Horizon Fuel Cell Technologies H-500 User manual

H-500 Fuel Cell Stack
User Manual
Updated 14 Aug. 2013
Model No.: FCS-C500
Manual_FCS-C500_V1.1_EN

Manual_FCS-C500_V1.1_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-500 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 
  specicfuelcell.
 ● Operatethefuelcellwithvalvesandblowers,thatarenotprovidedbyHorizonfor
  thespecied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speciedinthe
  usermanualprovideforthespecic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-C500_V1.1_EN
Table of Contents
1. Safety..............................................................................................
2. Terminology.......................................................................................
3. Stack and System Component Information......................................
4.TechnicalSpecications...................................................................
5. System Set Up..................................................................................
6. Notes for the set up ..........................................................................
7.SystemSetupDiagram....................................................................
8.OperatingProcedure........................................................................
9. Polarization Curves...........................................................................
10. Storage and Re-use..........................................................................
11. Troubleshooting&System Checks......................................................
12.FuelCellDrawing.............................................................................
13. FAQ.................................................................................................
1
6
10
12
13
20
22
23
26
27
28
32
33

Manual_FCS-C500_V1.1_EN 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.
•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ammablesubstance.Itis
highlycombustibleinthepresenceofoxygenandburnswithacolourlessame.
Leakinggasmaybehotandposeaburndanger.Stoptheowofgas–ifyouarenotindanger–
andusewatertocoolthearea.Ifreoccurs,donotattempttoextinguishames,allowthere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.

Manual_FCS-C500_V1.1_EN 2
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tting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xed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difcult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dened.Factorsknowntoinuence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, 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.

Manual_FCS-C500_V1.1_EN 3
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ames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ammable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ammable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deciency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.

Manual_FCS-C500_V1.1_EN 4
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22.8VDC(opencircuitvoltage).Thisvoltagedecreasesascurrentisdrawn
from the stack. The stack produces 14.4V 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.

Manual_FCS-C500_V1.1_EN 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.
Thesetemperaturesaresufcient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.

Manual_FCS-C500_V1.1_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.
Humidication:
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owchannelsvia
purge valve.
SCU:
Shortcircuitunit–theshortcircuitwillbecontrolledforgoodperformanceofthe
stack.
Mass ow per minute:
The amount of hydrogen consumed to run the fuel cell at a certain power.
HFCT:
Horizon Fuel Cell Technologies

Manual_FCS-C500_V1.1_EN 7
B
A
C
D
E
F
G
H
A: Warning lable
B: Blower
C: Controller connector
D: FC- connector
E: FC+ connector
F: Grounding cable
G: Hydrogen supply valve
H: Hydrogen purging valve
Note: Pictures in the manual are only for reference, takes material object as the
standard.

Manual_FCS-C500_V1.1_EN 8
A: Hydrogen input connector
B: Hydrogen output connector
C: This side up label
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 nished using, connect the silicon tube between
the input and output for keeping the membrane humidity. See FAQ how to
maintain the fuel cell stack.
A
C
B
D

Manual_FCS-C500_V1.1_EN 9
F
E
C
A
B
A: Logo
B: SCU(short circuit units) switch
C: ON/OFF button
D: Controller connector
E: Controller power supply DC 13V-
F: Controller power supply DC 13V+
G: Connect to Load+
H: Connect to FC+
I: Connect to FC-
DG
H
I

Manual_FCS-C500_V1.1_EN 10
3. Stack and System Component Information
6. Blowers
Supply air to the fuel cells and meanwhile decrease the
temperature in the stack.
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.
4. Short Circuit Unit
The short circuit unit can be turned on or off depending
on what application the stack is to be used in. When the
short circuit unit turns on, it can enhance performance of
the stack in applications where the stack is turned off for
prolonged periods.
5. On/Off Switch
It is the switch of the controller. Hold it for 2 seconds for
either on or off.
3. H2 Purging Valve
The purging valve purges out the water and air gas
redundant in the fuel cells.

Manual_FCS-C500_V1.1_EN 11
7. Controller Connector
Connectthestackcablestotheleadwiresof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 output & H2 Input
H2 output: connect the tube shown in 11 below.
H2 input: connect the tube shown in 11 below with the
hydrogen pressure between 0.45-0.55Bar.
.
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 . Fittings
For connecting the load.
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 6mm outer diameter and 3mm inner diameter is
connected to the purging valve on one end and the H2
OUTtheother.

Manual_FCS-C500_V1.1_EN 12
4. Technical Specication
*The ow rate may change with the power output
**System electronics need external power supply
*** The Specication is subject to change without notice.
Type of fuel cell PEM
Number of cells24
Rated Power 500W
Performance 14.4V @35A
H2 Supply valve voltage 12V
Purging valve voltage 12V
Blower voltage 12V
ReactantsHydrogen and Air
External temperature 5 to 30ºC
Max stack temperature 65ºC
H2 Pressure0.45-0.55bar
Hydrogen purity
≧99.995﹪dry H2
Humidification self-humidified
CoolingAir (integrated cooling fan)
Weight (with fan & casing) 2520grams(±50grams)
Controller 400 grams(±30grams)
Dimension 13cm x26.8 cm x 12.25cm
Flow rate at max output* 6.5L/min
Start up time ≦30S at ambient temperature
Efficiency of stack 40% @ 14.4V
Low voltage shut down 12V
Over current shut down 42A
Over temperature shut down
65
℃
External power supply** 13V(±1V), 5A

Manual_FCS-C500_V1.1_EN 13
5. System Set-Up
STEP 1:
Connect the connectors of the controller and the stack to get the blower, the temperature sensor,
thehydrogensupplyvalveandthepurgevalveundercontrol.Thenishedconnectionisshownin
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. 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 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 battery voltage is required to be 12-14V.
9. Keep the SCU always on. Only when it causes your load operating in difculty, 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.
1
2
3
4
5
6
7
8
Controller connector
Wire colours Connector pin # Periferals controlled
Blue #1 & #5 Hydrogen purge valve
Yellow #2 & #6 Hydrogen supply valve
Red and Black #3 & #7 Blowers (Red= +ve, Black= -ve)
Red #4 & #8 Temperature Sensor

Manual_FCS-C500_V1.1_EN 14
STEP 2:
Connectcontroller"FC+"tothestack"FC+"andcontroller"FC-"tostack"FC-&Load-".Thenished
connection is shown in 2B.
2A 2B
STEP 3:
Connectthecontrollertoastabilizedpowersupplythroughthe“13VDC”connectors(3A),andthe
external power supply should be 13V(±1V), ＜5A.
3A

Manual_FCS-C500_V1.1_EN 15
STEP 4:
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.
4A
STEP 5:
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 letter "P"
refers to the hydrogen input and "A" refers to hydrogen output.
Thenishedconnectionisshownin5E.
5B
5A

Manual_FCS-C500_V1.1_EN 16
5D
5E
5C
Warning:The tube between the
hydrogen pressure regulator and
the fuel cell gas input is required to
be less than 30cm.
STEP 6:
Connect the stack to the purge valve through the filter for a longer running time and a better
performance(6A-6D).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 6B

Manual_FCS-C500_V1.1_EN 17
6C 6D
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.
7A 7B
STEP 7:
Use the M4 (7mm) sleeve to unscrew the nut and then connect the grounding cable (7A-7B). Use
anothersleevetoxthenutintheopposite,andthenatthesametimetightthegroundingcable
nut.Thenishedconnectionisshownin7B.
Note: After the fuel cell stack is nished using, disconnect the grounding cable.