forklift fuel cell system testing deliverable d6.1 test protocol

FORKLIFT FUEL CELL SYSTEM TESTING

DELIVERABLE D6.1 TEST PROTOCOL SPECIFICATION FOR VIBRATION, SHOCK, CLIMATE AND DURABILITY TESTS

Dissemination Level: PUBLIC

HyLIFT Demo - WP6

Final Document

Revision 2.0 (14.06.2012)

Thomas Malkow, Alberto Pilenga, Antonio Saturnio (JRC),

Federico Zenith (SINTEF),

Peter August Simonsen (H2 Logic A/S)

Acknowledgement

This project is co-financed by European funds from the

Fuel Cells and Hydrogen Joint Undertaking under

FCH-JU-2009-1 Grant Agreement Number 256862.

The project partners would like to thank the EU for establishing the Fuel cells and hydrogen framework and or supporting this activity.

R E P O R T

Disclaimer

The staff of HyLIFT-DEMO partners prepared this report.

The views and conclusions expressed in this document are those of the staff of the respective HyLIFT-DEMO partner(s). Neither the HyLIFT-DEMO partner(s), nor any of their employees, contractors or subcontractors, makes any warranty, expressed or implied, or assumes any legal liability or responsibility for the accuracy, completeness, or usefulness of any information, product, or process enclosed, or represents that its use would not infringe on privately owned rights.


DELIVERABLE D6.1 TEST PROTOCOL SPECIFICATION FOR VIBRATION, SHOCK, CLIMATE AND DURABILITY

TESTS

i

CONTENTS

FIGURES .................................................................................................................................... III

ACRONYMS AND ABBREVIATIONS ................................................................................................ IV

EXECUTIVE SUMMARY ................................................................................................................ V

1 INTRODUCTION, MOTIVATION AND METHODOLOGY ............................................................. 7

2 SPECIFICATION OF SYSTEM UNDER TEST (H2 LOGIC) ........................................................ 8

2.1 System Dimensions and Weight ............................................................. 8

2.1.1 Location of fixture mounting points ............................................ 8

2.2 System Electrical Interfaces ................................................................... 9

2.2.1 Power Interface ....................................................................... 10

2.2.2 Data Interface ......................................................................... 10

2.3 Environment Interfaces ......................................................................... 11

2.3.1 Air Inlet ................................................................................... 11

2.3.2 Air Outlet ................................................................................. 12

2.3.3 Hydrogen Inlet ........................................................................ 12

2.3.4 Hydrogen Outlet ...................................................................... 12

2.3.5 Cooling ................................................................................... 12

2.3.6 Ambient Air Characteristics ..................................................... 12

2.4 H2Drive ratings ..................................................................................... 12

2.4.1 Power rating............................................................................ 12

2.4.2 Voltage and current ratings ..................................................... 12

2.4.3 Temperature ratings ................................................................ 13

3 TEST SYSTEMS SPECIFICATION ...................................................................................... 14

3.1 Test System for Vibration, Shock and Climate Test (JRC) .................... 14

3.2 Test System for 4000 hrs Operation Test (SINTEF) ............................. 14

3.2.1 Process equipment ................................................................. 14

3.2.2 Electrical Requirements .......................................................... 15

3.2.2.1 The Electrical Panel ..............................................15

3.2.3 Other Requirements ................................................................ 16

4 SYSTEM DIAGNOSTICS SPECIFICATION (H2 LOGIC) ......................................................... 17

5 DYNAMIC LOAD CYCLE DEFINITION (H2 LOGIC) .............................................................. 18

5.1 Adapted Base Cycle (SINTEF) ............................................................. 19



TESTS

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6 CLIMATE TEST ............................................................................................................... 20

6.1 Reference Test ..................................................................................... 20

6.1.1 Test Conditions ....................................................................... 20

6.1.2 Measurements ........................................................................ 20

6.2 High Temperature Operation Test ........................................................ 20

6.2.1 Test Conditions ....................................................................... 20

6.2.2 Measurements ........................................................................ 20

6.3 Keep Warm (frost protection) Procedure Test ....................................... 20

6.3.1 Test Conditions ....................................................................... 21

6.3.2 Measurements ........................................................................ 21

6.4 Low Temperature Operation Test ......................................................... 21

6.4.1 Test Conditions ....................................................................... 21

6.4.2 Measurements ........................................................................ 21

6.5 Summary of climate test ....................................................................... 21

7 VIBRATION AND SHOCK TEST (JRC) ............................................................................... 23

7.1 System Resonance and Damping ........................................................ 23

7.1.1 Test Conditions ....................................................................... 23

7.1.2 Measurements ........................................................................ 23

7.2 UL 2267 Vibration Test ......................................................................... 23

7.3 Shock test............................................................................................. 24

7.3.1 Abstract .................................................................................. 24

7.3.2 Test Conditions ....................................................................... 24

7.3.3 Measurements ........................................................................ 24



TESTS

iii

FIGURES

Figure 1: Shematic of H2Drive fixture mounting points ............................................ 8

Figure 2: Basic diagram of system under test and necessary equipment to monitor system and control load/power supply. ................................. 9

Figure 3: Powering the H2Drive control system with H2Drive battery power. ..................................................................................................11

Figure 4: Dynamic Load Test Cycle Definition ........................................................18



TESTS

iv

ACRONYMS AND ABBREVIATIONS EPO Emergency Power Off FC Fuel Cell FCS Fuel Cell System H2 Hydrogen MH Materials Handling RH Relative Humidity SL Standard Litres



TESTS

v

EXECUTIVE SUMMARY This report forms part of deliverable D6.1 entitled "TEST PROTOCOL SPECIFICATION FOR VIBRATION, SHOCK, CLIMATE AND DURABILITY TESTS" of the FH-JU funded Hylift-DEMO project (Grant Agreement Number 256862).

This protocol describes the test methodology and procedures for the fuel cell system (FCS) used to power materials handling (MH) vehicles, e.g. fork lifts.

Specifically, test methods are presented for dynamic load cycling and long term operation as well as test under climatic conditions and vibration & shocks in addition to the system specification and diagnostics.

The information in latter mentioned sections is exemplarily given to illustrate what information is recommended to be provided.

Similarly, the actual values as per test method are mainly recommendations and may be subject to particular conditions or applications when so agreed between the customer requesting the tests and the organisation conducting the tests.

Forklift Fuel Cell System Testing Report

7

1 INTRODUCTION, MOTIVATION AND METHODOLOGY The development of fuel cell (FC) powered materials handling (MH) vehicles, e.g. fork lifts and to demonstrate their market readiness requires to subject their core component, the FC system (FCS) to several tests under specified conditions relevant to MH applications.

Basically, the objectives of these tests are to establish reliability and to charcaterise performance characterisation of the FCS in a laboratory environment prior and complementary to field test trials of such new power technology at the phase of market introduction and increased deployment.

This report while forming part of deliverable D6.1 entitled "TEST PROTOCOL SPECIFICATION FOR VIBRATION, SHOCK, CLIMATE AND DURABILITY TESTS" of the FH-JU funded Hylift-DEMO project (Grant Agreement Number 256862) describes the test methodology and procedures for the fuel cell system (FCS) used to power materials handling (MH) vehicles, e.g. fork lifts.

The test methods consist of dynamic load cycling test and long term operation test as well as tests under climatic conditions and vibration & shocks.

In addition, system specification, diagnostics and test equipment specification are exemplarily described to illustrate which information should principally be given.

It is noted that the actual values listed in the test methods are mainly meant as recommendations and may be subject to change under particular conditions and applications. This will have to be agreed among the customer requesting the tests and the organisation conducting the tests.

<Report Title> Report

8

2 SPECIFICATION OF SYSTEM UNDER TEST (H2 LOGIC)

The following sections list the physical dimensions and operational characteristics of the H2Drive® DIN-10-3 system under test.

2.1 System Dimensions and Weight

H: 792mm

W: 709mm

L: 1029mm

M: 675 kg (batteries account for approx.: 225 kg)

2.1.1 Location of fixture mounting points

The fixture mounting points are holes cut in the chassis of the system. The upper holes are Ø11mm, the lower holes has a M10 thread, allowing for mounting a bolt from the inside before mounting the lid of the tank compartment.

With (x,y)=(0,0) in the lower left corner of the system, the centres of the fixture mounting points are located at:

(45mm, 30mm)

(45mm, 762mm)

(984mm, 30mm)

(984mm, 762mm)

See principal figure below.

Upper fixture mounting point:

(0,0)

Table

792m

1029m

Refuelin

g

Power

cable

Figure 1: Shematic of H2Drive fixture mounting points


9

Lower fixture mounting point:

2.2 System Electrical Interfaces

The following figure shows an overview of the H2Drive system under test and the necessary equipment for monitoring and loading the system. Systems for delivering hydrogen to the system under test and systems to control the environment are not included in the figure. The scope of H2 Logic's "System under test" delivery is H2Drive, Service Interface cable and "H2 Logic PC". Internet connection is only necessary where remote debugging of system is required. The following sections define the interfaces needed to monitor and run the system.

H2Drive

Service Interface

H2 Logic

Hydrogen Outlet

Air

Outlet

Air Inlet

Hydrogen Inlet

Internet

Connecti

Power Interface

Operator

PC

Data

Interface

[U,I]

Figure 2: Basic diagram of system under test and necessary equipment to monitor system and

control load/power supply.

Power

Supply

Load

[I]

45

30

30

45


10

2.2.1 Power Interface

The FCS power interface is an Anderson Power Connector SBE 320 Black – 80V / 320A / 70mm2 (Anderson Article no. E6363G8) or a compatible connector, e.g. REMA SRE 320 Black 80V 70mm2 article no. 78350-00.

2.2.2 Data Interface

The FCS data interface is a TE Circular Plastic Connector (CPC) part no.: 207485-1

• Pin 1/7: 84V to H2 Drive control system. (Battery power fused with 50A)

• Pin 2: Ignition/Key in (24V = on / 0V = off)

• Pin 3: Not used.

• Pin 4: GND

• Pin 5: EPO Out

• Pin 6: EPO Return (closed to EPO Out = system ok)

• Pin 8: Limp Home Out “Com”

• Pin 9: Limp Home Out (Switch Normally Open “NO”, closed to “Com” = Limp Home)

• Pin 10/15: GND to H2 Drive. (Battery power)

• Pin 11: GND Canbus

• Pin 12: CAN high. (Terminated with 120 Ohm)

• Pin 13: CAN Low.

• Pin 14: Shield CANbus (communication cables are often shielded; this pin connects the cable shield to a robust reference to eliminate noise)

• Pin 16: Not used.

The relevant CAN messages (see specification below) as well as Ignition, EPO and Limp Home signals must be controlled and monitored properly by a test system operator application (if automated test is performed).

The CAN data signals supply information of system variables such as tank pressure and if errors/faults are present. For LabVIEW there is the NI-CAN tool box and a CAN to USB adapter available for decoding can messages.

See Display Communication Protocol for H2Drive CAN specification (In forklift and tow tractor systems the CAN bus is used for a display).

Emergency Power Off (EPO) is used in emergencies to stop the H2Drive. When the two EPO pins are connected (shorted), it is read by the H2Drive as an OK signal. When the connection is opened (e.g. by hitting a switch or removing the plug) the H2Drive performs an emergency shutdown.


11

The Limp Home signal tells if the system has gone into a limited operation state, where it only produces ~4kW. When the connection between pins 8 and 9 is open, the system is OK, when closed (shorted) the system signals “limp home”.

Also 84 volt supply is necessary on pins 1/7 and 10/15. PIN 1/7 is common/parallel supply for 84V for the H2Drive control system (positive pole) and PIN 10/15 is common/parallel ground (negative pole). The 84V power can be supplied from H2Drive power connector (+84V of Anderson Connector connected to pin 1 and 7 and 0V of Anderson Connector connected to pin 10 and 15). This solution is advisable.

The reason for this “outside system” connection of the power back into the H2Drive is, in case of an emergency, to ensure that when the power connector is disconnected the supply to the H2Drive control system is also disconnected (effective shutdown).

For tests at JRC the system data interface is delivered with a superseal connector with 4 signals:

Pin 1 (blue): Key in (24V = on)

Pin 2 (black): GND (reference for key)

Pin 3 (grey): EPO out

Pin 4 (violet): EPO return (Shorted to EPO out = OK)

2.3 Environment Interfaces

2.3.1 Air Inlet

The system air inlet is located inside the H2Drive system, which draws air from system surroundings through vents in the system box.

Operator/

H2Logic PC

Supers

eal

connecData Interface

PIN

1,7

PIN 10,

15

H2Dri

ve

Power

Interfa

+

-

+

-

Figure 3: Powering the H2Drive control system with H2Drive battery power.

Anderson/REMA

ProConnect

Load / Power

Optic

fibres

Key and

Fibre to

CAN

+ +

- -


12

2.3.2 Air Outlet

Mechanical properties: Outlet for hose mounting Ø=19mm; to be fastened with clamp.

The exhaust consists of both air and water. Therefore, the hose guiding the exhaust shall not feature a local minimum, since this will form a water lock and may affect system performance.

2.3.3 Hydrogen Inlet

Hydrogen inlet is a WEH TN1 H2 receptacle, compatible with a WEH TK16 refuelling nozzle.

2.3.4 Hydrogen Outlet

Mechanical properties: Swagelok Bulkhead Union SS-400-61

Amounts of hydrogen purged when:

• Starting up: 10 s => ~TBD standard Litres (SL)

• Operating: ~3 SL / minute

2.3.5 Cooling

With an expected system efficiency of ~48 %, the system will deliver an amount of heat roughly equal to the FC system load, which the test system ventilation will have to compensate for.

2.3.6 Ambient Air Characteristics

The following characteristics of the air, ambient to the system under test, affect system performance and are therefore relevant to keep log of:

• Temperature, taken at the FCS' air inlet

• Humidity, taken at the FCS' air inlet

• Oxygen level, if operating in a closed space where oxygen could be depleted.

Since system produces heat to the ambient air, ventilation should ensure stable temperature. If oxygen level is not measured, ambient (inlet) air must be thoroughly ventilated.

2.4 H2Drive ratings

2.4.1 Power rating

Nominal power output: 10 kW (one hour mean)

Maximum power output: 35 kW for 15 s

2.4.2 Voltage and current ratings

Absolute maximum voltage rating: 115 V


13

Absolute minimum voltage rating: 60 V

2.4.3 Temperature ratings

Maximum storage temperature: 55 °C

Minimum storage temperature: -4 °C

Maximum operating temperature: 35 °C

Minimum operating temperature: TBD


14

3 TEST SYSTEMS SPECIFICATION

3.1 Test System for Vibration, Shock and Climate Test (JRC)

JRC test facilities comprises a vibration test system (multi-axial shaker table) housed in the centre of a walk-in environmental chamber are used.

The six-degrees-of-freedom (6DoF) shaker table is capable of vibrations at frequencies of up to 250 Hz. Its payload capacity is about 750 kg. The achievable acceleration range (at 250 kg payload) is between 6 g (lateral) and 9 g (vertical). The dynamic force is 62 kN. Displacement amplitudes are 51 mm horizontally and 102 mm vertically. Its top mountable area is 0.85 m x 0.85 m (or 1.5 m x 1.5 m with head expander).

The environmental chamber is capable of ambient temperatures between -40°C and +60°C with heating / cooling rates of 2 K/min for a 20 kW thermal load (mid chamber position) and relative air humidity from 15% to 95% (at 60°C). The ambient air is re-circulated inside this chamber during environmental testing.

For the electrical measurement a programmable TDI load (WC-Sys2012) of maximum 48 kW power is used. This equipment can be operated in the following three load modes: current, power and voltage.

3.2 Test System for 4000 hrs Operation Test (SINTEF)

The test system is planned to be assembled at H2 Logic's premises in Herning, Denmark.

3.2.1 Process equipment

Process units are expected to be laid out as shown approximately in the figure on the right.

The electronic load is provided by TDI (model WC488SYS35-400024), and can be directly power-controlled; it is water-cooled and its maximum rated power is 24 kW. The power supply, also by TDI, is an SGA 100X150C(D)-1C AA AA, which can be current- or voltage controlled (no direct power control), and has a maximum rated power of 15 kW.

An independent pump for circulation of coolant (30% propylene glycol in water) will be installed; the pump is a Grundfos CRE 5-4.

The electrolyser is a PIEL MP 9.0 model with a capacity of 6 Sm³/h of hydrogen, and is complemented by two drying filters and two deoxygenating filters ("deoxo units") to attain 5.0 hydrogen purity.

The electrolyser, electronic load, power supply and computer system for data logging and equipment control will be located in a container obtained by SINTEF which was previously used for hydrogen experiments, and is therefore fully equipped for the task


15

(inclined ceiling, circulation fan on top, hydrogen sensors, air intake and outlet on the side wall).

The container was equipped to be an Ex area, but as the new components are not Ex-safe it will not be classified as such. All hydrogen storage will be in the ex-HRS provided by H2 Logic, which is an Ex area.

It is suggested to place the containers as exemplified on the right. As the SINTEF container has two glass walls, the large one should point north to avoid direct sunlight hitting the electrolyser.

3.2.2 Electrical Requirements

The SINTEF container salvaged a used electrical panel, which was retrofitted by SINTEF for the necessities of this experiment batch.

It is important to note that the electrical panel cannot supply the electrolyser, as it is dimensioned for a maximum of 22 kW. As the electrolyser has its own shutdown button, this should not prove burdensome, but needs to be verified with safety requirements.

The SINTEF container needs appropriate grounding, as specified in documentation produced by IRD (previous operator of the container).

Power is provided as 400 VAC, 3-phase. Connection holes are already available in the low, far end of the container seen from the door. The 3-phase power cables will be split and go:

1. Directly to the electrolyser;

2. To the electrical panel.

The total rated power capacity should be about 60 kW, of which 40 for the electrolyser.

3.2.2.1 The Electrical Panel

The 3-phase power cables (wires L1, L2, L3, N and G) can be connected in the lower left end of the electrical panel. Most of the remaining connections have been taken care of from there already in Trondheim. Power is the routed to:

• A 24 VDC voltage source, supplying the safety systems exclusively. This is supposed to keep operating also when the emergency button is pressed. This provides power to the flame, smoke and hydrogen detectors.

• A 22 kW connector, activated by a manual switch in series with the emergency button beside the entry door. Note that the emergency button outside the door is inoperative (key was lost; it may be repaired if deemed


16

necessary by safety concerns at H2 Logic). Power proceeds from the connector to:

o Break switch and circuit breaker for power supply. This is the main power consumer (up to 16 kW).

o Residual circuit breaker and circuit breaker for cooling fans. As their power consumption is low compared to the whole system (0.1 kW), they do not have any control and are operated at 100% as soon as the circuit breaker is engaged. Note that the fans have not been operated in years, and a visual inspection of the fans is in order before trying to start them up.

o Residual circuit breaker and circuit breaker for single-phase units. These include the electronic load and the control system.

o Instruments in the top section of the panel: these have not been modified by SINTEF, and operate the roof fan with temperature control, the heater and the lights. Note that the orange cable is the thermocouple that controls internal ventilation.

3.2.3 Other Requirements

The electrolyser requires a steady stream of water for electrolysis. This has to be provided either by a pipe to the system or periodic refilling of the tank by H2 Logic personnel.

The cooling loop for the electronic load is going to have sections outside the container, in the Güntner air coolers. To avoid freezing in case of stops in winter months, an aqueous solution of 30% propylene glycol will be used. Propylene glycol is preferred to the more common ethylene glycol for its very low toxicity. A quantity of about 10 litres should be sufficient, depending on the actual plumbing.

Data connection for purposes of data backup should be provided, preferably by Ethernet cable. If not possible, practical or desirable, a wireless connection may be set up. The connection does not necessarily have to reach the Internet, but it should be possible for SINTEF personnel to log on the control system's PC from Trondheim.


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4 SYSTEM DIAGNOSTICS SPECIFICATION (H2 LOGIC)

This section specifies the system diagnostics test to be performed before and in between the specified tests. During the accelerated lifetime operation test, the system diagnostics test is performed regularly at a specified point in the operation load cycle.

The following data must be collected between tests:

- Fuel Cell I/V curve

- Compressor calibration setup


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5 DYNAMIC LOAD CYCLE DEFINITION (H2 LOGIC)

When running a dynamic load test, the following cycle will be the basis for designing the individual test load cycles.

The load cycle is based power consumption data logging done on a 3t battery powered forklift while running a VDI2198 driving cycle.

Between each point in the cycle, the power is changed on a linear slope: From t = 0 s to t = 0.5 s the power moves from 0 kW to 4.5 kW with a slope of 9 kW / s, from t = 0.5 s to t = 2 s the power is kept constant at 4.5 kW, etc.

Figure 4: Dynamic Load Test Cycle Definition

This cycle has a mean power load of 9.2 kW and lasts for 30 seconds.

Dynamic load test may be scaled with a percentage measure in two ways:

• Time scaling; specifying how for much of one hour the nominal load cycles are run. The rest of the hour, the system is on, but not loaded.

• Power scaling; specifying how the power levels at each step of the cycle is scaled.

Examples:

• 100%: The defined cycle is run continuously for 30 minutes, simulating one VDI 2198 test cycle.

• 60% time: Between each cycle the system is loaded with 0 A for 20 seconds, resulting in a total cycle run time of 36 minutes per hour (60% of 60 minutes).

-30

-20

-10

0

10

20

30

40

0 10 20 30

Test Cycle

Test Cycle

Time [s] Power [kW]

0 0

0.5 4,5

2 4,5

3 30,5

4 -10

4.25 -10

6.25 27

7 19

13 16

14.5 -25

16 -5

17 -5

17.5 1,2

19.5 1,5

20.5 25

25 27

25.5 0

30 0


19

• 60% power: One cycle is run every 30 second where every power/current measure is scaled by 60%

5.1 Adapted Base Cycle (SINTEF)

The Herning rig will be limited in that the electronic load can dissipate at most 24 kW, whereas the power supply can deliver at most 15 kW. It is therefore necessary to redefine the dynamic load cycle of section 5 to make it feasible; this is done in the table to the right.

The integral of this profile over its domain [0, 30] is 275.16 kJ, indicating that the system will consume an average of 9.2 kW. Assuming some loss in regenerative braking as the batteries are not ideal, 10 kW is a conservative estimate of the average power production from the fuel-cell stack.

Then, the load cycles to be applied are as follows:

• For 30 minutes as given in the table (100% scaling)

• For 30 minutes scaled at 65% of the power values in the table;

• For 30 minutes scaled at 45%;

• For 15 minutes with no load (0% scaling)

-30

-20

-10

0

10

20

30

40

0 10 20 30

Power / kW

Power corr. / kW

Time [s] Power [kW]

0 0

0.5 4.5

2 4.5

2.75 24

3.25 24

4 -10

4.25 -10

6 24

7 24

7.5 19

13 16

14 -15

16 -15

17.5 1.2

19.5 1.5

20.5 24

25.25 24

26 0

30 0


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6 CLIMATE TEST

6.1 Reference Test

System operation @ 20°C ambient temperature and 50% RH.

6.1.1 Test Conditions

The system is started and operated continuously using the adapted load cycle, until a stable operating condition is achieved. A stable operating condition (or steady state) is achieved, when the system temperatures have settled. These can be monitored using the service interface supplied by H2 Logic.

6.1.2 Measurements

Full system log during operation is via the DAQ of the system. The power output of the system is monitored by the TDI load.

6.2 High Temperature Operation Test

Increasing temperature from 35°C and up until cooling capacity is no longer sufficient at max power (12.5kW). Determine max steady power output at 40°C.


The system is stored overnight at 35°C ambient temperature and 40% RH. The system is started at full power (10 kW), until a stable operating condition is achieved. If system is not stable at 35°C, the temperature is decreased until a steady state is achieved. If the system is stable at 35°C, the temperature is increased until the system shuts down. If the temperature is below 40°C, the temperature is still raised to 40°C and the stable maximum system power output is determined at this temperature.

6.2.2 Measurements


Temperature monitoring of:

- Batteries

- Pressure relief valve (middle pressure)

- Tank compartment

- Control box

6.3 Keep Warm (frost protection) Procedure Test

Testing that stack module will keep warm at ambient temperatures of -10°C. The temperature of some other system components will have to be monitored as well at -10°C. This test can be as preparation of cold operation test.


21

Test is repeated at -20°C until steady state is achieved.


This test is performed after the system is stored overnight to achieve a cold start scenario.

6.3.2 Measurements


- Ambient


- Tank compartment

- Control box

6.4 Low Temperature Operation Test

System operation: -10 °C and -20 °C ambient temperatures.


The system is stored overnight at -10°C ambient temperature with a service charger attached. The system is started and operated continuously using the adapted load cycle, until a stable operating condition is achieved.

This test is repeated for -20 °C.

When a steady state is achieved at -20°C ambient temperature, the temperature is decreased slowly (1 K/min) until the system shuts down (but not below -30°C ambient temperature). The cause of the shutdown is logged by the system?

6.4.2 Measurements



- Purge output

- Cathode intercooler output


- Ambient at radiator end of system

6.5 Summary of climate test Test scenario H2Drive operating Service charger on Dynamic load profile Constant load

Reference test Yes No Yes No

High temperature test Yes No No Yes

Keep Warm @ -10 °C No Yes No No


22

Low temperature test @ -10 °C

Yes No Yes No

Keep Warm @ -20 °C No Yes No No

Low temperature test @ -20 → -30 °C

Yes No Yes No


23

7 VIBRATION AND SHOCK TEST (JRC)

7.1 System Resonance and Damping


Fuel cell system state: No Operation.

Vibration frequency sweep: 10-190 Hz

Vibration amplitude (peak): max 3 g (all three translational axis)

7.1.2 Measurements

This test has a “search-and-fix” nature and the fuel cell system is not in operation. Still, logs are kept of work conducted. These logs include as a minimum:

- Original resonance profile

- Identified resonance frequencies through visual check

- Identified source components and inserted appropriate damping.

- Check on resulting resonance profile

7.2 UL 2267 Vibration Test

Perform a sine sweep in the frequency range of 10-190 Hz at a rate of 1 Hz/s for the vertical axis (see table 1) and the other two axes (see table 2) to identify resonance frequencies of the system components at reduced peak acceleration levels (25% of the values given in table 1 and 2). If no resonances are detected, these levels should be increased in steps of 25%.

Table 1 Vertical axis vibration conditions

Frequency Range (Hz) Peak Acceleration (G)

10-20 3.0

20-40 2.0

40-90 1.5

90-140 1.0

140-190 0.75

Table 2 Longitudinal and lateral axes vibration conditions

Frequency Range (Hz) Peak Acceleration (G)

10-15 2.5

15-30 1.7

30-60 1.25

60-110 1.0

110-190 0.75


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Once appropriate damping is carried out, repeat the sine sweeps for the three axes.

Perform 60 sine sweeps at 10-190-10 Hz frequencies according to tables 1 and 2 for a total of four hours per axes (UL 2267 Sec. 7.2.1.2 b)).

7.3 Shock test

7.3.1 Abstract

Determining the fuel cell system robustness to shocks experienced during operation in MH vehicle upon vibration testing.


The fuel cell system is exited with 1, 2, 3 and 4 g acceleration half sine for 40 ms cycle duration. Upon visual inspection for damages, 100 of these cycles are performed at 4 g acceleration on the intact system.

7.3.3 Measurements

Following the shocks, the system is visually inspected for any damage.

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forklift fuel cell system testing deliverable d6.1 test protocol