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Page 2
CopyrightHorizonFuelCellTechnologies–T‐2.5KW_UM_V1.5Page2
Table of Contents
Table of Contents ..........................................................................................................................2
1.Important Safety Information................................................................................................3
1.1General information.....................................................................................................................3
1.2Using Hydrogen...........................................................................................................................3
1.3Handling Compressed Gas Cylinders ..........................................................................................4
1.4Hydrogen Leakage.......................................................................................................................4
1.5Flammability and volatility..........................................................................................................5
1.6Oxygen Depletion ........................................................................................................................5
1.7Electrical Safety ...........................................................................................................................6
1.8High Temperature ........................................................................................................................6
1.9Terminology.................................................................................................................................7
2.Introduction.............................................................................................................................8
2.1About This Manual ......................................................................................................................8
2.2PEM Technology .........................................................................................................................8
2.3The Horizon Solution...................................................................................................................9
3.The T-2.5KW System............................................................................................................10
3.1T-2.5KW Models .......................................................................................................................11
3.2Chassis Features.........................................................................................................................12
4.Operation ...............................................................................................................................29
4.1Hydrogen Connection ................................................................................................................30
4.2Wire Connection ........................................................................................................................31
4.3Grounding ..................................................................................................................................32
5.Applications Engineering .....................................................................................................32
5.1Storage Requirements ................................................................................................................32
5.2Site Requirements ......................................................................................................................32
5.3Load Engineering.......................................................................................................................32
Appendix A: T-2.5KW Specifications .......................................................................................33
Appendix B: System error and alarm information..................................................................34
Appendix B-1: Last ALM: XXXX............................................................................................34
Appendix B-2: Last ERR: XX...................................................................................................34
Appendix C: Circuit Diagram of Signal Output Connector ..................................................35
Appendix D: Circuit Diagram of Signal Input Connector .....................................................36
Appendix E: T-2.5KW Drawing:...............................................................................................37
Page 3
CopyrightHorizonFuelCellTechnologies–T‐2.5KW_UM_V1.5Page3
1. Important Safety Information
Pleasereadallinstructionscarefullypriortoproductuseandkeepthismanualforfuture
reference.
Thesafetyguidelinesincludedheremaynotcovereverysituation.Usecommonsense.
AlthoughtheT‐seriessystemsaredesignedwithsimple,easy‐to‐useinterfaces,prudentsafety
measuresshouldbefollowed.
1.1 General information
Forthisunittogenerateelectricalpower,asupplyofhydrogenfuelisnecessary.Itisimportantfor
anyoperatortobeawareof,understand,andfollowalllocalsafetyrequirementsrelatedtothe
handlingofhydrogenandcompressedgases.Ensurethatyourfacilityconformstoalllocal
regulatoryrequirements,includingbuildingcodesandrecommendations.
Thefuelcellsystemhasbuilt‐insafeguardsandisdesignedtoshutdownautomaticallyifanyout
ofrangeoperatingconditionoccurs.Possiblesituationsincludelowcellvoltage,highcurrent,high
temperature,lowfuelpressure.
Donotoperatethestackonagradeofmorethan45℃.
Donotconnectordisconnectpowercableswhenthefuelcellstackisenergised.
Donotdismantlethesystem.ContactHorizonifyouhaveanyconcernsaboutoperation.
1.2 Using Hydrogen
WARNING!FIREOREXPLOSION
Keepallsourcesofignitionawayfromhydrogen.
Thisunituseshydrogenfuel.Hydrogenisacolourless,odourlessandflammablesubstance.Itis
highlycombustibleinthepresenceofoxygenandburnswithacolourlessflame.
Leakinggasmaybehotandposeaburndanger.Stoptheflowofgas–ifyouarenotindangerand
usewatertocoolthearea.Iffireoccurs,donotattempttoextinguishflames,allowthefireto
burnout.
Preventoverexposuretohydrogen.Hydrogenisnon‐toxicbutcanactasasimpleasphyxiantby
displacingtheoxygenintheair.Therearenowarningsbeforeunconsciousnessresults.When
operatingthestackinanenclosure:
Ensureventilationslotsareclearandunobstructedatalltimesduringoperation.
Operatewithinthetemperatureslimitsstatedinthemanual.
Neveroperateifanalarmconditionexists.
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CopyrightHorizonFuelCellTechnologies–T‐2.5KW_UM_V1.5Page4
1.3 Handling Compressed Gas Cylinders
WARNING
Donothandlecompressedhydrogengascylinderswithouttrainingorexperience.
Useapressureregulatortocontrolthefuelinletpressuretothesystem.
Donotalterthefittingonaregulator.Askexperiencedpersonnelforhelp.
Donotattempttoforcegascylinderthreads.
Nevertransportagascylinderwithregulatorsattached.Ensurecylindercapsareinplace.
Alwaysuseacylindercartwithasafetystraporchain.
Secureahigh‐pressurecylindertoabench,post,orfixedobjecttoavoidaccidentalcontact.
AvoidunnecessarycontactwithOn/Offvalves.Theycaneasilymoveto“On”byaccident.
1.4 Hydrogen Leakage
Hydrogeniscolourless,odourlessandtasteless.Hydrogenisnon‐toxicbutcanactasasimple
asphyxiantbydisplacingtheoxygenintheair.Therearenowarningsymptomsbefore
unconsciousnessresults.
WARNING
Inhalinghydrogencanleadtounconsciousnessandasphyxiation.Hydrogenmoleculesaresmaller
thananyothergas,makinghydrogenmoredifficulttocontain.Itcandiffusethroughmany
materialsconsideredairtight.Fuellines,non‐weldedconnections,andnon‐metalsealssuchas
gaskets,O‐rings,pipethreadcompoundsandpackingspresentpotentialleakageorpermeation
sites.Furthermore,hydrogen’ssmallmoleculesizeresultsinhighbuoyancyanddiffusivity,so
leakedhydrogenwillriseandbecomedilutedquickly.
Constantexposuretohydrogencauseshydrogenembrittlementinmanymaterials.The
mechanismsthatcausehydrogenembrittlementeffectsarenotwelldefined.Factorsknownto
influencetherateandseverityofhydrogenembrittlementincludehydrogenconcentration,
hydrogenpressure,temperature,hydrogenpurity,typeofimpurity,stresslevel,stressrate,metal
composition,metaltensilestrength,grainsize,microstructureandheattreatmenthistory.
Moisturecontentinthehydrogengasmayleadtometalembrittlementthroughtheacceleration
oftheformationoffatiguecracks.Hydrogenembrittlementcanleadtoleakageorcatastrophic
failuresinmetalandnon‐metalliccomponents.
Asapreventativemeasure,thestackmustbeoperatedinawell‐ventilatedareainordertoinhibit
potentialhydrogenaccumulation.
WARNING
Alwaysoperatethestackinawell‐ventilatedareaandensurethatventilationslotsare
unobstructed.
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CopyrightHorizonFuelCellTechnologies–T‐2.5KW_UM_V1.5Page5
1.5 Flammability and volatility
Hydrogenisflammableoverconcentrationsof4–75%byvolumeinair,andisexplosiveover
concentrationsof15–59%.Asaresult,evensmallleaksofhydrogenhavethepotentialtoburnor
explode.Leakedhydrogencanconcentrateinanenclosedenvironment,therebyincreasingthe
riskofcombustionandexplosion.
Hydrogenflamesarepaleblueandarealmostinvisibleindaylightduetotheabsenceofsoot.Due
toitshighbuoyancyanddiffusivity,burninghydrogenrisesunlikegasoline,whichspreadslaterally.
Aflammableorexplosivehydrogenmixtureiseasilyignitedbyasparkorevenahotsurface.The
autoignitiontemperatureofhydrogenis500°C(932°F).Theenergyofahydrogengasexplosionis
2.4timesthatofgasolineormethaneforanequalvolume.Hydrogengasexplosionsaretherefore
moredestructiveandcarryfurther.
WARNING
Amixtureofhydrogenandairispotentiallyflammableandexplosiveandcanbeignitedbyaspark
orahotsurface.
Asinthepresenceofanyfuel,allsourcesofignition,includingsmoking,arenotpermittedinthe
vicinityofthestack.
WARNING
Keepallsourcesofignitionaway.Smokingisnotpermittedinthevicinityofthestack.
1.6 Oxygen Depletion
Oxygenisacolourless,odourless,non‐toxicandtastelessgas.Oxygenisessentialforlifein
appropriateconcentrations.
Ambientaircontainsupto21%oxygen.Oxygenlevelsbelow19.5%arebiologicallyinactiveand
mayactassimpleasphyxiants.Effectsofoxygendeficiencymayinclude:rapidbreathing,
diminishedmentalalertness,impairedmuscularcoordination,faultyjudgement,depressionofall
sensations,emotionalinstability,andfatigue.Asasphyxiationprogresses,nausea,vomiting,
prostration,andlossofconsciousnessmayresult,eventuallyleadingtoconvulsions,coma,and
death.Atconcentrationsbelow12%,immediateunconsciousnessmayoccurwithnopriorwarning
symptoms.
WARNING
Lackofoxygencanleadtounconsciousnessandasphyxiation.
Asapreventativemeasure,thestackmustbeoperatedinawell‐ventilatedareainorderto
compensatefortheoxygenusedwithinthefuelcells.
WARNING
Alwaysoperatethestackinawell‐ventilatedarea.
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CopyrightHorizonFuelCellTechnologies–T‐2.5KW_UM_V1.5Page6
1.7 Electrical Safety
WARNING
Avoidcontactwithanexposedfuelcellstack.Electricalshockcancausepersonalinjuryordeath.
•Donottouchfuelcellplatesoranyelectricalcomponentsatanytime.Arunningfuelcellstackis
apotentialelectricalhazardthatcancauseburnsorelectricalshock.
•Donotwearmetallicjewelryrings,bracelets,watchbands,ornecklaces–whenyouarecloseto
anexposedfuelcellstack.
•Minimisestaticdischarge.Ifpossible,groundallequipment.
•Minimiseconductivity.Avoidcontactwithsurfacesthatareincontactwithwaterorgases.Do
notoperateorstoreinwetordampconditions.
•Neverusedamagedextensioncords.
WARNING
Donottouchfuelcells,cellvoltagemonitoringequipmentorelectricalcomponents.Electronic
componentscanalsobedamagedastheresultofstaticdischarge.Tominimisethis,groundall
equipmentincontactwiththestack.Neverusedamagedextensioncords.Minimiseconductivity
byavoidingsurfacesincontactwithwater;handsandclothesmustbedry.Donotoperateorstore
thestackinwetordampconditions.
WARNING
Minimisestaticdischarge.Groundallequipment.Residualreactantswithinthestackcandevelopa
chargeinamatterofminuteswhenturnedoff.Areadingofzerovoltsacrosstheentirestackdoes
notguaranteethatallfuelcellsareuncharged.
WARNING
Alwaysassumethatthefuelcellstackischarged.Jewelry(suchasrings,necklaces,braceletsand
watches)mayconcentrateanelectriccurrentwhenitcomesintocontactwithcharged
components,orwhenashockpassesthroughthehumanbody.Accordingly,nojewelryshouldbe
wornnearthestack.
WARNING
Donotwearjewelrynearthestack.
Nopungentodor,paintandperfumeareallowedaroundstack.
1.8 High Temperature
Thefuelcellstackisdesignedtooperateatnormaltemperature.Operatingthesystemwhenthe
environmenttemperatureisabove45ºCmaycausetheperformancedrop.
WARNING
Avoidcontactwiththefuelcellstackorcomponentsthatconveyprocessorcoolingair.
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CopyrightHorizonFuelCellTechnologies–T‐2.5KW_UM_V1.5Page7
1.9 Terminology
PEM fuel cell:
APEM(ProtonExchangeMembrane)fuelcellisadevicethatconvertshydrogenandoxygeninto
waterandelectricity.
Reactants:
Reactantisamaterialusedtostartachemicalreaction.Inthefuelcellthereactantsareairand
hydrogenbywhichtheelectricitywillbegenerated.
Humidification:
Humidity,thefuelcellsneedforrunning.
Blower:
Supplyairtothefuelcellsandmeanwhiledecreasethetemperatureinthestack.
Mass flow per minute:
Thetotalamountofthehydrogenflowthroughthefuelcelleveryminute,whichthehydrogen
supplycanbecalculated.
HFCT:
HorizonFuelCellTechnologies
Page 8
CopyrightHorizonFuelCellTechnologies–T‐2.5KW_UM_V1.5Page8
2. Introduction
ThankyouforchoosingHorizon’sT‐2.5KWsystemasyourpowergeneratingsolution.Basedon
Horizon’sexpertiseinmodular,redundantfuelcellsystems,theT‐2.5KWsystemisthenextstepin
simplicity,scalability,modularityandreliability,providingclean,quiet,andreliablepowerfor
backuppowerapplications.
2.1 About This Manual
Thismanualisintendedtoprovidecustomerswithalltheinformationneededtoselect,install,
operate,maintain,andtroubleshoottheT‐2.5KWsystem.
2.2 PEM Technology
Whilethereareanumberoffuelcelltechnologiesavailable,themostcommonandpractical
technologyforstandbypoweristheprotonexchangemembrane,orPEM,fuelcell.
TheonlyinputstothefuelcellareindustrialGrade3.5hydrogen(99.995%H2concentration)and
oxygen(air),withtheonlybyproductsbeingpurewater/vaporandheat.Asaresult,fuelcellsare
consideredagreentechnology,makingthemanattractivesolutionforinstallationswithemissions
restrictions.
Oneoftheotherattributesofafuelcellthatmakesitattractivefordeploymentinmany
applicationsisthatafuelcellproducesDCpower.Thismakesafuelcellakintoastandbyrectifier
source,asthepowerprovidedfromthefuelcellcanbedirectlyconnectedtothesite’sDCpower
bus.Inanoutagesituation,thefuelcellturnsonautomatically,providingDCpower,whichwas
formerlyprovidedbytherectifiers.DCoutputalsomakesthefuelcellideallysuitedforhybrid
applicationswithsolar(photovoltaic),windandbatterysystems.
Thefuelcellisakintoagenerator,inthatthefuelcellissizedforthepowerrequirement,andcan
runindefinitelyprovidedithasasourceoffuel.Thismeansfuelcells,whencoupledwithan
appropriatelysizedfuelstoragesolution,canfunctioneffectivelyforlongreservetimesasa
standbypowersourceincustomerapplications.
TheT‐seriessystemisdesignedtobeabackuppowersolutionforDCpowerapplicationswithin
thetransportation,security,wirelineandwirelesstelecommunications,utility,andgovernment
sectors.
TheT‐seriessystemisintendedtoaugmenttraditionalDCpowersystems.AsimplifiedDC
connectiondiagramisshowninFigure2‐1.
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CopyrightHorizonFuelCellTechnologies–T‐2.5KW_UM_V1.5Page10
3. The T-2.5KW System
ThissectiondescribestheoperatingprinciplesoftheT‐2.5KWsystem.TheT‐2.5KWsystem
functionsasafueledDCpowersource.Theunitcanbestartedandstoppedmanuallyor
automatically.BecauseitselectricaloutputisDC,theT‐2.5KWsystemcanbeinstalleddirectlyin
parallelwithotherDCequipment.Theratedoutputvoltageis48V.
Forproperoperation,theT‐2.5KWrequiresairflow.Asourceofcleanairmustbesupplied.The
exhaustairishumid,whichmaycondenseoncoolersurfaces,andmaycontaintracehydrogen,
andthereforeshouldbeventedoutdoors.Thereisasmallperiodicfuelpurge(or“bleed”)that
mustalsobeventedoutdoors.AminimuminstallationforbasicoperationrequirestheT‐2.5KWto
haveallairexhaustsandfuelinletandoutletexhaustconnectionsplumbed,andthattheunitbe
connectedtoaDCbusattheappropriatevoltage,withanappropriateload.Acomplete
installationwillincludeprotectionfromweatherandtemperature.AllHorizonoutdoorenclosures
provideproperprotectionfromweatherandtemperature.
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3
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Page 1
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Page 1
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Page1
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Page 17
CopyrightHorizonFuelCellTechnologies–T‐2.5KW_UM_V1.5Page17
Whenthesystemstartsinmanualmode,thesystemwillneverreturntoStandby.Thefrontpanel
ON/OFFswitchallowstheusertomanuallyturnthesystemontogeneratepower.Andtheonly
methodtostoptheunitisbypressingtheswitchagain.
WhenchoosePrimaryModeorManualMode,pressentertothenextinterface,thenpressenter
againtostartthesystemorpressupkeytoresetthesystemmode.
3) LowVoltMode
Whenthesystemstartsinlowvoltmode,theunitwillattempttoachieveanoutputvoltagewhich
isthevaluesetintheFloatVoltfield.Oncethesystemhasachievedandheldfloatvoltagefora
periodoftime(setintheFloatTimerfield),theunitwillreturntoStandby.Thismodefunctionsas
abatterychargemode,chargingupanexternalbatterytothefloatvoltage,andthenreturningto
Standby.Whenthebatteriesdischargetothelowvoltagethreshold,thesystemwillstartagain.
Thischarge/dischargemethodisusefulforverysmallloads,wherethebatteryisproperlysizedto
supportthesmallload,andisrechargedbythefuelcell.Thefuelcellsystemwilloperate
“thermostatically”,turningonatthelowvoltagethreshold,andturningoffafterholdingthe
outputatthefloatvoltsettinguntilthefloattimerexpires.Whenprimarypowerisrestoredtothe
siteandthebusvoltageisheldatorabovethefloatvoltsettinguntilthefloattimerexpires,the
unitwillreturntoStandbyandremainthere,providedthebusvoltageremainsabovethelowvolt
threshold.
Lowvoltmodeisausefuloptionforoff‐gridhybridsystemsthatarerelativelylowpower.Thefuel
cellisusedtochargethebatteries,andthebatteriesthencarrytheloadforextendedperiods.The
totalsystemsolutionismostefficientforsmallloadsthatare<5%ofthefuelcellcapacity,withan
appropriatelysizedbattery.
Whenstartedinlowvoltmode,thefuelcellwilldeliverpoweruntiltheoutputbusvoltage
reachestheuser‐setfloatvoltage(whetherbecausetheunithassufficientpowertosupportthe
loadandchargethebatteries,orbecausetheexternalpowerwasrestored).Oncethefloatvoltage
isachieved,auser‐adjustablefloattimerwillstart.Whenthefloattimerexpires,theunitwillstop
deliveringpowerandreturntoStandby.
LowVoltThresholdintheuserinterfaceisusedtosetthevoltageatwhichthesystembeginsto
operatewheneitherLowVoltModeisenabled.Thisvoltagemustbeatleast0.5Vbelowthevalue
setinFloatVolt.
Thelowvoltthresholdrangeisfrom43.2Vto53V(factorydefaultis48V).
FloatVoltintheuserinterfaceisusedtosetthevoltageatwhichthesystemreturnstoStandby.
Andtherangeoffloatvoltisfrom50Vto57.6V(factorydefaultis52V).
FloatTimerintheUserInterfaceisusedtosetthetimerthatdeterminestheendofthefloatmode.
Floattimercanbesetfrom5to120minutesin5minuteincrements(factorydefaultis30
minutes).
Conditionsetting
Copyrigh
t
Fuelcell
backup
p
minutes
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Duringt
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valuewh
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Page 1
8
Page1
8
ance.Ifth
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Table 3-
4
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ay
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5KW_UM_V
1
4
Operation
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System st
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Spend 40
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System o
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System o
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System o
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Ambient t
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Fuel cell t
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Page 1
9
Page1
9
p
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elcell
9
9
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