Mounting (19" rack) Inlet air Rear view Earth terminal Power terminals Warning label Terminal cover Hydrogen connection Communication port Number 10009655. -
Page 8: Product Interface
The FCM-802/804 provides regulated DC at nominal output voltage, which can be defined by the user at a nominal 24V or 48V. The FCM-802/804 will hold the DC output at the nominal voltage while connected to an external battery or power supply so that the system will act as a hybrid system. -
Page 9: Connections
Do NOT disconnect the main power leads with the enable signal present. Warning: When the FCM-802/804 is running it will stay live if the power cables are disconnected. Warning: EVEN when the FCM802/804 is NOT running the cables may still be powered from the load side battery or external power source. -
Page 10: Electrical Isolation And Over-Current Protection
EN IEC 62485-2:2018. Safety requirements for secondary batteries and battery installations. Stationary batteries. Air supply To produce electrical power, the FCM-802/804 requires an unobstructed air supply which must not be recirculated between the exhaust and inlet. · Ensure that the air inlet cannot be blocked ·... -
Page 11: Communication Connection
Connections Communication connection To operate FCM-802/804, communications need to be provided through the D-type connector. The pins of the connector have the following functions: Performance Function Specification Enable Provides power to the FCM Enable Positive Power source for the Enable signal... -
Page 12: Potential Free Contacts
There are four potential free contacts (PFC) for auxiliary signals to and from the FCM. The PFCs are setup to be one output and three inputs. These are software configurable by Intelligent Energy. The signals are shown in the following table: Description... -
Page 13: Fcm-802/804 Software States
2 In all states, removing the Enable signal returns the FCM-802/804 to the module controller off state. 3 If the FCM-802/804 enters a fault condition the fault is latched. The Enable line must be cycled to clear it. 4 For start and stop criteria see section 13 Control parameters and standard factory setting. -
Page 14: Operation Of Fcm-802/804
Operation of FCM-802/804 Overview FCM 802/804 The FCM-802/804 provides regulated DC at nominal 24V or 48V output to a battery bus. The DC bus will be held at nominal voltage by a battery or external supply to act as a hybrid system. In the hybrid system, the battery is used to provide power whilst the fuel cell starts. -
Page 15: Faults
10.1 Mechanical mounting points The FCM-802/804 must be installed as a standard 19" rack unit. This should then be mounted on a flat surface with four retaining points, these must be tightened to a torque not exceeding 25Nm. When installing the FCM, inspect it and do not install if there is visible damage to the unit. -
Page 16: Mechanical Protection And Covers
10.5 Vibration and shock loads The mounting of the FCM-802/804 must ensure that it is not exposed to shock or vibration loads. Ensure that the FCM-802/804 is stationary while it is operating. Note: If the FCM has been stressed due to vibration or shock, return to Intelligent Energy for investigation. -
Page 17: Air Supply And Ventilation
However, the air exhaust design must consider the hydrogen risk. The FCM-802/804 must be provided with free venting air in the range of +5 to +40°C, it must not be operated outside this range. The installation of the FCM 802/804 must be considerate of other equipment near FCM 802/804 may elevate the local ambient temperature during their operation. -
Page 18: Hydrogen Connection
The FCM-802/804 will consume less than 70g/kWh at rated power. This is equivalent to 34sl/min (FCM-802) and 56sl/min (FCM-804) at rated power. It must be noted that the flow will spike high during hydrogen purges, which, if poorly regulated, can lead to a low pressure fault of the FCM. -
Page 19: Maintenance Procedures
Intelligent Energy Ltd. 11.2 Contact Intelligent Energy Product Support Team In the event of a fault with the FCM-802/804, please contact the Intelligent Energy Product Support Team. Either contact your local representative or email: servicing@intelligent-energy.com Please have the part number of your product and the serial number (on the name plate). -
Page 20: Check For Fuel Leak
Trouble-shooting guide 12.2 Check for fuel leak Remove sources of ignition Remove electrical load Set FCM to “Off” and “Disabled” Verify hydrogen source is at an Contact output pressure within specification IE Product Support Team (application specific) Isolate hydrogen source, pressure Can the leak source be Have a gas trained person conduct contact IE Product dropping... -
Page 21: Fuel Check Procedure
Trouble-shooting guide 12.3 Fuel check procedure No power from FCM Check that the hydrogen source Refuel the hydrogen source has pressure available (application specific) Check the hydrogen supply Open the hydrogen supply is fully open between the (application specific) source and the 800 unit Check that the regulator Increase pressure to pressure is >500mbar.g... -
Page 22: Electrical System Check Procedure
Trouble-shooting guide 12.4 Electrical system check procedure FCM will not start The FCM operates as a hybrid system. Contact IE Product Support Team to discuss Is there a battery in the Does the design have an complete application? external power supply? Adjust the Is the voltage from the supply to the power supply within... -
Page 23: Stack Temperature Check Procedure
Potentially live components 7 The dirty filter can be lifted out. 8 Discard dirty filter. 9 Place clean filter in front of FCM-802/804 and refit frame and screws. Do not touch the fuel cell stack during this procedure Number 10009655. A1... -
Page 24: Control Parameters And Standard Factory Setting
Control parameters and standard factory setting The FCM 800 series configuration is factory settable. If there is a need to adjust the configuration after installation contact Intelligent Energy Product support. 13.1 Power Setup Configuration (802) Parameter Unit Range Factory Setting... - Page 25 Control parameters and standard factory setting 13.2 Power Setup Configuration (804) Parameter Unit Range Factory Setting Factory Setting (24V) (48V) Target Output Voltage 15.0 to 56.0 Delayed Start Under-Voltage 0.0 to 60.0 Delayed Start Qualification Time 0 to 14400 Immediate Start Under-Voltage 0.0 to 60.0 Delayed Stop Over-Voltage 0.0 to 60.0...
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Page 26: Spare Parts, Storage And Disposal
10005293 Only use Intelligent Energy approved parts. 14.2 Disposal When the FCM-802/804 reaches end of life, please contact Intelligent Energy Product Support or your local representative for support with reconditioning or disposal. 14.3 Storage The FCM-802/804 must be stored as follows: ·... -
Page 27: Declaration Of Conformity
A copy of the official version of this certificate duly signed by an authorised signatory of the manufacturer is available upon request by emailing sales@intelligent-energy.com Intelligent Energy Limited, Charnwood Building, Holywell Park, Ashby Road, Loughborough, Leicestershire, United Kingdom, LE11 3GB 12th November 2018... - Page 28 Intelligent Energy’s business and its technology. This publication and its contents do not include all details which may be relevant to particular circumstances and should not be regarded as being a complete source of information. To the fullest extent permitted by law, Intelligent Energy offers no warranty as to the accuracy of the content of this publication, shall not be liable for the content of this publication and no element of this publication shall form the basis of any contractual relationship with a third party.
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