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Horizon Fuel Cell Technologies VL Series User Instructions

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VL50 Fuel Cell System
User Instructions
VL50 fuel cell system user instructions

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Summary of Contents for Horizon Fuel Cell Technologies VL Series

  • Page 1 VL50 Fuel Cell System User Instructions VL50 fuel cell system user instructions...
  • Page 2 Disclaimer This manual contains safety guidelines and operational recommendations. However, this does not mean that this manual can cover all circumstances. The customer is responsible for meeting all local safety requirements to ensure the safety of the fuel cell system during operation, maintenance, and storage.
  • Page 3 Revision history Revision history Revision# Description Author Date Draft Draft 2021/6/18 VL50 fuel cell system user instructions...

  • Page 4: Table Of Contents

    Contents Revision history ......................1 1. Product Uses and Functions .................. 1 Product Uses ......................1 Product Function ....................... 1 2. Product Performance Description ................ 2 Working Principle ..................... 2 Product Operating Conditions ................... 3 System Performance ....................10 3. Product Installation ..................... 12 Interface Description ....................

  • Page 5: Revision History

    1. Product Uses and Functions 1.1 Product Uses The VL50 fuel cell system of Horizon Fuel Cell Technologies (Horizon) is one of the best fuel cell systems in the hydrogen fuel cell industry. It is mainly applied in the following fields: 1.

  • Page 6: Product Performance Description

    2. Product Performance Description 2.1 Working Principle A fuel cell system is a power generation device that converts the chemical energy of hydrogen and oxygen directly into electric energy. Its core component is the fuel cell stack. For an operating fuel cell system, it also requires the matching oxygen supply system, hydrogen supply system, heat dissipation system and electrical control system.

  • Page 7: Product Operating Conditions

    2.2 Product Operating Conditions 2.2.1 Requirements of Fuel and Coolant To ensure the normal operation of the fuel cell system, there are strict requirements for hydrogen, air, and coolant. The detailed requirements are shown in Table 2-1 below. Table 2-1 gas and liquid specifications Type Specifications Hydrogen purity >99.97%...
  • Page 8 ＜0.008ppm Volatile organic compounds ＜0.01ppm NH Atmospheric particle composition ＜90μg/m PM10 ＜15μg/m PM2.5 Cooling fluid 50% deionized water + 50% glycol particle size＜100μm conductivity＜5μs/cm Note:  Choose the coolant carefully. Ordinary coolant may not be applicable. The additives may cause the conductivity to be too high or the insulation resistance of the system to be too low.
  • Page 9 Hydrogen pressure 10± 1bar (gauge pressure) Acceptable difference between hydrogen 20kPa and oxygen pressures 2.2.3 High and Low Voltage Power Distribution Requirements Parts of the fuel cell system require high and low voltages for operation. The power requirements are as shown in Table 2-3: Table 2-3 High and Low Voltage Power Supply Requirement table Distribution form Demand voltage...
  • Page 10 Inlet ambient air ℃ temperature System transient From minimum to sec. response time maximum speed Ingress Protection IP67 Rating Air compressor weight 8.6kg, Weight control weight 7.5kg An iso-view of the air compressor with controller Figure 2-2：Air Compressor Performance Map 2.2.5 DCDC Converter VL50 fuel cell system user instructions...
  • Page 11 The VL50 system requires an external DCDC converter. After physical matching and system verification, Horizon recommends the DCDC converter with the specification shown in Table 2-5 below. A view of the DCDC is shown in Figure 2-3 below: Table 2-5：DCDC Performance Parameters Parameter (unit) Value Note...
  • Page 12 Motor type Permanent magnet synchronous machine 2000-5650rpm Motor rated speed/peak speed (RPM) Ambient temperature (℃) -40-80 Coolant temperature (℃) -40-80 ≥97% Water pump efficiency Characteristic Curve of the Pump Figure 2-5 Vehicle Cooling Requirements The main DC/DC and air compressor and controller cooling cannot be integrated into the fuel cell cooling system.
  • Page 13 ≤28 Main ≥20 ≤65 φ25 1900 （20L/min） DC/DC ≤35kPa ≤65 φ10 compressor 1200 （4L/min） + controller 2.2.7 Other Balance-of-Plant (BOP) Components Table 2-8：Other BOP Components Item Picture Role Air filter Purifies air Monitor / feedback of Air flow meter air flow Hydrogen heat Heats hydrogen supply exchanger...

  • Page 14: System Performance

    Rejects heat from the Radiator system Heats coolant for PTC heater freeze startup Replenish water to the Water tank system Absorbs the ions in the coolant, reducing the Deionizer conductivity of the coolant Provides low voltage Low voltage distribution to the distribution box system Control system that...
  • Page 15 Maximum working current (A) Boost DC input Operating voltage (Vdc) 110-220 Boost DC input Boost DC output voltage（V） 450-700V/260-400 Rated at 560V Boost DC output current（A） 0-170 Ambient temperature (℃) -30-45 Storage temperature (℃) -40-60 ≤8 Idle power（kW） Response time (s) ≤30 Ambient temperature >...

  • Page 16: Product Installation

    positive and negative electrodes of the fuel cell system； 2、 Insulation resistance of the ≥2MΩ vehicle Communication mode CAN 2.0B If installed to other locations, need to Suggested to install in the Installation increase then protection from rain, cabin sun, collision 3.
  • Page 17 VL50 fuel cell system user instructions...

  • Page 18: Electrical Interface

    3.2 Electrical Interface External connectors are needed to connect the fuel cell system with the vehicle. External connectors are shown in table 3-2: Table 3-2：External connector description Wire Connector – Mating Connector – Item Size Note definition VL50 System Side Vehicle Side (mm2) 1(A)

  • Page 19: Detailed Installation

    maximum power ystem M8 terminal stud Y8-50 power demand of 3000W power supply DC12V 12Vdc to turn fuel 0.75 cell on ower Reserved Spare Reserved Spare voltage interface double CAN_H twisted FCU has no CAN CAN_L shield termination resistor wire block 3.3 Detailed Installation The system can be mounted on the vehicle longitudinal beam by 4 shock mounts.
  • Page 20 Installation steps are as follows: 1. Lift the radiator assembly to the installation position and fasten the mounting bolts and nuts; 2. Install the fuel cell system into the installation position, and fasten the mounting bolts and nuts; 3. Connect the relevant water pipes of the radiator and fasten the high and low voltage docking plug-ins of the fuel cell system into place;...

  • Page 21: System Running

    4. System Running The fuel cell system is equipped with a set of electrical control system. This system can allow engineers to perform manual, automatic, or monitoring operations on the fuel cell system, and it is also equipped with an automatic alarm and protection devices. When the fuel cell system in operation fails, it will automatically send out an alarm signal or even shut down to ensure that the fuel cell system is in a normal working state at any time or notify the engineer for targeted maintenance.
  • Page 22  Fuel cell system for stationary power stations 1. Turn on the 24V power. 2. The system status changes from 7 (self-test) to 4 (standby). 3. Apply high voltage and check whether the fuel cell input high voltage is normal or fluctuating.

  • Page 23: Safety Protection In Usage

    4.1.4 Shutdown Process  Fuel cell system for stationary power stations 1. Stop the system and the system status changes from 5 (shutdown) to 4 (standby). 2. Turn off the high voltage power, disconnect the 24V power, and turn off the hydrogen supply.

  • Page 24: Maintenance And Service

    4.4 System Error For more information, please refer to the Error Code Table. 5. Maintenance and Service 5.1 Maintenance of Fuel Cell System The daily maintenance of the fuel cell system includes: daily inspection and maintenance, weekly inspection and maintenance, monthly inspection and maintenance and long-term parking inspection and maintenance.

  • Page 25: Coolant Maintenance

    Remove foreign objects with an air Clean with no foreign System clean 5min gun or vacuum cleaner objects Table 5-3 Monthly Inspection and Maintenance Record of Fuel Cell System Estimated Maintenance item Specific operation method Note time Check whether the high and low High and low voltage voltage connectors are loose, whether Immediately report...

  • Page 26: Transportation And Storage

     Use a handheld conductivity tester regularly to check the conductivity of the coolant in the fuel cell system. If the conductivity is> 5 μs / cm², the deionizer needs to be replaced in time.  Fill every 2000 hours according to the liquid level. When the system is cold and the air bubbles in the system's cooling line are empty (the cooling water circuit can be exhausted by frequently turning on 24V electricity every 50s), the water level needs to be in between of the lowest and the highest levels, as shown in the figure below.

  • Page 27: Safety

    6.2 System Storage  The product is placed in a dry and ventilated environment, and the storage temperature is in the range of 5 ℃ ~ 35 ℃. Long term storage  Long-term storage means that the system will not boot for more than 1 month ...

  • Page 28: Safety At High Temperature And High Pressure

    7.2 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 29: Safety Of Hydrogen

     Operate electrical wires or electrical equipment with wet hands, or touch wet ground;  Use worn wires;  Each electrical interface is incorrectly connected or reconnected multiple times;  Short circuit occurred; 7.4 Safety of Hydrogen 1. Hydrogen is a colorless, odorless, highly flammable gas. 2.

  • Page 30: Safety Of Hypoxia

     Operate the stack beyond its maximum operating temperature. 7.6 Safety of Hypoxia When the stack is operating, it consumes oxygen. When the stack is poorly ventilated and the floor space is small, special attention needs to be paid to the oxygen concentration to not fall lower than health requirements.
  • Page 31 （4）Antifreeze warning sign VL50 fuel cell system user instructions...

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