Horizon educational Edustak junior User manual

EDUSTAK JUNIOR

BuildYourselfFuelCellStackKit–FCSU‐32

User ManualUser Manual

EDUSTAKJUNIORUserManualrev.1.1

Contents

1. Introductions…………………………………………….………………………………………………………………

2. Safety information……………………………………………..……………………………………………………..

Part

lists

Part

lists

……………………………………………..………………………………………………………………………….

4. EDUSTAK JUNIOR specifications……………………………………………..…………………. …………………………………………

5. O

eration

uide ……………………………………………..…………………. ………………………………………..

6. Disassembly guide ……………………………………………..……………………………………………………..

7. Assembly guide ………………………..………………………………………………………………………………….

8. Leakage testing……………………………………………..………………………………………………………............

9. FAQ ……………….. ………………………………………………………………………………………………..……

10. Troubleshooting ……………………………………………………………………………………………………. 31

EDUSTAKJUNIORUserManualrev.1.1

1 1 Foreword

1. Introduction

Foreword

ThankyouforchoosingHorizonFuelCellTechnologies’EDUSTAKJUNIOR.Wehopeyouwillenjoytouseit!

PleasereadalltheseinstructionsbeforeoperatingtheEDUSTAKJUNIORforthefirsttime,andshallkeepall

manuals for future reference

manuals



for



future



reference

IfyoustillhaveanyquestionsaboutoperatingorusingyourEDUSTAKJUNIOR.pleasecontactHorizon.

1 2 Production disclaimer

Production

disclaimer

Anyunauthorizedservice,modificationmayadverselyaffectthesafety,durability,andperformanceofthe

systemandshallimmediatelyvoidanywarrantyonthesystem.Misuse,neglect,orimproperservicingofthis

equipmentmayresultinthekitdamage.Donotoperatethiskitifitisdamaged.Failuretoobserveinstructions

contained in this manual will void any limited warranties and could result in suspension or denial of service

contained



this



manual



will



void



any



limited



warranties



and



could



result



suspension



denial



service

,

legalaction,orboth.

TheEDUSTAKJUNIORhasnotbeentestedatenvironmentaltemperatureextremes.Therefore,noguaranteeof

performanceismadeforoperationatambienttemperatureslessthan5°Candgreaterthan40°C.

1.3 Contact details

HorizonFuelCellTechnologies

5th Floor,Building19,No.2SuideRoad

Shanghai China

Shanghai

,

China

Tel:+862152709082*841

Email:[email protected]

EDUSTAKJUNIORUserManualrev.1.1

2. General Information

General Safety Instructions

General

Safety

Instructions

•ReadtheusermanualbeforeoperatingtheEDUSTAKJUNIOR,andkeepitclosetothedeviceatalltimes.

•EDUSTAKJUNIORanditsfuelcartridgemustnotbestoredattemperaturesover40℃(313K)andmustnot

be operated at temperatures over 40

℃

(313 K) Protect from heat and direct sunlight



operated



temperatures



over



℃

(313



.

Protect



from



heat



and



direct



sunlight

•OperatetheEDUSTAKJUNIORinawell‐ventilatedspace.

•WhentheEDUSTAKJUNIORisnotusedforalongtime,ensuretostoreitinacool,drystorage.

•DonotsmokeinthevicinityoftheEDUSTAKJUNIORoritsfuelcartridge.Protectfromheatandignition

sources Hydrogen is highly flammable!

sources

.

Hydrogen



highly



flammable!

•Afteranaccidentorintheeventofdamagetothefuelcartridgepotentiallyposesafirehazard.Keepaway

fromignitionsourcesandensuregoodventilation.

•KeepallEDUSTAKJUNIORanditsfuelcartridgesoutofreachofchildren,evenwhencartridgeisemptyor

only partly full

only



partly



full

•Theareasurroundingthefuelcartridgeshallbekeptclearandfreeofcombustiblematerials,gasolineand

otherflammablevaporsandliquids.

•Thisapplianceisnottestedforusewithmedicaldevices.

•

Save these instructions and review frequently during use

Save



these



instructions



and



review



frequently



during



use

EDUSTAKJUNIORUserManualrev.1.1

HYDROSTIK PRO SAFETY INFORMATION:

2. General Information

HYDROSTIK

PRO

SAFETY

INFORMATION:

•RemovetheHYDROSTIKPROfromthepressureregulatorimmediatelyafteruse.

•DONOTtrytodisassemble,openorrepairthecartridgeswhenbrokenorwornout!

•

DO NOT store cartridges under direct sunlight

•



NOT



store



cartridges



under



direct



sunlight

• Keepitawayfromfire.FireHazard!

• Keepitinasafe,dryandcoolplace.

• Keepitawayfromtemperaturesabove50˚Cwhilefilling,storageandusing.

•

Provide adequate ventilation and refrain from placing items on or around the appliance

•

Provide



adequate



ventilation



and



refrain



from



placing



items



around



the



appliance

duringoperation.Refrainfromplacingtheapplianceinenclosuresorcausingtheappliancetonotventfreely.

• Keepawayfromalkalineandacidicenvironment.

•Thisisnottoy– keepawayfromchildren.

•

The HYDROSTIK PRO cartridge must be placed horizontally when it is being charged otherwise the cartridge

•

The



HYDROSTIK



PRO



cartridge



must



placed



horizontally



when



being



charged



otherwise



the



cartridge

cancrack!

•HYDROSTIKPROcontentsareflammable.Donotdisassemble.

•AvoidcontactwithHYDROSTIKPROcontents.

•

Remove the HYDROSTIK PRO from the pressure regulator immediately after use

•

Remove



the



HYDROSTIK



PRO



from



the



pressure



regulator



immediately



after



use

•Whenusingtheappliance,basicsafetyprecautionsshouldalwaysbefollowedtoreduceriskoffire,or

personalinjury.

•Hydrogenshallbestored,handledandusedwithcautionsolifeandhealtharenotjeopardizedandtherisk

of property damage is minimized



property



damage



minimized

EDUSTAKJUNIORUserManualrev.1.1

3. Part List

a. EDUSTAK JUNIOR*

b. HYDROSTIK PRO**

c. Manometer

Electronic

PCB

card

Electronic

PCB

card

e. Blower fan

f. Air pump

g. HYDROATIK PRO base

Purging

valve

with

tube

abcd

Purging

valve

with

tube

i. Screws

j. Three port connector

k. 3 silicon tubes

l. Clamp with tube

m. Pressure regulator

n. HYDROSTIK PRO support

o. Wires

efgh

ijklmno

*TheEDUSTAKJUNIORisalreadyassembledwhenyoureceiveitforthefirsttime.

**TheHYDROSTIKPROcontainsnohydrogenwhenyougetitforthefirsttime,youhavetofullychargeitwith

therefillin

stationHYDROFILLPRO

(

soldse

aratel

orh

dro

enchar

tube

(

soldse

aratel

g ( py)yg gg (py)

EDUSTAKJUNIORUserManualrev.1.1

4. EDUSTAK JUNIOR Specifications

Type of fuel cell PEM

Number of cells 10

Rated Power 4W

Performance

6V @ 0 7A

Performance

Reactants Hydrogen and Air

External temperature 5 to 35ºC

Max stack temperature 55ºC

H2 Pressure 0.45-0.55bar

Hydrogen purity ≧99.995﹪dry H2

Humidification self-humidified

Cooling

Air (integrated cooling fan)

Cooling

Air

(integrated

cooling

fan)

Dimension 125mm*60mm*95mm

Weight 510 g

Flow rate at max output* 0.05 L/min

Start up time ≦30S at ambient temperature

Efficiency of stack 40% @ at full power

Low voltage shut down 5V

Over current shut down

* The flow rate may change with the power output.

** The specification is subject to change without notice.

Over

current

shut

down

Over temperature shut down 50ºC

EDUSTAKJUNIORUserManualrev.1.1

5. Operating Guide

Usingadvices

InordertoreachthebestperformancesfromyourEDUSTACKJUNIOR,andtoguaranteehislifespan;we

stronglyrecommendtorespectthefollowingadvises:

●Strictlyfollowtheuser’smanual.

●MakesuretheEDUSTAKJUNIORhaspassedtheleakagetestingbeforeoperation.

●Operateitinawell‐ventilated,dryarea.

●HYDROSTIKPROshouldbeconnectedtothepressureregulatortightlywhenoperation.

●MakesuretorespectthepolaritywhenyouconnecttheEDUSTAKJUNIORtoaload.

●TheEDUSTAKJUNIORPCBisnotallowedtocontactthemetalpartsincaseshortingcircuitoccurs.

●Operateitunderambienttemperature.Keepitawayfromthestrongdirectsunlight.

●Manuallyusethepurgingvalvetopurgethesystemevery3minutesforgoodperformance.

●EDUSTAKJUNIORisnotacellphonecharger,butitcouldbeusedasademonstrationdevice.

●Afteryouhavefinishedusingthesystem,disconnecttheHYDROSTIKPROfromthepressureregulator

immediately.storeitintheziplockbagforstorage.

●Ifleakagehappensafterseveralassemblies,placetheEDUSTAKJUNIORintothepurifiedwaterwithoutthe

electricalPCBcard.Usetheairpressurebulb toinjectairintothestack.Observewherethebubblescomefrom

andthenadjustthestackassembly.Butthestackmustnotbetestedandoperatedwiththewatervaporinside.

Thestackmustbedry.

●Avoidstrongcollision.

EDUSTAKJUNIORUserManualrev.1.1

5. Operating Guide

Note: The EDUSTAK JUNIOR is already assembled when you receive it for the first time

Note:

The

EDUSTAK

JUNIOR

already

assembled

when

you

receive

for

the

first

time

which could be directly tested.

Step 1: Clips the EDUSTAK JUNIOR and the electronic PCB card directly together. Ensure the connection in the good

sense

(

electronic

s in the same side than the win

nuts on the EDUSTAK.

)

(pg g )

EDUSTAKJUNIORUserManualrev.1.1

5. Operating Guide

Step 2: Unscrew the pressure regulator bolt, and pass it around the longest silicon tube. Connect one tube end to the main

part of the pressure regulator. Ensure the connection in tight and then, screw the bolt on the pressure regulator. Do the

same operation between the other end of the tube and the upper nozzle of the EDUSTAK JUNIOR close to the PCB card.

Ste

3: Unscrew the lower nozzle bolt

and

ass it around the

valve tube. Connect it to the lower nozzle of the

,p pgg

EDUSTAK JUNIOR and then screw the bolt.

Make sure all the tube connections are tight.

EDUSTAKJUNIORUserManualrev.1.1

5. Operating Guide

Step 4:

Put the HYDROSTIK PRO support on its base Ensure both part meet perfectly Place the HYDROSTIK PRO onto its

Step

Put

the

HYDROSTIK

PRO

support

its

base

Ensure

both

part

meet

perfectly

Place

the

HYDROSTIK

PRO

onto

its

support and lightly screw the pressure regulator onto the HYDROSTIK PRO nozzle. Stop to screw it as soon as both part meet

together. On the opposite, the hydrogen will go out of the HYDROSTIK PRO.

Ste

5: Plu

the two crocodiles

incers into the sockets located on the electric card.

Ensure to respect the polarity shown by the color code.

EDUSTAKJUNIORUserManualrev.1.1

5. Operating Guide

Step 6:Connect the crocodiles pincers to the blower fan wires. Ensure to respect the polarity shown by the color code.

Now your system is ready to work.

EDUSTAKJUNIORUserManualrev.1.1

5. Operating Guide

Step 7: Finish to screw the pressure regulator to the HYDROSTIK PRO. As soon as it will be done, the blower

fan will start and the LEDs on it will light on.

EDUSTAKJUNIORUserManualrev.1.1

6. Disassembly Guide

Note: If you wish to disassemble the stack by yourselves do the following guide

Note:

you

wish

disassemble

the

stack

yourselves

the

following

guide

Step 1: Start by unscrew the right closest corner wing nut (1) only on the half of the available length. Do the same

with the left opposite (2) corner wing nut, then with the closest left one and finish by the bottom right corner. After that,

restart the operation in the same order and fully unscrew the wing nut. Put off the washers.

1 - 5

2 - 6 3 - 7

EDUSTAKJUNIORUserManualrev.1.1

6. Disassembly Guide

Step 2: Hang the system and remove the long screw from their position. Your cell is disassembled.

EDUSTAKJUNIORUserManualrev.1.1

6. Disassembly Guide

Now you have disassembled the EDUSTAK JUNIOR you get the following parts from the EDUSTAK

Now

you

have

disassembled

the

EDUSTAK

JUNIOR

you

get

the

following

parts

from

the

EDUSTAK

a. Upper end plate

b. Low end plate

Single

cell

(

pcs)

acd

Single

cell

(

pcs)

d. Sealing (11pcs)

e. Plastic plate (11pcs)

f. Plastic cell

g. Screw rods

h. Wing nuts

i. Washers

j. Bolts

efgh

Note: For any manipulation of dismounted elements, be sure not to insert elements

which could disturb the system sealing, damage MEAs and/or create short-circuit.

EDUSTAKJUNIORUserManualrev.1.1

7. Assembly Guide

Note: Now you may assemble the EDUSTAK JUNIOR please do the following guide

Note:

Now

you

may

assemble

the

EDUSTAK

JUNIOR

please

the

following

guide

Tools maybe needed during the assembly.

Step 1: Pass the screw rods through the basis of the low end plate. Return the basis and put it on a plane area.

Note: Pay close attention to the direction of the low end plate.

The side of the plate with the Horizon logo should face downwards.

EDUSTAKJUNIORUserManualrev.1.1

7. Assembly Guide

Step 2: Insert the plastic plate with the rubber sealing ring facing downwards on the screw and ensure the grooves are putted

on the upper side.

Note: Pay close attention to the “+” and “-” on the plastic plate. Make sure all the plastic plate should face the same

direction.

Sealing ring

EDUSTAKJUNIORUserManualrev.1.1

7. Assembly Guide

Step 3: Add a rubber seal in the corresponding groove and ensure it is deeply inserted.

Note: Pay close attention to the direction of the rubber seal. The round side of the rubber seal

should be facin

wards.

EDUSTAKJUNIORUserManualrev.1.1

7. Assembly Guide

Step 4: Put the first single cell on it. Ensure the white nozzles are on the upper side.

Note: Pay close attention to the direction of the single cell. Ensure to put the two ends of the cell

in the same side than the side of the plastic plate without the raised edge.

EDUSTAKJUNIORUserManualrev.1.1

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