H-Tec Education D203 User manual

Operating instructions
D203 Fuel Cell Concept Car & Gas Station

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H-TEC EDUCATION GmbH
1902 Pinon Dr. Ste. B
College Station, TX 77845
USA
Phone: [phone]
Email: [e-mail]
Website: www.myhtec.com

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Table of contents
Introduction
About these instructions
Safety instructions
Content
Overview
Starting up
Operation
Technical data
Troubleshooting
Shutting down
Maintenance
Transport and storage
Disposal
04
05
05
06
09
11
13
18
20
22
23
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Introduction
Dwindling resources, increasing environmental pollution and an ever-growing energy demand lead
companies in the energy sector to rethink their business models. Both the automotive industry and
mineral oil companies are increasingly investing in hydrogen technology, because it can offer a
way out: The use of hydrogen technology allows for a more efficient energy supply while
conserving natural resources as much as possible.
The hydrogen filling station “Gas Station” is used to generate and store hydrogen. The car
named the “Fuel Cell Concept Car” is filled with hydrogen, showcasing the technology of future
fuel cell vehicles under realistic conditions.
These devices allow for the function of PEM fuel cells (PEM = proton exchange membrane) and
PEM electrolyzers to be demonstrated.
We hope you enjoy many instructive hours with the Gas Station and Fuel Cell Concept Car.
Sincerely yours,
H-TEC EDUCATION

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About these instructions
These operating instructions are intended for the supervisor in charge.
■ These operating instructions must be read and observed before use.
■
These operating instructions must be available for reference and must be stored in a safe place.
■ All safety instructions must be observed.
■ This product may only be put into operation and operated under the direction of the supervi-
sor in charge.
Safetyinstructions
Product-specificsafetyinstructions
The product may only be used:
■ According to its intended use
■ In compliance with all safety instructions
■ In perfect working order
The components of this product feature freely accessible, live electric contact surfaces.
Connecting to an impermissible operating voltage may result in a fire hazard, a risk of electric
shock and damage to the components.

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tube
with shut-off valve
Content
filling station
car
overflow

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transport box with insert
(optional)
water bottle
companion book
operating instructions
general safety instructions

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Fig. 1: The filling station at a glance
Overview
The "Gas Station" filling station at a glance
The “Gas Station” filling station consists of an electrolyzer, a hydrogen storage tank, a water
reservoir and three solar modules, mounted to a base plate. When the solar modules are
provided with adequate light, the electrolyzer produces hydrogen which is stored in the
hydrogen storage tank. Hydrogen is removed via the tube. The electrolyzer is connected to the
solar modules via banana plugs using two 2 mm female connectors. The individual
components are shown in the following graphic.
Solar modules
Shut-offvalve
Water reservoir
electrolyzer
Overflow
Hydrogen storage
tank
Tube
(hydrogen out let)
Cap

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The “Fuel Cell Concept Car” at a glance
Fig. 2: The car at a glance
The “Fuel Cell Concept Car” consists of a two-cell, air-breathing fuel cell stack and a hydrogen storage
tank, mounted to a vehicle base plate. The car can be operated when it is supplied with hydrogen
via the hydrogen storage tank. The individual components are shown in the following graphic.
Connection
Vehicle base
plate
ON/OFF switch
Cap
(concealed)
Fuel cell stack
Hydrogen storage
tank

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Fig. 3: Assembly
Starting up
Assemble the filling station as shown in figure 3.
■Attach the overflow to the hydrogen storage tank using a clockwise motion.
■Attach the tube to the connection on the hydrogen storage tank.
Do not yet connect the cables to the electrolyzer.
Assembly

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Fig. 4: Filling
■Open the shut-off valve on the tube.
■Fill the water reservoir up to the mark with distilled water (σ< 2 µS/cm) as shown in figure
4.
■Fill the hydrogen storage tank up to the mark with distilled water (σ< 2 µS/cm) as shown in
figure 4.
■Briefly open the cap on the electrolyzer until a small amount of water comes out of the
opening. Close the cap again.
■Fill the hydrogen storage tank again up to the mark with distilled water (σ< 2 µS/cm).
Filling
dist. H2O
σ< 2 μS/cm

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Operation
CAUTION
Risk of injury from hydrogen ignition
Damaged tubes or leaking connections may cause hydrogen to leak.
Hydrogen and hydrogen-air mixtures may ignite when in proximity to
an ignition source.
Check tubes and connections for damage before each setup and
before each use.
CAUTION
Risk of injury from hot surfaces
The protection diode on the electrolyzer becomes very hot in case of
incorrect polarity.
Touching the diode on the electrolyzer may cause injuries.
Before starting up, ensure correct polarity of the connecting cables
and the electrical connections (red = “+”, black = “-”).
Do not touch the diode.
CAUTION Risk of injury from hot surfaces
The surface of solar modules may become very hot during operation.
Touching the surface of solar modules may cause injuries.
Do not touch the surface of solar modules during operation. Let the
surface of the solar modules cool to 40 °C before removing.
CAUTION Risk of injury from hydrogen ignition
Escaping hydrogen may ignite when in proximity to an ignition
source.
Prevent hydrogen from escaping. Completely use up all hydrogen at
the end of experiments and before dismantling.

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CAUTION
Risk of fire due to electrical overload
Any operation beyond the electrical specifi cations will lead to
excessive overheating of the electrolyzer. This may cause a fire.
Never operate the electrolyzer beyond the electrical specifi cations
stated in the technical data.
CAUTION
Risk of damage due to electrical overload
Any operation beyond the electrical specifications will lead to
irreparable damage to the electrolyzer.
Never operate the electrolyzer beyond the electrical specifi cations
stated in the technical data.
CAUTION Risk of damage due to insufficient distance to lamps
The solar module may become excessively hot or sustain irreparable
damage if it is too close to the lamp.
Observe the minimum distance defined by the manufacturer when
operating solar modules with lamps.
CAUTION Risk of damage due to improper handling
Operating the electrolyzer using water with an electrical conductivity
of ≥2 µS/cm will cause irreparable damage to the electrolyzer. Only
fi ll the electrolyzer using distilled water with an electrical
conductivity of < 2 µS/cm.
NOTE Water in the fuel cell
Ensure that there is no water in the tube of the filling station. Remove
any water in the tube by briefly opening the tube clamp or the shut-
off valve, if and as needed.
If water enters the fuel cell by way of the tube, a film of water on
the electrode surface may suppress the reaction of hydrogen and
oxygen within the fuel cell. In such cases, the output of the fuel cell
will be inadequate.

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■Close the shut-off valve (A).
■Connect the cables of the solar modules (B) with the connections (C) on the electrolyzer while
ensuring correct polarity (red = "+", black = "-").
■Provide solar modules with adequate direct sunlight or with light from a power, concentrated
electrical light source.
The water is split into hydrogen and oxygen at a ratio of 2:1. Oxygen escapes into the room via
the water reservoir.
Operating the filling station
Fig. 5: Operating the filling station
B
A
C

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■After each refill with distilled water, the residual air must be purged from the system. To do
this, produce approximately half a tank of hydrogen and release the gas by briefly opening the
shut-off valve, and venting most of the gas. Repeat 2-3 times to ensure pure hydrogen.
■When the hydrogen storage tank is filled, excess hydrogen escapes as bubbles. Gas
production must then be stopped by removing the cables of the solar modules from the
connections of the electrolyzers
■The filling station is now ready for use.
■During operation, small amounts of water pass through the PEM from the oxygen side to the
hydrogen side. This may cause the water level to rise on the hydrogen side and fall on the
oxygen side. check, and if necessary, adjust the water level regularly during operation, To this
end, the water on the hydrogen side mus be removed and supplied to the oxygen side. If the
water level needs to be adjusted, hydrogen production must be stopped by removing the
cables of the solar modules from the connections of the electrolyzers.
■The distilled water is consumed during operation. Pay attention to the water levels and
regularly top off with a little distilled water(σ<2µS/cm). The water levels in the water reservoir
and in the hydrogen storage tank should be kept approximately at the fill level marking at all
times. (For the hydrogen storage tank, this is only possible of no hydrogen is being stored.

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Fig. 6: Operating the car
■1. Set the switch to “OFF”.
■2. Attach the tube to the connection on the hydrogen storage tank of the car.
■3. Open the cap on the fuel cell stack.
■4. Open the shut-off valve.
■5. Wait until the column of water inside the overflow of the filling station’s hydrogen storage
tank has completely dropped. The hydrogen is now inside the hydrogen storage tank of the
car.
■6. Close the cap on the fuel cell stack.
■7. Close the shut-off valve.
■8. Remove the tube from the connection on the hydrogen storage tank of the car.
■9. To start operation of the car, set the switch to “ON”. The driving range on one full tank is
approximately seven minutes.
Operating the car
1, 9
2, 8
4, 7
5
3, 6

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Technical data
Item name: ................................................... Fuel Cell Concept Car & Gas Station
Item no: ........................................................ D203
Filling station “Gas Station”
H x W x D: ..................................................... 245 mm x 360 mm x 150 mm
Weight: ......................................................... 1250 g
Permissible operating pressure: .................... 0 - 20 mbar
Solar module:
Active solar area: .......................................... approx. 180 cm²
Open-circuit voltage: ..................................... approx. 2000 mV DC
Operating current: ......................................... approx. 1050 mA*
Electrolyzer:
Number of cells: ........................................... 1
Active surface per cell: .................................. 17 mm x 17 mm
Operating medium: ....................................... distilled water (σ< 2 µS/cm)
Permissible operating voltage: ...................... 0 - 2 V DC
Permissible operating current: ...................... 0 - 1.5 A
Rated power consumption: ........................... 1.5 W
H2gas production at rated power output ....... approx. 5 mL/min
O2gas production at rated power output ....... approx. 2.5 mL/min
Gas storage tank and water reserve:
Fill volume H2O, H2-side: .............................. approx. 30 mL
Fill volume H2O, O2-side: .............................. approx. 95 mL
Gas storage volume H2: ................................ approx. 25 mL
Gas storage volume O2: ................................ –
* Under standard test conditions (STC)

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** from ambient air
Car “Fuel Cell Concept Car”
H x W x D: ..................................................... 70 mm x 105 mm x 245 mm
Weight: ......................................................... 320 g
Permissible operating pressure: .................... 0 - 20 mbar
Gas storage tank:
Gas storage volume H2: ................................ approx. 10 mL
Gas storage volume O2: ................................ –
Fuel cell:
Number of cells: ........................................... 2
Active surface per cell: .................................. 20 mm x 20 mm
Operating media: .......................................... hydrogen and atmospheric oxygen from air
Open-circuit voltage: ..................................... Max 2V DC
Short circuit current: ..................................... Max 650 mA
Rated power output: ..................................... approx. 300 mW
H2gas consumption at rated power output: .. approx. 6 mL/min
O2gas consumption at rated power output: .. approx. 3 mL/min**
Drive/propulsion:
Type: ............................................................. electric motor
Number of motors: ........................................ 2
Rated power consumption (total): .................. approx. 150 mW

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Possible cause:
■ The fuel cell was stored too dry or for too long. A fuel cell with a dry polymer electrolyte
membrane (PEM) will lose power.
Solution:
■ Continue operation. The fuel cell moistens itself during operation, which slowly allows it
to reach its full capacity again.
Despite hydrogen being present, the load connected to the fuel cell (e.g. the motor) is
not working.
Possible cause:
■ Water has entered the fuel cell during operation (e.g. through the gas storage tanks). This
may cause a rapid decline in performance.
Solution:
■ Dry the fuel cell by opening and blowing out the connections.
CAUTION Risk of damage due to compressed air
The use of compressed air for drying the fuel cell may cause
irreparable damage to the fuel cell.
When drying it, only blow out the fuel cell without using any
high pressure air.
With the solar module connected, no hydrogen is produced in the electrolyzer
Possible cause:
■ The light intensity is insufficient.
Solution:
■ Operate the solar module(s) using either adequate direct sunlight or concentrated light
from a powerful electrical light source. Energy-saving light bulbs, fluorescent tubes etc.
are unsuitable for the operation of solar modules.
Troubleshooting
The fuel cell only has a low output.