Instructor Experiment Guide16-30

8/14/2019 Instructor Experiment Guide16-30

1/15

A.3 Fuel Cell Module FC50 4

Heliocentris Energizing education

5.3 Manual operation, self-powered by the VC100 module:

Place the FC50 panel into the upper right area of the support frame, and the VC100 in thelower center area.

Using the supplied test leads, connect the FC50 stack power output (8) to the voltageinput of the VC100. Observe correct polarity.

Using the provided 3-pin cable, connect the output marked "Parasitic load" of the VC100to the "12V =" jack (7) of the FC50.

Connect a load (e.g. EL200 or TL10) to the output marked "available power" of theVC100. Observe correct polarity. (In addition to the VC100, you can connect additional

loads directly to the FC50 stack power output.) Use only the supplied test leads forconnecting loads.

If you are using the Electronic Load Module EL200 as a load:(See chapter A.4 for details)

o Place the EL200 panel into the lower right area of the support frame.

o Using the supplied power cord, connect the EL200 to an AC power outlet, and turn onthe power switch (located behind the front plate, right side).

o Using the short test leads, connect the stack power output (8) of the FC50 to the loadinput of the EL200. Observe correct polarity.

o Ensure that the multi-turn load potentiometer is set to zero (fully counterclockwise).o Turn the switch on the EL200 front plate to "ON".

Attach your chosen hydrogen supply with the quick-coupler to the hydrogen input (1) ofthe FC50. Connect the cable of your hydrogen supply s solenoid valve to connector "H2-supply" (3).For the correct start-up of your hydrogen supply refer to the appropriate installation andoperating instructions found in chapters A.8 to A.10 of this guide.

Set the fan power knob (10) to AUTO.

Turn the main switch (5) to ON.

Press the Start button (2).

Initially powered by the starting battery of the VC100, the FC50 system now performs aself-check for about 10 seconds. If no error occurs, the FC50 begins operating. TheVC100, now receiving voltage from the fuel cell stack, continues to power the FC50 withregulated 12V DC. If an error message is displayed, please refer to section 8 of thischapter Error messages and causes .


2/15

5 Fuel Cell Module FC50 A.3


5.4 Computer-assisted operation:

Computer-assisted operation is available regardless of how the FC50 is powered. Incomputer-assisted operation, you can adjust the EL200 load current and FC50 fan poweronly through the computer. The computer monitors and logs all system parameters of theFC50 and also, through the RS485 data connections, the EL200 and VC100.

Before you run the FC50 software, ensure the following conditions exist:

The long 9-pin cable connects "RS232" (4) on the FC50 with a COM port on thecomputer.

The short 9-pin cables connect "RS485" (6) on the FC50 with the EL200 and if necessaryconnect the EL200 and VC100.

The provided experiment software has been correctly installed on the computer. The FC50 is not yet started .

Then run the software and select one of the experiment programs. The program will ask youto start the FC50 by pressing the start button (2). When you do, the FC50 begins to run in acomputer-assisted mode. See chapter A.7 Control software for details of the FC50experiment software.

6 Shutting down

When you are through using the system, proceed as follows to shut down and turn off: Turn off any attached load.

If using the EL200:Turn the potentiometer fully anti-clockwise, move the switch to the "OFF" position and turnoff the power switch located on the side of the module. See chapter A.4 for details.

Turn the fan control knob (10) to "AUTO" and turn the main switch (5) to "OFF".

Shut down the hydrogen supply following the detailed descriptions found in chapters A.8 to A.10 in this Guide.

Compressed gas cylinder: Shut off cylinder main valve.Metal hydride storage canister: Close shut-off valve of the storage canister.

Disconnect the quick-coupler at the FC50 hydrogen inlet (1).


3/15



7 Factors affecting operation

The performance of a fuel cell system and the voltages of individual cells of the stack areaffected by various factors. The most important are:

Current

Temperature

Air supply

Prior operating conditions, especially the wetness of the membrane.

Because of the complexity of the system, no universal rules for its management can begiven. In the Experiments Guide detailed investigations are described, in which parameterscan be varied, to demonstrate the relations and dependences of those parameters. Usuallyoptimal operating parameters are achieved only after a series of tests.

We recommend using the experiment guide as the basis of your work,observing the guidelines contained there.

Before attempting your own experiments with the fuel cell system, become familiar with thesystem parameters as described in the Experiments Guide. Also, in order to avoid damage tothe fuel cells and to achieve good electrical efficiency:

Control the fan power so that the stack temperature does not exceed 45 C. If thetemperature exceeds 50 C, the system automatically shuts down.

The longer the fuel cell stack is in continuous operation, the more powerful the stackbecomes. After long periods without use, the membranes can dry out and the stackmay need a longer time to reach its full power.

8 Error messages and causes

The microprocessor control of the FC50 is responsible for the management of the fuel cellsystem, for the monitoring of limit values and for the safety shut down of the system. In caseof an operation error, the system will go into an error state, in which it:

Puts the system into a safe condition, switching off the hydrogen supply and

disconnecting the power output from the stack; Displays an error code for 30 seconds in the top-left windowlabeled "H2 flow";

After 30 seconds turns off the system completely.

While the system is in the error state, or after turning off, you can restart it by pressing thestart button. If the reason for the error still exists, the system again displays the error code.

The following table lists individual errors and appropriate responses.


4/15

7 Fuel Cell Module FC50 A.3


Error

code

Description State : reason Response

Er 01 Hydrogen ismissing

Starting: after three seconds ofpurging the cell, the voltage of thelast cell of the stack is still below0.6 V

See if hydrogen supply is empty,or improperly connected.

Er 02 Voltage of thefuel cell stack toolow

Starting: < 7.5 V

Operation: < 4 V Excessive load Fan power set too low

Reduce load on the fuel cellsystem

Set fan power knob to "AUTO

Er 03 Temperature ofthe fuel cell stacktoo high

Starting: > 45 C

Operation: > 50 C Fan power set too low

Ensure cooling fans are working Set fan power higher or to

"AUTO Ensure the ambient temperature

is within range

Er 04 Load current toohigh

Current > 10.5 A In self-powered mode,

activating the purge valve brieflyincreases the load

Ensure no short-circuit is present Reduce the load

Er 05 Leaking in the

system

Starting: Hydrogen flow > 60

ml/min with no currentOperation: Hydrogen flow > 40ml/min over expected value

If this error occurs several times, the

system has a hydrogen leak. Return FC50 to the manufacturer

for examination.

Er 06 No voltagesupply to FC50

In self-powered mode: Fuel cell stack power output not

connected to VC100 input

Ensure stack power output isconnected to the input of VC100

Er 07 Communicationwith computerinterrupted

Computer-assisted operation: RS232-cable not connected Control program not running Computer too slow to respond

Ensure RS232 cable attached Start control software Ensure your computer meets

requirements

Er 08 EL200 problem Temperature in Electronic Load toohigh

Voltage at the input of ElectronicLoad > 20 V

Turn off the EL200 Ensure cooling fans at the rear of

the EL200 are working

Er 10 Cooling fancontrol

Starting: Cooling fan power not setto "AUTO"

Set fan power knob to "AUTO

Er 11 No internalpower in VC100

In self-powered mode: Starting battery dead or

improperly installed

Ensure cells are properly installedin the VC100.

Renew cells if necessary.


5/15



9 Improper modes of operation

The fuel cells must be sufficiently supplied with hydrogen at all times. Starving thestack of hydrogen while current is being drawn can lead to the destruction of themembranes or catalysts.

Never connect the fuel cell to an external power source (e.g. laboratory powersupply or solar module). A current flow forced from outside can immediatelydestroy the fuel cell.

10 Technical data

Fuel cell stack

Rated power output 40 W

Maximum power output Approx. 50 W

Open circuit voltage Approx. 9 V

Current at rated power 8 A

Voltage at rated power 5 V

Maximum Current 10 A

Hydrogen consumption during ratedoutput Approx. 580 NmL/min

Hydrogen nominal pressure 0.6 0.1 bar gauge

Max. permissible hydrogen pressure 0.40.8 bar gauge

Max. permissible cell temperature Operation: 50 CStarting: 45 C

Module FC50

Supply voltage 12V DC

Power consumption no-load operation: 5.2 Wat 10A load current: 6.4 W

Hydrogen connection Swagelok quick-coupler type QM2-S

Ambient operating temperature +5 +35 C

Dimensions 400 x 297 x 200 mm (WxHxD)

Weight 3.5 kg

Noise emissions < 70 dB(A)

Transport and storage conditions Protect against reactive chemicals and frost


6/15

1 Electronic Load Module EL200 A.4


A.4 Electronic Load Module EL200

1 Use

The EL200 Electronic Load Module is used as a variable load in the hy-Expert TM Instructor system. It is designed to work optimally with the FC50 fuel cell stack.

It is intended to be used only for educational and research purposes.

2 Overview and parts list

+

P A A 6 V T r

P I @ D I r

Q r G r v t r

W

T U 6 U V T

2 3 ( 5 $ 7 , 2 1

% ( 7 5 , ( %

( 5 5 2 5

) ( + / ( 5

1 RS485 system data bus connectors2 Status indicator3 Switch to connect/disconnect load4 Load adjustment5 Connection to load6 (on the right side) Socket for power cord and main on/off switch

2

1

3

4

5

6


7/15

A.4 Electronic Load Module EL200 2


3 Basic function

When connected to a voltage source this electronic load functions as an electronicallyregulated resistance converting electrical energy into heat in a controlled way. The EL200works in the so-called constant current mode compensating for voltage fluctuations in theload circuit and adjusting the resistance to maintain a constant current. A 10-turnpotentiometer on the front panel allows the load current to be precisely set.

4 Operation directions

4.1 Start-up

Place the EL200 panel into the lower right area of the support frame. Ensure sufficient aircirculation at the rear of the module, so heat produced in the device can be dissipated. Inparticular, do not block the vent openings.

Attach the power cord to the AC power socket (6) at the right rear of the module and plugit into an AC power outlet.

Set the load control (4) to zero (anti- clockwise) and the front panel switch (3) to OFF.This will prevent an uncontrolled load current flowing when the module is turned on.

Turn on the power switch (6) at the right rear of the module.

Using two of the supplied 4mm test leads, connect the load input (5) to either the FC50power output or the VC100 power output.

4.2 Manual operation

Set the front panel load switch (3) to "ON".

Use the potentiometer (4) to adjust the current flowing into the electronic load. The loadcurrent is shown in the current display of the FC50. The actual power drawn by theelectronic load (load current times the clamp voltage) is shown in the power display ofthe EL200.

Changing the position of load switch (3) will make abrupt changes in the load. However,before you make large load changes in this way, make sure that the fuel cell has been inoperation for a while. Sudden large changes in loading can damage cells that are notthoroughly wet.


8/15

3 Electronic Load Module EL200 A.4


4.3 Computer-assisted operation

Connection/disconnection of the load and a current setting can be externally controlledthrough the RS485 interface (1). Power values from the EL200 are also available throughthis interface. Thus the EL200 can be operated with the FC50 in computer-assisted mode.

In order to control the EL200 through your computer, proceed as follows:

Using the supplied data cable, connect the RS485 socket (1) on the EL200 with theRS485 plug on the FC50.

Start computer-assisted operation of the FC50, as described in section 3.6.

Set the front panel load switch (3) to "ON".

4.4 Shutting down

Set the load control potentiometer (4) to zero (anti-clockwise).

Set the front panel load switch (3) to "OFF".

Turn off the power switch (6) at the right rear of the module

If appropriate, remove all cables from the equipment.

5 Possible malfunctions

Overloading the EL200 leads to excess temperatures and a temporary safety shutdown.When the temperature has returned to normal, operation is automatically restored.

If the excess voltage protection activates, disconnect the load from the voltage source torestore operation.

All other malfunctions and irregularities can only be repaired by the manufacturer. In suchcases please notify your dealer, who will advise you about further measures to be taken.

6 Improper modes of operation

The Electronic Load EL200 must not be connected to sources of alternatingcurrent. It must not be connected to sources of direct current that exceed 20 V.

Always operate the EL200 with the supplied test leads, in order to keep the contactresistances to a minimum and prevent heating of the supply terminals.


9/15

A.4 Electronic Load Module EL200 4


7 Technical data

Maximum continuous load 200 W (cooling by fans)Load voltage 1.220 V DC

Load current 010 A

Control Manual by 10-turn potentiometer,externally by RS485 data bus

Stability (with V load 20%) 0.1% of I max + 3 mA

Overload protection Power limiter, cut-off at excesstemperatures, automatic power restore

Protection against reverse polarity Diode and fuse

Overvoltage protection Disconnection at V Load, max + 10%Insulation voltage 1,5 kV eff load input to cabinet

2,5 kV eff mains to load input

AC power supply 115/230 V AC, 5060 Hz

Ambient operating temperature +5 +35 C

Noise emission < 70 dB(A)

Dimensions 400 x 297 x 135 mm

Weight 5.4 kg

Transportation and storage conditions Protect against humidity


10/15

1 Voltage Converter Module VC100 A.5


A.5 Voltage Converter Module VC100

1 Use

The VC100 Voltage Converter Module supplies regulated power for the FC50 module controland fans, so that you can operate the hy-Expert TM Instructor fuel cell sys tem as a grid-independent power supply. It can also provide power for other devices that need 12V DC.

It is intended to be used only for educational and research purposes.

2 Overview and parts list

! W 2

! W 2

+

+

I y r v t

W W@ v t r i r q h s

Q h h v v p G h q 6 h v y h i y r Q r

2 8 7

, 1

1 RS485 system data bus connectors2 Start-up battery holders3 12V DC power output for FC50 control system and fans4 12V DC power output5 Unregulated power input (210 V DC)

2

1

3 4

5


11/15

A.5 Voltage Converter Module VC100 2


3 Basic functions

The VC100 acts as a DC-to-DC converter or a kind of "step-up transformer". It converts aninput voltage within the range of 210 V DC into a regulated 12 V DC output.

To avoid thermal overload caused by exceeding the output power level, the converter hasintegrated current regulation to limit the input current.

When the voltage converter is connected so it supplies the FC50 with control and fan power,(modeling a grid-independent system), an internal battery allows the VC100 to provide powerto the system during the 10-second starting sequence until the fuel cell itself can generatepower.

4 Operation directions

Place the VC100 panel into the lower middle area of the support frame. Ensure sufficientair circulation at the rear of the module, so heat produced in the device can be dissipated.In particular, do not block the vent openings.

Place the 8 supplied alkaline cells into the battery holders. Observe the polarity asindicated in the battery holders. Press the battery holders into the VC100 front panel untilthey positively engage.

Use the 4mm test leads to connect the VC100 power input (5) with the FC50 stack poweroutput.

If you want to operate the system in self-powered (grid-independent) mode, use theprovided cable to connect the output (3) of the VC100 (3pin socket) with the FC50connector labeled "12V =".

Use the provided test leads to attach suitable loads such as the traffic light module TL10and/or the electronic load EL200 to the VC100 output. Pay attention to the voltage andpower consumption of the attached loads.

For computer-assisted operation, use the 9-pin data cable to connect the VC100 and theFC50 via its RS485 bus. If the EL200 is already connected to the FC50 data port, you canconnect the VC100 to the EL200.

5 Technical data

Input voltage 210 V DC

Output voltage 12 V DC

Max. input current 10 A

Max. input power 100 W (with V in = 10 V)

Power output max.40 W (with V in = 5 V)

Starting battery 8 x 1.5 V cells in series, type AA

Operating ambient temperature + 5+ 35 C

Noise emission < 70 dB(A)

Dimensions, weight 200 x 297 x 95 mm, 1.0 kg

Transportation and storage conditions Protect against humidity


12/15

1 Traffic Light Module TL10 A.6


A.6 Traffic Light Module TL10

1 Use

The TL10 Traffic Light Module is a 12 V sample load for the hy-Expert TM Instructor f uel cellsystem.

2 Overview

P I @ D I r

+6 V U P

1 LED arrays2 Mode switch3 12V DC power input

The operation mode switch (2) has three positions. In the middle position the TL10 isswitched off. In the position AUTO the TL10 cycles as a traffic light. In position ON allthree LED arrays are lit.

3 Technical data

Input voltage 12 V DC

Capacity approx. 8 W (position "ON")

Ambient operating temperature +5+ 35 C

Dimensions / weight 100 x 297 x 140 mm / 0.6 kg

1

2

3


13/15


14/15

1 Control software A.7


A.7 Control software

The FC50 system including integrated microprocessor can be operated manually through its

fan power and load knobs. You can alternatively run a program to operate it in a computer-assisted mode, in which the physical knobs dont work. It is necessary run a program before starting the FC50. (See section 5.4 of chapter A.3 .)

1 Running an FC50 Program

To run a program and operate the system in computer-assisted mode, you must connect theFC50 module to your computer through the RS232 interface. Start a program as follows:

The FC50 ON/OFF switch can be ON, but the system must not be operatingthat is, thephysical panel displays must not be illuminated.

On the Windows Start menu, selectPrograms > FC50 Software > FC50 Software 1.2E. The following selection menu appears:

In the item Serial Port select the port you are using to connect the computer to the FC50fuel cell module.

Click to expand the Experiments categories if needed, then select a program in one ofthe three program groups:

o User Interface: This application displays an image of the physical FC50 fuel cellpanel on your computers monitor. It also controls the FC50 and the EL200 modulesand displays actual data from the system. The most important parameters aredisplayed in a time-dependent graph.

o Experiments: Using the programs listed in this group, you can perform experimentsand collect data. The collected data are not analyzed, but only stored in a file wherethey can be used in other programs or printed out for analysis. For additionalinformation, refer to the Experiments Guide .

o Automated Experiments: These programs are similar to some in the Experimentsgroup, but they run and collect data automatically. Data points are plotted and savedfor further examination.

Click START.

Descriptions typical of programs in the three categories are given below.


15/15

A.7 Control software 2

2 Control window (left side)

A common control window appears at the left side of the screen in all the FC50 programs. Itcontains buttons to start and exit, system messages, names of the log file and data storagefile, and program sequence controls. The actual appearance of the control window may varyin different programs.

The Messages text box contains requests and notesabout the operation of the system.If an error occurs in the system, for 30 seconds theError Messages text box displays an error code anda short description. See section 8 Error messages and causes of chapter A.3 . In addition an errormessage appears on the screen. You can click thedisplayed OK button after the Instructor is turned off(automatically after 30 seconds or by turning the mainswitch off). Then correct the cause of the error, restartthe FC50 and continue with the experiment. Thepreviously measured values are not lost.The FC50 software can store measured data in twoways simultaneously: as an array of selected valuesparticular to the experiment being performed, and as acontinual stream of logged values. The itemExperiment Data specifies the name of a text filecontaining the array of selected values. If the filealready exists, new values are appended to theexisting file.The item Log File specifies the name of a text filecontaining a stream of measured values. Click StartLogging to store values every 100 ms. This functionis particularly helpful when analyzing abrupt changesin the load. Log files can become very large, andshould not be allowed to grow over long periods. It isbetter to save several smaller files.The item Starting Temperature specifies a stacktemperature that must be reached before someexperiments can begin to make and savemeasurements.Clicking the Start Measuring button begins theexperiment. If the stack temperature is less than thespecified minimum, the warm-up panel is displayed.Clicking the EXIT button terminates the currentprogram and returns to the selection menu.Measurements already taken are retained.

Documents

Instructor Experiment Guide16-30