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Summary of Contents for Fronius 25F
- Page 1 / Battery Charging Systems / Welding Technology / Solar Electronics Operating Instructions 25F/50F Energy cell Energy cell 42,0410,1562 006-11022013...
- Page 3 Read the manual carefully and you will soon be familiar with all the many great features of your new Fronius product. This really is the best way to get the most out of all the advantages that your machine has to offer.
- Page 5 Safety rules DANGER! „DANGER!“ indicates immediate and real danger. If it is not avoided, death or serious injury will result. WARNING! „WARNING!“ indicates a possibly dangerous situation. Death or serious injury may result if appropriate precautions are not taken. CAUTION! „CAUTION!“...
- Page 6 General remarks All safety and danger notices on the device (continued) must be kept in a legible state must not be damaged/marked must not be removed must not be covered, pasted or painted over. For the location of the safety and danger notices on the device, refer to the section headed „General remarks“...
- Page 7 Environmental Operation or storage of the device outside the stipulated environmental conditions conditions will be deemed to be not in accordance with the intended purpo- se. The manufacturer shall not be liable for any damage resulting from such improper use. For exact information on permitted environmental conditions, please refer to the „Technical data“...
- Page 8 Protecting Keep all people, especially children, away from the unit and its accessories. yourself and If, however, there are people in the vicinity, others make them aware of all the dangers associated with the back-up battery (risk of a build-up of explosive acids and gasses that are detrimental to the health, possible risk of suffocation due to lack of oxygen in the air, danger from output current, etc.) provide suitable protective equipment.
- Page 9 EMC measures Care must be taken during installation to ensure that no electromagnetic interference occurs in electrical and electronic devices. Electrical instal- Electrical installations must only be set up set up to the relevant national lations and local standards and regulations. Safety measures Only operate the device when all protection devices are fully functional.
- Page 10 Specific areas of Keep hands, hair, clothing and tools away from moving parts, for example risk fans. The cover of the electrical connection compartment may only be removed by trained personnel. All other covers and housing in general may only be opened/removed by trained manufacturer’s personnel.
- Page 11 Danger from If the device is equipped with pressure tanks with hydrogen, all safety pressure tanks regulations for pressure tanks should be observed. Pressure tanks contain gas under pressure and can explode if damaged. They must therefore be handled with great care. Protect the pressure tank from excessive heat, mechanical impact, naked flames, sparks and arcs.
- Page 12 Carrying out a The operator is required to carry out a safety inspection of the unit at least once every safety inspection 12 months, and to have the safety elements on the unit function tested, including (continued) calibration of the sensors. The entire system must be checked in accordance with the applicable national regulations.
- Page 13 Copyright Copyright of these operating instructions remains with the manufacturer. The text and illustrations are all technically correct at the time of going to print. Right to effect modifications is reserved. The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser.
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Page 15: Table Of Contents
Contents General ................................3 Functionality and device concept ......................3 Advantages ............................... 3 Features ..............................3 Inputs and outputs ............................. 4 Warning notices on the device ........................4 Control elements and connections ......................... 6 Safety ................................ 6 Housing front panel ........................... 6 Housing rear panel - overview of process connections ................ - Page 16 Annual safety inspection ......................... 47 Every 1500 operating hours ........................48 Maintenance work every 1000 operating hours ..................48 Disposal ..............................48 Technical data .............................. 49 Fronius Energy Cell 25F ......................... 49 Fronius Energy Cell 50F ......................... 51 Fronius Worldwide...
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Page 17: General
General Functionality and The energy cell generates electrical device concept energy from hydrogen and oxygen in the surrounding air according to the fuel cell principle. The electrochemical unit in the device consists of several individual cells connected in series. A digital control unit supplies it with hydrogen and air in the appropriate ratio and maintains the operating temperature. -
Page 18: Inputs And Outputs
Service interface USB-B RS485 Hydrogen 5.0 (3.0 available on Electrical output request) Energy cell 25F: 24 V DC, 2 kW Energy cell 50F: 48 V DC, 4 kW Cooling air Combustion air Battery / primary supply for Reaction chamber outgoing air... - Page 19 Warning notices WARNING! Inadequate ventilation increases the risk of fire, explosion and on the device suffocation. The device should be set up so that it is independent of the (continued) surrounding air. This means that the combustion and cooling air is supplied from the atmosphere and the outgoing air from the reaction chamber and cooling system is dissipated into the atmosphere.
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Page 20: Control Elements And Connections
When the energy cell is integrated into a system, the Emergency Stop (11) button is to be removed from the device by a Fronius-trained service engineer. (10) (2) USB-B interface For reading operating data using the... - Page 21 (8) Terminals X0 for DC power and earthing panel Electrical output power (continued) Energy cell 25F: 24 V, 2 kW Energy cell 50F: 48 V, 4 kW (9) Strain relief device For securing the connected cables (10) Plug connections for CAN X3 interface For reading operating data;...
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Page 22: Housing Rear Panel - Overview Of Process Connections
Housing rear panel - overview of process connections Fig. 6 Non-electrical connections and cooling air ducts IMPORTANT! The ducts (6) and (7) for supplying and removing cooling air (1) are not part of the scope of supply and should be designed to suit the conditions at the installa- tion location and as described in the „Commissioning“... - Page 23 Housing rear No. Function panel - overview (5) Attachment for the reaction chamber outgoing pipe of process The outgoing air and backflushed air from the reaction chamber are dissipated into connections the atmosphere. Hydrogen sensors and a level monitor for the backflushing air (continued) ensure safe operation.
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Page 24: Layout Of Process Connections
Layout of the process connec- tions 475 mm, 18.7 in. 403.75 mm, 15.9 in. 330.25 mm, 13 in. 297.75 mm, 11.72 in. 214.75 mm, 8.45 in. 156.75 mm 6.17 in. 12 mm 185 mm 185 mm 19 mm .47 in. 7.28 in. -
Page 25: Before Commissioning
Before commissioning Safety WARNING! Incorrect operation may result in serious injury or damage. Do not use the functions described here until you have thoroughly read and understood the following documents: these operating Instructions all the operating instructions for the system components, especially the safety rules The device is designed exclusively for generating electrical energy from gaseous Proper use... -
Page 26: Connections
Connections The device is designed for the hydrogen supply and output voltages indicated on the rating plate. The hydrogen supply must be provided as described in „Installation examp- le“ in the „Commissioning“ section. If there are no connections, lines or valves attached to your device, fit these compon- ents so that they conform to the relevant national standards. -
Page 27: Commissioning
Commissioning Safety WARNING! Work carried out incorrectly and electric shocks can have fatal results. The cover over the electrical connection compartment must only be removed by a trained technician All other covers and housing should generally only be opened/removed by the manufacturer’s trained technicians. Unauthorised opening or manipulation of the device will invalidate the warranty and create the risk of serious injury or damage. -
Page 28: Wiring Terminals For Dc Power And Earthing (X0)
Fig. 8 Connecting cables for DC power and earthing For external sensors: establish an earth connection for the cable shields using one of the two C-rails to fix the strain relief devices. Energy cell 25F Description Housing / earthing DC+ battery... -
Page 29: Wiring Terminals For Safety-Related Inputs And Outputs (X2)
Emergency Stop: contact 21 Emergency Stop: contact 22 Note regarding the external Emergency Stop: If required, a Fronius-trained service engineer can remove the Emergency Stop button and integrate pins 5 and 6 into an Emergency Stop circuit on the system side. If the external Emergency Stop is not used, bypass pins 5 and 6 by jumpering them accordingly. - Page 30 Wiring terminals Maximum cable cross-section: 2.5 mm² (0.00388 in.²) for inputs and Recommended tightening torque for terminal screws (1): 0.6 Nm outputs 1. Insert the cable ends with ferrules into the terminals of the 9-pin plugs X3 and X4 2. Secure cables using terminal screws (1) 3.
- Page 31 Wiring terminals X3 - Potential-free input Description for inputs and outputs Digital input 0: + 10 - 30 V DC 7 mA (continued) X4 - Potential-free input Description Digital input 0: - 10 - 30 V DC 7 mA Digital input 1: + 10 - 30 V DC 7 mA Digital input 1: -...
- Page 32 Wiring terminals Important! The Modbus interface RS485 is designed for reading device-specific data for Modbus and only is intended for Fronius trained staff. The two additional RJ45-plugs (1) for the interface RS485 Modbus interface RS485 are not included. Specifications for the 5-pin plug connection X5: Maximum cable cross section: 1,5 mm²...
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Page 33: Wiring The Service Interface
IMPORTANT! The service interface (1) and the contents of this section are intended for vice interface Fronius-trained service technicians only. The plug for the service interface is not part of the scope of supply. A RJ45 plug connector is required. -
Page 34: Setup Independent Of Surrounding Air
With the dimensions shown on the side with the housing openings (3) in the illustra- tion For a volumetric flow of 700 Nm³/h (25000 cfh) - energy cell 25F 1400 Nm³/h (50000 cfh) - energy cell 50F Duct for removing cooling air Duct for supplying cooling air 185 x 425 mm, 7.28 x 16.73 in. -
Page 35: Setup Dependent On Surrounding Air
Setup indepen- dent of surroun- DN 50 ding air (1.97 in.) (continued) 22 mm 165 mm 165 mm 0.87 in. 6.5 in. 6.5 in. 50 mm 1.97 in. Fig. 13 Arrangement of the predrilled holes for cooling air ducts Setup dependent WARNING! Inadequate ventilation increases the risk of fire, explosion and on the surroun- suffocation. -
Page 36: Connecting The Hydrogen Supply
There must be no leaks from the screwed joint with the counterpart Hydrogen supply pressure 5 to 13.6 bar (72.49 - 197.18 psi.) Hydrogen volumetric flow 1.7 Nm³/h (60.71 cfh) - energy cell 25F Hydrogen volumetric flow 3.3 Nm³/h (117.86 cfh) - energy cell 50F Fig. - Page 37 Stainless steel version (VE-water-resistant) Diameter 6 mm (.24 in.) Volumetric flow up to 2 l/h (.53 gal/h) - energy cell 25F Volumetric flow up to 3 l/h (.79 gal/h) - energy cell 50F Fig. 16 Connecting the outlet pipe 1.
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Page 38: Connecting The Reaction Chamber Outgoing Pipe
Connecting the WARNING! A covered hydrogen sensor increases the risk of fire, explosion reaction chamber and suffocation. The following conditions must be fulfilled during and after outgoing pipe assembly of the reaction chamber outgoing pipe: The reaction chamber outgoing pipe must only be pushed onto the attachment. -
Page 39: Installation Example For Battery Current > 85 A
Installation Where batteries for an electrical load greater than 85 A are being used, the consumer example for must be connected in parallel with them. battery current > 85 A Deviations in the case of energy cell 50F: The 5 - 10 kOhm pre-resistors indicated thus * are required The battery voltage is 48 V instead of 24 V WARNING! An inadequate or missing fuse protection for the batteries or improper handling of batteries can cause dangerous situations and result in... -
Page 40: Installation Example With A Charging Current Limit
Installation The charging current must be limited in situations where low-capacity batteries are example with a being used in order to protect them. The consumer must be connected to the dedicated charging current load connections „load“ on terminals X0. limit Deviations in the case of energy cell 50F: The 5 - 10 kOhm pre-resistors indicated thus * are required The battery voltage is 48 V instead of 24 V... -
Page 41: Operation
+3 °C to +40 °C (37.4 °F to 104 °F). standby 1. Turn the keylock switch to the - I - position „FRONIUS Energy Cell“ appears on the display The energy cell runs a safety test and the display reads „Standby“. The system display then appears. -
Page 42: Manual Mode
Manual mode When the end-of-charging voltage set at the factory is reached for the connected battery, the energy cell starts to idle. The energy cell is switched off manually by turning the keylock switch to the - O - position as described under „Manual mode: switching off the energy cell“. -
Page 43: Automatic Mode: Switching Off The Energy Cell
Automatic mode: Apply a voltage of 10 - 30 V to pin 4 9-pin plug X4 starting the and pin 5 of input X4 - Run (System energy cell start) (continued) Maximum cross-section of voltage signal cable: 2.5 mm² (0.00388 in.²) IMPORTANT! The recommended tighte- 0.6 Nm ning torque for the locking screws in the... -
Page 44: Display
Display The display The display is for information and documentation only, and is not used to set the energy cell enables the energy cell to be started from standby allows the energy cell to return to standby from the operating state The system shows display... -
Page 45: Service
Battery display This shows the following for the start and back-up battery battery voltage (V) output current of the energy cell (A) Service WARNING! Starting up the device without having performed safety-related maintenance work is done at your own risk. The manufacturer accepts no liability for damage caused by inadequate maintenance or the non-perfor- mance of maintenance. -
Page 46: Navigation
Warnings „Service“ (continued) This indicates that servicing is nearly due. The warning appears from 1 month before the service date. If the service was missed, the warning symbol signals that the service interval was exceeded. Press keys „left“, „right“ and „scroll“ to Tastenfeld select buttons, symbols and settings change values... -
Page 47: Error List
Error list In the event of an error, the energy cell generates an error code. There is an overview of the error codes in the „Error diagnostics and troubleshooting“ section. Every new error code is added to a list of errors. The error list can be accessed using the „ALARM“... -
Page 48: Overview
Overview... - Page 49 Detailed explana- Buttons: tion of the sys- „Fav“ tem display Switches to the Favourites display „START“ Starts the energy cell if it is in standby „STOP“ Returns the energy cell to standby if it is in the operating state Warning symbols: An explanation of the warning symbols can be found in the „Warnings“...
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Page 50: Detailed Description Of The Favourites Display
Detailed descrip- Buttons: tion of the Favou- „SETUP“ rites display Used to access the menu for calling and configuring the measured values „ALARM“ Used to open the alarm list. The „ALARM“ button only appears if at least one error code is stored. Warning symbols: An explanation of the warning symbols can be found in the „Warnings“... -
Page 51: Displaying Measured Values
Displaying At the end of the „Display“ section there is an overview and explanation of the available measured values measured values. To call up any measured value: 1. Select the „SETUP“ button from the Favourites display 2. Press the „OK“ key to confirm 3. -
Page 52: Changing The Favourites
Changing the To select and arrange the values for the Favourites display: favourites 1. See the „Displaying measured values“ section, e.g. „TAout“, for how to navigate to the required value 2. When you have selected the value, press the „OK“ The window for arranging the Favourites display opens 3. - Page 53 Configuration of Select the desired setting, e.g.: „Size“ for the tank the tank indicator size (L) (continued) Press the „OK“ key to confirm Use the „left“ / „right“ keys to move the cursor to the first position to be changed Use the „scroll“...
- Page 54 Configuring It is possible to set the display value and unit separately for each unit in order to cor- external ana- rectly display the external analogue sensor inputs. Depending on the setting, it may be logue sensor necessary to connect a suitable sensor to the corresponding analogue input. inputs 1.
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Page 55: Overview And Explanation Of Available Measured Values
Overview and Measured values can be called up for the following explanation of system components: the available 1. Hydrogen tank measured values 2. Energy cell 3. Battery To display the view shown above: Select the „SETUP“ button from the Favourites display Press the „OK“... - Page 56 Measured values „SYS-CTRL“ ... System control for the energy pIn: cell Hydrogen supply pressure (bar) (continued) cond: Conductibility of the cooling fluid (micro-Siemens) Umin1 Specifies the cell with the lowest voltage (mV) Umi1# Number of the cell with the lowest voltage State System status Start...
- Page 57 Measured values „COOLSYS“ ... Cooling system temperatures for the energy TCin: cell Cooling fluid incoming temperature (°C) (continued) TCout: Cooling fluid return temperature (°C) TAout: Temperature of the process outgoing air (°C) „DC- / DC“ ... DC / DC converter Ubat: Battery voltage (V) Iout:...
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Page 58: Measured Values For The Battery
Measured values „EXT-AI“ ... External analogue sensor inputs for the energy cell You will find detailed information in the „Configuring external analogue sensor inputs“ (continued) section. Measured values 1. Select the symbol for the battery for the battery 2. Press the „OK“ key to confirm The following measured values are displayed for the start and back-up batteries: Battery voltage (V) -
Page 59: Troubleshooting
NOT be replaced by any other screws that do not provide a reliable PE conductor connection. Energy cell fault Contact: diagnostics Fronius International GmbH 4600 Wels-Thalheim, Günter-Fronius-Straße 1, Austria E-mail: energycell@fronius.com http://www.fronius.com The unit has no function Cause: Battery not connected or connected incorrectly... -
Page 60: Displayed Service Codes
Make a note of the error message shown on the display, and of the serial number and configuration of the unit, and contact the manufacturer, giving a detailed description of the error. Contact: Fronius International GmbH 4600 Wels-Thalheim, Günter-Fronius-Straße 1, Austria E-mail: energycell@fronius.com http://www.fronius.com 10010 | E-stop Cause:... - Page 61 Cause: DSP reports a power module error Remedy: Restart / cannot be remedied: Contact After-Sales Service 31010 | Service Cause: Servicing by Fronius-trained personnel required Remedy: Contact After-Sales Service 13020 | Fira 01 Error Cause: Air mass sensor error Remedy:...
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Page 62: Care, Maintenance And Disposal
A safety inspection is required at certain intervals, as is the maintenance specified below. A safety inspection is required once a year. The safety inspection must be carried out Annual safety by a Fronius-trained service technician and includes checking all the safety features of inspection the device. -
Page 63: Every 1500 Operating Hours
Every 1500 The H sensor must be replaced after 1500 operating hours. A warning message operating hours appears on the display 200 operating hours before this period has elapsed. If the deadline for the function test of the hydrogen sensor has passed, the warning symbol indicates that the function test was not carried out on time. -
Page 64: Technical Data
Technical data Fronius Energy Input data Cell 25F Fuel Hydrogen 5.0 (3.0 possible on request) Hydrogen supply pressure: 5 – 13.6 bar 72.49 - 197.18 psi Hydrogen consumption < 1.7 Nm³/h < 60.71 cfh Hydrogen connection 1/4 in. NPT Cooling air / combustion air 700 Nm³/h... - Page 65 Fronius Energy General data Cell 25F (continued) Data interface RS485, USB, CAN Degree of protection IP 20 Marks of conformity CE, TÜV Süd Fuel Cell Safety Safety standard EN 62282-5-1:2007 Dimensions l x w x h 850 x 470 x 850 mm 33.46 x 18.5 x 33.46 in.
- Page 66 Fronius Energy Input data Cell 50F Fuel Hydrogen 5.0 (3.0 possible on request) Hydrogen supply pressure: 5 – 13.6 bar 72.49 - 197.18 psi Hydrogen consumption < 3.3 Nm³/h < 117.86 cfh Hydrogen connection 1/4 in. NPT Cooling air / combustion air 1400 Nm³/h...
- Page 67 Fronius Energy General data Cell 50F (continued) Data interface RS 485, USB, CAN Degree of protection IP 20 Marks of conformity CE, TÜV Süd Fuel Cell Safety Safety standard EN 62282-5-1:2007 Dimensions l x w x h 850 x 470 x 850 mm 33.46 x 18.5 x 33.46 in.
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Page 69: Fronius Worldwide
Fronius Worldwide - www.fronius.com/addresses Fronius International GmbH 4600 Wels-Thalheim, Günter-Fronius-Straße 1, Austria E-Mail: energycell@fronius.com http://www.fronius.com Under http://www.fronius.com/addresses you will find all addresses of our sales branches and partner firms!
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