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Spectronik PROTIUM-300 User Manual

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PROTIUM-300
PROTIUM ECO MARATHON (PEM) PACKAGE
USER GUIDE V1.0-1.0
VERSION V1.0-1.0 24.04.17

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Summary of Contents for Spectronik PROTIUM-300

  • Page 1 PROTIUM-300 PROTIUM ECO MARATHON (PEM) PACKAGE USER GUIDE V1.0-1.0 VERSION V1.0-1.0 24.04.17...

  • Page 2: Safety, Handling & Support

    300 Fuel Cell System (PROTIUM-300) or other property. Handling Handle PROTIUM-300 with care. It is made of thin sheet metal, graphite, and plastic and has sensitive electrochemical membrane and components inside. PROTIUM-300 is not designed for extreme conditions, rough handling, vibration, shock or drop. Keep PROTIUM-300 away from heat, flame, strong sunlight, water, dust, soil or mud.
  • Page 3 OVERVIEW 1.1 PROTIUM-300 FUEL CELL OVERVIEW Top View Front View Left View Right View ITEM DESCRIPTION Power/Signal receptacle Gas purge solenoid valve Cooling fan (x2) gas outlet connector Pressure sensor (x2) gas inlet connector Protective mask Gas supply solenoid valve...

  • Page 4: Electronic Controller

    Unregulated stack power out receptacle DC-DC converter Programming port (6-pin) DC-DC power out (XT-60 female) On-Off push button External power supply receptable Status LED *Also Gas Pressure Transducer data transmission receptacle compatible with Spectronik’s Eco-Marathon Pressure Regulator CHAPTER 1 | OVERVIEW...
  • Page 5 1.3 ULTRACAPACITOR PACK Ø3mm Ultracapacitor Pack ITEM DESCRIPTION External power supply connector (XT-60 female) Load connector (XT-90 female) DC-DC power out connector (XT-60 male) Digital Voltage Display CHAPTER 1 | OVERVIEW...

  • Page 6: Standard Accessories

    1.4 STANDARD ACCESSORIES 0287020.PXCN 0FHA002ZXJ External power supply cable, power/signal extension cable *In compliance with Shell Eco Marathon competition rules, the fuel cell power output cable comes with ATOF®-series 20A, 32V fast acting Blade Fuse (Part No. 0287020.PXCN) fuse-holder (Part No. 0FHA0002ZXJ). ITEM DESCRIPTION External power supply header USB connector to PC...
  • Page 7 1.5 MECHANICAL DIMENSION – PROTIUM-300 ALL DIMENSIONS IN MM 220.50 112.50 100.00 86.80 CHAPTER 1 | OVERVIEW...
  • Page 8 1.6 MECHANICAL DIMENSION – ELECTRONIC CONTROLLER ALL DIMENSIONS IN MM 163.40 113.00 131.40 3.20 (4x) 43.10 63.20 68.60 85.00 145.00 104.20 CHAPTER 1 | OVERVIEW...
  • Page 9 1.7 MECHANICAL DIMENSION – ULTRACAPACITOR PACK ALL DIMENSIONS IN MM 341.00 180.00 353.00 5.20 (4X) 168.00 90.00 CHAPTER 1 | OVERVIEW...
  • Page 10 1.8 MECHANICAL DIMENSION – STANDARD ACCESSORIES ALL DIMENSIONS IN MM 1000 1800 1000 1000 CHAPTER 1 | OVERVIEW...
  • Page 11 Mount PROTIUM-300 in the recommended orientation above, using the mounting brackets provided. For optimal oxidant and cooling airflows, it is also recommended that there is...
  • Page 12 1.9 ORIENTATION, AIR CLEARANCE AND MOUNTING Dimensions of the mounting holes ALL DIMENSIONS IN MM 278.00 5.40 265.50 224.00 50.00 90.10 35.00 CHAPTER 1 | OVERVIEW...

  • Page 13: Specifications

    SPECIFICATIONS 2.1 FUEL CELL TECHNICAL DATA SHEET Fuel Cell PROTIUM-300 Type No. of cells Architecture Open cathode Coolant Air cooled Rated/gross power 300/360W Rated/gross current 12.5/15A Voltage output 24-36VDC Start-up time <30s Operating ambient temperature [0,35] Operating altitude without power derating...

  • Page 14: Test Conditions

    6.00 8.00 10.00 12.00 14.00 16.00 Current (A) Nominal polarization curve for a fully conditioned PROTIUM-300 at its Beginning-of-Life (BOL). TEST CONDITIONS • Ambient temperature: 24 • Relative humidity: 60% • H supply pressure: 10psig • Dead-ended operation • Balance-of-plant (BOP) powered by fuel cell •...
  • Page 15 Hydrogen consumption and efficiency for a fully conditioned PROTIUM-300 at BOL. NOTES ▪ Hydrogen consumption is instantaneous reading taken from mass flowmeter at STP. ▪ PROTIUM-300 is most efficient in the 50-200W range which is the typical nominal cruising power of Eco-Marathon vehicles (prototype category). CHAPTER 2 | SPECIFICATIONS...
  • Page 16 The output voltage (V_set) and output current (I_set) of the DC-DC converter can be changed according to the user’s needs. This provides flexibility for PROTIUM-300 to be compatible with various DC motor’s voltage input range. To protect against current overdraw or to maintain the fuel cell’s output at its most optimum power level, I_set can also be configured to limit the maximum...
  • Page 17 2.4 ULTRACAPACITOR PACK DATASHEET Ultracapacitor Pack Pack Max Voltage Pack Max Capacitance 18.75F Pack Max Energy @ 60V 9.38Wh Ultra Capacitor Model Maxwell BCAP0450 P270 S18 Number of UC cells 24 in series Pack Weight 3.4kg Pack dimension 353 x 180 x 90mm NOTES The Ultracapacitors serve several functions: To provide external power supply to the Electronic Controller during start-up.
  • Page 18 2.5 ULTRACAPACITOR PACK – VOLTAGE-TO-ENERGY GRAPH V-to-J 35000 30000 25000 20000 15000 10000 5000 Charge Voltage/V V-to-Wh 10.00 9.00 8.00 7.00 6.00 5.00 4.00 3.00 2.00 1.00 0.00 Charge Voltage/V EXAMPLE Suppose your electric motor can accept 52V to 48V input voltage range. Energy stored at 52V = 0.5 * Capacitance (F) * Voltage (V) = 0.5 x (18.75F) x (52V) = 25,350J...
  • Page 19 2.6 SYSTEM BLOCK DIAGRAM - PERMUTATIONS Default Setup: FC (Regulated Output) + Ultracapacitor Pack (UP) FC Stack LOAD (16) FC_Out (22) Regulated Output FC EC (13) DCDC (21) (Aux_V) (20) (14) *Default setup (Regulated Output) + Power-Supply-Unit (PSU) / Battery FC Stack LOAD Regulated...

  • Page 20: System Operation Flow

    2.7 SYSTEM OPERATION FLOW Standby Phase (when Electronic Controller receives power) Starting Phase (initialization system checks when instructed to turn on) Running Phase (fuel cell system is operational) Shutdown Phase (when instructed to turn off) Abnormal Shutdown Phase Stasis Mode (occurrence of error/ (fuel cell in momentary...

  • Page 21: Operating Procedures

    Download the PEM GUI PC app from PROTIUM-300 product webpage and install it on your PC. ▪ Follow its instructions in Section 5. If you do not wish to use the PEM GUI, you can turn on/off PROTIUM-300 by using the physical ▪ On-off push button (18) .
  • Page 22 ≤0.5barg. Also, ensure that your pressure regulator can maintain ≥0.4barg output pressure while supporting the fuel cell’s highest Hydrogen consumption rate. Tip: A good practice is to prepare a gas pressure regulator that can supply 2x PROTIUM-300’s maximum Hydrogen consumption, i.e. around 12L/min at ≥0.4barg.
  • Page 23 *with purchase of Spectronik Eco-Marathon Pressure Regulator. NOTES ▪ If you are using the Default Setup configuration as per Section 2.6, PROTIUM-300 will deliver a stable voltage output (V_set) though the DCDC. Also, it will not deliver more than the I_set current limit to the load.
  • Page 24 2. In the GUI, click “end” button. Alternatively, press and hold the 3s. The message “Shutdown Initiated” will appear in the GUI and PROTIUM-300 will enter its Shutdown Phase. The system is now OFF. LED will blink at 60% on standby awaiting the next start-up command.
  • Page 25 There has been an unwarranted pressure drop between "Gas Tank Outlet is Leaking" *◉ Gas Tank and Supply Valves. Please verify gas line connections. Emergency Shutdown = "Abnormal Shutdown" would be activated ◉ with purchase of Spectronik Eco-Marathon Pressure Regulator CHAPTER 4 | SYSTEM MONITORING & PROTECTIONS...
  • Page 26 The pressure in the gas tank is below 10 Bar. Emergency Shutdown = "Abnormal Shutdown" would be activated ◉ LED flashing at 80% to alert warning in the running ● with purchase of Spectronik Eco-Marathon Pressure Regulator CHAPTER 4 | SYSTEM MONITORING & PROTECTIONS...
  • Page 27 4.3 SYSTEM WARNING & PROTECTIONS – LED STATUS & OTHER MESSAGES LED status: Phase Blink % (at 1Hz) Meaning 5s after start-up power is provided into the Electronic Controller, LED will blink at 10%, Power ON indicating that the system is ready to receive its “start”...
  • Page 28 2. Select the correct ’Com Port’ and set the Baud Rate as 57600’. 3. Click the Spectronik S logo button to connect to the PEM fuel cell Electronic Controller. The S Logo button should light up and a welcome header appears in the ‘Status Display’ box.
  • Page 29 5.2 PEM GUI – CONFIGURE V_set PEM DCDC output voltage “V_set” can be set via PEM GUI only during Standby Phase. 2. Type the following command into the message box: ‘v’ <enter> ‘V_set value’ <enter> (V_set value allows one decimal place.) For example: ‘v’...
  • Page 30 5.3 PEM GUI – CONFIGURE I_set PEM DCDC output current limit “I_set” can be set via PEM GUI only during Standby Phase. 2. Type the following command into the message box: ‘i’ <enter> ‘I_set value’ <enter> (I_set value allows one decimal place.) For example: ‘i’...
  • Page 31 5.4 PEM GUI – V_set & I_set ACKNOWLEDGEMENTS PROTIUM-300 will check and accept values within the minimum and maximum power, voltage and current limits. Successful entries will get acknowledgements “V_set loaded successfully” and “I_set loaded successfully”. REMINDER ▪ The integrated DCDC converter has the following user configurable output ranges:...
  • Page 32 (13) and Ultracapacitor Pack. ▪ PROTIUM-300 will autonomously enter hibernation when the auxiliary power source – in this case the Ultracapacitor Pack (UCB_V) is charged to near V_set; It will autonomously exit the Stasis Mode and back to Running Phase when UCB_V has dropped.
  • Page 33 2. PROTIUM-300 will enter Starting Phase. And the START button would fade away. 3. During the Starting Phase, PROTIUM-300 will do a series of internal checks to ensure that all parameters are in good working conditions before entering Running Phase.
  • Page 34 Fan buttons at 1% and 5% pwm resolutions. To return to the default program, press FAN AUTO. ▪ PROTIUM-300 also has pre-programmed purge control based on optimizing fuel saving and cell performance. You can do additional water removal and Hydrogen line flushing by manually pressing the PURGE button.
  • Page 35 5.8 PEM GUI – SYSTEM SHUTDOWN PHASE ON/OFF push To shutdown the system, click the END button on the GUI or press and hold the button (18) of the Electronic Controller for 3 seconds. 2. The system enters Shutdown Phase to properly end the fuel cell system operations. After the complete shutdown, the START button would reappear as it returns to Standby Phase.
  • Page 36 During Starting Phase and Running Phase, in case of any serious erroneous conditions, PROTIUM-300 will immediately enter Abnormal Shutdown Phase. 2. PROTIUM-300 will return to Standby Phase and can only be restarted after the problem has been resolved. Refer to section 4 for a complete list of possible errors and the recommended corrective actions.
  • Page 37 5.10 PEM GUI – BACKGROUND PHOTO Click on “A” or “B” to change background images. Background image for fuel cell in inactive state. During “Standby Phase”, “Starting Phase”, and “Stasis”. Background image when fuel cell is in active state. During “Running Phase”. It will prompt for your file location.

  • Page 38: Maintenance And Storage

    MAINTENANCE AND STORAGE 6.1 MAINTENANCE FOR PROTIUM-300 When not in use, Spectronik recommends that PROTIUM-300 is reconditioned at least once a month. Set up PROTIUM-300 as per instructions in Section 3, taking note of the following differences: a. Use a DC power supply instead of the Ultracapacitor pack. Set the DC power supply to 24V 2A.

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