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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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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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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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.