Horizon Fitness H-1000 User manual
H-1000 Fuel Cell Stack
User Manual
Updated 18 May 2011
H-1000_UM_V4.4_EN
H-1000 Fuel Cell Stack User Manual V4.4
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-1000 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,underanycircumstance,todisassembleorinappropriatelytamperwith
the fuel cell.
● OperatethefuelcellwithacontrollernotdesignedandbuiltbyHorizonforthe
specicfuelcell.
● Operatethefuelcellwithvalvesandblowers,thatarenotprovidedbyHorizonfor
thespeciedfuelcellandcontroller.
● Disassemblethefuelcell.
● Disassemblethecontroller.
● Operatingthefuelcellandcontrollerthatisnotinthesetupand/orspeciedinthe
usermanualprovideforthespecicproduct.
● OperatethefuelcellstackwithoutthecontrollerproducedbyHorizonorwiththe
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
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:
H-1000 Fuel Cell Stack User Manual V4.4
Table of Contents
1. Safety..............................................................................................
2. Terminology.......................................................................................
3. Stack and System Component Information......................................
4.TechnicalSpecications...................................................................
5. System Set Up..................................................................................
6. Notes for the set up ..........................................................................
7.SystemSetupDiagram....................................................................
8.OperatingProcedure........................................................................
9. Polarization Curves...........................................................................
10. Storage and Re-use..........................................................................
11. Troubleshooting&System Checks......................................................
12.FuelCellDrawing.............................................................................
13. FAQ.................................................................................................
1
6
10
12
13
20
22
23
26
27
28
32
33
H-1000 Fuel Cell Stack User Manual V4.4 1
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.
•Donotoperatethestackonagradeofmorethan65℃.
•Donotconnectordisconnectpowercableswhenthefuelcellstackisenergised.
•Donotdismantlethesystem.ContactHorizonifyouhaveanyconcernsaboutoperation.
1.2 Using Hydrogen
WARNING!FIREOREXPLOSION
Keep all sources of ignition away from hydrogen.
Thisunituseshydrogenfuel.Hydrogenisacolourless,odourlessandammablesubstance.Itis
highlycombustibleinthepresenceofoxygenandburnswithacolourlessame.
Leakinggasmaybehotandposeaburndanger.Stoptheowofgas–ifyouarenotindanger–
andusewatertocoolthearea.Ifreoccurs,donotattempttoextinguishames,allowthereto
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:
•Ensureventilationslotsareclearandunobstructedatalltimesduringoperation.
•Operatewithinthetemperatureslimitsstatedinthemanual.
•Neveroperateifanalarmconditionexists.
Note: We highly recommend customer use a hydrogen sensor(not provided) to detect the
hydrogen leakage.
H-1000 Fuel Cell Stack User Manual V4.4 2
1.3 Handling Compressed Gas Cylinders
WARNING
Donothandlecompressedhydrogengascylinderswithouttrainingorexperience.
•Useapressureregulatortocontrolthefuelinletpressuretothesystem.
•Donotalterthettingonaregulator.Askexperiencedpersonnelforhelp.
•Donotattempttoforcegascylinderthreads.
•Nevertransportagascylinderwithregulatorsattached.Ensurecylindercapsareinplace.Always
use a cylinder cart with a safety strap or chain.
•Secureahigh-pressurecylindertoabench,post,orxedobjecttoavoidaccidentalcontact.
•AvoidunnecessarycontactwithOn/Offvalves.Theycaneasilymoveto“On”byaccident.
1.4HydrogenLeakage
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
thananyothergas,makinghydrogenmoredifculttocontain.Itcandiffusethroughmanymaterials
consideredairtight.Fuellines,non-weldedconnections,andnon-metalsealssuchasgaskets,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
thatcausehydrogenembrittlementeffectsarenotwelldened.Factorsknowntoinuencetherateand
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, 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.
H-1000 Fuel Cell Stack User Manual V4.4 3
1.5 Flammability and volatility
Hydrogenisflammableoverconcentrationsof4–75%byvolumeinair,andisexplosiveover
concentrationsof15–59%.Asaresult,evensmallleaksofhydrogenhavethepotentialtoburnor
explode.Leakedhydrogencanconcentrateinanenclosedenvironment,therebyincreasingtheriskof
combustion and explosion.
Hydrogenamesarepaleblueandarealmostinvisibleindaylightduetotheabsenceofsoot.Dueto
its high buoyancy and diffusivity, burning hydrogen rises unlike gasoline, which spreads laterally.
Aammableorexplosivehydrogenmixtureiseasilyignitedbyasparkorevenahotsurface.Theauto-
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!
Amixtureofhydrogenandairispotentiallyammableandexplosiveandcanbeignitedbyasparkora
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.
1.6OxygenDepletion
Oxygenisacolourless,odourless,non-toxicandtastelessgas.Oxygenisessentialforlifein
appropriate concentrations.
Ambientaircontainsupto21%oxygen.Oxygenlevelsbelow19.5%arebiologicallyinactiveand
mayactassimpleasphyxiants.Effectsofoxygendeciencymayinclude:rapidbreathing,diminished
mentalalertness,impairedmuscularcoordination,faultyjudgement,depressionofallsensations,
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
below12%,immediateunconsciousnessmayoccurwithnopriorwarningsymptoms.
WARNING!
Lackofoxygencanleadtounconsciousnessandasphyxiation.
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.
H-1000 Fuel Cell Stack User Manual V4.4 4
1.7 Electrical Safety
WARNING!
Avoidcontactwithanexposedfuelcellstack.Electricalshockcancausepersonalinjuryordeath.
•Donottouchfuelcellplatesoranyelectricalcomponentsatanytime.Arunningfuelcellstackisa
potential electrical hazard that can cause burns or electrical shock.
•Donotwearmetallicjewellery–rings,bracelets,watchbands,ornecklaces–whenyouarecloseto
an exposed fuel cell stack.
•Minimisestaticdischarge.Ifpossible,groundallequipment.
•Minimiseconductivity.Avoidcontactwithsurfacesthatareincontactwithwaterorgases.Donot
operate or store in wet or damp conditions.
•Neverusedamagedextensioncords.
Thestackgeneratesupto72VDC(opencircuitvoltage).Thisvoltagedecreasesascurrentisdrawn
from the stack. The stack produces 43.2V 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
avoidingsurfacesincontactwithwater;handsandclothesmustbedry.Donotoperateorstorethe
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,
orwhenashockpassesthroughthehumanbody.Accordingly,nojewelleryshouldbewornnearthe
stack.
WARNING!
Donotwearjewellerynearthestack.
H-1000 Fuel Cell Stack User Manual V4.4 5
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.
Thesetemperaturesaresufcienttocauseburnsorseverediscomfort.Accordingly,avoidcontactwith
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.
H-1000 Fuel Cell Stack User Manual V4.4 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.
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.
Humidication:
humidity that the fuel cells need for running.
Blower:
supply air to the fuel cells and meanwhile decrease the temperature in the stack.
Mass ow per minute:
thetotalamountofthehydrogenowthroughthefuelcelleveryminute,whichthehydrogensupply
can be calculated.
HFCT:
Horizon Fuel Cell Technologies
H-1000 Fuel Cell Stack User Manual V4.4 7
A: Hydrogen Inlet connector
B: Blower
C: Hydrogen Outlet connector
D: Supply valve
E: Purge valve
B
A
C
DE
H-1000 Fuel Cell Stack User Manual V4.4 8
A: Lable (FC- and Load-)
B: FC- and Load- connecter
C: FC+ connecter
D: Lable (FC+)
E: Warning Labels
A
B
D
C
E
H-1000 Fuel Cell Stack User Manual V4.4 9
FG
H
E
DI
K
J
C
A
B
A: 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-
H-1000 Fuel Cell Stack User Manual V4.4 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 and purge
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. Short Circuit Unit
The short circuit unit can be turned on or off depending
on what application the stack is to be used in. It ensures
enhanced performance of the fuel cells in applications
where the stack is turned off for prolonged periods.
4. On/Off Switch
It is the switch of the controller. Hold it for 2 seconds for
either on or off.
5. Blower
Supply air to the fuel cells and meanwhile decrease the
temperature in the stack.
H-1000 Fuel Cell Stack User Manual V4.4 11
6. Controller Connector
ConnectthestackcablestotheleadwiresoftheT-sensor/
blower/purgingvalve/inputvalveonthecontroller.
7. Controller
Controls the stack temperature, blowers, hydrogen input,
purging and short circuiting of the stack.
8. H2 out & H2 In: connect tube in 10 below
H2OUT:connecttubeshownin10below.
H2 IN: connect tube shown in 10 below.
9. Fuel Cell +/- Load Connectors
FC+ is connected to the fuel cell positive pole.
FC- is connected to the fuel cell negative pole.
10 . Tube for H2 Input & Output
The tube with 6mm outer diameter and 3mm inner
diameter is connected to the H2 Inlet and outlet as in
9 above and to the input valve and output valve of the
hydrogen source.
11 . Fittings
For connecting the load.
H-1000 Fuel Cell Stack User Manual V4.4 12
4. Technical Specication
Controller connector
Wire colours Connector pin # Periferals controlled
Blue #1 & #5 Hydrogen purge valve
Yellow #2 & #6 Hydrogen supply valve
Red #4 & #8 Temperature Sensor
Red and Black #3 & #7 Blowers (Red= +ve, Black= -ve)
Blowers signal Blowers power
The blower is PWM control, so it needs pins #9 & #10 to give the signal to the
control blowers power.
1
2
3
4
5
6
7
8
9
10
11
12
*the ow rate may change with the power output
**system electronics need external power supply
*** The Specication is subject to change without notice.
Type of fuel cellPEM
Number of cells72
Rated Power 1000W
Performance43.2V @ 24A
H2 Supply valve voltage 12V
Purging valve voltage 12V
Blower voltage 12V
ReactantsHydrogen and Air
External temperature 5 to 30ºC
Max stack temperature65ºC
H2 Pressure0.45-0.55bar
Hydrogen purity
≧99.995﹪dry H2
Humidification self-humidified
CoolingAir (integrated cooling fan)
Weight (with fan & casing) 4500 grams(±100grams)
Controller 400 grams(±30grams)
Dimension21.5cm x 12.5 cm x 30cm
Flow rate at max output* 14 l/min
Start up time ≦30S at ambient temperature
Efficiency of stack 40% @ 43.2V
Low voltage shut down 36V
Over current shut down 30 A
Over temperature shut down
65℃
External power supply** 13V(±1V), 5A~8A
H-1000 Fuel Cell Stack User Manual V4.4 13
5. System Set-Up
STEP1:
Connect the connectors of the controller and the stack to get the blower, the temperature sensor,
thehydrogensupplyvalveandthepurgevalveundercontrol.Thenishedconnectionisshownin
1B.
1A 1B
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. Using the fuel cell stack with water inside can irreparably damage it!
3. Disconnect the hydrogen supply completely within 5 minutes after the fuel cell stack is shut down. Since
hydrogen gas can leak into the fuel cell and destroy the stack.
4. The stack must be standing on the clear plastic feet.
5. Make sure the dry Hydrogen gas to be used must be ≥99.995% purity.
6. Make sure you have purged the water out of the stack thoroughly if you injected water into the stack.
7. Do not vibrate the stack when it is in operation.
8. Keep the stack in ventilation when it is in operation.
9. The external battery voltage is required to be 12-14V.
10. Keep the SCU always on. Only when it causes your load operating in difculty, turn off the SCU.
11. 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.
H-1000 Fuel Cell Stack User Manual V4.4 14
STEP2:
Connectthecontrollerandthestackastheoutputpoweralsoshouldbeundercontrol.Thenished
connection is shown in 2E.
2A 2B
2C 2D
2E
H-1000 Fuel Cell Stack User Manual V4.4 15
STEP3:
Connectthestacktoastabilizedvoltagesupplythroughthe“13VDC”connectors(3A),andthe
voltage of the power should be between 12V and 14V.
STEP4:
KeeptheSCU(ShortCircuitUnit)switchat“-”forusualuse.
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
4A
STEP5:
Connect the output of the hydrogen supply valve to the stack (see the arrow on the valve). The
hydrogen supply valve will prevent damage from the hydrogen while the stack is off. Pay attention
tothedirectionoftheconnectionoftheHydrogensupplyvalve.Thenishedconnectionisshown
in 5H.
5B
5A
H-1000 Fuel Cell Stack User Manual V4.4 16
5D
5E
5C
5F
5G
5H
H-1000 Fuel Cell Stack User Manual V4.4 17
STEP6:
Connect the stack to the purge valve through the filter for a longer running time and a better
performance (6A-6F). 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.
6A
6C
6B
6D
6E 6F
Note: 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.
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