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Spectronik PROTIUM-2500 User Manual

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PROTIUM-2500
FUEL CELL SYSTEM
USER GUIDE
VERSION 3.0 APRIL 2022

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Summary of Contents for Spectronik PROTIUM-2500

  • Page 1 PROTIUM-2500 FUEL CELL SYSTEM USER GUIDE VERSION 3.0 APRIL 2022...

  • Page 2: Safety, Handling & Support

    PROTIUM-2500 Fuel Cell System (PROTIUM-2500) or other property. Read all the safety information below before using PROTIUM-2500. Handling Handle PROTIUM-2500 with care. It is made of thin sheet metal, graphite, and plastic and has sensitive electrochemical membrane and components inside. PROTIUM-2500 is not designed for extreme conditions, rough handling, vibration, shock or drop.

  • Page 3: Item Description

    OVERVIEW 1.1 PROTIUM-2500 SYSTEM OVERVIEW Figure 1.1.1 Top view of PROTIUM-2500 Figure 1.1.2 Bottom view of PROTIUM-2500 ITEM DESCRIPTION Oxidant blower (x2) Cooling fan (x6) Oxidant flow manifold Protective mask Mounting plate (left) Cathode outlet duct Mounting plate (right) CHAPTER 1 | OVERVIEW...
  • Page 4 1.1 PROTIUM-2500 SYSTEM OVERVIEW Can also be seen more clearly in Fig 1.1.2 Figure 1.1.3 Right view of PROTIUM-2500 Figure 1.1.4 Left view of PROTIUM-2500 ITEM DESCRIPTION Gas pressure sensor 1 Gas pressure sensor 2 H2 supply valves (right) H2 supply valves (left)
  • Page 5 1.1 PROTIUM-2500 SYSTEM OVERVIEW Figure 1.1.5 Front view of PROTIUM-2500 (Can also be in Fig 1.1.2) Figure 1.1.6 Back view of PROTIUM-2500 ITEM DESCRIPTION Power/Signal receptacle Stack power output (-ve) Stack power output (+ve) CHAPTER 1 | OVERVIEW...

  • Page 6: Electronic Controller

    1.2 ELECTRONIC CONTROLLER Figure 1.2.1 Top, Left and Right views of Electronic Controller ITEM DESCRIPTION Radio telemetry transmitter On/Off push button Mounting hole (x4) Status LED Stack power output (+ve) Balance-of-plant (BOP) switch Stack power output (-ve) Load connector (XT-90 female) Power/Signal header Telemetry transmitter port Programming port...

  • Page 7: Standard Accessories

    1.3 STANDARD ACCESSORIES Figure 1.3.1 Accessories ITEM DESCRIPTION Power/Signal extension cable Free-end wires for user’s load Stack power output (+ve) extension cable Load connector (XT-90 male) Stack power output (-ve) extension cable P2 sensor cable Free-end wires for user’s power supply USB connection to PC External power supply header Radio modem receiver...
  • Page 8 1.4 MECHANICAL DIMENSIONS – PROTIUM-2500 All dimensions in mm 94.50 646.60 457.60 343.50 550.60 170.00 CHAPTER 1 | OVERVIEW...
  • Page 9 1.5 MECHANICAL DIMENSIONS – ELECTRIC CONTROLLER All dimensions in mm 163.40 131.40 35.40 145.00 113.00 63.20 41.00 43.10 85.00 15.00 68.60 107.10 3.20 (4x) 55.60 CHAPTER 1 | OVERVIEW...
  • Page 10 1.6 MECHANICAL DIMENSIONS – STANDARD ACCESSORIES All dimensions in mm 1000.00 1000.00 1000.00 600.00 1000.00 1800.00 1000.00 CHAPTER 1 | OVERVIEW...
  • Page 11 Figure 1.7.1 Recommended orientation of PROTIUM-2500 PROTIUM-2500 cannot be mounted in any orientation due to internal routings of the gas streams within the fuel cell stack. The stack should also be level to ensure water does not get trapped in the Cathode channels, obstructing the oxidant flow and causing potential performance drop and cell damage.
  • Page 12 1.8 MECHANICAL DIMENSION – MOUNTING AND CLEARANCE Figure 1.8.1 Dimensions of the mounting holes All dimensions in mm 8.00 150.00 R3.25 510.60 (centre to centre) CHAPTER 1 | OVERVIEW...

  • Page 13: Specifications

    SPECIFICATIONS 2.1 PROTIUM-2500 TECHNICAL DATA SHEET Fuel cell PROTIUM-2500 Type No. of cells Architecture Closed cathode Coolant Air cooled Rated/gross power 2500/3000W Rated/gross current 52.5/62.5A Voltage output 48-72VDC Start-up time Operating ambient temp. [-10,45] Operating altitude without power derating 1500m AGL...
  • Page 14 20.0 30.0 40.0 50.0 60.0 70.0 Current (A) Figure 2.2.1 Nominal polarization curve for a fully conditioned PROTIUM-2500 at its Beginning-of-Life (BOL). TEST CONDITIONS • Ambient temperature: 24 • Relative humidity: 60% • H supply pressure: 10psig • Dead-ended operation •...

  • Page 15: System Block Diagram

    • Status LED & Buzzer • Oxidant System • Valves • Sensors Electronic BOP Switch 1/0 • Communications Controller Communication PROTIUM-2500 • USB or fuel cell stack • Radio telemetry transmitter Fuel cell Fuel cell power IN power OUT 48-72V...

  • Page 16: Operating Procedures

    (37 and 38). Make sure that the external power supply is OFF at this stage. 6. PROTIUM-2500 has two H2 gas inlet connectors (10 and 15). Connect your Hydrogen gas supply Caution: ensure that the to both inlets.
  • Page 17 3.2 TURNING ON PROTIUM-2500 1. Connect the Radio modem receiver (43) to a PC via the USB cable (42). Launch the Spectronik Data Acquisition Graphic User Interface (DAQ GUI) software. Choose the Com Port, set the Baud Rate Tip: the latest DAQ GUI software and user manual can be (57600) and click the S logo.
  • Page 18 2500W. If hybrid battery is connected at the load, PROTIUM-2500 will provide up to its maximum rated output and the rest is augmented by the battery. The total power available depends on the capacity of the battery. If no...
  • Page 19 3. The message <System OFF> will appear in the GUI. PROTIUM-2500 is now turned off. Status LED will blink at 60% on standby awaiting the next start-up command.
  • Page 20 “start” and “end” command via the GUI. 4.2 SYSTEM WARNING & PROTECTIONS PROTIUM-2500 has several in-built protections. The LED will flash and error message will appear in the GUI. Follow the basic troubleshooting guide below. Most errors should be rectified once the suggested corrective action has been done and the system restarted.
  • Page 21 Stack open circuit voltage is too low. Check and ensure sufficient hydrogen supply and correct delivery pressure. Restart after 1 min. ◉ Emergency Shutdown = "Abnormal Shutdown" would be activated * with purchase of optional Spectronik accessories (gas tank and pressure regulator) CHAPTER 4 | SYSTEM MONITORING & PROTECTIONS...
  • Page 22 Please check for abnormalities. ◉ Emergency Shutdown = "Abnormal Shutdown" would be activated ● LED flashing at 80% to alert warning in the running * with purchase of optional Spectronik accessories (gas tank and pressure regulator) CHAPTER 4 | SYSTEM MONITORING & PROTECTIONS...
  • Page 23 4.2 SYSTEM WARNING & PROTECTIONS (Cont.) Other messages: Message Meaning Fan PWM auto Cooling fans control is in auto mode Blower auto Oxidant blower control is in auto mode Mileage Cumulative Watt-Hour of the system Shutdown initiated Entering “Normal Shutdown Phase” Abnormal Shutdown initiated Entering “Abnormal Shutdown Phase”...

  • Page 24: Maintenance And Storage

    When not in use, Spectronik recommends that PROTIUM-2500 is reconditioned at least once a month. 1. Set up PROTIUM-2500 as per instructions in Section 3, using a DC electronic load in lieu of your regular load. 2. After the system enters “Running Phase”, set constant voltage (CV) load of 50V and run the system for 1h.

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