Horizon Fitness H-100 User manual

H-100 Fuel Cell Stack
User Manual
Updated 28 Mar. 2016
Model No.: FCS-C100
Manual_FCS-C100_V2.2_EN

Manual_FCS-C100_V2.2_EN
Disclaimer
This manual incorporates safety guidelines and recommendations. However, it is not intended to
cover all situations. It is the responsibility of the customer to meet all local safety requirements and
to ensure safety during operation, maintenance and storage of the H-100 stack.
Although all efforts have been made to ensure the accuracy and completeness of the information
contained in this document, Horizon reserves the right to change the information at any time and
assumes no liability for its accuracy.
Actions that will void the fuel cell and controller warranty:
●Attempt, under any circumstance, to disassemble or inappropriately tamper with
the fuel cell.
●Operate the fuel cell with a controller not designed and built by Horizon for the
specific fuel cell.
●Operate the fuel cell with valves and blowers, that are not provided by Horizon for
the specified fuel cell and controller.
●Disassemble the fuel cell.
●Disassemble the controller.
●Operating the fuel cell and controller that is not in the setup and/or specified in the
user manual provide for the specific product.
●Operate the fuel cell stack without the controller produced by Horizon or with the
controller not produced by Horizon.
IMPORTANT
In order for the warranty to come into effect the stack must be registered on the Horizon
Warranty Page at: www.horizonfuelcell.com/warranty.htm
Do not attempt, under any circumstance, to disassemble or
inappropriately tamper with the fuel cell. There will be no repair,
replace or refund should disassembly or tampering occur. If you have
questions or need help with regards to the fuel cell and its technology
please contact:
[email protected]

Manual_FCS-C100_V2.2_EN
Table of Contents
1. Safety...............................................................................................
2. Terminology......................................................................................
3. Stack and System Component Information.....................................
4. Technical Specification.....................................................................
5. System Set-Up.................................................................................
6. System Set-up Diagram.....................................................................
7. Notes for the set up .........................................................................
8. Operating Procedures.......................................................................
9. Performance Characteristics.............................................................
10. Storage and Re-Use........................................................................
11. Trouble Shooting&System Checks..................................................
12. Fuel Cell Drawing............................................................................
13. FAQ.................................................................................................
1
6
10
12
13
20
21
22
25
26
27
31
32

Manual_FCS-C100_V2.2_EN
1. Safety
Please read all instructions carefully prior to product use and keep this manual for future reference.
The safety guidelines included here may not cover every situation. Use common sense.
1.1 General information
For this unit to generate electrical power, a supply of hydrogen fuel is necessary. It is important
for any operator to be aware of, understand, and follow all local safety requirements related to the
handling of hydrogen and compressed gases. Ensure that your facility conforms to all local regulatory
requirements, including building codes and recommendations.
The fuel cell system has built-in safeguards and is designed to shut down automatically if any out-
of-range operating condition occurs. Possible situations include low cell voltage, high current, high
temperature, low fuel pressure.
•Do not operate the stack on a grade of more than 65℃.
•Do not connect or disconnect power cables when the fuel cell stack is energised.
•Do not dismantle the system. Contact Horizon if you have any concerns about operation.
1.2 Using Hydrogen
WARNING! FIRE OR EXPLOSION
Keep all sources of ignition away from hydrogen.
This unit uses hydrogen fuel. Hydrogen is a colourless, odourless and flammable substance. It is
highly combustible in the presence of oxygen and burns with a colourless flame.
Leaking gas may be hot and pose a burn danger. Stop the flow of gas – if you are not in danger –
and use water to cool the area. If fire occurs, do not attempt to extinguish flames, allow the fire to
burn out.
Prevent overexposure to hydrogen. Hydrogen is non-toxic but can act as a simple asphyxiant by
displacing the oxygen in the air. There are no warnings before unconsciousness results. When
operating the stack in an enclosure:
•Ensure ventilation slots are clear and unobstructed at all times during operation.
•Operate within the temperatures limits stated in the manual.
•Never operate if an alarm condition exists.
Note: We highly recommend customer use a hydrogen sensor(not provided) to detect the
hydrogen leakage.
1

Manual_FCS-C100_V2.2_EN
1.3 Handling Compressed Gas Cylinders
WARNING
Do not handle compressed hydrogen gas cylinders without training or experience.
•Use a pressure regulator to control the fuel inlet pressure to the system.
•Do not alter the fitting on a regulator. Ask experienced personnel for help.
•Do not attempt to force gas cylinder threads.
•Never transport a gas cylinder with regulators attached. Ensure cylinder caps are in place. Always
use a cylinder cart with a safety strap or chain.
•Secure a high-pressure cylinder to a bench, post, or fixed object to avoid accidental contact.
•Avoid unnecessary contact with On/Off valves. They can easily move to “On” by accident.
1.4 Hydrogen Leakage
Hydrogen is colourless, odourless and tasteless. Hydrogen is non-toxic but can act as a simple
asphyxiant by displacing the oxygen in the air. There are no warning symptoms before unconsciousness
results.
WARNING
Inhaling hydrogen can lead to unconsciousness and asphyxiation. Hydrogen molecules are smaller
than any other gas, making hydrogen more difficult to contain. It can diffuse through many materials
considered airtight. Fuel lines, non-welded connections, and non-metal seals such as gaskets, O-rings,
pipe thread compounds and packings present potential leakage or permeation sites. Furthermore,
hydrogen’s small molecule size results in high buoyancy and diffusivity, so leaked hydrogen will rise and
become diluted quickly.
Constant exposure to hydrogen causes hydrogen embrittlement in many materials. The mechanisms
that cause hydrogen embrittlement effects are not well defined. Factors known to influence the rate and
severity of hydrogen embrittlement includehydrogen concentration, hydrogen pressure, temperature,
hydrogen purity, type of impurity, stress level, stress rate, metal composition, metal tensile strength,
grain size, microstructure and heat treatment history. Moisture content in the hydrogen gas may lead to
metal embrittlement through the acceleration of the formation of fatigue cracks. Hydrogen embrittlement
can lead to leakage or catastrophic failures in metal and non-metallic components.
As a preventative measure, the stack must be operated in a well-ventilated area in order to inhibit
potential hydrogen accumulation.
WARNING!
Always operate the stack in a well-ventilated area and ensure that ventilation slots are unobstructed.
2

Manual_FCS-C100_V2.2_EN
1.5 Flammability and volatility
Hydrogen is flammable over concentrations of 4 – 75% by volume in air, and is explosive over
concentrations of 15 – 59%. As a result, even small leaks of hydrogen have the potential to burn or
explode. Leaked hydrogen can concentrate in an enclosed environment, thereby increasing the risk of
combustion and explosion.
Hydrogen flames are pale blue and are almost invisible in daylight due to the absence of soot. Due to
its high buoyancy and diffusivity, burning hydrogen rises unlike gasoline, which spreads laterally.
A flammable or explosive hydrogen mixture is easily ignited by a spark or even a hot surface. The auto-
ignition temperature of hydrogen is 500 °C (932 °F). The energy of a hydrogen gas explosion is 2.4
times that of gasoline or methane for an equal volume. Hydrogen gas explosions are therefore more
destructive and carry further.
WARNING!
A mixture of hydrogen and air is potentially flammable and explosive and can be ignited by a spark or a
hot surface.
As in the presence of any fuel, all sources of ignition, including smoking, are not permitted in the vicinity
of the stack.
WARNING!
Keep all sources of ignition away. Smoking is not permitted in the vicinity of the stack.
1.6 Oxygen Depletion
Oxygen is a colourless, odourless, non-toxic and tasteless gas. Oxygen is essential for life in
appropriate concentrations.
Ambient air contains up to 21% oxygen. Oxygen levels below 19.5% are biologically inactive and
may act as simple asphyxiants. Effects of oxygen deficiency may include: rapid breathing, diminished
mental alertness, impaired muscular coordination, faulty judgement, depression of all sensations,
emotional instability, and fatigue. As asphyxiation progresses, nausea, vomiting, prostration, and loss
of consciousness may result, eventually leading to convulsions, coma, and death. At concentrations
below 12%, immediate unconsciousness may occur with no prior warning symptoms.
WARNING!
Lack of oxygen can lead to unconsciousness and asphyxiation.
As a preventative measure, the stack must be operated in a well-ventilated area in order to compensate
for the oxygen used within the fuel cells.
WARNING!
Always operate the stack in a well-ventilated area.
3

Manual_FCS-C100_V2.2_EN
1.7 Electrical Safety
WARNING!
Avoid contact with an exposed fuel cell stack. Electrical shock can cause personal injury or death.
•Do not touch fuel cell plates or any electrical components at any time. A running fuel cell stack is a
potential electrical hazard that can cause burns or electrical shock.
•Do not wear metallic jewellery – rings, bracelets, watchbands, or necklaces – when you are close to
an exposed fuel cell stack.
•Minimise static discharge. If possible, ground all equipment.
•Minimise conductivity. Avoid contact with surfaces that are in contact with water or gases. Do not
operate or store in wet or damp conditions.
•Never use damaged extension cords.
The stack generates up to 19VDC (open circuit voltage). This voltage decreases as current is drawn
from the stack. The stack produces 12V at maximum power. This voltage is exposed at the output
power connections. These low voltages may constitute a shock hazard and can damage electronic
components if shorted. Therefore, do not touch individual fuel cells, cell voltage monitoring equipment
or electrical components.
WARNING!
Do not touch fuel cells, cell voltage monitoring equipment or electrical components. Electronic
components can also be damaged as the result of static discharge. To minimise this, ground all
equipment in contact with the stack. Never use damaged extension cords. Minimise conductivity by
avoiding surfaces in contact with water; hands and clothes must be dry. Do not operate or store the
stack in wet or damp conditions.
WARNING!
Minimise static discharge. Ground all equipment. Residual reactants within the stack can develop a
charge in a matter of minutes when turned off. A reading of zero volts across the entire stack does not
guarantee that all fuel cells are uncharged.
WARNING!
Always assume that the fuel cell stack is charged. Jewellery (such as rings, necklaces, bracelets and
watches) may concentrate an electric current when it comes into contact with charged components,
or when a shock passes through the human body. Accordingly, no jewellery should be worn near the
stack.
WARNING!
Do not wear jewellery near the stack.
No pungent odor, paint and perfume are allowed around stack.
4

Manual_FCS-C100_V2.2_EN
1.8 High Temperature
The fuel cell stack is designed to operate at 65ºC. At this operating temperature, the air exhaust stream
temperature can reach 55ºC and the cooling air stream can reach 17ºC above ambient conditions. These
temperatures are sufficient to cause burns or severe discomfort. Accordingly, avoid contact with the fuel cell
stack, or components that convey process or cooling air.
WARNING!
Avoid contact with the fuel cell stack or components that convey process or cooling air.
5

Manual_FCS-C100_V2.2_EN 6
2. Terminology
PEM fuel cell:
A PEM (Proton Exchange Membrane) fuel cell is a device that converts hydrogen
and oxygen into water and electricity.
A fuel cell stack:
It includes a plurality of plate-like fuel cells arranged along an axis generally
parallel to cell thickness with electrically conductive separator plates between
each pair of cells.
Reactants:
Reactant is a material used to start a chemical reaction. In the fuel cell the
reactants are air and hydrogen by which the electricity will be generated.
Humidification:
A process to humidify the proton exchange membranes for optimal performance.
Blower:
Fans attached to fuel cell stack to supply cooling air and process air.
Purging valve:
Excess water and hydrogen will be dispelled from the fuel cell flow channels via
purge valve.
SCU:
Short circuit unit – the short circuit will be controlled for good performance of the
stack.
Mass flow per minute:
The amount of hydrogen consumed to run the fuel cell at a certain power.
HFCT:
Horizon Fuel Cell Technologies

Manual_FCS-C100_V2.2_EN 7
B
A
C
E
F
G
A: Warning labels
B: FC+ connector
C: FC- & load- connector
D: Grounding cable connector
E: Controller multi-connector
F: H2 supply valve
G: H2 purge valve
H: Fuel cell air inlet side
Note: Pictures in the manual are only for reference, takes material object as the
standard.
D
H

Manual_FCS-C100_V2.2_EN 8
B
A
C
A: H2 inlet connector
B: Blower
C: H2 outlet connector
D: Silicon tube
Note: The silicon tube connected between the hydrogen input and hydrogen output
is to keep the membrane humidity to maintain the fuel cell stack in best performance.
After the stack is finished using, connect the silicon tube between the input and output
for keeping the membrane humidity. See FAQ how to maintain the fuel cell stack.
D

Manual_FCS-C100_V2.2_EN 9
FG
H
E
DI
K
J
C
L
A
B
A: Horizon Logo
B: LED
C: Product No.Label
D: Connect plug
E: SCU(short circuit units) switch
F: ON/OFF button
G: Connect to FC+
H: Connect to FC-
I: Connect to Load+
J: Controller power supply DC 13V+
K: Controller power supply DC 13V-
L: LCD connector (optional LCD, not provided)

Manual_FCS-C100_V2.2_EN 10
3. Stack and System Component Information
1. Stack
Is made up of plate-like cells with air channels to allow
the flow of air across the membrane. The membrane
facilitates the flow of Hydrogen creating the release
of electrons. Electrically conductive separator plates
between each pair of cells enable the flow of electrons.
The stack aspect is that they are all placed on top of each
other and held together by epoxy endplates.
2. H2 Supply Valve
It controls the H2 input. When the controller turns on, also
the H2 supply valve does. When system turns off, it is in
the off position for preventing hydrogen leakage.
3. H2 Purge Valve
It purges out the water and air gas redundant in the fuel
cells.
4. Short Circuit Unit
It ensures best performance of the fuel cells.
5. On/Off Switch
Hold it for 2 seconds for either on or off operation.
6. Blower
Supply air to the fuel cells and meanwhile decrease the
temperature of the stack.

Manual_FCS-C100_V2.2_EN 11
7. Controller Connector
Connect the stack to the T-sensor/blower/purging valve/
input valve on the controller.
8. Controller
Controls the stack temperature, blowers, hydrogen input,
purging and short circuiting of the stack.
9. H2 Input/Output connectors
H2 OUT: connect the tube shown in 11 below.
H2 IN: connect the tube shown in 11 below.
10. Fuel Cell +/Fuel Cell-&Load- Connectors
FC+ of the controller is connected to the fuel cell positive
pole.
FC- of the controller is connected to the fuel cell negative
pole.
12. Grounding cable
Make stack grounded.
Note: After the fuel cell stack is finished using, disconnect
the grounding cable.
11. Tube for H2 Input and Output
The tube with 6mm outer diameter and 3mm inner
diameter is connected to the H2 IN as in 9 above and to
the input valve of the hydrogen source. H2 output tube
with 4mm outer diameter and 2mm inner diameter is
connected to the purging valve on one end and the H2
OUT the other.

Manual_FCS-C100_V2.2_EN 12
4. Technical Specification
y.
Type of fuel cell PEM
Number of cells 20
Rated Power 100W
Performance 12V @8.3A
H2 Supply valve voltage 12V
Purging valve voltage 12V
Blower voltage 12V
Reactant Hs ydrogen and Air
External temperature 5 to 30ºC
Max. stack temperature 65ºC
H2 Pressur 0e .45-0.55bar
Hydrogen purity
≧
99.995
﹪
dry H2
Humidification self-humidified
Coolin Ag ir (integrated cooling fan)
Stack weight (with fan & casing) 1460 grams(±50grams)
Controller weight 400 grams(±30grams)
Dimensio 1n 1.8cm x 10.4cm x 9.4cm
Flow rate at max output* 1.3 L/min
Start up time
≦
30S at ambient temperature
Efficiency of stack 40% @ 12V
Low voltage shut down 10V
Over current shut down 12A
Over temperature shut down
65
℃
External power supply** 13V (±1V), 5A

Manual_FCS-C100_V2.2_EN 13
5. System Set-Up
STEP 1:
Connect the controller to the stack to get the blower, the temperature sensor, the hydrogen supply
valve and the purge valve under control. The finished connection is shown in 1B.
1A 1B
Controller connector
Wire colours Connector pin # Periferals controlled
Yellow #1 & #5 Hydrogen supply valve
Blue #2 & #6 Hydrogen purge valve
Red and Black #3 & #7 Blowers (Red= +ve, Black= -ve)
Red #4 & #8 Temperature Sensor
1 2 3 4
5 6 7 8
PLEASE READ CAREFULLY BEFORE STARTING
WARNINGS:
1. The tube between the hydrogen pressure regulator and the fuel cell gas input is required to be less
than 30cm. The inner diameter of the hydrogen supply tube is required to be more than 3mm. The input
pressure to the stack is required to be 0.45-0.55Bar .
2. Disconnect the hydrogen tube from the hydrogen inlet immediately after the fuel cell stack is shut down.
Since hydrogen gas can leak into the fuel cell and destroy the stack.
3. The stack must be standing on the clear plastic feet.
4. Make sure the dry Hydrogen gas to be used must be ≥99.995% purity.
5. Make sure you have purged the water out of the stack as much as possible before use if you injected
water into the stack. Using the fuel cell stack with too much water inside can irreparably damage it!
6. Do not vibrate the stack when it is in operation.
7. Keep the stack in ventilation when it is in operation.
8. The external power voltage is required to be 12-14V.
9. Keep the SCU always on. Only when it causes your load operating in difficulty, turn off the SCU.
10. The tube between stack output and purging valve is required to be less than 20cm. The tube
connected to the purging valve output is required to be less than 30cm. The inner diameter of the tube is
required to be more than 2mm.

Manual_FCS-C100_V2.2_EN 14
2C 2D
STEP 2:
Connect the controller to the stack as the output power also shall be under control.
Use the grounding cable to connect the FC-&Load - to the grounding connector.
The finished connection is shown in 2D.
2A 2B
Note: After the fuel cell stack is finished using, disconnect the grounding cable.

Manual_FCS-C100_V2.2_EN 15
STEP 3:
Keep the SCU (Short Circuit Unit) switch ON at “-” for usual use.
Warning: Some home appliances may not be suitable for this activation process. It may cause
damaging. you can shut off the short circuit by switching it to "O", but it will cause at least 20%
performance loss.
3A
STEP 4:
Connect the output of the hydrogen supply valve to the stack (pay attention to the arrow direction
on the valve). The hydrogen supply valve will prevent damage from the hydrogen while the stack is
off. Pay attention to the direction of the connection of the Hydrogen supply valve.
The finished connection is shown in 4E.
4B
4A

Manual_FCS-C100_V2.2_EN 16
STEP 5:
Connect the stack to the purge valve through the filter for a longer runtime and a better
performance (5A-5E). If not, the gas out of stack may have a negative effect on the purge valve
after a long-time running. Connect the output of the purge valve to a place away from the stack in
case of the damage caused by the Hydrogen leakage.
5B
5A
Warning:The tube between the
hydrogen pressure regulator and
the fuel cell gas input is required to
be less than 30cm.
4D
4C
4E

Manual_FCS-C100_V2.2_EN 17
Note: The tube is required to be less than 20cm between stack output and purging valve.
The tube connected to the purging valve output is required to be less than 30cm. The inner
diameter of the required to be more than 2mm.
5E
5C
5E
5D
plastic nozzle :
output
metal nozzle:
input