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Experiments guide and components description for the Hy-ExpertTM Instructor Fuel Cell System
5th Edition, October 2011
Copyright © 2005 Heliocentris Energiesysteme GmbH
All rights reserved. These manual and individual parts thereof are protected by copyright. All exploitation, duplication or photocopying is prohibited except in cases permitted by law. Components of the hy-Expert™ Instructor Fuel Cell System are protected by patent applications and/or registered designs.
General notes
© Heliocentris – Energizing education
General notes
Heliocentris Energiesysteme GmbH provides this documentation to facilitate the safe and correct use of the hy-ExpertTM Instructor fuel cell system. All statements, technical information and recommendations in this documentation and accompanying documents are believed reliable, but the accuracy and completeness thereof are not guaranteed or warranted. They are not intended to be, nor should they be understood to be, representations or warranties concerning the products described.
The following Components Description is a brief version of the hy-ExpertTM Instructor Operation Guide. It is intended to assist while operation under the supervision of trained personnel and does not replace the Operation Guide. Before operating this fuel cell system, please make sure to read and understand the information of the hy-ExpertTM Instructor Operation Guide. If you have questions, please contact Heliocentris Energiesysteme GmbH or your supplier.
The hy-ExpertTM Instructor fuel cell system has been sold subject to the limited warranties set forth in the warranty statement. Further, Heliocentris reserves the right to make changes in the specifications of the products described in this manual at any time without notice and without obligation to notify any person of such changes.
Table of contents
© Heliocentris – Energizing education
Table of contents
A: Operating References
A.1 Warnings and safety references
A.2 Product overview
A.3 Fuel Cell Module FC50
A.4 Electronic Load Module EL200
A.5 Voltage Converter Module VC100
A.6 Traffic Light Module TL10
A.7 Control software
A.8 Hydrogen supply option I: Connection set for compressed hydrogen cylinders
A.9 Hydrogen supply option II: Metal hydride storage with refilling kit
A.10 Hydrogen supply option III: Hydrogen generator with metal hydride storage
B: Technical basics and didactics
B.1 Learning objectives
B.2 Teaching references and methodology
B.3 Recommended web sites
B.4 References for further reading
Table of contents
© Heliocentris – Energizing education
C: Teacher guides for the experiments
C.1 The basic functions of the fuel cell system
C.2 The characteristic curve of a fuel cell
C.3 Parameters influencing the characteristic curve
C.4 Determination of the hydrogen current curve
C.5 Efficiency of the fuel cell stack
C.6 Set-up of a fuel cell power supply
C.7 Efficiency of a fuel cell power supply
C.8 Fuel cell application I: Remote traffic light
C.9 Fuel cell application II: Fuel cell car
D: Student experiments
D.1 The basic functions of the fuel cell system
D.2 The characteristic curve of a fuel cell
D.3 Parameters influencing the characteristic curve
D.4 Determination of the hydrogen current curve
D.5 Efficiency of the fuel cell stack
D.6 Set-up of a fuel cell power supply
D.7 Efficiency of a fuel cell power supply
D.8 Fuel cell application I: Remote traffic light
D.9 Fuel cell application II: Fuel cell car
A.1 Warnings and Safety References 1
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A.1 Warnings and Safety References
1 Symbols used in this guide
The following symbols are used in the Experiments Guide to indicate warnings and specific dangers:
Warning Indicates a potentially dangerous situation. Serious injuries can occur if this reference is ignored.
Warning Indicates danger of explosion.
Warning Indicates danger from rotary parts.
Warning Indicates danger of short-circuits or electrical shock.
Prohibition No open fire!
Prohibition Smoking prohibited!
Prohibition Do not attempt to extinguish with water!
Reference Draws attention to application tips and other usefulinformation. This is not a reference to dangerous situations.
Indicates highly flammable material.
2 Warnings and Safety References A.1
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2 General Warnings and Safety Instructions
The hy-ExpertTM Instructor fuel cell system has been developed and manufactured according to recognized technical regulations and is tested for function and safety before delivery.
The hy-ExpertTM Instructor fuel cell system is a laboratory instrument designed for operation by trained personnel in education and research. The hy-ExpertTM Instructor is not a "consumer-oriented" product, whose appropriate operation is generally known and which is protected against operation errors or inappropriate use. Improper operation or abuse can lead to dangers to the health of the operator, the fuel cell system itself and other property items. The Fuel cell system produces low voltage electricity by converting hydrogen electrochemically. The hydrogen is stored in pressurized cylinders, a metal hydride tank, or generated by a special hydrogen generator.
The operating and maintenance conditions laid down in these Components Descriptions must be observed. If the hy-ExpertTM Instructor fuel cell system is passed on to a third party, the Operating Instructions must also be passed on.
3 Restricted use
The hy-ExpertTM Instructor fuel cell system and its components may only be used for experimentation, demonstration or research purposes. All other uses are not intended and therefore prohibited.
For safety reasons, unauthorized modifications or changes to the system or its components are prohibited. The parts and components of the system may not be disassembled. In particular, all gas components, such as the gas fittings or the mounting bolts of the fuel cell stack must not be loosened, since this can cause hydrogen leakage.
4 Sources of danger
Source of danger Possible consequences Precautions Use of hydrogen Fire and danger of
explosion Avoid open fire and smoking in the
vicinity.
Avoid electrostatic charges.
Wrong polarity when making electrical
connections
Danger of short-circuits Make sure to have the correct polarity when making the electrical
connections.
Rotating parts of the cooling fans
Danger from rotating parts Do not put your fingers or other items into the fan housing.
A.1 Warnings and Safety References 3
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5 Authorized operators
Anyone setting-up, operating or maintaining the hy-ExpertTM Instructor fuel cell system must be aware of applicable local industrial health and safety regulations. Measures must be taken to prevent unauthorized persons installing, operating or maintaining the system.
In education, the hy-ExpertTM Instructor fuel cell system may only be used by students under the supervision of teaching staff. As the teacher you must ensure proper handling of the system. You have an obligation to draw attention to potential dangers. Installation, start-up, shut-down—and if necessary, maintenance—of the hydrogen supply as well as filling the metal hydride storage device may be done only through the teaching staff.
6 Workplace
The hy-ExpertTM Instructor fuel cell system is intended for installation and operation in a suitable laboratory area. In particular, the room must be equipped with an effective air-evacuation system that prevents the formation of explosive hydrogen-air mixtures in the event of any uncontrolled escape of hydrogen. Measures must also be taken to avoid electrostatic discharge. Local safety regulations that apply at the installation site must be observed. This applies in particular to the use and storage of hydrogen compressed gas cylinders that are not part of the supplied system. The fuel cell system must be installed on a stable, horizontal and solid base; it must stand firm.
The catalysts and membranes of the fuel cell are sensitive to dust and reactive chemicals, e.g. H2S and other sulfur compounds, carbon monoxide, ammonia, chlorine compounds, solvents, etc. The system must therefore not be set up, operated or stored in rooms where there is a risk of exposure to these substances.
The permissible working temperature is between +5 °C and +35 °C.
4 Warnings and Safety References A.1
© Heliocentris – Energizing education
7 Safety information about using hydrogen
• Hydrogen is a highly flammable gas.• Users must take care to ensure that hydrogen is not allowed to collect in an
enclosed or unventilated area, which would cause a flammability hazard• Avoid heat in the area surrounding the fuel cell system and hydrogen source.• Smoking and open flames are forbidden.• Measures must be taken to avoid electrostatic charge.
In addition to its fire danger, hydrogen if allowed to collect in an enclosed or unventilated area can displace oxygen, thereby creating a risk of asphyxiation. The operator must ensure the following safety precautions are met:
• Adequate ventilation of the laboratory area
• Proper installation of the hydrogen equipment
• Regular examination of the hydrogen piping and connections for leaks.
8 Safety precautions in an emergency
Significant hydrogen escape: • Do not operate electrical devices, light switches, etc. as an explosive gas mixture
could be present in the area.
• Immediately shut off the hydrogen source.
• Provide adequate ventilation to clear the affected area.
Fire or explosion: • Immediately shut off the hydrogen source.
• Report the fire and follow the fire response procedures for your laboratory.
• Leave escaping hydrogen to "burn down". The flame of burning hydrogen is notvisible!
• Use a class D fire extinguisher or dry sand to extinguish burning metal hydridepowder. Do not use water or CO2 extinguishers. If smoldering metal hydridepowder cannot ignite adjacent materials, it may be best to leave the hydride burning.
Other emergencies not involving hydrogen escape: Immediately switch off the FC50, remove its hydrogen connecting tube and if necessary close the valve of the compressed hydrogen cylinder or the metal hydride storage canister.
1 Product Overview A.2
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A.2 Product overview
1 Basic package
The Basic system package includes essential components of the hy-ExpertTM Instructor fuel cell system. These are the minimum components needed to perform experiments 1 through 5 (basic experiments). Hydrogen is supplied using one of the three listed options. Pressurized hydrogen cylinders needed for options I and II must be obtained from the local technical gas supplier.
Module FC50
+
Air
Current Strom�
Voltage Spannung�
mlmin
Fan PowerH Flow2
MIN AUTO
AV
%
°C
Flow Meter Durchflussmesser�
H2
Valve Ventil��
MAXH Durchfluss2 Lüfterleistung
Temperatur
OFF AUS��
ON EIN��
12V =
STATUSOPERATIONBETRIEBERRORFEHLER
H O2
Temperature
Luft
Module EL200
+
OFF AUS�
ON EIN�
Power Leistung�
W
STATUSOPERATIONBETRIEBERRORFEHLER
Component Item No. Fuel Cell Module FC50 (including power supply, control software, documentation)
610
Electronic Load module EL200 620 Choice of Hydrogen Supply Options: I Connection set for compressed gas cylinders II Metal hydride storage with refilling kit III Hydrogen generator with metal hydride storage
630 642 652
Hydrogen Supply Option I, II or III
A.2 Product Overview 2
© Heliocentris – Energizing education
2 Off-grid package
In addition to essential components of the hy-ExpertTM Instructor fuel cell system, the Off-grid system package includes the additional devices which are necessary to build a grid-independent fuel cell power supply. With this package the application-orientated experiments 6 through 9 can also be performed. Hydrogen is supplied using one of the three listed options. Pressurized hydrogen cylinders needed for options I and II must be obtained from the local technical gas supplier.
Module FC50
+
Air
Current Strom�
Voltage Spannung�
mlmin
Fan PowerH Flow2
MIN AUTO
AV
%
°C
Flow Meter Durchflussmesser�
H2
Valve Ventil��
MAXH Durchfluss2 Lüfterleistung
Temperatur
OFF AUS��
ON EIN��
12V =
STATUSOPERATIONBETRIEBERRORFEHLER
H O2
Temperature
Luft
ON EIN��
+AUTO
2 ... 10 V =
12 V =
+
+
Nutzleistung
W WEigenbedarf
Parasitic Load Available Power
OUT
IN
+
OFF AUS�
ON EIN�
Power Leistung�
W
STATUSOPERATIONBETRIEBERRORFEHLER
TL10 VC100 Module EL200
Component Item No. Fuel Cell Module FC50 (including power supply, control software, documentation)
610
Electronic Load Module EL200 620 Voltage Converter Module VC100 621 Traffic Light Module TL10 622 Choice of Hydrogen Supply Options: I Connection set for compressed gas cylinders II Metal hydride storage with refilling kit III Hydrogen generator with metal hydride storage
630 642 652
Hydrogen Supply Option I, II or III
Solutions 1 The basic functions of the fuel cell system C.1
© Heliocentris - Energizing education
Required devices:
Description Item I 630 II 642 Hydrogen supply (alternates) III 652
Fuel cell FC50 610 Electronic load EL200 620 Voltage converter VC100 (optional) 621 Traffic light TL10 (optional) 622
Arrange the devices as in the following diagram:
Elektronische Last EL200
Fuel cell FC50
Hydrogen supply
SpannungswandlerVC100 (optional)
Traffic light TL10
Electronic Load EL200
Fuel Cell FC50
Hydrogen supply
Voltage Converter VC100 (optional)
Traffic Light TL10 (optional)
Solutions 2 The basic functions of the fuel cell system C.1
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Task:
Learn about the FC50 Fuel Cell System and its components by stepping through their operation. Notice how the system reports operation errors and learn how to correct them.
Execution:
Note: This procedure shows you the operating modes of the individual components and later helps you to easily recognize and correct errors. You should follow the sequence step by step as indicated here. If you notice a mistake or omission in the procedure steps, you should nevertheless do the steps as indicated in order to learn the behavior of the system in the event of an error. To solve the following problems and answer the questions it will be necessary to refer to the Component Descriptions of the devices used.
1 Installation and start-up of FC50, EL200 and hydrogen supply:
When setting up and starting the equipment, follow the instructions provided in Part A: Component Descriptions for the individual components, especially the safety instructions. During experiments, ensure the area has adequate ventilation and keep away from sources of ignition.
1.1 Place the modules into the mounting frame arranged as shown in the above illustration. Use the AC power cord to connect the EL200 Electronic Load to the source of AC power. (Connection is on the right side behind the front panel.) Ensure the toggle switch on the EL200 front panel is OFF. Use two short test leads to connect the FC50 with the EL200, paying attention to the polarity.
1.2 On the FC50, set the main (toggle) switch to ON and press the START button. Which problem occurs and how can it be corrected? Problem: The FC50 shows no reaction and does not start. Solution: Attach the AC power pack to the 12V= DC Input socket, to supply power to its
control board.
Solutions 3 The basic functions of the fuel cell system C.1
© Heliocentris - Energizing education
1.3 After you have corrected the problem, press the START button again. Which problem now occurs and how can it be corrected? Use the error list in A.3 Fuel Cell Module FC50 to explain. Problem: The FC50 reacts, but immediately displays error Er01 in the ‘H2 flow' window. Solution: On the “Error messages” list (see A.3 Fuel Cell Module FC50) the error description
is: 'hydrogen is missing'. To correct this problem, put the hydrogen supply you are using into operation, following the appropriate instructions in section A.8 – A.10. Pay particular attention to the correct assembly of the quick-coupler at the FC50 and to connecting the 9-pin plug of the relief valve with the FC50 port 'H2 SUPPLY'.
1.4 Press the START button again. For approx.10 seconds a system test is performed. If this is successful, the displays are illuminated. The FC50 is now ready for use.
1.5 Turn the main power switch located behind the EL200 front panel on. The ‘Power’ display is illuminated. Turn the 10-turn potentiometer, in order to apply a load current. What does this show? Problem: Both on the 'CURRENT' display on the FC50 and 'Power' on the EL200 indicates no
load current and no power. Solution: The AC voltage supply of the EL200 is switched on; however the load is not applied.
The toggle switch on the front panel must be switched to 'ON'. As an indication, the green operating-LED is lit when the EL200 is active.
1.6 The load current previously set on the potentiometer is drawn from the Fuel cell and can be read on the appropriate display. The power Pload absorbed by the electronic load is shown in the EL200 display window.
1.7 Cooling fans supply air necessary for the operation of the fuel cell. The speed of the fans can be adjusted to suit the load current automatically or manually. Use the knob beside the display ' Fan Power ', to set a fan power between 5 % and 100 %. Try setting different operating points on the EL200 and try to set an appropriate fan power. Watch how the system reacts when you change these settings.
Solutions 4 The basic functions of the fuel cell system C.1
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1.8 Now apply a load current of 9 A and reduce the fan power slowly to 5 %. Watch the stack voltage display. What did you observe? Use the “Error messages” list (see A.3 Fuel Cell Module FC50) in order to explain why the FC50 shut off. Problem: After reducing the fan power, the voltage falls. The FC50 switches off automatically
and announces Er02. Solution: In the “Error messages” list see the error description: “Voltage of the fuel cell stack
too low.” The FC50 has a protection circuit which automatically switches the system off when the voltage falls below 4 V thereby protecting the fuel cell from damage.
Note: See a detailed explanation of the problem in experiment C.3 "Parameters influencing the characteristic curve".
1.9 Switch the FC50 off. Ensure that the potentiometer of the EL200 is set to zero and the toggle switch on the front panel is OFF.
1.10 If you are not making further measurements with the system, proceed to shut down and switch off the system as follows: • On the EL200, turn the potentiometer to zero, set the toggle switch to OFF, and turn
off the main power switch behind the front panel.• On the FC50, turn the fan control knob to AUTO and turn the main switch OFF.• Follow the correct procedure to shut down your hydrogen supply, as described in
sections A.8, A.9 or A.10 as appropriate.• Remove the hydrogen supply from the FC50 by opening the quick-coupler.
2 Installation and start-up of COMPUTER-SUPPORTED Operations
To operate the FC50 in the COMPUTER-SUPPORTED mode, it is necessary to have a computer with RS232 interface on which you have installed the provided software. Refer to operation of the software in the section A.7 "Control Software".
2.1 Connect the port ' RS232 ' of the FC50 to the appropriate interface on your computer using the provided long 9-pin data cable. Start the program 'FC50 software' on your computer selecting the menu option 'user Interface' and click the 'START' button. Follow the instructions in the reporting window of the control software.
Solutions 5 The basic functions of the fuel cell system C.1
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2.2 When you are requested from the software, switch on the FC50 and start it. Which problem occurs and how can it be corrected? Problem: Both FC50 and the software announce Er10 (Cooling fan control) Solution: Before starting the FC50 the fan control must be set to ' AUTO'.
Follow the instructions in the error message: Switch the FC50 off, correct the error by placing the fan power on ' AUTO ' and start the FC50 again. Afterwards you can acknowledge the error message with the "Ok" Button and continue working.
2.3 The measured values of the FC50 are now shown on both the module and on your computer. But you can adjust the fan power only through the software.
2.4 Also, setting the load current is only possible through the software. Set a value of Iload = 2 A Why doesn't the EL200 react? Problem: The EL200 does not react to computer-set values. Solution: Communication between EL200 and FC50 is made through the RS485 bus.
Therefore it is necessary to connect the two components with the provided short 9-pin cable. Also you must ensure that both the toggle switch on the front panel of the EL200 and the switch in the software are in the 'ON’ position.
2.5 In the 'user Interface' of the FC50 software click the label 'data display'. Observe the behavior of the different fuel cell parameters when you change the load current.
2.6 When you are through with the system, proceed to shut down and switch off the system as follows: • Terminate the FC50 software. The FC50 sees the interruption of communication
and displays an error.• Turn the potentiometer of the EL200 to zero, set the toggle switch to OFF and
switch off the main switch behind the front panel.• Turn the knob for the fan power to AUTO and turn the FC50 main switch OFF.• Put the hydrogen supply out of operation correctly.• Remove the hydrogen inlet to the FC50 by disconnecting the quick-coupler.
Solutions 6 The basic functions of the fuel cell system C.1
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3 Installation and start-up of VC100 and TL10 (optional)
This part can only be performed if the voltage converter VC100 and the traffic light TL10 is available. It does not matter if the FC50 is operating in COMPUTER-SUPPORTED mode or in manual mode.
Follow the safety instructions provided in section A: Component Descriptions for the individual components.
3.1 In the following the fuel cell system is self-powered. Switch the FC50 off and remove the AC power pack. Instead connect the 12 V DC input of the FC50 to the “Parasitic Load” output of the VC100 using the provided 3-pin cable. From the “Available Power” output of the VC100, the traffic light TL10 or other loads can be supplied. Use the provided short 9-pin RS485 data cable to connect the VC100 to the unused interface port of the EL200, to provide communication in the COMPUTER-SUPPORTED mode. Start the FC50. Which error occurs? Problem: The FC50 starts, but after the system test announces: Er06 (No voltage supply to
FC50). Solution: The voltage input of the VC100 must be attached at the output of the FC50. During
the system test the FC50 is supplied by the batteries inside the VC100. Afterwards the supply is switched to the voltage converter, which is supplied by the fuel cell. If this connection between output of the FC50 and input of the VC100 is missing, the FC50 loses power and switches off.
Note: See a detailed explanation of the problem in experiment C.6 "Structure of a network-independent current supply".
3.2 Restart the FC50 and wait for the system test to complete. In the VC100 display ‘parasitic load' see the power consumed by the FC50. In the display 'available power' see the power consumed by the attached load. Briefly try out the traffic light TL10 and observe the ‘available power’ display: At switch position ON all lamps shine; at position AUTO, a normal traffic light sequence occurs. In the middle position the device is off.
Solutions 7 The basic functions of the fuel cell system C.1
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3.3 The electronic load EL200 can be operated in parallel with the traffic light. Gradually increase the load current of the fuel cell using the EL200 potentiometer. Try to reach the maximum EL200 load current. Explain why the FC50 switches off. What has to be considered when restarting? Problem: The FC50 automatically turns off and announces Er04 (Load current too high). Solution: The load current reached a value of 10.5 A. In order to protect the fuel cell, the
system switches off at this value. To restart, set the potentiometer of the EL200 to zero.
Note: See a detailed explanation of the problem in experiment C.6 "Structure of a network-independent current supply".
3.4 When you are through with the system, proceed to shut down and switch off the system as follows: • Turn the potentiometer of the EL200 to zero, set the toggle switch to OFF and
switch off the main switch behind the front panel.• Turn the knob for the fan power to AUTO and turn the FC50 main switch OFF.• Put the hydrogen supply out of operation correctly.• Remove the hydrogen inlet to the FC50 by disconnecting the quick-coupler.
4 Summary
Considering the problems and the associated error messages again, look at the error list in section A.3 Fuel Cell Module FC50. Explain why it is useful to divide the errors into two groups: start-up errors and operating errors. Give at least one example of each group. Start-up errors are recognized by the FC50 during the system test. This group includes errors in the structure, the previous condition or in the start-up sequence. For example the error message Er01 (Hydrogen is missing) appears. The cause of the error is an incorrect installation of the hydrogen supply or an empty hydrogen storage device. To remedy the error activate the hydrogen supply, referring to the appropriate section in Component Descriptions or refill your hydrogen storage. In operating errors, parameters reach certain limit values during operation. For example the error message Er03 (Temperature of the fuel cell stack too high) appears. The reason for this error is a stack temperature exceeding 50 °C. The FC50 will not restart until the stack temperature falls below 45 °C. To remedy the error, increase the fan power to cool the fuel cell stack.
