Fronius 25F Operating Instructions Manual Download

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25F/50F Energy cell

Operating Instructions

/ Battery Charging Systems / Welding Technology

Solar Electronics

Energy cell

42,0410,1562

006-11022013

Summary of Contents for 25F

Page 1: ...25F 50F Energy cell Operating Instructions Battery Charging Systems Welding Technology Solar Electronics Energy cell EN 42 0410 1562 006 11022013 ...

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Page 3: ...t features of your new Fronius product This really is the best way to get the most out of all the advantages that your machine has to offer Please also take special note of the safety rules and observe them In this way you will help to ensure more safety at your product location And of course if you treat your product carefully this definitely helps to prolong its enduring quality and reliability ...

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Page 5: ...arefully The operating instructions must always be at hand wherever the device is being used In addition to the operating instructions generally applicable and local regulations regarding accident prevention and environmental protection must be made available and observed General remarks Important WARNING indicates a possibly dangerous situation Death or serious injury may result if appropriate pr...

Page 6: ...r Notify the manufacturer or his representative immediately so that the device can be checked and any affected parts replaced Utilisation in accordance with intended purpo se All safety and danger notices on the device must be kept in a legible state must not be damaged marked must not be removed must not be covered pasted or painted over For the location of the safety and danger notices on the de...

Page 7: ... described in the documentation All cables and leads must be complete undamaged insulated and adequa tely dimensioned Loose connections scorched damaged or inadequately dimensioned cables and leads must be immediately repaired by authorised personnel Leaks in the hydrogen supply can lead to fire or explosions The hydrogen supply must be set up according to the relevant standards and connection pla...

Page 8: ...ng openings for the inlet and outlet cooling air factory setting if there is sufficient ventilation in rooms with a volume of more than 130 m Danger from gases hazardous materials and suffocation Keep all people especially children away from the unit and its accessories If however there are people in the vicinity make them aware of all the dangers associated with the back up battery risk of a buil...

Page 9: ...disable protection devices Before switching on the device ensure that no one is likely to be endangered The procedure for turning the device on and off safely is described in chap ter entitled Operation in the device operating instructions Make sure that the installation location has an adequate incoming and outgoing air supply or operate the unit in an environment that is not dependent on the sur...

Page 10: ...mage to people or property Protect batteries from dirt and mechanical damage Perform a regular visual inspection to ensure that the acid electrolyte level in the battery is at the Max mark If any of the following occurs do not start the device or stop immediate ly if already in use and have the battery checked by an authorised workshop uneven acid levels and or high water consumption in individual...

Page 11: ...ected leave the cap on the pressure tank valve The manufacturer s instructions must be observed as well as applicable national and international regulations for pressure tanks and accessories Danger from pressure tanks The duration of the guarantee for the device depends on the supply con tract However the manufacturer will not accept any liability if the damage was caused by one or more of the fo...

Page 12: ...and has recei ved the marks of conformity for product safety Marks of confor mity The operator is required to carry out a safety inspection of the unit at least once every 12 months and to have the safety elements on the unit function tested including calibration of the sensors The entire system must be checked in accordance with the applicable national regulations Follow the appropriate national ...

Page 13: ... to print Right to effect modifications is reserved The contents of the operating instructions shall not provide the basis for any claims whatsoever on the part of the purchaser If you have any suggestions for improvement or can point out any mistakes that you have found in the operating instructions we will be most grateful for your comments Copyright ...

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Page 15: ...rounding air 19 Setup dependent on surrounding air 20 Connecting the hydrogen supply 21 Connecting the hydrogen vent lines 21 Connecting the reaction condensate outlet pipe 22 Connecting the reaction chamber outgoing pipe 23 Installation examples for automatic mode 23 Installation example for battery current 85 A 24 Installation example with a charging current limit 25 Operation 26 Safety 26 Opera...

Page 16: ...f available measured values 40 Measured values for the H2 tank 40 Measured values for the energy cell 40 Measured values for the battery 43 Troubleshooting 44 General 44 Energy cell fault diagnosis 44 Displayed service codes 45 Care maintenance and disposal 47 General 47 Once a year every 1000 operating hours 47 Annual safety inspection 47 Every 1500 operating hours 48 Maintenance work every 1000 ...

Page 17: ...e to the extent that no further explosion protection measures are re quired at the installation location Fig 1 Energy cell Water is the only combustion product of the energy cell which means that it does not produce any pollutants Another advantage of the cell is that it is quiet and requires practically no maintenance In contrast to conventional generators the energy cell electrochemically conver...

Page 18: ...g notices on the device HOT SURFACE WARNING Optionen 48 V 82 A 4000 W FRONIUS Energiezelle 50F 4 220 021 100 A 3 C 40 C 38 F 104 F Hydrogen Quality 5 0 5 to 13 6 bar 3 3 Nm h Ambient temperature Pressure Flow rate Fuel type www fronius com Type Ser No EN 62282 5 1 EN 61000 6 2 EN 61000 6 3 IP20 Art No IBATT max P el nom UDC nom Cooling air Electrical output Energy cell 25F 24 V DC 2 kW Energy cell...

Page 19: ...ounding air it may only be operated by taking in air from the room if protective grilles 1 are fitted on the housing openings for the cooling air supply and outlet factory setting there is sufficient ventilation it is used in rooms with a volume of more than 130 m the outgoing air from the reaction chamber is dissipated into the atmos phere to avoid oxygen depletion in the surrounding air 1 NOTE T...

Page 20: ...d and understood the following documents these operating Instructions all the operating instructions for the system peripherals gas supply battery etc especially the safety rules NOTE After firmware updates you may find that your device has certain functions that are not described in these operating instructions Individual illustrations may also differ slightly from the actual controls on your dev...

Page 21: ...48 V 4 kW 9 Strain relief device For securing the connected cables 10 Plug connections for CAN X3 interface For reading operating data for integration into the entire system contact the manufacturer first 11 Plug connections for Modbus interface RS485 For reading device specific data Housing front panel continued ...

Page 22: ...y dissipated into the atmosphere in the event of overpressure in the hydrogen supply 1 4 in NPT with internal thread supply pressure protection and stack protection 4 Locking ring connection for the reaction condensate outlet pipe Swagelok 6 mm 0 24 in Hexagonal width across flats 14 mm 0 55 in 1 6 7 2 3 4 5 Fig 6 Non electrical connections and cooling air ducts IMPORTANT The ducts 6 and 7 for sup...

Page 23: ... dissipated into the atmosphere Hydrogen sensors and a level monitor for the backflushing air ensure safe operation These measures are known as the device internal or prima ry explosion protection DN 50 1 97 in 6 Duct for removing cooling air 7 Duct for supplying cooling air Housing rear panel overview of process connections continued ...

Page 24: ...9 in 297 75 mm 11 72 in 214 75 mm 8 45 in 156 75 mm 6 17 in 12 mm 47 in 185 mm 7 28 in 185 mm 7 28 in 19 mm 75 in 22 mm 87 in 637 mm 25 08 in 426 mm 16 77 in 155 mm 6 1 in 30 mm 1 18 in Layout of the process connec tions 330 25 mm 13 in 128 mm 5 04 in 622 5 mm 24 51 in 870 mm 34 25 in 912 5 mm 35 93 in ...

Page 25: ...tal injury Place devices on a solid level surface so that they remain stable Please also see Environmental conditions in the Safety rules section The device must only be set up and operated in a suitable dry enclosed space with adequate ventilation The manufacturer accepts no liability for any damage caused due to use in an unsuitable space To operate without problems the device must be set up hor...

Page 26: ...ogen supply must be configured according to the applicable standards and the Technical data section The technical data shown on the rating plate applies CAUTION Inadequately dimensioned installations and consumers can cause serious damage Consumers connected to the device must conform to the output voltages of the device The technical data shown on the rating plate applies 1 Check the hydrogen cyl...

Page 27: ...ved by a trained technician All other covers and housing should generally only be opened removed by the manufacturer s trained technicians Unauthorised opening or manipulation of the device will invalidate the warranty and create the risk of serious injury or damage Safety Advance infor mation Not all of the following wiring tasks will be needed for basic operation of the energy cell The following...

Page 28: ...0 Pin Description U Imax 1 Housing earthing 2 DC battery 48 V DC 100 A 3 DC battery 100 A 4 DC consumer 48 V DC 100 A 5 DC consumer 100 A 6 Housing earthing Fig 8 Connecting cables for DC power and earthing Wiring terminals for DC power and earthing X0 Maximum cable cross section 35 mm 0 0543 in Recommended tightening torque for terminal screws 1 4 5 Nm 1 Insert the cable ends with ferrules into t...

Page 29: ... Alarm output Pin Description U Imax 1 Standby 10 30 V DC 2 Standby 10 30 V DC The X2 alarm output is part of the safety related inputs and outputs This output is only active in the event of a safety related fault X2 External Emergency Stop Pin Description 5 Emergency Stop contact 21 6 Emergency Stop contact 22 Note regarding the external Emergency Stop If required a Fronius trained service engine...

Page 30: ...3 Tank valve 1 Pin Description U 25 F 50 F Imax 3 Tank valve 1 contact 13 20 30 V 45 60 V 2 A 0 4 A 4 Tank valve 1 contact 14 20 30 V 45 60 V 2 A 0 4 A X3 Tank valve 2 Pin Description U 25 F 50 F Imax 5 Tank valve 2 contact 13 20 30 V 45 60 V 2 A 0 4 A 6 Tank valve 2 contact 14 20 30 V 45 60 V 2 A 0 4 A X3 Relay Pin Description U 25 F 50 F Imax 7 Relay contact 13 20 30 V 45 60 V 2 A 0 4 A 8 Relay ...

Page 31: ...put Pin Description U Imax 1 Digital input 0 10 30 V DC 7 mA 2 Digital input 1 10 30 V DC 7 mA 3 Digital input 1 10 30 V DC 7 mA 4 Run system start 10 30 V DC 7 mA 5 Run system start 10 30 V DC 7 mA X4 Sensor supply Pin Description Imax 6 5 V 125 mA X4 Analogue input Pin Description U r in 7 AI0 0 5 V DC 20 kOhm 8 AI1 0 5 V DC 20 kOhm 9 AI2 0 5 V DC 20 kOhm ...

Page 32: ...nnection X5 Maximum cable cross section 1 5 mm AWG28 Recommended tightening torque for terminal screws 2 0 2 Nm 1 Insert the cable ends with ferrules into the terminals of the 5 pin plug X5 2 Secure cables using terminal screws 2 3 Plug the 5 pin plug into 5 pin base 5 pin base X5 2 0 2 Nm 1 1 2 1 3 1 4 1 5 1 2 2 2 2 2 3 5 pin plug X5 RJ45 X7 7 6 5 4 3 2 1 1 8 RJ45 X6 7 6 5 4 3 2 1 1 8 5 pin plug ...

Page 33: ...not part of the scope of supply A RJ45 plug connector is required RJ45 X13 7 6 5 4 3 2 1 1 Fig 11 Connecting the CAN interface 8 RJ45 plug connector X13 Pin Description Imax 1 7 V DC 500 mA 2 GND 3 High 4 R Terminate 5 R Terminate 6 Low 7 GND 8 NC RJ45 plug X6 Pin Description 1 GND 2 NC 3 X6 Pin 3 4 RX Wiring terminals for Modbus interface RS485 continued Pin Description 5 RX 6 X6 Pin 6 7 NC 8 GND...

Page 34: ...n location is adequately ventilated despite the exchange of air with the outside The device should ideally be set up so that it is independent of the surrounding air This means that the combustion and cooling air is supplied from the atmosphere and the outgoing air from the reaction chamber and cooling system is dissipated into the atmos phere Information about how to connect a suitable pipe for t...

Page 35: ...mbustion and cooling air is supplied from the atmosphere and that the outgoing air from the reaction chamber and cooling system is dissipated into the atmosphere If the device cannot be set up so that it is independent of the surrounding air it may only be operated by taking in air from the room if protective grilles are fitted to the housing openings for the inlet and outlet cooling air factory s...

Page 36: ...quirements There must be no leaks from the screwed joint with the counterpart Hydrogen supply pressure 5 to 13 6 bar 72 49 197 18 psi Hydrogen volumetric flow 1 7 Nm h 60 71 cfh energy cell 25F Hydrogen volumetric flow 3 3 Nm h 117 86 cfh energy cell 50F Connecting the hydrogen supply Connecting the hydrogen ventila tion lines WARNING Incorrectly routed hydrogen ventilation lines increase the risk...

Page 37: ...nergy cell 50F 1 Insert the reaction condensate outlet pipe 1 into the locking ring 2 2 Tighten the locking ring 2 hexagonal width across flats 14 mm 0 55 in First tighten by hand Then use a hexagon spanner to tighten a further 1 1 4 turns Fig 16 Connecting the outlet pipe 2 1 Fig 15 Connecting the ventilation lines 1 1 1 Screw the ventilation lines firmly to their counterparts on the screw connec...

Page 38: ...on chamber outgoing line and within the device Fig 17 Connecting the outgoing pipe 1 WARNING A covered hydrogen sensor increases the risk of fire explosion and suffocation The following conditions must be fulfilled during and after assembly of the reaction chamber outgoing pipe The reaction chamber outgoing pipe must only be pushed onto the attachment A reaction chamber outgoing pipe must not be i...

Page 39: ... connects to the battery The applicable national and international regulations regarding the safe installati on of batteries and the information provided by the battery manufacturer must be observed Fig 18a Installation example Explosion zone Reaction condensate Hydrogen store Ex zone 2 for example a wall in F90 or protected zone Hydrogen overpressure valves Explosion zone Reaction chamber outgoin...

Page 40: ...cted by a 100 A fuse at the point where it connects to the battery The applicable national and international regulations regarding the safe installati on of batteries and the information provided by the battery manufacturer must be observed Explosion zone Reaction condensate Hydrogen store Ex zone 2 for example a wall in F90 or protected zone Hydrogen overpressure valves Explosion zone Reaction ch...

Page 41: ... in the overview as required For more de tailed information see the Set up menu section This device is designed to be used in a frost free environment within a temperature range of 3 C to 40 C 37 4 F bis 104 F If the device is started up at a temperature of less than 20 C 68 F the nominal output will not be available until the required process temperature is reached If the device is operated at hi...

Page 42: ...l Manual mode Manual mode switching off the energy cell When the connected battery reaches a critical charge level a higher level control unit sends a start signal to the energy cell as described in the Starting the energy cell automatic mode section The energy cell then starts automatically Once the final charging voltage set at the factory for the connected battery has been reached the higher le...

Page 43: ... ensure that charging is as fast as possible 2 In phase 2 the ability of the batteries to absorb energy decreases The charging current is reduced before outgassing starts at the edges of the electrode plates The charging voltage remains constant Now even the lower layers of the electrode plates are gradually converted 1 2 I I U U I U t Fig 21 Charging characteristic The charging characteristic set...

Page 44: ... sections warning messages The system display shows the symbols for setting and calling up measured values for tank indicator the energy cell battery display SystemControl displays the tank pressure if the tank indicator and analogue sensor inputs are configured and a suitable sensor is connected tank pressure bar tank temperature C calculated quantity of energy in the stored hydrogen kWh Tank ind...

Page 45: ...st of the hydrogen sensor is imminent The warning appears from 200 operating hours before the function test is due If the deadline for the function test of the hydrogen sensor has passed the warning symbol indicates that the function test was not carried out on time This shows the following for the start and back up battery battery voltage V output current of the energy cell A Battery display WARN...

Page 46: ...d Press the OK key Hold down the OK key automatic Service This indicates that servicing is nearly due The warning appears from 1 month before the service date If the service was missed the warning symbol signals that the service interval was exceeded Warnings continued Tastenfeld Press keys left right and scroll to select buttons symbols and settings change values Note The EXIT button can often be...

Page 47: ... ALARM button does not appear until the error list contains at least one error The error list can contain up to 10 errors If another error occurs the oldest error is deleted Open error list 1 Select ALARM button 2 Press the OK key to confirm To open lower level displays 1 Select the relevant entry 2 Press the OK key to confirm The following are displayed sometimes in lower level displays error cod...

Page 48: ...34 Overview Start System status displays System peripheral displays Press the OK key Hold down the OK key automatic ...

Page 49: ...the Warnings section Pred Pmax Perm Test H2 Sensor Service Displays System status e g RUN Displays the current operating status Standby Startup RUN operation Shutdown returns to Standby Ubat battery voltage Voltage of the starting and back up battery PTank Tank pressure If the tank indicator and analogue sensor inputs are configured and a suitable sensor is connected You will find detailed informa...

Page 50: ...f the warning symbols can be found in the Warnings section Pred Pmax Perm Test H2 Sensor Service Favourites Individual selection and arrangement of four measured values as described in the Changing the favourites section e g Ucmin to TCin If no individual selection is made the display contains the values as shown in the illustration above A detailed explanation of the display values can be found i...

Page 51: ...ect the required display value e g TAout for the temperature of the process outgoing air in C The following changes to the display are possible Changing the Favourites display Overview with an individual selection and arrangement of 4 measured values from all the available measured values Configuration of the external analogue sensor inputs Setting the display format number of decimal places and u...

Page 52: ... display opens 3 Use the scroll key to determine the position of the selected value 4 Press the OK key to save this arrangement 5 Select the EXIT button 6 To select and arrange other values continue as described for TAout You will need to specify the following in order to correctly display the remaining hydro gen level Total volume of all H2 tanks L Maximum filling pressure of the H2 tanks bar A d...

Page 53: ...r inputs are not yet selected Configuration of the tank indicator continued 9 Use the left right keys to move the cursor to the next position and continue as described above until the entire input value has been changed 10 Press the OK key to confirm 11 Repeat as appropriate for the p max setting maximum tank pressure 12 To configure external analogue sensor inputs see the next section Configuring...

Page 54: ...nalogue input 3 Select the energy cell symbol 4 Press the OK key to confirm 5 Select the EXT AI symbol 6 Press the OK key to confirm 7 Use the scroll key to select the required analogue input e g AI0 9 Use the right key to move the cursor to the positi on for the display value 10 Use the scroll key to set the decimal point 11 Use the right key to move the cursor to the positi on for the unit e g C...

Page 55: ...ogen tank 2 Energy cell 3 Battery 1 Select the symbol for the H2 tank 2 Press the OK key to confirm All the other information can be found in the Configu ring the tank display section To display the view shown above Select the SETUP button from the Favourites display Press the OK key to confirm 1 Select the symbol for the energy cell 2 Press the OK key to confirm The measured values for the indivi...

Page 56: ...gen supply pressure bar cond Conductibility of the cooling fluid micro Siemens Umin1 Specifies the cell with the lowest voltage mV Umi1 Number of the cell with the lowest voltage State System status Start Number of starts already carried out Operating Hours Number of operating hours ...

Page 57: ...l continued DC DC DC DC converter TCin Cooling fluid incoming temperature C TCout Cooling fluid return temperature C TAout Temperature of the process outgoing air C Ubat Battery voltage V Iout Output current of the energy cell A UStk Stack voltage V IStk Stack output current A ...

Page 58: ...nalogue sensor inputs section Measured values for the energy cell continued Measured values for the battery The following measured values are displayed for the start and back up batteries Battery voltage V Output current of the energy cell A 1 Select the symbol for the battery 2 Press the OK key to confirm ...

Page 59: ...tional GmbH 4600 Wels Thalheim Günter Fronius Straße 1 Austria E mail energycell fronius com http www fronius com The unit has no function Cause Battery not connected or connected incorrectly Remedy Check the contacts and cables and check that polarity of the charged battery is correct Cause No hydrogen supply inadequate hydrogen supply pressure Remedy Establish a hydrogen supply with sufficient p...

Page 60: ...or fault Remedy Restart the energy cell cannot be remedied Contact After Sales Service 15020 U Stack min Cause Stack fault undervoltage Remedy Restart the energy cell cannot be remedied Contact After Sales Service 15030 Battery Cause Battery fault undervoltage Remedy Charge battery reduce the load 15040 Ucellmin Cause Individual cell voltage too low Remedy Restart the energy cell cannot be remedie...

Page 61: ... remedied Contact After Sales Service 15080 H2 Sensor Cause Hydrogen sensor error Remedy Contact After Sales Service 15090 FS CTRL Cause Safety system error Remedy Restart cannot be remedied Contact After Sales Service 15100 EEPROM Cause Error in the control unit s memory Remedy Restart cannot be remedied Contact After Sales Service 15110 RTC Cause Error in the control unit s real time clock Remed...

Page 62: ...t up an easy to understand warning sign to stop anybody inadvertent ly switching it back on again using a suitable measuring instrument ensure that electrically charged components e g capacitors have been discharged A safety inspection is required once a year The safety inspection must be carried out by a Fronius trained service technician and includes checking all the safety features of the devic...

Page 63: ...serious injury or damage Maintenance technical inspections and checks must only be carried out by qualified personnel All repairs and maintenance work must be performed exclusively using original replacement parts Any changes to the device or the use of parts that are not original parts requires the approval of the manufacturer If these conditions are not met the manufacturer cannot guarantee the ...

Page 64: ... DC Maximum output current 82 A System efficiency up to 47 Other output data Hydrogen ventilation 10 Nm h 357 14 cfh Hydrogen venting connection 2 1 4 in NPT Hydrogen ventilation line PN 16 231 98 psi 10m DN 15 max 32 ft 9 7 in 0 59 in Concentration of hydrogen in the outgoing air average over one minute 25 LEL Cooling air outlet 700 Nm h 25000 cfh Reaction chamber outgoing pipe DN 50 1 97 in 65 N...

Page 65: ...l Safety Safety standard EN 62282 5 1 2007 Dimensions l x w x h 850 x 470 x 850 mm 33 46 x 18 5 x 33 46 in Weight 125 kg 275 58 lb Permissible ambient temperature 3 C 40 C with 85 rel humidity 37 4 F 104 F Permitted storage temperature 3 C 50 C with 85 rel humidity 37 4 F 122 F Altitude above sea level max 2000 m 6500 ft Must be set up horizontally ...

Page 66: ...ystem voltage 48 56 V DC System efficiency up to 47 Other output data Hydrogen ventilation 10 Nm h 357 14 cfh Hydrogen venting connection 2 1 4 in NPT Hydrogen ventilation line PN 16 231 98 psi 10 m DN 15 max 32 ft 9 7 in 0 59 in Concentration of hydrogen in the outgoing air average over one minute 25 LEL Cooling air outlet 1000 Nm h 35714 cfh Reaction chamber outgoing pipe DN 50 1 97 in 65 Nm h 2...

Page 67: ...l Safety Safety standard EN 62282 5 1 2007 Dimensions l x w x h 850 x 470 x 850 mm 33 46 x 18 5 x 33 46 in Weight 132 kg 291 01 lb Permissible ambient temperature 3 C 40 C with 85 rel humidity 37 4 F 104 F Permitted storage temperature 3 C 50 C with 85 rel humidity 37 4 F 122 F Altitude above sea level max 2000 m 6500 ft Must be set up horizontally ...

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Page 69: ...alheim Günter Fronius Straße 1 Austria E Mail energycell fronius com http www fronius com A Fronius Worldwide www fronius com addresses Under http www fronius com addresses you will find all addresses of our sales branches and partner firms ...

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