Horizon Fitness H-1000XP User manual

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Date:2013-08-05
Part Number:H-1000XP
Version:20130805
Manual
H-1000XP Fuel Cell System
User

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Revision History
Release No. Date Revised by Revision Description
Rev. 0 12/13/10 Tony User’s Manual draft
Rev. 0.9 12/24/10 WRP 1. Modified PART LIST
2. Modified GENERAL INFO
3. Modified SYSTEM SET UP
4. Modified SOFTWARE
5. Added MAINTENENCE
Rev. 0.95 01/13/11 WRP 1. Modified SAFETY
2. Modified SOFTWARE
3. Modified MAINTENANCE
4. Added TROUBLESHOOTING
Rev. 0.96 01/19/11 WRP 1. Modified Ultra Capacitor Bank
Rev. 0.97 02/10/11 WRP 1. Added note to Stack Holder
2. Added note to Hydrogen Sensor
Rev. 0.98 02/25/11 WRP 1. Modified Software Installation
Rev. 0.99 03/29/11 WRP 1. Added H2 sensor external power
2. Added fuse usage to Step 7 & 11
Rev. 0.99 05/11/11 WRP 1. Fix mistake of supply / purge valve
direction arrow.
Rev. 0.10 05/23/11 WRP 1. Add note for not too long purge
line.
2. Add warning for not to turn off by
error protection.
Rev. 0.11 11/11/11 WRP 1. Modify H2 sensor related.
Rev. 0.12 12/05 /02 Jason
1. Added a blower controller
2. Modified the supply & purge valves
3. Changed the gas tube
4. Modified the DC/DC convertor
Stone
Rev. 0.13 07/12/12 Jason 1. Change the Dimensions value
Rev. 0.14 03/13/13 Jason 1. Change the input&output valves
Rev. 0.15 08/05/13 Jason 1. Change the Stack Holder color

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OVERVIEW OF THE SYSTEM
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Thank you for choosing our fuel cell stack. The Horizon fuel cell stack is an
air-cooled, light weight and compact fuel cell stack.
H-1000XP is specially developed for SHELL Eco-marathon event,(please refer to
www.shell.com/ecomarathon/for more details), this system has been designed
according to event rules, it only needs a start up battery(12V) to start the system and
will be self-sustainable after that, some of the features may not be necessary for other
applications, please contact HORIZON for more details
Please read all instructions carefully prior to product use and keep this manual for
future reference.
Further copies can be obtained from Horizon Fuel Cell Technologies or by emailing:
[email protected]
Please refer to the Horizon website for latest information: www.horizonfuelcell.com
Actions that will void the fuel cell and controller warranty:
●Do not 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 no that is not in the setup and/or
specified in the user manual provide for the specific product.
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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
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Disclaimer
Information contained in this data sheet is considered to be accurate and reliable, to the best of our
knowledge, at time of printing. However, we do not guarantee or warrantee its accuracy, reliability or
completeness. Information may be subjected to revision and edition at our discretion. It is the User’s
obligation to use the product safely and within the scope advised in this publication. Information
relates only to the specific product/material mentioned and may not be applicable where such
product/material is used with any other.

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Table of Content
1.0 Safety…………………………………………………………6
2.0 Part list………………………………………………………12
3.0 General information…………………….……….…………18
4.0 System set up……………………………………………….27
5.0 Software …………………………………………………….42
6.0 Maintenance………………………………………….….….47
7.0 Troubleshooting ……………………………………….……50

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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
Blower controller:
When no load is connected, turn off the blower controller to reduce the power consumption
of the stack.

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1.0 SAFETY

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1.0 SAFETY
NOTE: 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.
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, or hydrogen leak
detection.
• Do not dismantle the H-1000XP 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 colorless, odorless and flammable
substance. It is highly combustible in the presence of oxygen and burns with a
colorless 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
asphyxia by displacing the oxygen in the air. There are no warnings before
unconsciousness results. When operating the H-1000XP power module in an
enclosure:
• Ensure ventilation slots are clear and unobstructed at all times during operation
• Operate within the temperatures limits stated on the H-1000XP system
nameplate
• Never operate if an alarm condition exists
1.3 Handling Compressed Gas Cylinders
WARNING!
Do not handle compressed hydrogen gas cylinders without
training or experience.

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• 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 colorless, odorless and tasteless. Hydrogen is non-toxic but can act
as a simple asphyxiated 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 include hydrogen 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, H-1000XP must be operated in a well-ventilated area
in order to inhibit potential hydrogen accumulation.
WARNING!
Always operate H-1000XP in a well-ventilated area and ensure that
ventilation slots are unobstructed.

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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 system.
WARNING!
Keep all sources of ignition away. Smoking is not permitted in the
vicinity of the H-1000XP
1.6 Oxygen Depletion
Oxygen is a colorless, odorless, 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 asphyxiates. Effects of oxygen
deficiency may include: rapid breathing, diminished mental alertness, impaired
muscular coordination, faulty judgment, 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.

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WARNING!
Lack of oxygen can lead to unconsciousness and asphyxiation.
As a preventative measure, H-1000XP must be operated in a well-ventilated area
in order to compensate for the oxygen used within the fuel cells.
WARNING!
Always operate H-1000XP in a well-ventilated area.
1.8 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 conductive metallic items when you are close to an exposed fuel
cell stack.
•Minimize static discharge at all times If possible, ground all equipment to your
common ground.
•Minimize 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.
H-1000XP generates up to 48 VDC (open circuit voltage). This voltage decreases
as current is drawn from the module. 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
minimize this, ground all equipment in contact with H-1000XP. Never use
damaged extension cords. Minimize conductivity by avoiding surfaces in contact
with water; hands and clothes must be dry. Do not operate or store H-1000XP in
wet or damp conditions.

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WARNING!
Minimize static discharge. Ground all equipment.
Residual reactants within the H-1000XP can develop a charge in a matter of
minutes when turned off. A reading of zero volts across the entire power module
does not guarantee that all fuel cells are uncharged.
NOTE: The cathode has already been connected to
the stack shell.
The stack cathode should be connected to common ground of
all the equipments.
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 H-1000XP.
1.9 High Temperature
The fuel cell stack is designed to operate above 60ºC sometimes, 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.

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2.0 PART LIST

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2.0 PART LIST
The H-1000XP fuel cell stack is a cathode-cooled proton
exchange membrane (PEM) fuel cell stack designed to
provide stable electrical power while operating on air and dry
hydrogen.
Tube size for hydrogen connector Φ6
1. Stack
3. Hydrogen supply valve
4. Hydrogen purging valve
Purging valve: the controller will control the purging time
For purging the water and air gas redundant in the fuel
cells.
Please note the label and the direction of the arrow.
Tube size for hydrogen connector Φ6
2. Stack holder
It helps to fix the fuel cell stack on the place you want.
There are 4 in the package. As showed on stack picture
above, each side (left or right) can place 2.
NOTE: Please use bolts provided together with
spring washer. Do not over tighten. The use of
wrong screw length will damage the stack.
With innovative materials, the H-1000XP achieved
1000W power output with more efficiency comparing to standard H1000.
Supply valve controls the H2 input. The supply valve will
open when the system is operational. This valve will act
as emergency shut down valve in the case of leakage in
excess of 1% hydrogen in air when triggered by the
hydrogen sensor. Please take note of the label and
direction of the gas flow.

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7. Hydrogen sensor (Optional)
It triggers at 25% of LFL, which is 1% hydrogen
concentration.
NOTE: This sensor has a delayed respond (for
about 15 seconds).
5. SCU switch
It is to turn the SCU on/off. For SCU, Please refer to
Terminology.
It is the connector which connect startup ba ery to
the controller
8. Start up battery connector
6. LCD display
It displays the system status, current, voltage, temperature
etc.
Please refer to trouble shooting section for more details
Power supply for hydrogen sensor
Please attached this wire to your on-board battery (12V) to
power the hydrogen sensor.

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It can supply power output during system
short-cir (please refer to Short Circuit Unit for
more details), which could enable system con nuous
opera on without external power supply
Rated voltage: 50V
Capacitance: 1.25F
If regenera ve braking is required, please put a bigger
ultra capacitor bank to store this energy.
If a higher capacity ultra capacitor is used, you can
replace this set of capacitors. (Please note that the
maximum voltage of the fuel cell is 48V, so size your
ultra capacitors accordingly).
11.Ultra capacitor bank (Optional)
The DC/DC will regulate the output voltage for the
controller. It can step down the stack voltage (27.5V to
48V) to 12V for the fuel cell controller and other
peripheral parts.
10.DC/DC converter (Optional)
9. Ambient temperature sensor
It senses the ambient temperature.
The sensor should be place opposite to the blower side of
the fuel cell stack. As is showed in system set up section.
12.Blower controller
When no load is connected, turn off the blower controller
to reduce the power consumpon of the stack.

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Hydrogen sensor connector On/OFF switch
RS 232 connector
Emergency stop switch Start up battery connector
DC/DC connector Ultra capacitor connector System output connector Power cord connector Control signal connector
It controls the stack and all peripheral parts to perform at its
optimal condition. It has the following features
Control Stack temperature
Control Stack purge rate
Monitoring stack current and voltage
Monitoring H2 concentration(H2 sensor needed)
Protect stack from possible failures, like stack low
voltage, over current, over temperature
Control Hydrogen supply and shut off
RS232 Communication with computer
13.System controller
LCD displa
y
socket
Status LED

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Controller Signal Connector from Controller box at the wire side:
WirecolorsConnectorpin#Peripheralscontrolled
Red#1&#2StackTemperatureSensor
Grey#3&#4AmbientTemperatureSensor
Red&Black#5&#6Blowers(Red#5=+ve,Black#6=‐ve)
Black#7&#8HydrogenPurgeValve(Black#7=+ve,Black#8=‐ve)
Yellow#9&#10HydrogenSupplyValve(Yellow#9=+ve,Yellow#10=‐ve)
Blue#11&#12ShortCircuitSwitch
Red&Black#13&#14N/A
Black#15N/A
Black#16BlowerPWM
Table2.1ControllerConnector
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3.0 GENERAL
INFORMATION

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3.0 GENERAL INFORMATION
3.0 GENERAL
INFORMATION
Figure 3.1.1 Views and dimensions of H-1000XP stack
Figure3.1.2 Views and dimensions of controller
3.1 Dimensions
264
203 213
264
79
104
203
79
114

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eulaVyrogetaC MEPllecleuffoepyT
Physical
05sllecforebmuNDimensions 264mm x 203mm x 104mm
6Mx4gnitnuoM
Weight stack less than 4.9kg
system less than 6.8kg
Performance W0011rewopkaeP
Rated current 0 - 33.5A @ 30V
V84-V52egatlovCD
Fuel
riAdnanegordyHstnatcaeR 2Hyrd%99.99noitisopmoC ISP4.9-2.7erusserp2H
Hydrogen consumption
@1000W or flowrate 12.5SLPM
operation
External temperature 5 - 35°C
C°56erutarepmetkcatsxaM Humidification Self-humidified
riagnilooC
Relative humidity 10%-95%RH non-condensing
V21yrettabputratS
Monitoring RS232 System status / Historical data
Chart 3.2 General Specifica on of H-1000XP
3.2 General specification