Related Manuals for Intelligent Energy FCPM
Summary of Contents for Intelligent Energy FCPM
- Page 1 2.4kW UAV Fuel Cell Power Module User Manual Users must read all instructions provided and retain the manual for future reference Document No. 10010371...
- Page 2 Glossary This is the user manual for the 2.4kW Fuel Cell Power Module (FCPM) Glossary of terms designed and manufactured by Intelligent Energy. Function or Users of this product must follow the instructions and warnings laid out in Term Definition...
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Page 3: Table Of Contents
UART format CAN format Connecting output power cables 7.5.1 CAN data to FCPM 3.1.1 Disconnecting SPMs from central module 7.5.1 CAN Data sent by FCPM 3.1.2 Connecting SPM to central module Mounting Electrical considerations 3.2.1 Mounting point information Battery charge limits 3.2.2 Mounting dimensions... -
Page 4: Safety Warnings
The customer is responsible for ensuring all technicians and pilots are suitably trained, accredited and operate in compliance with local laws and H&S regulations. • The customer is responsible for ensuring the safe operation of the FCPM in line with the User Manual at all times. •... -
Page 5: Key Components
Safety features Dual redundant power system and backup battery Other features Internal data storage for firmware update, performance and diagnostics SD card communication port; to UAV FCPM or accessories UART/CAN FCPM is not IP rated Output electrical connector M8 ring terminal/AS150... -
Page 6: System Diagram
2 Key components System diagram Central Module Power Control Module (PCM) Stack Power Module 1 (SPM 1) Stack Power Module 2 (SPM 2) Power Output Module (POM) FCPM exploded rear view... - Page 7 6. Battery Diagnostic Module (BDM) 2 7. Battery Diagnostic Module (BDM) 1 SPM 2 Central Module SPM 1 Fuel Cell Power Module (FCPM) Front view SPM 1 Hydrogen Inlet Start Button Status LED SPM 2 Hydrogen Inlet SPM 1 Central Module...
- Page 8 2 Key components 8. HMI (UART/CAN) 9. HMI (Digital/Analogue) 10. Regulator Interface 11. SD Card SPM 2 Central Module SPM 1 FCPM Rear View SPM 1 Electronics Cooling Fan SPM 2 Electronics Cooling Fan Power Control Module (PCM) Bottom View...
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Page 9: Assembly
3 Assembly Connecting output power cables The output power leads can be connected to the FCPM once the PCM has been disconnected. Note All the power leads require an M8 ring terminal to attach to the POM. 1. Ensure battery is isolated from the cables before connecting to the POM, use a suitable connector between battery and ring terminals for the power rating of the application. -
Page 10: Disconnecting Spms From Central Module
3 Assembly 3.1.1 Disconnecting SPMs from central module to allow power connection STEP 1 STEP 2 STEP 1 STEP 2 STEP 3 STEP 4 STEP 5 * SPM 2 removed for clarity * Steps 1-3 in reverse BAT + PWR + STEP 4 * SPM 2 removed for clarity BAT +... -
Page 11: Connecting Spm To Central Module
3 Assembly 3.1.2 Connecting SPM to central module STEP 5 STEP 5 * Steps 1-3 in reverse * Steps 1-3 in reverse... -
Page 12: Mounting Point Information
3 Assembly Mounting 3.2.1 Mounting point information Each SPM has four mounting points which accept an M3 thread. Mounting brackets are provided which can be fixed to the SPMs and have two M4 through holes for customer use. The complete assembly must have a minimum of two mounting brackets in total. -
Page 13: Mounting Dimensions
Up to 1m /min of airflow is required to the power electronics located at the bottom of each SPM. Do not cover the vents when mounting, airflow must not be blocked when operating the FCPM. SPM 1 Power electronics fans... -
Page 14: Spm Cooling Fans
The two mounting brackets are included to aid the creation of an air gap. This is required to allow up to a 20m /min of airflow through the FCPM. It is important to have an even airflow distribution to both SPMs allowing the system to work... -
Page 15: Hydrogen High Flow Light Weight (Hflw) Regulator
4 Hydrogen connection Hydrogen High Flow Light Weight (HFLW) Regulator The 2.4kW FCPM is designed to be operated with an Intelligent Energy HFLW Regulator. Note The FCPM could be permanently damaged if operated with incorrect hydrogen inlet pressure or insufficient hydrogen flow. -
Page 16: Electrical Connections
5 Electrical connections In order to function, the FCPM must have the following attached to the unit. See section 2.2 for reference to connection locations. Connection No. Description Comments Output negative Common ground Battery negative Common ground Output positive Output is live once battery connected... -
Page 17: Operating The Fcpm
1. Pull up (3.3V) start pins Start 1 and Start 2 on the HMI analogue/digital connector for 4 seconds. Shutdown using the Start button The procedure to shut down the FCPM: 1. Press button for 4 seconds. 2. Wait until LED stops flashing orange before moving to next step (removing battery early will corrupt the micro SD card). -
Page 18: Software Update Procedure
7. Wait for LED to change from rapid amber flashing to rapid green flashing. 8. Remove hybrid batteries. 9. Configuration update has been completed. LED states FCPM LED (located on top of central module next to start button) colour denotes specific running states and errors, as follows: Colour State... -
Page 19: Logging And Data Connections
7 Logging and data connections SD card formatting The FCPM takes a micro SD card. This logs health and performance data as well as fault codes. The micro SD card format must be FAT32. No files are required for initial operation, the FCPM will create the necessary files for operation. -
Page 20: Uart Format
7 Logging and data connections UART format The output format is listed below which is comma separated. The error codes are hexadecimal which are listed in section 12.2. The baud rate is 9600, 8 data bit, no parity, 1 stop bit. The parameters available via UART are: UART Word number... -
Page 21: Can Format
7 Logging and data connections CAN format The FCPM provides data through the CAN interface. Signals can be sent to the FCPM or transmitted from it. 7.5.1 CAN data to FCPM The CAN network operates at 500kbits/sec. Variable Name CAN message ID... -
Page 22: Can Data Sent By Fcpm
7 Logging and data connections 7.5.1 CAN Data sent by FCPM The CAN network operates at 500kbits/sec. Update CAN message ID Variable Name Time [ms] (decimal) Byte Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7... - Page 23 7 Logging and data connections Update CAN message ID Variable Name Time [ms] (decimal) Byte Bit 0 Bit 1 Bit 2 Bit 3 Bit 4 Bit 5 Bit 6 Bit 7 SPM1 Flags C extended 1000 (d1056 + slave ID) SPM1 Flags D (h420 + slave ID) SPM2 Flags A...
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Page 24: Electrical Considerations
Emergency battery usage The 2.4kW FCPM has redundancy offered by this kind of architecture. If one SPM has a critical fault, the remaining SPM 1.2kW and battery are still operational to provide power. -
Page 25: Storage And Maintenance
Hydrogen pipework is still in good condition with no leaks • Fans rotate freely In the event of it being stored for more than 60 days, the FCPM should be operated at >80% rated capacity for at least 40 minutes. Recommended storage... -
Page 26: Troubleshooting
Table of all codes are shown in Appendix A. 10.2 Contact Product Support In the event of a fault with the FCPM, please contact the Intelligent Energy Product Support Team. Either contact your local representative or email: product.support@intelligent-energy.com Please provide as much detail of the issue as possible including unit serial number and log files. -
Page 27: Appendix
12 Appendix 12.1 Connector specifications 12.1.1 Regulator Interface [Port No 10] The electrical connection of the HFLW regulator to the FCPM. The connector is of the type JST 08-CPT-B1-2A. Pin No. Description Range 0 to 5V Tank pressure signal 0.5-4.5V (0-100% range) Low pressure signal 0.5-4.5V (0-100% range) -
Page 28: Uart And Can [Port No 8]
12 Appendix 12.1.3 UART and CAN [Port No 8] This connector facilitates UART and CAN communications to and from the FCPM. The connector is of the type JST 12CPT-B-2A. Pin No. Description Range 0 to 5V +3.3V 0 to 3.3V... -
Page 29: Fault Codes
12 Appendix 12.2 Fault codes 12.2.1 PCM fault codes The fault codes output in hexadecimal, the faults also stack so must be decoded if more than one error appears. The last 12 sections from the UART data stream correspond to the fault codes, 7-10th relate to the PCM in the table below: Reference section 7.4 for UART data output sequence. - Page 30 12 Appendix Flag Code Description 00000100 CorruptConfigFault Configuration Fault – memory corrupt or not set. The CRC of the data from NVM is incorrect 00000080 ConfigValueRangeFault Configuration Fault – value out of range. A configuration value is out of range. 00000040 PreStartSleepCommand The system is off/idle and has been commanded...
- Page 31 12 Appendix Flag Code Description 40000000 TurnaroundTimeFault Coms Fault 20000000 Spm1RxCommsLengthFault SPM Coms Fault 10000000 Spm1RxCyclicCounterFault SPM Coms Fault 08000000 Spm1RxLineCounterFault SPM Coms Fault 04000000 Spm1RxShortLengthFault SPM Coms Fault 02000000 Spm1RxDecodeEncodeFault SPM Coms Fault 01000000 Spm1RxecodeCrcFault SPM Coms Fault 00800000 Spm2RxCommsLengthFault SPM Coms Fault 00400000...
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Page 32: Spm1 & 2 Fault Codes
12 Appendix 12.2.1 SPM1 & 2 fault codes The last 8 UART outputs (11-18) reference fault codes on SPM 1 & 2, 11-14 are SPM1 and 15-18 are for SPM2. The fault codes are in hexadecimal and the faults stack so will require decoding. - Page 33 12 Appendix Flag Code Description 00000002 DisableExternalOutputCheck Digital output tell-back not the same as set 00000001 EnableStackOutputCheck Digital output tell-back not the same as set 80000000 StackTxSensor1OverTemperature Above temperature limit (>58°C) 40000000 StackTxSensor2OverTemperature Above temperature limit (>58°C) 20000000 NegativeEndPlateTxSensorOverTemperature Above temperature limit (>58°C) 10000000 PositiveEndPlateTxSensorOverTemperature Above temperature limit (>58°C) 08000000...
- Page 34 12 Appendix Flag Code Description 00000020 SelfArbitrate Communications from PCM lost 00000010 PcmCommsLostShutdown Cyclic Counter lost 00000008 FanEscTelemetryStartFailed Esc Telemetry failed during start up 00000004 MaxCooling Fans are at their maximum set point 00000001 EngineeringFault Development warning flag 80000000 Not currently in use 40000000 Not currently in use 20000000...
- Page 35 12 Appendix Flag Code Description 10000000 PcmRxCyclicCounterFault PCM Coms Fault 08000000 PcmRxLineCounterFault PCM Coms Fault 04000000 PcmRxShortLengthFault PCM Coms Fault 02000000 PcmRxDecodeEncodeFault PCM Coms Fault 01000000 PcmRxecodeCrcFault PCM Coms Fault 00800000 PcmTxLengthFault PCM Coms Fault 00400000 PcmTxEncodeFault PCM Coms Fault 00200000 I2c1AckFailure I2C fault...
- Page 36 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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