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Spectronik PROTIUM-3000 User Manual

Fuel cell system
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PROTIUM-3000
FUEL CELL SYSTEM
USER GUIDE – P-3000-4.1-1.7
VERSION P-3000-4.1-1.7 | 24.07.16

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Summary of Contents for Spectronik PROTIUM-3000

  • Page 1 PROTIUM-3000 FUEL CELL SYSTEM USER GUIDE – P-3000-4.1-1.7 VERSION P-3000-4.1-1.7 | 24.07.16...

  • Page 2: Safety, Handling & Support

    3000 Fuel Cell System (PROTIUM-3000) or other property. Handling Handle PROTIUM-3000 with care. It is made of thin sheet metal, graphite, and plastic and has sensitive electrochemical membrane and components inside. PROTIUM-3000 is not designed for extreme conditions, rough handling, vibration, shock or drop. Keep PROTIUM-3000 away from heat, flame, strong sunlight, water, dust, soil or mud.
  • Page 3 OVERVIEW 1.1 PROTIUM-3000 FUEL CELL Top View Bottom View 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: Item Description

    1.1 PROTIUM-3000 FUEL CELL Right View Left View ITEM DESCRIPTION Gas pressure sensor 1 Gas pressure sensor 2 H2 gas outlet connector (left) H2 supply valves (right) - PU Tubing OD 6 x 4 H2 gas inlet connector (right) H2 purge valves (left) - PU Tubing OD 8 x 5.5...
  • Page 5 1.1 PROTIUM-3000 FUEL CELL Front View Back View ITEM DESCRIPTION Power/Signal receptacle Stack power output (XT-90 female) CHAPTER 1 | OVERVIEW...

  • Page 6: Electronic Controller

    Status LED Mounting holes (x4) External power supply receptacle Balance-of-plant (BOP) switch Gas pressure transducer receptacle (Only used with purchase of Telemetry transmitter port (4-pin) Spectronik Miniature Gas Pressure Regulator) Programming port (6-pin) Load connector (XT-90 female) CHAPTER 1 | OVERVIEW...

  • Page 7: Standard Accessories

    Free-end wires for user’s power supply USB connector to PC External power supply header Gas pressure transducer signal wires* Free-end wires for user’s load Gas pressure transducer header* *(Only used with purchase of Spectronik Miniature Gas Pressure Regulator) CHAPTER 1 | OVERVIEW...
  • Page 8 1.4 MECHANICAL DIMENSIONS – PROTIUM-3000 ALL DIMENSIONS IN MM 489.00 624.50 174.00 325.50 CHAPTER 1 | OVERVIEW...
  • Page 9 1.5 MECHANICAL DIMENSIONS – ELECTRIC CONTROLLER ALL DIMENSIONS IN MM 174.60 137.60 159.00 24.30 148.00 83.50 CHAPTER 1 | OVERVIEW...
  • Page 10 1.6 MECHANICAL DIMENSIONS – STANDARD ACCESSORIES ALL DIMENSIONS IN MM 1000.00 1000.00 1000.00 1800.00 1000.00 500.00 CHAPTER 1 | OVERVIEW...
  • Page 11 1.7 MOUNTING AND AIR CLEARANCE Recommended Orientation of PROTIUM-3000 PROTIUM-3000 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 Dimensions of the mounting holes ALL DIMENSIONS IN MM 149.40 457.00 441.00 CHAPTER 1 | OVERVIEW...

  • Page 13: Specifications

    SPECIFICATIONS 2.1 PROTIUM-3000 TECHNICAL DATA SHEET Fuel Cell PROTIUM-3000 Type No. of cells Architecture Closed cathode Coolant Air cooled Rated/gross power 3000/3600W Rated/gross current 62.5/75A Voltage output 48-72VDC Start-up time Operating ambient temp. [-10,45] Operating altitude without power derating 1500m AGL System weight 10.0kg...

  • Page 14: Test Conditions

    70.0 80.0 Current (A) FC VI H2 Consumption FC WI Nominal polarization curve for a fully conditioned PROTIUM-3000 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

    ▪ Cooling fans ▪ Oxidant blowers ▪ Solenoid valves BOP Switch Electronic ▪ Sensors ▪ 1/0 Controller Communication (Data Telemetry) PROTIUM-3000 fuel cell stack ▪ UART to USB Fuel cell power IN Fuel cell power OUT 48-72V DC-DC converter (optional) Hybrid Output Source (optional) e.g.

  • Page 16: System Operation Flow

    Shutdown Phase (when instructed to turn off) Abnormal Shutdown Phase Stasis Mode* (occurrence of error/ (fuel cell in momentary potential hazard) hibernation ) *only with purchase of Spectronik Cerebral-55 Smart DC-DC Converter. Also see Section 3.4. CHAPTER 2 | SPECIFICATIONS...

  • Page 17: Operating Procedures

    0.5-0.7bar gauge. Reminder: ensure that all gas tubing and electrical wire connections are firm and secure. The setup is now completed and PROTIUM-3000 is ready to be turned on. CHAPTER 3 | OPERATING PROCEDURES...
  • Page 18 PROTIUM-3000 is now ready to power your application. NOTES Download the DAQ GUI PC app from Protium-3000 product webpage and install it on your PC. ▪ Follow the instructions in its user manual. If you do not wish to use the DAQ GUI, you can turn...
  • Page 19 Turn ON your load and draw power as per normal. below 48V or draw power beyond 3000W. If Hybrid Output Source (e.g. Lithium battery) is connected at the load, PROTIUM-3000 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.
  • Page 20 To ensure user’s safety, Stasis Mode is currently only available with the purchase of Spectronik Cerebral-55 Smart DC-DC Converter and its accompanying DAQ GUI (PRO) version.
  • Page 21 Status LED & Buzzer ▪ ▪ Cooling fans ▪ Oxidant blowers BOP Switch ▪ Solenoid valves Electronic ▪ Controller ▪ Sensors Communication PROTIUM-3000 (Data Telemetry) Fuel cell stack UART to USB ▪ Fuel cell power IN Fuel cell power OUT 48-72V CEREBRAL-55...
  • Page 22 2. In the GUI, click END. Alternatively, press and hold the for more than 2s. The message “Shutdown Initiated” will appear in the GUI and PROTIUM-3000 will enter its Shutdown Phase by carrying out a series of shutdown procedures such as turning off the gas supply valves, cooling fans and oxidant blowers.
  • Page 23 PROTECTIONS & MANUAL CONTROL 4.1 MANUALLY CONTROLLING THE PROTIUM-3000 The PROTIUM-3000 comes with in-built firmware control that is optimized to bring out its best performance over the applicable ambient environment range. In normal use-case scenario, there is no need for user to fine-tune the parameters. For advanced user who wishes to control the fuel cell manually, the following commands can be entered via the GUI’s keyboard function:...
  • Page 24 Gas Tank Outlet is Leaking *◉ between Gas Tank and Supply Valves. Please verify gas line connections. Emergency Shutdown = Abnormal Shutdown Phase would be activated ◉ with purchase of Spectronik Miniature Gas Pressure Regulator CHAPTER 4 | SYSTEM MONITORING & PROTECTIONS...
  • Page 25 The pressure in the gas tank is below 10 Bar. Emergency Shutdown = Abnormal Shutdown Phase would be activated ◉ Status LED flashing at 80% to alert warning during Running Phase ● with purchase of Spectronik Miniature Gas Pressure Regulator CHAPTER 4 | SYSTEM MONITORING & PROTECTIONS...
  • Page 26 4.5 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/ Standby Phase indicating that the system is ready to receive its “start”...

  • Page 27: Maintenance And Storage

    When not in use, Spectronik recommends that PROTIUM-3000 is reconditioned at least once a month. Set up PROTIUM-3000 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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