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FCM-802/804 User Manual

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Summary of Contents for FCM-802

Page 1: ...FCM 802 804 User Manual Retain for future reference ...

Page 2: ...ible for complying with any relevant health and safety policies and procedures that may apply to the operation of stationary and portable power applications and use and storage of hydrogen on any sites Intelligent Energy warrants to the recipient and it will repair and or replace any defective equipment resulting from the authorised use of the equipment provided Notwithstanding the above Intellige...

Page 3: ... 10 1 Mechanical mounting points 10 2 Mechanical protection and covers 10 3 Mechanical connection to the power terminals 10 4 Mechanical connection to the Ground terminal 10 5 Vibration and shock loads 10 6 Air supply and ventilation 10 7 Hydrogen connection 10 8 Hydrogen fuel physical requirements 11 Maintenance procedures 19 11 1 User maintenance 11 2 Contact Intelligent Energy Product Support T...

Page 4: ...is course of action would not be appropriate where it is intended as the single source of supply or in the provision of critical supplies to for example medical equipment emergency lighting interlocking etc Where the intended use is outside that assessed by Intelligent Energy the customer must assess and design their system appropriately with regard to this limitation 1 1 In case of an emergency S...

Page 5: ...inal cover must always be fitted except during installation and maintenance For use in a ventilated indoor environment or For use in a weather protected outdoor environment must protect from wind and rain ingress Environmental protection required from snow excessive dust and vegetation Do not use FCM if there is water visible on it Do not install equipment above FCM that could release flammable co...

Page 6: ...ns available 6 9 Physical Mass 18kg FCM 802 20kg FCM 804 Max dimensions 448mm W 306mm H 473mm D 10 Connections gas G1 8 parallel BSP threaded port with face seal female Connections electrical Power studs 2 M10 GND Stud 1 M10 1 FCM run input 1 FCM enable input 1 CAN hi low GND 1 30mA driver status 4 PFC Normal operating conditions Altitude 0 4000m 7 9 Operating ambient temperature range 5 C to 40 C...

Page 7: ...it serial number label Earth terminal Power terminals Display screen Air filter Terminal cover Communication port Hydrogen connection Warning label Rating plate Mounting 19 rack Exhaust air Inlet air The key components of the FCM 802 804 are Rear view ...

Page 8: ... the battery is used to provide power whilst the fuel cell starts supports the load during the fuel cell Performance Optimisation Cycle POC and in the standby state Hydrogen gas must be provided at a regulated pressure to the module inlet The FCM 802 804 will generate power when it is given both Enable and Run signals see Section 7 1 7 2 During normal operation the FCM 802 804 will conduct a POC w...

Page 9: ...m output current of the unit acceptable cable voltage drop cable length cable grouping and thermal loading etc The cable runs should be as short and direct as practicable The isolator should be rated for the maximum power deliverable in the installed application See table below Battery bank FCM Enable command FCM running signal FCM Run command External DC load Battery isolator FCM 802 804 FCM 802 ...

Page 10: ...ts Sulphur Hydrocarbons Carbon Monoxide Ammonia Hydrogen fuel The FCM 802 804 must be set up in a well ventilated environment with consideration given to the precautions of hydrogen safety The hydrogen supply needs to be regulated to 650mbar g 150mbar g and maintain the pressure during rapid changes of flow rate When installing and operating hydrogen systems hydrogen general safety guidance must b...

Page 11: ... reference 6 Run Starts the fuel cell 7 Run Positive Power for the start command 8 Status Status indicator 9 Isolated ground Ground pin CAN RTN ground Run Isolated 3 3V Isolated ground Status CAN Lo Enable Isolated 3 3V CAN Hi 6 6 6 7 Communication connection To operate FCM 802 804 communications need to be provided through the D type connector The pins of the connector have the following function...

Page 12: ...w is at a low level for example less than 6 Amps as default for FCM 804 the FCM will go to standby state The battery voltage will be monitored If it drops below the nominal battery voltage user defined Delay Start Under Voltage see 13 Control Parameters the fuel cell will then switch back to running mode FCM 802 804 status A continuous FCM 802 804 status signal via the Communication Connection wil...

Page 13: ... controller off state 3 If the FCM 802 804 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 Standby Auto start criteria Auto stop criteria Starting Shutdown Shutdown Fault trip State map for the FCM 802 804 Power down Power up Enable off Running 7 4 FCM 8...

Page 14: ...M 802 804 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 suspended for up to 12 seconds during the cycle so an external power source may be needed to briefly provide power to the load Standby state As a ...

Page 15: ...urface with four retaining points these must be tightened to a torque not exceeding 25Nm When installing the FCM inspect it and do not install if there is visible damage to the unit Any surfaces in contact with the FCM must not be above 50 C The FCM is 473mm deep 45mm for the connection terminals Allow at least 50mm to the rear of the FCM for the cables pipes to run in It is recommended to mount o...

Page 16: ...d may distort the internal busbars During Electrical maintenance installation the FCM must be off and the load side battery or external power supply must be made safe 1 Two spanners 13mm 2 One to hold first nut to prevent it from rotating Note There is a lock nut at the back holding the stud in place which must not be adjusted 3 The other to tighten the second nut to secure cable conductor termina...

Page 17: ...ust be considerate of other equipment near FCM 802 804 may elevate the local ambient temperature during their operation A local increase of ambient temperature may affect the performance of the fuel cell Do not use if the air has contaminants such as smoke volatile organics or corrosive chemicals present Hot air that is generated by other equipment within 0 6m of the inlet of the FCM 802 804 must ...

Page 18: ...pressure fault of the FCM It is required that the external system has an automatic shut off valve as part of the hydrogen feed line This allows the hydrogen to be isolated at source if required Hydrogen Connection Hydrogen connection The FCM 802 804 requires hydrogen to fuel the electro chemical reaction Connection of the hydrogen fuel will be at the rear of the module The connection type is a fem...

Page 19: ...can perform the following maintenance on the FCM 802 804 Monthly filter inspection Filter change Troubleshooting see below Not performing these basic checks will reduce unit efficiency For all other maintenance tasks contact Intelligent Energy Ltd Contact Intelligent Energy Product Support Team In the event of a fault with the FCM 802 804 please contact the Intelligent Energy Product Support Team ...

Page 20: ...ation Inform IE Product Support of issue Can the leak source be identified Have a gas trained person repair or replace faulty component s Isolate hydrogen source contact IE Product Support Team urgently Have a gas trained person conduct pressure decay test on external hydrogen supply system Isolate hydrogen source contact IE Product Support Team yes yes yes pressure stable no no no pressure droppi...

Page 21: ...d during a purge Has the tank been purged with hydrogen The purity must be 99 9 hydrogen Does the fuel supply meet the fuel requirements Restart FCM Return FCM to operation Inform IE Product Support Team of issue Refuel the hydrogen source application specific Open the hydrogen supply application specific Increase pressure to 650mbar g 150mbar g Reduce pressure to 650mbar 150mbar Isolate hydrogen ...

Page 22: ...it start Return FCM to operation Inform IE Product Support Team of issue Are the batteries at similar voltages yes yes yes no yes yes yes yes Contact IE Product Support Team Charge the battery pack Charge the low cells no no no The FCM operates as a hybrid system Contact IE Product Support Team to discuss Does the design have an external power supply Is the voltage from the power supply within the...

Page 23: ...ity range for operation to Contact IE Product Support Team to discuss Return FCM to operation Inform IE Product Support Team of issue Replace filter yes yes no yes no no no yes 1 Switch off the Enable and Run signals 2 Isolate hydrogen supply 3 Wait 15 minutes 4 Remove two quarter turn thumb screws from the frame on the front of FCM 802 804 5 Remove the retaining clamp 6 Pull top of frame forward ...

Page 24: ...Stop UC Qualification Time s 0 to 3600 20 20 Deny Start Under Voltage V 0 0 to 50 0 20 40 System Index 1 to 8 1 1 Output Voltage Rise Rate V s 0 017 to 2000 00 0 017 0 017 Minimum Output Voltage V 0 0 to 60 0 24 48 Output Current Limit A 0 0 to 80 0 60 80 Hard Set Output Voltage 0 or 1 0 0 Output Power Limit W 0 to 2400 1920 2400 Restart Delay s 0 to 3600 20 20 Control parameters and standard fact...

Page 25: ...lification Time s 0 to 3600 60 60 Delayed Stop Under Current A 0 0 to 120 0 6 6 Delayed Stop UC Qualification Time s 0 to 3600 20 20 Deny Start Under Voltage V 0 0 to 50 0 20 40 System Index 1 to 8 1 1 Output Voltage Rise Rate V s 0 017 to 2000 00 0 017 0 017 Minimum Output Voltage V 0 0 to 60 0 24 48 Output Current Limit A 0 0 to 120 0 105 120 Hard Set Output Voltage 0 or 1 0 0 Output Power Limit...

Page 26: ...tic bag Do not place desiccant inside the plastic bag The FCM 802 804 can be stored in temperatures between 40 C and 70 C However the ideal temperature for storage is between 10 C and 25 C The FCM 802 804 must be protected from moisture and dust during storage The FCM 802 804 hydrogen inlet port must be protected during storage Transportation For transportation follow the guidance for storage taki...

Page 27: ...ts EN 62282 3 100 2012 Fuel cell technologies Stationary fuel cell power systems Safety EN 60204 1 2006 A1 2009 Safety of machinery Electrical equipment of machines 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 4 2007 A1 2011 Electromagne...

Page 28: ...tion and its contents do not include all details which may be relevant to particular circumstances and should not be regarded 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...

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