FRO­NIUS 25F User manual

25F/50F Energy cell Operating Instructions
/ Battery Charging Systems / Welding Technology / Solar Electronics
Energy cell
EN
42,0410,1562 006-11022013

ud_fr_st_et_00493 01/2012
EN
Dear Reader
Thank you for choosing Fronius - and congratulations on your new, technically high-
grade Fronius product! This instruction manual will help you get to know your new
machine. Read the manual carefully and you will soon be familiar with all the many
great 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 - things
which are both essential prerequisites for getting outstanding results.
Introduction

I
EN
Safety rules
DANGER!
WARNING!
CAUTION!
„NOTE!“ indicates a risk of flawed results and possible damage to the
equipment.
NOTE!
The device is manufactured using state-of-the-art technology and according
to recognised safety standards. If used incorrectly or misused, however, it
can cause
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the opera-
tor,
- inefficient operation of the device.
All persons involved in commissioning, operating, maintaining and servicing
the device must
- be suitably qualified,
- have knowledge of and experience in dealing with
gas installations
electrical installations
batteries
- read and follow these operating instructions carefully.
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 precautions are not taken.
„CAUTION!“ indicates a situation where damage or injury could occur. If it
is not avoided, minor injury and/or damage to property may result.
„Important!“ highlights tips for correct operation and other particularly useful
information. It does not indicate a potentially damaging or dangerous situati-
on.
If you see any of the symbols depicted in the „Safety rules“, special care is
required.
„DANGER!“ indicates immediate and real danger. If it is not avoided, death
or serious injury will result.

II
The device is to be used exclusively for its intended purpose.
Utilisation for any other purpose, or in any other manner, shall be deemed to
be „not in accordance with the intended purpose“. The manufacturer shall
not be liable for any damage resulting from such improper use.
Utilisation in accordance with the „intended purpose“ also comprises
- that the device is undamaged and in perfect condition
- carefully reading and obeying all the instructions in these operating
instructions, especially the safety rules and all safety and danger notices
- setting up and installing according to the operating instructions
- performing all stipulated inspection and servicing work
- observing all advice from the manufacturer regarding gas supply com-
ponents
- observing all advice from the battery manufacturer
- obeying other relevant national safety rules
The device may not be used if any part has been submerged in or flooded
with water. 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 device, refer to the
section headed „General remarks“ in the operating instructions for the
device.
Before switching on the device, remove any faults that could compromise
safety.
Your personal safety is at stake!
General remarks
(continued)
CAUTION! Operating the device in frost or wet conditions can
result in damage. The device may only be used in a frost-free, dry
environment.
Safety measures
at the installation
location
When installing devices with openings for cooling air, ensure that the cooling air can
enter and exit unhindered through the air ducts. Only operate the device in accordance
with the degree of protection shown on the rating plate. Refer to the „Setup regulations“
chapter in the device operating instructions

III
EN
Operation or storage of the device outside the stipulated environmental
conditions will be deemed to be not in accordance with the intended purpo-
se. The manufacturer shall not be liable for any damage resulting from such
improper use.
For exact information on permitted environmental conditions, please refer to
the „Technical data“ chapter.
The ambient air must be clean and free from
- potential sources of ignition
- smoke
- open flames and fire
- flammable materials
- petrol and other combustible liquids or vapours
- dust
- acids
- corrosive gases or substances
Height above sea level: up to 2000 m (6500 ft)
Environmental
conditions
Safe use The operating instructions are primarily aimed at system integrators who
use the energy cells as components in a larger system. The contents are
therefore intended for qualified personnel. An electric shock can be fatal. Do
not perform any actions other than those 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
plan in the „Commissioning“ chapter. Maintenance and repair work on the
hydrogen supply must be carried out according to the relevant standards
and national regulations. The technical data shown on the rating plate
applies.
Maintenance and repair work on the device may only be carried out by
manufacturer-authorised personnel.
It is impossible to guarantee that bought-in parts are designed and manuf-
actured to suit their application, or that they satisfy safety requirements. Use
only original replacement parts (also applies to standard parts).
Do not carry out any modifications, alterations, etc. without the
manufacturer’s consent.
Components that are not in perfect condition must be replaced immediately.

IV
The fuel is supplied in the form of gaseous hydrogen. Hydrogen is a dange-
rous substance, which requires great care when handling. Further informati-
on on handling hydrogen can be found in the EU RL 91/155 EEC and 93/
112 EU safety data sheets.
Only use the device in well ventilated areas to prevent the accumulation of
explosive gas. Spaces are not deemed to be at risk of explosion if a concen-
tration of hydrogen of less than 4 % can be guaranteed by the use of natural
or forced ventilation.
Connect suitable hydrogen ventilation lines to the screw connections provi-
ded as described in the „Commissioning“ section and run them into the
open air to dissipate the excess hydrogen in the event of overpressure in
the hydrogen supply.
The unit should be set up so that it is independent of the surrounding air.
This means that the reaction and cooling air is supplied from the atmosphe-
re and the outgoing air from the reaction chamber and cooling system is
dissipated into the atmosphere.
If such a setup is not possible, operating the device to use ambient air is
only permitted:
- if protective grilles are fitted to the housing openings for the inlet and
outlet cooling air (factory setting)
- if there is sufficient ventilation
- in rooms with a volume of more than 130 m³
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 build-up of explosive acids and gasses that are detrimental to
the health, possible risk of suffocation due to lack of oxygen in the air,
danger from output current, etc.)
- provide suitable protective equipment.
Before leaving the work area, ensure that no-one and nothing can come to
any harm in your absence.
Protecting
yourself and
others
CAUTION! Danger of suffocation when the unit is operated in
areas with inadequate ventilation (uses up the oxygen). Ensure
an adequate supply of fresh air.
Using the device in spaces with inadequate ventilation can cause suffocati-
on with no visible or otherwise detectable warning. The cause of this is the
oxygen consumption of the device, which can lead to a lack of oxygen in the
room if it is inadequately ventilated. Setting up the device to take in and
expel air into the atmosphere rather than the room helps prevent this. For
more information on this, see the chapter entitled „Commissioning“.

V
EN
Care must be taken during installation to ensure that no electromagnetic
interference occurs in electrical and electronic devices.
EMC measures
Electrical instal-
lations
Electrical installations must only be set up set up to the relevant national
and local standards and regulations.
Only operate the device when all protection devices are fully functional. If
the protection devices are not fully functional, there is a risk of
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the opera-
tor,
- inefficient operation of the device.
Any safety equipment that is not in full working order must be repaired by
the manufacturer before the unit is switched on.
Never bypass or 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 surrounding air
- Ensure that the cooling air can enter and exit the unit unhindered
- Always fix hydrogen cylinders in place securely and fit a protective cap
before transporting
- Refer to the „Care, maintenance and disposal“ chapter in the unit’s
operating instructions
- Regularly check the unit and its accessories for obvious damage and
proper functioning of safety equipment
- Never run the unit if there is any evidence of damage
- Only operate the unit with the degree of protection shown on the rating
plate
Safety measures
in normal mode

VI
Batteries contain acid which is harmful to the eyes and skin. During char-
ging, gases and vapours are released that can harm health and are highly
explosive in certain circumstances.
Battery acid must not get into the eyes or onto the skin or clothes. Wear
protective goggles and suitable protective clothing. Rinse any acid splashes
with copious amounts of clean water, seek medical advice if necessary.
Danger from
batteries
On no account inhale any of the gases and vapours released
To prevent short circuits, do not place any tools or conductive metals on the
battery
General informa-
tion regarding
the handling of
batteries
- Follow the manufacturer’s advice
- Observe the manufacturer’s safety regulations during installation, opera-
tion, maintenance and repair
- Equip batteries with the correct fuse in order to avoid damage 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 cells
caused by a possible fault.
- heating of the battery over 55 °C (131 °F).
Keep hands, hair, clothing and tools away from moving parts, for example
fans.
The cover of the electrical connection compartment may only be removed
by trained personnel. All other covers and housing in general may only be
opened/removed by trained manufacturer’s personnel. Unauthorised ope-
ning or manipulation of the device will invalidate the guarantee and holds
the risk of serious damage to people and property.
The moist outgoing air from the reaction chamber can reach a temperature
of up to 70 °C (158 °F), which can scald.
Specific areas of
risk

VII
EN
If the device is equipped with pressure tanks with hydrogen, all safety
regulations for pressure tanks should be observed.
Pressure tanks contain gas under pressure and can explode if damaged.
They must therefore be handled with great care.
Protect the pressure tank from excessive heat, mechanical impact, naked
flames, sparks and arcs.
Mount the pressure tank vertically and secure according to instructions to
prevent it falling over.
Keep pressure tank away from electrical circuits.
Always use suitable pressure vessels that are approved for the application
along with suitable, approved accessories (regulator, hoses and fitting). All
pressure vessels and accessories used must be in perfect condition.
If the device remains out of operation for a long period, close the valve of
the pressure tank.
If the pressure tank is not connected, 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 following:
- Use of the device „not in accordance with the intended purpose“
- Improper installation and operation
- Operating the device with faulty protective equipment
- Non-compliance with the operating instructions
- Unauthorised modifications to the device
- Catastrophes caused by foreign objects and force majeure
Warranty and
liability
A safety inspection must be carried out by a qualified expert
- before using for the first time
- after any changes are made
- after additional parts are installed or after any conversions
- after repair, care and maintenance has been carried out
- at least every twelve months.
Carrying out a
safety inspection

VIII
The user is responsible for the safekeeping of any changes made to the
factory settings. The manufacturer accepts no liability for any deleted
personal settings.
Data protection
Devices with the CE marking satisfy the essential requirements of the
Machinery and EMC Directives. (Further details can be found in the appen-
dix or the chapter entitled „Technical data“ in your documentation).
Safety symbols
Do not dispose of this device with normal domestic waste!
To comply with the European Directive 2002/96/EC on Waste Electrical and
Electronic Equipment and its implementation as national law, electrical
equipment that has reached the end of its life must be collected separately
and returned to an approved recycling facility. Any device that you no longer
require must be returned to your dealer, or find out about the approved
collection and recycling facilities in your area.
Ignoring this European Directive may have potentially adverse affects on the
environment and your health!
Disposal
The device has been tested at the manufacturer’s voluntary request by TÜV
SÜD for compliance with the requirements of EN 62282-5-1 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 and international standards and directives when che-
cking the safety of the entire system.
Maintenance, technical inspections and checks must only be carried out by qualified
personnel (service organisations) who have been trained in the safety and maintenance
of these devices. In addition, all repair and maintenance work must be performed
exclusively using original replacement parts. All changes to the device and the use of
parts that are not original replacement parts may only be made with the approval of the
manufacturer.
If these conditions are not met, the manufacturer cannot guarantee the safety of the
device. Starting up the device without having performed safety-related maintenance
work is done at your own risk.
The manufacturer therefore accepts no liability for damage caused by inadequate
maintenance carried out by a third party or by the non-performance of maintenance.
Carrying out a
safety inspection
(continued)

IX
EN
Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of going 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

1
EN
Contents
General .......................................................................................................................................................... 3
Functionality and device concept .............................................................................................................. 3
Advantages ............................................................................................................................................... 3
Features .................................................................................................................................................... 3
Inputs and outputs ..................................................................................................................................... 4
Warning notices on the device .................................................................................................................. 4
Control elements and connections ................................................................................................................. 6
Safety ........................................................................................................................................................ 6
Housing front panel ................................................................................................................................... 6
Housing rear panel - overview of process connections ............................................................................. 8
Layout of process connections................................................................................................................ 10
Before commissioning ...................................................................................................................................11
Safety .......................................................................................................................................................11
Proper use ...............................................................................................................................................11
Setup regulations ..................................................................................................................................... 11
Connections ............................................................................................................................................ 12
Before using for the first time .................................................................................................................. 12
Commissioning............................................................................................................................................. 13
Safety ...................................................................................................................................................... 13
Advance information ............................................................................................................................... 13
Preparation for installation....................................................................................................................... 13
Wiring terminals for DC power and earthing (X0).................................................................................... 14
Wiring terminals for safety-related inputs and outputs (X2).....................................................................15
Wiring up terminals for inputs and outputs .............................................................................................. 16
Wiring the service interface ..................................................................................................................... 18
Setup independent of surrounding 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
Operating conditions ............................................................................................................................... 26
Switching the energy cell to standby ....................................................................................................... 26
Manual mode .......................................................................................................................................... 27
Manual mode: starting the energy cell .................................................................................................... 27
Manual mode: switching off the energy cell ............................................................................................ 27
Automatic mode ...................................................................................................................................... 27
Automatic mode: starting the energy cell ................................................................................................ 27
Automatic mode: switching off the energy cell ........................................................................................ 28
Charging characteristic for the connected battery ................................................................................... 28
Display ......................................................................................................................................................... 29
The display .............................................................................................................................................. 29
System display ........................................................................................................................................ 29
Favourites display ................................................................................................................................... 29
System control ........................................................................................................................................ 29
Tank indicator .......................................................................................................................................... 29
Battery display......................................................................................................................................... 30
Service .................................................................................................................................................... 30
Warnings ................................................................................................................................................. 30
Keypad .................................................................................................................................................... 31
Navigation ............................................................................................................................................... 31
Error list ................................................................................................................................................... 32

2
Error display ............................................................................................................................................ 32
Overview ................................................................................................................................................. 33
Detailed description of the System display.............................................................................................. 34
Detailed description of the Favourites display ......................................................................................... 35
Displaying measured values ................................................................................................................... 36
Configuration ........................................................................................................................................... 36
Changing the favourites .......................................................................................................................... 37
Configuration of the tank indicator........................................................................................................... 37
Configuration of external analogue sensor inputs ................................................................................... 39
Overview and explanation of 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 operating hours ...................................................................................... 48
Disposal .................................................................................................................................................. 48
Technical data .............................................................................................................................................. 49
Fronius Energy Cell 25F ......................................................................................................................... 49
Fronius Energy Cell 50F ......................................................................................................................... 51
Fronius Worldwide

3
EN
Features - Fuel cell-based generator
PEM type (polymer electrolyte membrane)
- Easy to use
- High standard of safety due to explosion protection integrated into the device
- High degree of efficiency
- Quiet, low-maintenance operation
- Interface for data communication
General
Functionality and
device concept
The energy cell generates electrical
energy from hydrogen and oxygen in the
surrounding air according to the fuel cell
principle. The electrochemical unit in the
device consists of several individual cells
connected in series. A digital control unit
supplies it with hydrogen and air in the
appropriate ratio and maintains the
operating temperature.
When used correctly, hydrogen is a safe
source of energy. The energy cell has a
range of safety features that comply with
all applicable standards. The explosion
protection requirements are covered by
precautionary measures integrated into
the device 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 converts the chemically-bound energy of the hydrogen directly into
electrical power. The hydrogen consumption is therefore very low.
Hydrogen is an ideal energy source that effectively stores solar energy over the long
term and makes it available 24/7, 365 days a year. This means, for example, that a
mains-independent photovoltaic system no longer has to be designed to take account
of peak winter requirements. In this way, the energy cell can be used as the basis for
setting up a cost-optimised and reliable stand-alone supply.
In view of the dwindling energy resources and the need for environmentally-friendly
energy sourcing, the energy cell sets the bar for energy efficiency and zero emissions.
Benefits

4
Fig. 2 Inputs and outputs, data communication
The energy cell is fitted with safety symbols and a rating plate. The safety symbols and
rating plate must not be removed or painted over.
Fig. 3a Rating plate and safety symbols on the reaction chamber outgoing pipe
CAUTION! Danger of burns from hot outgoing pipe (1) and risk of scalding
from hot, moist reaction chamber outgoing air. This can reach temperatures
of up to 70 °C (158 °F). During operation:
- do not touch the outgoing pipe (1)
- keep away from the reaction chamber outgoing air
(1)
Inputs and out-
puts
Warning 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 Nm³/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.
I BATT max.
P el. nom.
U DC nom.
Cooling air
Electrical output
Energy cell 25F: 24 V DC, 2 kW
Energy cell 50F: 48 V DC, 4 kW
Battery /
primary supply for
standby and start
Energy cell 25F: 24 V
Energy cell 50F: 48 V
External Emergency Stop
Digital inputs and outputs
Analogue inputs
Service interface
USB-B
RS485
Hydrogen 5.0
Reaction chamber outgoing air
Reaction condensate
(deionised water, non-potable)
Cooling air outlet
Combustion air
(3.0 available on
request)

5
EN
Warning notices
on the device
(continued)
Fig. 3b Safety symbol on the protective grille
WARNING! Inadequate ventilation increases the risk of fire, explosion and
suffocation. The device should 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 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 (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 m³
- the outgoing air from the reaction chamber is dissipated into the atmos-
phere to avoid oxygen depletion in the surrounding air
(1)
NOTE! The illustration shows only one protective grille. Both grilles are re-
quired for operation independent of the surrounding air. See the „Commissio-
ning“ section for more information on setting up the device independently of
the surrounding air.
WARNING
Do not operate the device
without protective covering!

6
Housing front
panel No. Function
(1) Emergency Stop
Immediately interrupts the power
generation in an emergency.
When the energy cell is integrated
into a system, the Emergency Stop
button is to be removed from the
device by a Fronius-trained service
engineer.
(2) USB-B interface
For reading operating data using the
software tool (available from the
manufacturer)
(3) Keylock switch
For switching the energy cell on and
off manually
(4) Display
Instructions for the user. Also displays
relevant operating data.
(5) Keypad
For navigating around the display
(6) Terminals X2 for safety-related
inputs and outputs
(7) Terminals X3 and X4 for inputs and
outputs
Control elements and connections
WARNING! Incorrect operation may result in serious injury or damage. Do
not use the functions described here until you have thoroughly read 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 device, but
these controls function in exactly the same way. If you have any further questi-
ons, please contact the manufacturer.
In the rest of these instructions, the device is shown with the cover over the electrical
connection compartment removed.
WARNING! Work carried out incorrectly and electric shocks can have fatal
results.
- The cover over the electrical connection compartment must only be
removed by a trained technician
- Before removing the cover, make sure that you have thoroughly read
and understood the safety instructions in the “Commissioning” section.
Safety
(6)
(7)
(8)
Fig. 4 Housing front panel
(4)(3)(2)(1)
(5)
(9)
(10)
(11)