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Summary of Contents for Horizon Fuel Cell Technologies HFC Series
- Page 1 5kW fuel cell system specification 5kW fuel cell system specification...
- Page 2 Disclaimer This manual contains safety guidelines and operation suggestions. However, this does not mean that this manual can cover all situations. The customer is responsible for meeting all local safety requirements to ensure the safety of the fuel cell system during operation, maintenance and storage.
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Page 3: Table Of Contents
Content 1. Product Uses and Functions ..................3 1.1 Product Uses ........................3 1.2 Product Function ......................3 2. Product performance introduction ................3 2.1 Working Principle ......................3 Product Composition ...................... 5 2.3 Product operating conditions ..................8 2.4 System Performance ....................... 9 3. - Page 4 8.4 Safety of Hydrogen ....................... 32 8.5 Safety of Stack Ablation ....................32 8.6 Safety of Hypoxia ......................32 8.7 Warning Sign Description .....................33 5kW fuel cell system specification...
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Page 5: Product Uses And Functions
1. Product Uses and Functions 1.1 Product Uses Horizon 5kW fuel cell system is one of the best fuel cell systems in the hydrogen fuel cell industry, which is mainly used in forklift trucks, emergency power supplies, and university test and experiment systems. - Page 6 The fuel cell system is a power generation device that converts the chemical energy of hydrogen and oxygen directly into electrical energy. Its core part is the electric pile, which needs to match the oxygen supply system, hydrogen supply system, heat dissipation system, electrical control system, etc.
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Page 7: Product Composition
Product Composition Functionally, the fuel cell system is mainly composed of five subsystems: oxygen supply system, hydrogen supply system, heat dissipation system, electrical control system and fuel cell stack. Oxygen supply system: Oxygen supply system is mainly composed of air filter, air flow meter, air compressor and humidifier, etc. - Page 8 Table 2-2: Hydrogen supply system parts list Item Drawing Function Control the entry of external Solenoid valve hydrogen 3. Cooling system: The cooling system is mainly composed of radiator, water pump, PTC heater, water tank and deion meter, etc.The parts are shown in Table 2-3: Table 2-3: Heat dissipation system parts list Item Drawing...
- Page 9 4. electrical control system: The electrical control system is mainly composed of DCDC, low-voltage distribution box and controller, parts diagram and function as shown in Table 2-4: Table 2-4: Electrical control system parts list Item Drawing Function Convert the stack voltage to DCDC provide a high voltage platform for external loads...
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Page 10: Product Operating Conditions
steel pipes or wire hoses.The fixing of each component of the system requires support, and the whole system needs to fix the frame, and is fixed together through the frame connection.Finally, many electrical parts in the system need to be connected with high-voltage or low-voltage wiring harnesses. 2.3 Product operating conditions 2.3.1 Fuel and coolant requirements The fuel cell reactor generates electricity by converting the chemical energy generated by the reaction of... -
Page 11: System Performance
＜0.01ppb NH Atmospheric particulate components PM10 ＜90μg/m PM2.5 ＜15μg/m Coolant 50% deionized water + 50% glycol Particle diameter＜100μm Conductivity＜2μs/cm Warning: Choice of coolant should be prudent, the widespread use of coolant in the market may not applicable, it may contain additives to lead to high conductivity, insulation resistance is too low, and therefore need to be coupled with the device which can monitor electrical conductivity. -
Page 12: System Operation
Operating pressure ≤50kPa IP rating IP54 Vibration noise ≤89dB Rated Power 5kW@54V System size (mm) 860*820*825 System weight(kg)(Includes DC and radiator) DC output voltage(V) Stack operating temperature(℃) 60-70 H2 purity ＞99.97% Hydrogen inlet pressure（Mpag） 0.6-1 Hydrogen reserved interface mode 1/2 inches Card sleeve joint Hydrogen flow rate(l/min) ≤250 Insulation resistance (Ω/V) -
Page 13: Running Process
2．Hydrogen concentration detection. Use a hydrogen leak detector to detect the hydrogen concentration above the system. If there is a leak point, open the hydrogen valve under ventilation to find the leak point and carry out maintenance. 3．Check the interface. The cooling water valve of the fuel cell engine system is closed, and there is no leakage or loosening at the interface. -
Page 14: Safety Precautions During Use
3.4 Safety Precautions during use Periodically check whether the fuel cell system has abnormal phenomena such as water leakage, gas leakage, hydrogen tail row length opening or other abnormal sound, and timely report and deal with it, and periodically check whether the water level of the water tank is normal every day. 1. -
Page 15: System Connection Description
4.1 System Connection Description You need to connect the tailpipe of the system, the hydrogen inlet (connected to the hydrogen source), and the high voltage end of the DCDC (connected to the load). After all the pipes are connected, a certain amount of deionized water is manually added to the system kettle. -
Page 16: System Communication Cable Connection
Figure 4-1 c System connection diagram 4.2 System Communication Cable Connection As shown in Figure 4-2, this is how the communication lines between the system and the computer are connected. We connect with a communication line configured by KVASER, one end of the communication line is connected to the CAN2 interface of the system ECU, and the other end of the KVASER is connected to the computer. -
Page 17: Screen Control Description
4.3 Screen Control description As shown in Figure 4-3, it is the control interface of our system, which can start and shut down the system and modify the power through the control of the screen. Operation 1：When you click this button , it will become , At this time, it can be operated on the display screen, Otherwise, Ethernet operation will be performed. -
Page 18: Software Operation Instructions
5. Software operation instructions 5.1 Open the Software Unzip the application package, run Horizon VL series monitor.exe. Note: if the package decompressed to the C drive, please right click the computer mouse to allow Horizon VL series monitor.exe operation in administrator mode. -
Page 19: Monitoring System Status
3) . Click the button which is marked in 3 to start the fuel cell system. If the system need to be stop, please click the button marked in 3 again. Before run the fuel cell system, the water pump need to be turn on to expelling the air in the coolant line. When the coolant inlet pressure stabilizes between ±... -
Page 20: Calibration Parameters
5.3.2 Chart On the chart page, you can see the Historical data curve of some observed values. Both X axis and Y axis can change the axis range by modifying the numbers on both sides of the axis, Y axis supports mouse operation. -
Page 21: System Shutdown
Fig5-4 Calibration parameters interface 5.5 System Shutdown Click the Stop button and wait for the system to execute the shutdown command. When the system status turn into standby, it means the shutdown command is over. Fig5-5 Shutdown steps 5kW fuel cell system specification... -
Page 22: Firmware Update
5.6 Firmware Update When the stack is in self-check, standby and fault state, you can click the update ECU firmare button to update the program. Select the .srz file required by the update program and click start to start the update. After the program is updated, click update ECU firmare again to shrink the window before starting the operation. -
Page 23: Open The Exhaust Valve Manually
5.7 Open the exhaust valve manually Before the pure hydrogen test, you need to manually open the exhaust valve, and then open the intake switch to ensure that the exhaust time exceeds 5s, and then close the exhaust valve (at this time the intake switch is normally open), then the system can be operated. -
Page 24: Stop Horizon Vl Series Monitor
5.8 Stop Horizon VL series monitor Click the STOP button to stop the Horizon VL series monitor software running. 5.9 Data Record After the program runs correctly, Labview will automatically save the datas to the folder named Save which belongs to the same foder where the application programmes located. 5kW fuel cell system specification... -
Page 25: Maintenance And Repair
6. Maintenance and repair 6.1 Regularly Maintenance of Fuel Cell System The daily maintenance of the fuel cell system is divided into: daily inspection and maintenance, monthly inspection and maintenance and long-term parking inspection and maintenance. The following is a brief description in the form of a table. - Page 26 vacuum cleaner (do not use a water gun to clean) Table 6-3 Monthly Inspection and Maintenance Record of Fuel Cell System Estimated No. Maintenance item Specific operation method Note time Each high voltage and low voltage plug-in of the system has a latch. Visually check whether the latch is in place.
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Page 27: Maintenance Of System Components
Estimated Maintenance project Specific operation method Note time Ensure that the fuel cell is normally shut (special antifreeze for down and purged, and the 24V power main fuel cell must be used Long downtime before brake is closed. If the planned shutdown time 10min when the lowest storage... - Page 28 deionizer depends on the alarm threshold of the test insulation value or the requirement of the conductivity value. The final replacement depends on the actual value. It is recommended to replace the deionizer when the conductivity value exceeds 5us/cm. Fuel cell specific Exchange 6,000h or 1 year coolant...
- Page 29 three times, replace it with a new one. Low voltage Multimeter Check Check 1,000h distribution box fuse whether the fuse works 6.2.2 Maintenance operations of system components 1、 Regularly check of coolant is required for fuel cell system 1) If the minimum ambient temperature is below 5 ° C, all coolant needs to be replaced with fuel cell antifreeze.
- Page 30 1）Make sure fuel cell system is power off and is cut off from high and low voltage system; 2）drain and recycle coolant, remove coolant filter, using high pressure water to clean filter screen; 3）Re-install coolant filter and refill the coolant to cooling system. coolant filter 4、Deionizer change procedures 1）...
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Page 31: After-Sales
Bolt Corresponding torque Clamp Corresponding torque 5±0.5N.M Clamp 11-20 3±0.5N.M 10±1.0N.M Clamp 14-27 3±0.5N.M American double clamp 24±2.4N.M 5.4±0.8N.M 17-32 German double 45±4.5N.M compensation clamp 5.4±0.8N.M 25-40 German double 75±7.5N.M compensation clamp 5.4±0.8N.M 30-50 German double compensation clamp 5.4±0.8N.M 40-60 German double compensation clamp 5.4±0.8N.M... -
Page 32: System Storage
The transportation temperature should be in the range of -20 ℃ ~ 40 ℃. The product should be able to adapt to sea and air transportation conditions. When the product is transported by sea or air, it should be sealed and packed with other protective ... -
Page 33: Safety At High Temperature And High Pressure
8.2 Safety at High Temperature and High Pressure 1. When operating in an outdoor environment, the temperature of the fuel cell stack can reach 80 ° C and above. Do not touch the stack during the operation of the stack or within a short period of time after the stack comes to a stop. - Page 34 8.4 Safety of Hydrogen 1. Hydrogen is a colorless, odorless, highly flammable gas. 2. When operating hydrogen, strictly follow the specifications and the recommendations of the gas supplier. 3. Hydrogen is non-toxic, but will consume oxygen in the air and cause hypoxia. No alarm will occur before an accident occurs.
- Page 35 8.7 Warning Sign Description (1) Cautious of high temperature warning signs: （2）Cautious of electric shock warning signs: （3）Prohibition of stepping warning signs 5kW fuel cell system specification...
- Page 36 （4）Antifreeze warning sign 5kW fuel cell system specification...
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