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Intelligent Energy FCM-801, User Manual

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Intelligent Energy FCM-801 User Manual Download Page 15

15

Label information

The FCM-801 is labelled as shown below. It should be visible or duplicated on the full 
installation outer case.

Mechanical mounting points

The FCM-801 should be installed (clamped) in a similar manner to a heavy duty 
commercial vehicle or marine battery. Mount on a flat surface ideally in the horizontal 
orientation as illustrated. Whilst the fuel cell can operate in any orientation, verification 
testing has only been conducted in the horizontal orientation. Installation in non-
verified orientations could potentially result in reduced performance or even system 
shutdown, especially at environmental extremes. An example of a suggested 
mounting method for FCM-801. 

10.1

10.2

Name plate information

Unit serial number

Flammable gas 

hazard warning

DC power hazard warning 

Installation and set up

10

Summary of Contents for FCM-801

Page 1: ...FCM 801 User Manual Read before installation and use ...

Page 2: ...0 Installation and set up 15 10 1 Label information 10 2 Mechanical mounting points 10 3 Mechanical protection and covers 10 4 Vibration and shock loads 10 5 Air supply and ventilation 10 6 Hydrogen connection 10 7 Hydrogen fuel physical requirements 11 Trouble shooting guide 19 11 1 Check for fuel leak 11 2 Fuel check procedure 11 3 Electrical system check procedure 11 4 Stack temperature check p...

Page 3: ...pment provided The recipient acknowledges that the manner in which the equipment is stored used or operated is not under the control of Intelligent Energy Limited Intelligent Energy has made every effort to ensure that this User Manual is accurate and disclaims liability for any inaccuracies or omissions that may have occurred No naked flames or sources of ignition in the vicinity of the FCM 801 o...

Page 4: ... parallel BSP threaded port with face seal female Connections electrical Power leads 2 8AWG 8mm2 1 Positive cable 1 Negative earth cable 1 CAN hi low gnd 1 LED driver 1 FCM Run input 1 FCM Enable input Normal operating conditions Altitude 0 4000m 8 Operating ambient temperature range 5 C to 40 C Relative humidity 10 to 90 9 Storage temperature 40 C to 70 C 1 Hybrid battery provides power for start...

Page 5: ...ts of the FCM 801 3 Power cables Carry handle Air filter Communication Port Hydrogen inlet Power cables Grab handle Air filter fixings Exhaust air Inlet air The major components of the FCM 801 are Rear view ...

Page 6: ...al Air inlet 0 6 500 slpm 5 40 C Ambient air filtration and supply 170 240mm duct Exhaust air 0 6 500 slpm 5 60 C Air exhaust to ambient 150 150mm duct Power connection 15 0 56 0V Delivered current 0 40Amps Start up Shutdown current draw 0 4Amps Connection to DC bus 8AWG 8mm2 Communication port See Section 6 5 Max cable length 3m Operational commands diagnostics D type 9 way 4 1 Interface specific...

Page 7: ...dicates that the battery is already fully charged If during normal operation the load drops to a low level a pre set level from the configuration used the fuel cell will enter a standby state see Section 8 4 This is designed to optimise fuel consumption If the DC Bus voltage then dips below a preset voltage the fuel cell will restart This document is to help the users for operation user maintenanc...

Page 8: ...plete installation does not have a negative earth When the FCM 801 is running the power output will stay electrically live if the power cables are disconnected This therefore represents a high current electrical hazard The battery pack should provide power at the desired voltage The battery pack should be capable of powering the load during module performance optimisation cycle see Section 8 3 For...

Page 9: ...nd will see a maximum flow of 16 slpm When installing and operating hydrogen systems hydrogen general safety guidance should be considered The hydrogen should be at least 99 9 pure and comply with the specification ISO 14687 3 2014 grade E category 3 ISO TR 15916 basic considerations for the safety of hydrogen systems Hydrogen connection The hydrogen connection to the system is below the air exhau...

Page 10: ...nnector have the following functions Enable and Run command cables must be 3m in length Consideration to the communication earth should be considered when collecting multiple FCM 801 6 5 Pin No Description Function 1 Enable Reset ve Negative for Enable Reset line 2 Enable Reset ve Positive for Enable Reset line 3 CAN high CAN pin 4 CAN low CAN pin 5 CAN return ground CAN reference 6 Run ve Negativ...

Page 11: ...ted to the Positive Enable pin and held This can be done by making a connection between the Enable Positive and Negative pins 1 2 In the event of a fault the Enable connection needs to be cycled to reset the fault status Module Run To produce power the Run Negative pin needs to be connected to the Positive Run pin and held This can be done by connecting the Run Positive and Negative pins 6 7 N B E...

Page 12: ...he FCM 801 enters a fault condition the fault is latched The Enable line must be cycled to clear it 4 For start and stop criteria see Section 13 Control Parameters and Standard Factory Setting Fault state Fuel cell standby Auto start criteria Auto stop criteria Run on Run off Run off Fault trip State map for the FCM 801 Enable Reset Off Enable Reset On Enable Reset Off Fuel cell running The states...

Page 13: ...resence of sufficient air to sustain this safety dilution is monitored and interlocked Performance optimisation cycle During normal operation the FCM 801 will periodically conduct an optimisation cycle which improves the performance of the fuel cell Multiple cycles are triggered in rapid succession at start up Cycles occur less than 15 times an hour during running Power production is reduced or su...

Page 14: ...on of the fuel cell to try to compensate but if this is not possible then a fault is triggered When a fault has been triggered the controller will latch To clear the fault the controller needs to be reset by cycling the Enable Reset signal Any faults that are trigger before start will prevent the unit starting For reset instructions see Section 9 Faults Optimising the Fuel Consumption of FCM 801 T...

Page 15: ... the horizontal orientation as illustrated Whilst the fuel cell can operate in any orientation verification testing has only been conducted in the horizontal orientation Installation in non verified orientations could potentially result in reduced performance or even system shutdown especially at environmental extremes An example of a suggested mounting method for FCM 801 10 1 10 2 Name plate info...

Page 16: ...ed outside If installed inside the installer must ensure there is sufficient ventilation see Section 10 5 Air supply and ventilation The covers and the installation must protect the FCM 801 from ingress of precipitation flooding and vegetation or excessive dust The covers should consider the need for maintenance access to the filter or for unit exchange The covers of the FCM 801 must not be remove...

Page 17: ...mperature may affect the performance of the fuel cell Do not use if the air has smoke or corrosive gas present Hot air that is generated by other equipment within 0 6m of the inlet of the FCM 801 is of concern and should be limited to 5 of expected operating power of the FCM 801 in order to limit the ingestion of hot air The FCM 801 should not be located in an area where sleeping may occur The FCM...

Page 18: ...aks Particularly when connectors have been remade such as cylinder exchange or installation Hydrogen fuel physical requirements The fuel cell requires fuel pressure to feed hydrogen into the cell The inlet pressure should be 0 5 Bar g to 0 7 Bar g The FCM 801 will consume less than 16 slpm at rated power It must be noted that the flow will spike high during hydrogen purges which if poorly regulate...

Page 19: ...rature 11 1 Check for fuel leak Remove electrical load from fuel cell Set fuel cell to Off and Disabled Remove sources of ignition Verify hydrogen source pressure is within specification application specific Contact IE Product Support Team Can the leak source be identified Isolate hydrogen source contact IE Product Support Team urgently Have a gas trained person repair or replace damaged component...

Page 20: ...Support Team Investigate if the regulator is letting fuel by when idle yes yes yes yes yes yes yes no no Refuel the hydrogen source application specific Open the hydrogen supply application specific Increase pressure to 600mbar 100mbar g Investigate why hydrogen regulator is dropping during purge contact IE Product Support Team Does the fuel supply quality meet the fuel standard Does restarting th...

Page 21: ...range Turn the power supply on yes Replace missing batteries Are all the batteries at similar voltages Charge the low batteries Does the total battery bank have sufficient voltage to meet the specification Charge the battery bank yes no yes yes yes yes no no no no yes no no Contact IE Product Support Team 11 3 Electrical system check procedure Is the voltage of the power supply within the design r...

Page 22: ...in the fuel cell stack during this procedure as it may be live fuel cell stack will have voltage present even after it has been switched off This is a high current electrical hazard Fuel cell not operating or derated Is the max load within the fuel cells specification What is the cause of the high load Contact IE Product Support Team to discuss Provide the ambient temperature and humidity for the ...

Page 23: ...ction Filter change Troubleshooting see below For all other maintenance tasks please contact Intelligent Energy Contact Intelligent Energy Product Support In the event of a fault with the FCM 801 please contact the Intelligent Energy Product Support Team Either contact your local representative or email product support intelligent energy com If you have a fault please provide as much detail as pos...

Page 24: ...d Stop Over Voltage V 0 0 to 60 0 54 27 Delayed Stop OV Qualification Time s 0 to 3600 60 60 Delayed Stop Under Current A 0 0 to 120 0 2 2 Delayed Stop UC Qualification Time s 0 to 3600 20 20 Deny Start Under Voltage V 0 0 to 50 0 40 20 System Index 1 to 8 1 1 Output Voltage Rise Rate V s 0 017 to 2000 00 0 017V s 0 017V s Minimum Output Voltage V 0 0 to 60 0 48 24 Output Current Limit A 0 0 to 40...

Page 25: ...iliary power source is started e g Photovoltaic array requires a time delay to be triggered see below Delayed Stop OV Qualification Time s The time for the auxiliary power present trip to be completed to leave running mode see above Delayed Stop Under Current A Trigger to prevent the FCM running if there is a low load designed to prevent poor overall system efficiency Requires a time delay to be t...

Page 26: ...rtation For transport follow the guidance for storage taking care that The FCM 801 should be transported in a level orientation The FCM 801 should not be subjected to mechanical shocks where possible Spare parts For spare parts contact IE Product Support Team at product support intelligent energy com Spare part list Filter intake air 009016 Filter retaining plate 009015 Filter retaining screws 000...

Page 27: ...ty EN 60204 1 2006 A1 2009 Safety of machinery Electrical equipment of machines General requirements EN 13611 2007 A2 2011 Safety and control devices for gas burners and gas burning appliances General requirements EN 60079 10 1 2015 Classification of areas Explosive gas atmospheres EN 61000 6 2 2005 Electromagnetic compatibility EMC Generic standards Immunity for industrial environments EN 61000 6...

Page 28: ...garded as being a complete source of Information To the fullest extent permitted by law Intelligent Energy offers no warranty as to the accuracy of the content of this publication shall not be liable for the content of this publication and no element of this publication shall form the basis of any contractual relationship with a third party Printed October 2020 61825 IE UM 202010 Published by Inte...

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