EFOY 1600 User manual

GB
User Manual UM1
Automatic Charge Control
1600 | 1200 | 900 | 600

2

1. Introduction
3
1. Introduction
1.1
Foreword
Thank you for purchasing an EFOY product. We hope that
you will enjoy your new unit.
Please read these instructions first before using.
Should you have any questions about installation or
operation, please consult the EFOY hotline.
SFC Smart Fuel Cell AG
Eugen-Sänger-Ring 4
D-85649 Brunnthal-Nord
Hotline: [phone]
Freecall: 00800 732 762 78*
Fax: [phone]
[e-mail]
www.efoy.com
*The toll-free number is available in the following
countries: Germany, Belgium, Denmark, France, Great
Britain, Italy, the Netherlands, Norway, Austria, Sweden,
Switzerland and Spain.

1. Introduction
4
1.2
Safety Information
Read the instructions before operating and keep them
nearby. Be sure to follow all directions in the manual.
Do not open unit or fuel cartridges. Do not use force to
open cartridges and do not refill them. Any
modifications to the unit may affect safe operation,
will lead to a loss of license and will void the warranty
Use only original EFOY equipment.
Do not store unit and fuel cartridges at temperatures
above 45° C. Do not operate at temperatures above
40° C. Keep away from heat and direct sunlight.
Store the unit where there is no danger of freezing, or
use the automatic antifreeze feature.
Do not smoke when handling the unit or the fuel
cartridges.
Keep away from heat and open flame.
There is a danger of fire if methanol leaks out
following an accident, or if the unit or the fuel
cartridge has been damaged. Keep away from open
fire and make sure area is well ventilated. Small
amounts of methanol which may leak out will
evaporate without leaving any residue.
Keep unit and fuel cartridges (including empty or
partially filled cartridges) out of children’s reach.
Operate the unit only in accordance with instructions
and keep operating area well ventilated. Do not block
exhaust. Avoid inhaling exhaust fumes directly or for
prolonged periods of time.

1. Introduction
5
There is no risk of coming into contact with methanol
provided that you handle the unit and fuel cartridges in
accordance with instructions.
We are required by law to print the following notice.
Methanol is toxic if inhaled, ingested or if it comes into
contact with skin. Irreparable damage may occur if
inhaled, ingested or if it comes into contact with skin. In
the event of an accident or if nausea occurs, consult a
physician immediately. Be sure to bring the fuel cartridge
label or these instructions to the consultation. (A caution
concerning methanol can be found in the appendix.)
System exhaust may contain harmful components. Avoid
inhaling exhaust directly or for prolonged periods of time.
Use the exhaust hose to conduct exhaust gases to the
exterior.
Improper use or improper connection to other electrical
devices may result in damage.
In addition to these safety instructions, please observe
the passages in bold type. Otherwise, you may endanger
yourself and others.

1. Introduction
6
1.3
Normal Operation
The EFOY 600, EFOY 900, EFOY 1200 and EFOY 1600 are
automatic charging devices for 12V lead batteries.
The unit may be used only to charge lead batteries that
conform to the specifications in Chapter 3.4, S. 12).
The specifications allow for solid-state operation (see
Chapter 3.4) on boats and on motor vehicles. Operate only
with original-equipment EFOY fuel cartridges.
The unit is not intended for emergency medical power
generation, or for powering life-sustaining or agricultural
devices.
Do not operate unit if housing is damaged.
1.4 Declaration of Conformity
SFC Smart Fuel Cell AG, Eugen-Saenger-Ring 4, 85649
Brunnthal-Nord declares that the EFOY 600, EFOY 900,
EFOY 1200 and the EFOY 1600 conform to the European
Community’s 89/336/EWG guidelines for electro-
magnetic compatibility. The following norms apply:
DIN EN 61000-6-1, DIN EN 61000-6-3

1. Introduction
7
1.5 Seals of Approval
These units have been tested in accordance with ECE
Regulation No. 10 for electro-magnetic compatibility.
Operation in motor vehicles is permitted.
Approval number: E24 10R-020234
These units have undergone voluntary testing by TÜV
SÜD for conformity with the basic requirements of IEC
62282-5 and have been awarded the seal of approval for
product safety.
1.6
E 24
Warranty
1. Warranty
SFC provides
a) a 36-month warranty for up to 3,000 hours of
operation. The warranty covers defects caused by
materials or by the manufacturing process, provided
that the manufacturer has a written registration of the
unit on record. The unit must be registered online or by
sending in the warranty card. The unit must be
registered no later than 4 weeks after date of purchase.
Registration is subject to the purchaser agreeing to
have his data recorded by the manufacturer.
b) a 24-month warranty for up to 3,000 hours of
operation. The warranty covers defects caused by
materials or by the manufacturing process should there
be no registration of the unit on record as described in
warranty 1a.
The warranty does not extend to cover improper use of
the unit or operation that is not in accordance with the
user manual, in particular:
If fuel cartridges other than original EFOY fuel
cartridges are used,
Inappropriate handling,
Water damage,
Improper transportation,
If the unit has been opened.

1. Introduction
8
2. Extent of the warranty
The warranty covers defects (see 1. Warranty) from the
time of sale.
The manufacturer shall remedy such defects by either
repair or replacement (updated model where
applicable) as he deems appropriate. Should the
manufacturer provide a warranty, the warranty period
with regard to repair or replacement parts shall not
recommence from the time of service. Instead, the
warranty from time of sale will remain in force. Any
other claims, in particular claims for damages on the
part of the purchaser or a third party, are invalid. The
provisions of the product liability law remain in effect as
well as any claims against the manufacturer pertaining
to warrantees remain in force as provide by law. The
warranty does not extend to any extra costs associated
with mounting or dismounting the unit such as
disassembling furniture or parts of a motor vehicle.
3. In Case of Claim
Always notify the EFOY service center in writing in case
of malfunction. Please describe the defect in detail.
Please also indicate serial number and include the
original invoice. The purchaser must bring or send the
unit to the manufacturer at his own risk so that the
manufacturer can determine whether the defect is
covered by the warranty. The unit must be sent to the
factory as freight. If the defect is covered by the
warranty, the factory shall assume the transportation
costs. Should the defect not be covered by warranty, the
manufacturer shall notify the customer, informing the
customer of what repair costs the manufacturer shall
not assume. The customer shall bear the cost of
transportation in this case.

1. Introduction
9
The manufacturer’s address is:
SFC Smart Fuel Cell AG
Eugen-Saenger-Ring 4
D-85649 Brunnthal
Tel.: +49 89 / 673 59 20
Free Call: 00800 / 73 27 62 78**
Fax.: +49 89 / 673 592 369
[e-mail]
www.efoy.com
Service
EFOY customer service is available for technical
inquiries concerning EFOY fuel cells during normal
business hours at the following numbers:
Toll-free number: 00800/73 27 62 78*
If calling from outside the countries listed below,
please dial +49 89 / 673 5920
*The toll-free number is available in the following
countries: Germany, Austria, Belgium, Denmark,
France, Great Britain, Italy, the Netherlands, Norway,
Spain, Sweden and Switzerland.

1. Introduction
10
1.7
Disposal
Packaging
Packaging protects your unit during shipping. All
materials used are environmentally compatible and
recyclable.
We recommend saving the packaging for eventual
winter storage.
Should you nevertheless wish to dispose of the
packaging, please do so properly.
Your dealer or your local recycling center can provide
information about proper disposal.
Danger of Suffocation!
Keep packaging away from children. Plastic wrapping
and cartons may cause suffocation.
Fuel Cartridges
Sort empty fuel cartridges with plastics. Dispose of
partly filled fuel cartridges in the same manner as
solvents or paint.
Old Units
Old units are still valuable! Proper disposal can yield
valuable raw materials while protecting the
environment.
The EFOY hotline:
Tel.: [phone] or 00800 732 762 78*
can advise you about returning old units.

2. Table of Contents
11
2. Table of Contents
1. Introduction 3
1.1 Foreword 3
1.2 Safety Information 4
1.3 Normal Operation 6
1.4 Declaration of Conformity 6
1.5 Seals of Approval 7
1.6 Warranty 7
1.7 Disposal 10
2. Table of Contents 11
3. Configuration 13
3.1 Standard Equipment 13
3.2 Overview 14
3.3 Remote Control 14
3.4 Specifications 15
4. Installation 17
4.1 Tools and Materials 17
4.2 Space Requirements 18
4.3 Securing the unit 20
4.4 Off-heat duct 21
4.5 Installing the fuel-cartridge holder 23
4.6 Electrical Connections 24
4.7 Connecting the Remote Control 30
5. Operation 32
5.1 Connecting the Fuel Cartridge 32
5.2 Automatic Operation 34
5.3 Switching on the Fuel Cell 35
5.4 Display Information 35
5.5 Select Language 37
5.6 Switching Off the Fuel Cell 37
5.7 Automatic Antifreeze Feature 38
5.8 Storage 39
6. Maintenance 41
6.1 Service 41
6.2 Cleaning 41

2. Table of Contents
12
7. Troubleshooting 42
7.1 Safety 42
7.2 Problems and Solutions 43
7.3 Problems without Error Messages 46
7.4 Changing the Fuse 47
7.5 Replacing Service Fluid 48
8. Appendix 49
8.1 Accessories and Spare Parts 49
8.2 Output characteristic 50
8.3 Material Safety Data Sheet Methanol 52

3. Configuration
13
3. Configuration
3.1 Standard Equipment
The following is standard equipment:
Unit
Remote control with data line RC1
Fuel-cartridge holder with belt FH 1
Mounting plate with belt MP 1
Exhaust hose (1.5 m) EH 1
Charge line
Service-Kit
UM1 user manual
Unit
Remote control with data
line RC1
Fuel-cartridge holder with
belt
FH1
Mounting plate with belt MP1
Eexhaust hose EH1
Off-heat duct OD1
Service kit
Connecting line to fuel-cell 1m
Battery fuse power 7.5A Battery fuse sense 2A

3. Configuration
14
3.2 Overview
1 Charge line connection
2 Remote-control connection RC 1
3 Data interface
4 G-fuse 250V 8A M, 5 x 20 mm
5 Fuel-cartridge connection
6 Connection for EH 1 exhaust hose and nozzle for
service fluid
7 Cooling inlet (reverse)
8 Warm-air outlet and connection for off-heat duct
3.3 Remote Control
auto
reset
!
1Display
2Information button and language-selection button >>
3On/Off button
4Button for automatic operation auto
5Yellow warning light “Please change fuel cartridge“
6Red error warning light
7Reset button reset

3. Configuration
15
3.4 Specifications
Performance
Product EFOY 600 EFOY 900 EFOY 1200 EFOY 1600
Rating 25 W 38 W 50 W 65 W
Charge capacity 600 Wh/Day
(50 Ah/Day)
900 Wh/Day
(75 Ah/Day)
1200 Wh/Day
(100 Ah/Day)
1600 Wh/Day
(130 Ah/Day)
Nominal voltage 12 V 12 V 12 V 12 V
Charging current @ 12 V 2.1 A 3,1 A 4.2 A 5.4 A
Turn on threshold* Ubatt < 12.3 V Ubatt < 12.3 V Ubatt < 12.3 V Ubatt < 12.3 V
Cut off threshold* Ubatt >14.2 V
and
Iout < 2.0 A
Ubatt >14.2 V
and
Iout < 2.0 A
Ubatt >14.2 V
and
Iout < 2.0 A
Ubatt >14.2 V
and
Iout < 2.0 A
Required starting voltage > 10.8 V > 10.8 V > 10.8 V > 10.8 V
Quiescent current
requirement 15 mA 15 mA 15 mA 15 mA
Methanol requirement 1.1 l/kWh 1.1 l/kWh 1.1 l/kWh 1.1 l/kWh
Compatible batteries 12 V rechargeable (lead-acid or lead-gel) batteries
10 to 100 Ah 15 to 150 Ah 20 to 200 Ah 25 to 250 Ah
General Specifications
Sound pressure level at 7 m 23 dB(A) 23 dB(A) 23 dB(A) 23 dB(A)
Weight 6,3 kg 7,1 kg 7,1 kg 7,3 kg
Dimensions (L x W x H) 43,5 x 20,0 x 27,6 cm
* factory setting

3. Configuration
16
Environmental conditions
Space requirement (L x W x H)
51 x 35 x 30 cm minimum
continual: 35°Inclination along the direct
axis temporary (<10 min): 45°
Inclination along the
quadrature axis
continual: 20°
Operating temperature -20 to +40 °C
Start temperature +5 to +40 °C
Storage temperature +1 to +45 °C
Instrumentation
Operation via remote control with four buttons and multilingual display
Electrical interface MNL 4-prong plug
Type Tyco Electronics AMP Universal Mate-N-Lok (Mfr. No.
350779)
Fuse G fuse 250V 8.0A M, 5 x 20 mm
Fuel Cartridge M5 M10
Volume 5 liter 10 liter
Weight 4.3 kg 8.4 kg
Dimensions (L x W x H) 19.0 x 14.5 x 28.3 cm 23.0 x 19.3 x 31.8 cm

4. Installation
17
4. Installation
Securely fasten unit and fuel cartridges when using on
board motor vehicles.
Do not operate unit if there is danger of explosion.
Unit is not watertight. Make sure that no water can
enter.
Keep unit and fuel cartridges away from children,
temperatures in excess of 45° C and direct sunlight.
4.1 Tools and Materials
You will need the following tools and sealants to install
the fuel cell in an RV:
electric drill
jigsaw
screwdriver
hexagonal (Allen) wrench
sealant such as Sikaflex
Use the following screws, depending on the mounting
surface (screws are not included):
8 screws to attach the mounting plate
4 screws to attach the remote control
4 screws to attach the fuel-cartridge holder
cable clamps and fixing screws, if needed

4. Installation
18
4.2 Space Requirements
Installation should be carried out by trained personnel
only. Wear proper work clothes. Avoid flowing
garments and wear a hair net if you have long hair.
Clothing and hair can get caught in moving or rotating
parts such as in a drill.
Be sure to leave enough space behind the installation
area when drilling or cutting out openings. Also be sure
to follow the tool manufacturer’s safety instructions.
Solvents used in sealants may emit fumes. Make sure
that there is sufficient ventilation and follow the
instructions for the sealing compound.
Make sure when choosing a location, that the
temperature ranges between –20° C and +40° C.
This unit generates heat, thus requiring ventilation.
Please take this into account when considering
possible locations.
min.
10 cm
Zuluft
Provide for a vent opening measuring at least 10 cm
across when installing. Use the off-heat duct (included)
to remove warm air.
Install only in upright position. Use the mounting plate
(included).
cooling
air

4. Installation
19
Make sure that the device does not exceed the
maximum inclination.
Inclination along the direct axis:
continual: 35°
temporary (<10min): 45°
Inclination along the quadrature axis:
continual: 20°
All electrical connections, the fill opening for service
fluid and the fuel cartridge should be easily accessible.
max. 30 cm
Make sure that the fuel cartridge is located within
reach of the connecting hose (30 cm) and that the hose
is neither kinked nor crushed.
The fuel-cartridge hose and the exhaust hose may not
be damaged. Do not substitute another hose for either
of the two.
Use only original-equipment EFOY hoses.

4. Installation
20
4.3 Locations
1
23
Ideas for installation:
1 false floor or side compartment
2 seat bench
3 rear storage area
4.4 Securing the unit
Select a suitable location as described in Chapter 4.2,
paying attention to the dimensions in Chapter 3.4.
1. Run the belt in the groove under the mounting plate.
2. Secure the mounting plate tightly to the desired
location. Use eight proper screws and dowels, if
necessary, so that the mounting plate cannot shake
loose in case of an accident.
3. Place the unit onto the mounting plate.