FRO­NIUS HyLOG Fleet 24015F User manual

/ Perfect Charging / Perfect Welding / Solar Energy
42,0426,0271,EN 003-22112018
HyLOG Fleet
24015F
Operating Instructions
Energy cell
EN

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3
EN
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.

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EN
Contents
Safety rules ................................................................................................................................................ 7
Explanation of safety symbols .............................................................................................................. 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 8
Safety measures in operation ............................................................................................................... 9
Environmental conditions...................................................................................................................... 9
Safe use................................................................................................................................................ 9
Protecting yourself and others .............................................................................................................. 10
Danger from gases, hazardous materials and suffocation.................................................................... 10
Safety measures in normal operation ................................................................................................... 10
Specific hazards.................................................................................................................................... 11
General information regarding the handling of batteries....................................................................... 11
Danger from batteries ........................................................................................................................... 11
Danger from pressure vessels .............................................................................................................. 11
Warranty and liability............................................................................................................................. 12
Safety inspection................................................................................................................................... 12
Safety symbols...................................................................................................................................... 12
Disposal ................................................................................................................................................ 12
Copyright............................................................................................................................................... 13
General ...................................................................................................................................................... 14
Functionality and device concept.......................................................................................................... 14
Advantages ........................................................................................................................................... 14
Properties.............................................................................................................................................. 15
System configuration ............................................................................................................................ 15
Warning notices on the device.............................................................................................................. 16
Control elements and connections............................................................................................................. 18
Safety.................................................................................................................................................... 18
Controls and connections ..................................................................................................................... 18
Control panel......................................................................................................................................... 20
Before commissioning................................................................................................................................ 23
Safety.................................................................................................................................................... 23
Proper use/intended purpose................................................................................................................ 23
Before using for the first time ................................................................................................................ 24
Connections .......................................................................................................................................... 24
Start-up ...................................................................................................................................................... 26
Safety.................................................................................................................................................... 26
Advance information ............................................................................................................................. 26
Connecting the power interface to the vehicle ...................................................................................... 26
Pin assignment for the vehicle connection............................................................................................ 27
Specification for the vehicle connection................................................................................................ 27
Potential Equalization ........................................................................................................................... 28
Application example for the vehicle connection .................................................................................... 28
Refuelling ................................................................................................................................................... 29
Safety.................................................................................................................................................... 29
General ................................................................................................................................................. 29
General refuelling.................................................................................................................................. 29
Time-optimised refuelling...................................................................................................................... 30
Pressure tolerances .............................................................................................................................. 32
Refuelling process ................................................................................................................................ 32
Operation ................................................................................................................................................... 33
Safety.................................................................................................................................................... 33
Operating conditions ............................................................................................................................. 33
Starting energy delivery ........................................................................................................................ 34
Stopping energy delivery ...................................................................................................................... 34
Troubleshooting ......................................................................................................................................... 35
Safety.................................................................................................................................................... 35
Fault diagnosis...................................................................................................................................... 35
Displayed service codes ....................................................................................................................... 36
Care, maintenance and disposal ............................................................................................................... 38
Safety.................................................................................................................................................... 38

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Minimum maintenance work ................................................................................................................. 39
Once a year / every 1000 operating hours............................................................................................ 39
Annual safety inspection ....................................................................................................................... 39
Maintenance work every 1000 operating hours ....................................................................................40
Service life ............................................................................................................................................ 40
Pressure equipment.............................................................................................................................. 40
Disposal ................................................................................................................................................ 40
Technical data............................................................................................................................................ 41
HyLOG Fleet 24015F............................................................................................................................ 41

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EN
Safety rules
Explanation of
safety symbols DANGER!
Indicates immediate and real danger.
If it is not avoided, death or serious injury will result.
WARNING!
Indicates a potentially 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.
NOTE!
Indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT!
Indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety rules" chapter, special care is re-
quired.
General 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 operator,
- inefficient operation of the device
According to the extent to which they are operating and using the device, all users (drivers,
service personnel, etc.) must
- be suitably qualified
- be trained
- 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, attention must also be paid to any generally appli-
cable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device:
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.

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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.
The following problems can result in safety issues, and must therefore be resolved before
the device is commissioned:
- dirty or blocked cooling air inlet
- power connector connected incorrectly
This is for your personal safety!
These Operating Instructions are concerned only with the vehicle's energy delivery system
and describe the technical and safety-relevant interfaces on the vehicle relating to energy
delivery.
The overall safety of the system (HyLOG Fleet device, vehicle and its operation in a work-
ing area) is the responsibility of the vehicle manufacturer / system integrator. The vehicle
manufacturer / system integrator is the manufacturer of the logistics vehicle that installs the
energy cell in the vehicle and is responsible for the conformity of the system as a whole.
The overall system safety encompasses:
- Weight compensation (driving stability, traction, etc.)
- Information provided to the driver and surrounding area concerning safety-relevant
operating states of the energy cell (warning of hydrogen leak, etc.)
- Analysis of overall system safety and supply of general system user documentation
(energy cell and vehicle) adapted for use of the vehicle with the HyLOG Fleet energy
cell.
Proper use The device is to be used exclusively for its intended purpose.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.
Proper use includes:
- ensuring that the device is undamaged and in perfect condition
- carefully reading and obeying all the instructions in these operating instructions, espe-
cially the safety rules and all safety and danger notices
- installing the device in accordance with the vehicle manufacturer's operating instruc-
tions
- carrying out all the specified inspection and maintenance work *
- observing all instructions of the vehicle manufacturer and the refuelling system man-
ufacturer
- obeying other relevant national safety rules
Inspection and maintenance work form part of the responsibility of the operator. However,
the operator may arrange for the manufacturer of the vehicle or the fuel cell system to per-
form inspection and maintenance work (e.g. as part of a maintenance agreement).
The device must only be operated in rooms with a volume of more than 10 m³ (353.15 ft³)
and with an air circulation rate of not less than 0.6/h. With a room volume of 10 m³ (353.15
ft³), an air circulation rate of 0.6/h means that 6 m³ (211.89 ft³) of air are renewed per hour.
The device may not be used if any part has been submerged in or flooded with water. Notify
the manufacturer or its representative immediately so that the device can be checked and
any affected parts replaced.
The device must not be used in conditions of frost or (condensing) humidity. Operating the
device in frosty or humid conditions can result in damage. Only use the device in rooms
that are free from frost and condensing air. Detailed information can be found in the "Tech-
nical data" chapter.

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EN
Remove the device before washing the vehicle. Never clean the device itself with water,
liquid detergents or steam cleaners.
Information on cleaning the device can be found in the "Care, maintenance and disposal"
chapter.
Safety measures
in operation
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 charger in accordance with the
degree of protection shown on the rating plate. Observe the "Operating conditions" chapter
of the device operating instructions.
Environmental
conditions Operation or storage of the device outside the stipulated environmental conditions will be
deemed to be not in accordance with the intended purpose. The manufacturer shall not be
held liable for any damage arising from such usage.
Additional information on the permitted environmental conditions can be found in the
"Technical data" chapter.
The surrounding air must be clean and free from
- possible ignition sources
- smoke
- naked flames and light
- petrol and other flammable materials in the form of liquids, vapours or electrically con-
ductive dusts, e.g. metallic powder
- corrosive gases or substances
Can be used at altitudes of up to 1600 m (5249 ft.)
Safe use The operating instructions are primarily intended for system integrators who incorporate
the device as a component into an overall vehicle. The contents are therefore intended for
qualified personnel.
The user must have received verifiable training from a qualified technician authorised by
the manufacturer.
The user must also observe all warning notices of the vehicle supplier and for the hydrogen
refuelling system.
An electric shock can be fatal. Do not perform any actions other than those described in
this documentation. All cables and leads must be secured, undamaged, insulated and ad-
equately dimensioned. Loose connections, scorched, damaged or inadequately dimen-
sioned cables and leads must be immediately repaired by authorised personnel.
Leaks in the hydrogen supply, in combination with an ignition source, pose a risk of fire and
explosion. The hydrogen refuelling system must therefore be set up in compliance with the
applicable standards and guidelines and operated in accordance with the manufacturer's
instructions. The technical data shown on the rating plate applies.
Maintenance and repair work on the device may only be carried out by trained personnel
authorised by the manufacturer.
It is impossible to guarantee that bought-in parts are designed and manufactured to suit
their application, or that they satisfy safety requirements. Use only original replacement
parts (also applies to standard parts).

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Do not carry out any modifications, alterations, etc. to the device without the manufactur-
er's consent.
Components that are not in perfect condition must be replaced immediately.
Protecting your-
self and others Keep unauthorised persons, especially children, away from the device and the vehicle con-
taining the device during operation. If, however, there are people in the vicinity,
- make them aware of all dangers associated with use of the device (possible risk of suf-
focation due to lack of oxygen in the air, danger from output current, etc.)
- adhere to the permitted operating conditions as specified in the "Operating conditions"
section of the "Operation" chapter
Before leaving the vehicle in which the device is installed, make sure that no injury or dam-
age can occur in your absence.
Danger from gas-
es, hazardous
materials and suf-
focation
The fuel is supplied in the form of gaseous hydrogen. Hydrogen is a dangerous substance,
which requires great care when handling. Further information on handling hydrogen can
be found in the safety data sheet of the hydrogen supplier.
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 concentration of hydrogen of less than
4% by volume can be adequately guaranteed by the use of natural or forced ventilation.
Keep possible ignition sources, fires and naked flames away from the device, also inflam-
mable materials, liquids and gases.
Using the device in spaces with inadequate ventilation can cause suffocation with no visi-
ble or otherwise detectable warning. This is because of the oxygen consumption of the de-
vice, which can lead to a lack of oxygen in the room if it is inadequately ventilated. The
device must only be operated in rooms with a volume of not less than 10 m³ and with an
air circulation rate of not less than 0.6/h. Example: With a room volume of 10 m³, an air
circulation rate of 0.6/h means that 6 m³ of air are renewed per hour. Other spatial condi-
tions require an exact calculation of the air circulation rate in consultation with the device
manufacturer.
Safety measures
in normal opera-
tion
Only operate the device if all of its protection devices are fully functional. If the protection
devices are not in full working order, 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 operator
- inefficient operation of the device
Any safety devices that are not functioning properly must be repaired before switching on
the device.
Never bypass or disable protection devices.
Before switching on the device, ensure that no one is likely to be endangered.
Observe the commissioning and operating requirements as set out in the "Before commis-
sioning" and "Commissioning" chapters.

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EN
Generally-speaking, the following applies:
- Ensure adequate ventilation of the installation location
- Ensure that the cooling air can flow into and out of the device unhindered
- Refer to the "Care, maintenance and disposal" chapter of the device Operating In-
structions
- Regularly check the device and its accessories for obvious damage and proper func-
tioning of safety device(s)
- Never operate the unit if there is any evidence of damage
- Always use the unit in compliance with
- the "Proper use" section of the "Before commissioning" chapter
- the "Operating conditions" section of the "Operation" chapter
Specific hazards Keep hands, hair, clothing and tools away from moving parts, for example fans.
Unauthorised opening or tampering with the device will invalidate the guarantee and poses
the risk of serious damage to people and property.
General informa-
tion regarding the
handling of bat-
teries
The unit contains a back-up battery (NiMH-technology) which requires careful handling.
- The back-up battery is maintenance-free
- It must not be tampered with by unauthorised personnel
- If external recharging of the back-up battery is required, this must only be carried out
with a battery charging system approved by the manufacturer (maximum charging cur-
rent: 35 A, e.g. Acctiva Professional 35A, item number 4,010,335,874. The need to re-
charge the battery externally represents a fault that can only occur in special situations
(prolonged shutdown, overuse, etc.)
- Do not expose the back-up battery to excessive heat (e.g. do not leave the vehicle
parked in bright sunlight)
- The back-up battery is equipped with a protective circuit. This protects it against:
- Overcharging of the cells (damages the cells)
- Deep discharge of the cells (damages the cells)
- Destruction of cells by short circuit
- Polarity reversal
- Incorrect charging
- Overtemperature
Danger from bat-
teries The unit contains a back-up battery (NiMH-technology), which requires careful handling.
Batteries contain substances harmful to the eyes and skin. These can only be released in
the event of serious damage (e.g. overheating, accident, etc.).
- Substances escaping from batteries must not come into contact with the eyes, skin or
clothes.
- Do not inhale escaping gases or vapours, and make sure premises are well-ventilated
- Avoid short circuits
- Do not expose the battery to excessive heat or throw it onto an open fire
Further details can be found in the supplementary safety data sheet available from the
manufacturer.
Danger from
pressure vessels The device is fed with hydrogen from an integrated pressure vessel. Ensure compliance
with the safety rules for pressure vessels.
There is a container of pressurised hydrogen in the device, and it must therefore be treated
with care. Detailed information on proper use can be found in the "Before commissioning"
section.

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Protect the pressure vessel from excessive heat, mechanical impact, naked flames, sparks
and arcs.
Keep pressure vessels away from electrical circuits.
The manufacturer's instructions must be observed as well as applicable national and inter-
national regulations for pressure vessels and accessories.
Warranty and lia-
bility The duration of the guarantee for the device depends on the supply contract. However, the
manufacturer will not accept any liability if the damage was caused by one or more of the
following:
- Use of the charger not in accordance with the intended purpose
- Incorrect operation
- Operating the charger with faulty protection devices
- Non-compliance with the operating instructions
- Unauthorised modifications to the charger
- Catastrophes caused by the activities of third parties and force majeure
Safety inspection A safety inspection must be carried out by a qualified expert
- before using for the first time after installing in the vehicle
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- and at least once every twelve months
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. Applicable national
regulations must be observed.
Maintenance, technical inspections and checks must only be carried out by qualified per-
sonnel (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 de-
vice. 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 mainte-
nance carried out by a third party or by the non-performance of maintenance.
Safety symbols Devices with the CE marking satisfy the essential requirements of the applicable European
directives. Further information can be found in the "Technical data" chapter.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive 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
either be returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially adverse af-
fects on the environment and your health!

13
EN
Copyright Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We reserve the
right to make changes. The contents of the operating instructions shall not provide the ba-
sis 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 instructions, we will
be most grateful for your comments.

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General
Functionality and
device concept
The HyLOG Fleet device allows transport
vehicles for internal logistics to be operated
with hydrogen as the energy source. This
eliminates the long breaks in operation re-
quired with normal charging times, as re-
fuelling takes only a few minutes. The result
is higher productivity and lower maintenan-
ce costs. Ideally the hydrogen is generated
locally from renewable energy sources. The
only emissions from HyLOG Fleet are small
quantities of pure water.
The key component of HyLOG Fleet is the electrochemical unit in the device - the fuel cell.
This generates electrical energy from hydrogen and from oxygen in the surrounding air.
The fuel cell consists of several individual cells connected in series. A digital control unit
supplies it with hydrogen and air in the correct ratio and maintains the operating tempera-
ture.
When used correctly, hydrogen is a safe source of energy. The energy cell has a range of
safety features that comply with applicable standards. The explosion protection require-
ments are covered by precautionary measures integrated into the device to the extent that
no further explosion protection measures are required at the installation location. Care
must be taken to ensure sufficient circulation of air in the operating environment.
Advantages A great economic advantage of HyLOG Fleet is that long battery charging times are re-
placed by a refuelling process that takes only a few minutes. This results in greater avail-
ability and productivity of the in-house transport vehicles, combined with lower
maintenance costs. The hydrogen tank can be refilled virtually any number of times, within
the intended product life cycle of 10 years, whereas batteries always have a limited service
life.
Use of the fuel cell offers a range of other benefits as well:
Water is the only combustion product of the fuel cell, which means that it does not produce
any pollutants. Another advantage of the fuel cell is that it is quiet and requires practically
no maintenance. In contrast to conventional generators, the fuel cell electrochemically con-
verts the chemically-bound energy of the hydrogen directly into electrical power. The hy-
drogen consumption is therefore very low.
Given the finite nature of energy resources and the need for environment-friendly energy
production, HyLOG Fleet sets new standards for energy efficiency and emission reduction.
The overall logistics system is particularly environment-friendly when renewable energy
sources are used, for example:
- Solar
- Wind
- Water
- Biomass
- Biogas

15
EN
The benefits of using HyLOG Fleet as the energy source for internal transport vehicles can
be summed up as follows:
- Long battery charging times of 8 to 10 hours are replaced by a refuelling process that
takes less than 3 minutes
- Lower maintenance costs mean optimum productivity compared with conventional
battery solutions
- Lower operating costs thanks to longer service life of the fuel-cell-based system
- Less space required since there are no battery charging stations
- Absence of poisonous and odorous emissions
- Quiet
- Energy efficiency is roughly 3 times better than that of conventional systems using in-
ternal combustion engines
Properties - Fuel cell-based generator
PEM type (polymer electrolyte membrane)
- Simple to operate
- Can easily be integrated into existing vehicle designs
- High standard of safety due to safety functions integrated into the device and explo-
sion protection
- High degree of efficiency
- Quiet, low-maintenance operation
- Interface for data communication
System configu-
ration
Fuel Cell Control Unit
NiMH-Battery Power
Control panel
Signal
Refilling
Condensate
Tank

16
Warning notices
on the device
The device is fitted with a rating plate and safety symbols. The rating plate and safety sym-
bols must not be removed or painted over.
System components
Position Explanation Detailed explanation, specification
Fuel cell Fuel cell Generates electricity via an electrochemical process
from hydrogen and oxygen in the surrounding air ("cold
combustion"). Therefore the fuel cell is extremely effi-
cient.
Battery Battery with nick-
el-metal hydride
technology
Since the fuel cell always works at close to optimum ef-
ficiency, it is used primarily to charge the batteries in or-
der to store the energy. If power consumption increases
due to heavy acceleration of the vehicle, this is largely
met by the battery.
On the other hand, when the vehicle is braked, surplus
braking energy is stored in the battery again. The vehi-
cle's drive unit is therefore a highly efficient hybrid sys-
tem. Once the battery is fully charged, the fuel cell stops.
When the state of charge drops below a certain level, the
fuel cell starts recharging again.
The battery also supplies the energy needed to start the
fuel cell.
Tank A steel vessel for
hydrogen gas
with a capacity of
27 litres (7.13 gal-
lons)
Contains the energy for operating the vehicle in the form
of hydrogen gas. During the refuelling process, the hy-
drogen is compressed to a pressure of 350 bar (5074.55
psi.), resulting in high storage density and long operating
intervals between refuelling stops.
Control
Unit
Control and regu-
lation unit
Controls the battery charging process and the related
activity of the fuel cell. The optimum state of charge of
the battery is always adapted to the current vehicle op-
eration.
4,005,101
00000000000
Fronius HyLog Fleet 24015F
26 V
500 A
1800 W
250 A
+2°C...+40°C (60°C)
Hydrogen SAE J2719
350/438 bar
27 l
IP20
SAE J2600 H35
240 kg
Ambient temperature
Pressure nom./max.
Capacity
Fuel type
www.fronius.com
Type
Ser.No.
Art.No.
I BATT max.
P EL. nom.
U DC nom.
Weight
2015 2016 2017 2018
Receptacle
WARNING:
OPERATE IN VENTILATED AREAS ONLY - min. Room size 10m³
FOR INDOOR USE ONLY. Do not operate outdoors!
Pressure Vessel production year
0036
CONTAINS HYDROGEN GAS,
HIGHLY FLAMMABLE
DO NOT JET WASH!

17
EN
WARNING!
Danger of serious injury and damage.
The battery must never be short-circuited, penetrated, thrown into a fire, crushed, im-
mersed in water, forcibly discharged or exposed to temperatures outside the permissible
range for the device. The battery must never be used if it is in a defective condition.
In the event that electrolyte and gases escape from the battery as a result of improper treat-
ment, you should proceed as follows:
- If anyone breathes in the escaping gases they may experience breathing difficulties:
Immediately provide air from a fan or take the person outside for fresh air, and in more
serious cases summon medical assistance immediately
- If electrolyte comes into contact with skin, irritations may develop:
Wash the affected area of skin thoroughly with soap and water
- If electrolyte comes into contact with eyes, irritations of the eye may develop:
Immediately rinse the eyes thoroughly with water for 15 minutes and then call a doctor
Inadequate ventilation increases the risk of fire, explosion and suffocation. Al-
ways operate the device
- with protective grilles fitted on the housing openings for the cooling air sup-
ply and outlet
- with sufficient ventilation
- in rooms with a volume of more than 10 m³ (353.15 ft³), with an air circula-
tion rate* of at least 0.6/h
- whilst avoiding oxygen depletion of the surrounding air by ensuring ade-
quate room ventilation
Earthing symbol: A permanent potential equalization must be established be-
tween the HyLOG Fleet unit and the vehicle chassis.
Possible sources of ignition, such as fire, sparks and naked lights, must be kept
away from the HyLOG Fleet device.
Degree of protection IP20: For indoor use only. Do not expose to rain.
Do not use the functions until you have read all the Operating Instructions.
Do not dispose of used devices with domestic waste. Dispose of them according
to the safety rules.
Fire hazard! Ensure that the pressurised hydrogen container built into the device
is never exposed to high temperatures, mechanical impact, naked flames or
arcs.
There is a container of pressurised gas in the device, and it must therefore be
treated with care. Never use anything other than a damp cloth to clean the de-
vice. Ensure that the device is never exposed to damp conditions.
Pressure Vessel Production Year
* Example: With a room volume of 10 m³ (353.15 ft³), an air circulation rate of 0.6/h
means that 6 m³ (211.89 ft³) of air are renewed per hour.

18
Control elements and connections
Safety NOTE!
After firmware updates, you may notice that your device has certain functions that
are not described in these operating instructions.
Certain 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 questions, please
contact the manufacturer.
WARNING!
Operating the equipment incorrectly can cause serious damage and injury.
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.), es-
pecially the safety rules
WARNING!
Work carried out incorrectly and electric shocks can have fatal results.
► All covers of the device and the housing in general should only be opened or removed
by trained technicians
► Unauthorised opening or tampering with the device will invalidate the warranty and cre-
ate the risk of serious injury or damage.
Controls and con-
nections
The device is intended to be installed in vehicles with side-on battery replacement. The de-
vice is symmetrically designed in terms of the provided mechanical fixing elements and can
therefore be mounted on the vehicle turned through 180°. This allows you to choose
whether to have the filler connection on the left or right hand side of the vehicle. This issue
should be addressed by the vehicle manufacturer when installing the device in the vehicle.
(3)
(2)
(4)
(5)
(1)
(6)
(8)
(7) (7)(8) (8) (8)

19
EN
No. Function
(1) Process air intake
Housing openings for admission of combustion air of the fuel cell process. The vol-
umetric flow is 100 m³/h (3531.5 ft³/h)
WARNING!
If operation of the device is impaired by blocked process air intake openings, there
is a risk of explosion.
Keep all air openings completely clear.
(2) Tank cover, includes:
Tank connection 350 bar (5074.55 psi)
Connection for refilling the compressed hydrogen gas 5.0 (3.0 possible on re-
quest), via connection in accordance with ISO 17268 / SAE J2600, connection:
DMB HFR 350 bar (5074.55 psi)
Detailed information can be found in the supplementary document "Refuelling reg-
ulations".
Connection socket for condensate drainage
For draining the collection container for reaction water that occurs as condensate.
Detailed information can be found in the supplementary document "Refuelling reg-
ulations".
NOTE!
If operation of the device is impaired by a blocked condensate drainage connection,
there is a risk of water leakage.
Keep the condensate drainage connection completely clear.
(3) Cooling air outlet and process exhaust air
Cooling air and exhaust air from the fuel cell process containing steam as a com-
bustion product. The volumetric flow is up to 600 m³/h (21,188.8 ft³/h) at a maxi-
mum of 65 °C (149 °F).
WARNING!
If operation of the device is impaired by blocked process air exhaust openings, there
is a risk of explosion.
Keep all air openings completely clear.
(4) Power interface
Connection for the electricity produced. Constant power is up to 1.8 kW at 25.6 V
DC, connection socket: REMA 75012-56
and equipotential bonding
Connection to static equipotential bonding
(5) Connection for the control panel
Connection for the external control panel, which can be mounted on the vehicle
(6) Cooling air intake
Housing openings for admission of cooling air. The volumetric flow is up to 500 m³/
h (17,657.3 ft³/h) at an ambient temperature of up to 40 °C (104 °F)
WARNING!
If operation of the device is impaired by blocked cooling air intake openings, there
is a risk of explosion.
Keep all air openings completely clear.

20
(7) Locking of the device on the vehicle
Pins for securing the device in the vehicle
If the device is not successfully locked in place, the vehicle will operate in creep
mode (slow travel speed).
WARNING!
Devices that fall over can cause serious injury and damage.
Always ensure that the pins are properly locked.
(8) Crane holder
For transporting the device with suitable load-carrying equipment
WARNING!
Falling devices can cause serious injury and damage.
When transporting with a crane, only use chains or ropes of the same length.
Mount chains or ropes at all the fixing points of the crane holder.
Route the chains or ropes so that the angle to the vertical is as small as possible.
Control panel
No. Function
(1) Display
The "H2 Tank Level" indicator shows how much hydrogen is left, from 0 to 100% of
the available tank capacity.
Call up of information on operating hours and maintenance
Display of specific text messages on indicators (6), (8), (9) and (10)
(2) "ON" button
Pressing the "ON" button starts energy delivery. The energy is available immedi-
ately. Initially it is provided only by the back-up battery, which at the same time sup-
plies the energy needed to start the fuel cell. The "Power ON" indicator (10) lights
up green.
(2) (3) (4) (5)
(7)
(8)
(6)
(9)
(11)
(10)
(12)
(1)