Intelligent energy 10005518 User manual

Lightweight Hydrogen Regulator

User Manual

Users must read all instructions provided and retain the manual for future reference

Document No: 10010368

1 Safety warnings 3

2 Lightweight Hydrogen Regulator 4

2.1 Product speciﬁcation 4

2.2 Main components 5

3 Assembly and connection 6

3.1 Assembly of regulator to cylinder 6

3.2 Filling of cylinder 7

3.3 Hydrogen fuel 7

3.4 Hydrogen connection 8

4 Refuelling 9

5 Troubleshooting 9

6 Contacting Intelligent Energy Product Support 10

7 End of life treatment and disposal 10

8 EU Declaration of Conformity 11

Contents

Federal Communications Commission (FCC) Statement

This equipment has been tested and found to comply

with the limits for a Class B digital device, pursuant to part

15 of the FCC rules. These limits are designed to provide

reasonable protection against harmful interference in a

residential installation. This equipment generates, uses

and can radiate radio frequency energy and, if not installed

and used in accordance with the instructions, may cause

harmful interference to radio communications. However,

there is no guarantee that interference will not occur in

a particular installation. If this equipment does cause

harmful interference to radio or television reception,

which can be determined by turning the equipment

oﬀ and on, the user is encouraged to try to correct the

interference by one or more of the following measures:

· Reorient or relocate the receiving antenna.

· Increase the separation between the

equipment and receiver.

· Connect the equipment into an outlet on a circuit

diﬀerent from that to which the receiver is connected.

· Consult the dealer or an experienced

radio/TV technician for help.

This device complies with Part 15 of the FCC Rules.

Operation is subject to the following two conditions:

(1) this device may not cause harmful interference and

(2) this device must accept any interference received,

including interference that may cause undesired operation.

You are cautioned that changes or modiﬁcations not

expressly approved by the party responsible for compliance

could void the user’s authority to operate the equipment.

The CE label shows that the product complies with the

basic requirements of the applicable directives. For the

declaration of conformity contact the manufacturer at

servicing@intelligent-energy.com

· Only qualiﬁed technicians trained in high pressure ﬂammable gases

must carry out ﬁtting of regulators and ﬁlling of cylinders, and do so in

accordance with local laws and Health and Safety (H&S) regulations.

· The customer is responsible for ensuring all technicians and pilots are

suitably trained, accredited and in compliance with local laws and H&S

regulations.

· The customer is responsible for ensuring the safe operation of the

Lightweight Hydrogen Regulator.

· Do not open or dismantle the Lightweight Hydrogen Regulator.

· Do not remove any external covers or cowlings.

· Pressurised hydrogen present. Highly ﬂammable!

· Do not use the Lightweight Hydrogen Regulator if the unit is damaged.

· The Lightweight Hydrogen Regulator should be inspected for damage

and leak checked prior to use.

· Not to be used in residential areas (EMC).

When shipping or transporting your Unmanned Aerial Vehicle and

Fuel Cell Power Module (FCPM), the FCPM must always be disconnected

from the hydrogen source.

When transporting pressurised gas check for relevant local regulations.

Safety warnings1

This user manual is intended as a general guidance only and does not purport to address the speciﬁc situations

that could potentially arise from the use of the Lightweight Hydrogen Regulator with pressurised hydrogen

systems and their usage in connection with UAVs. The recipient is responsible for ensuring that all personnel

have read and understood this User Manual before being allowed to handle, operate, install and store any

equipment supplied by Intelligent Energy.

The recipient must ensure that any personnel responsible for handling the Lightweight Hydrogen Regulator

with hydrogen cylinders and operating UAVs are suitably trained and certiﬁed in compliance with any

applicable local, state and federal laws and regulations and good industry practice. The recipient is responsible

for complying with any relevant health and safety policies and procedures that may apply to the operation of

UAVs and use and storage of hydrogen on any sites.

Intelligent Energy warrants to the recipient and it will repair and replace any defective equipment resulting

from the authorised use of the equipment provided, in accordance with the warranty terms. Notwithstanding

the above, Intelligent Energy, to the fullest extent permitted by law, accepts no liability (including liability in

respect of any error or defects in the Lightweight Hydrogen Regulator) for any damage caused as a result of

Recipient’s unauthorised use of the equipment provided. The recipient acknowledges that the manner in which

the equipment is stored, used or operated is not under the control of Intelligent Energy Limited.

Intelligent Energy has made every eﬀort to ensure that this User Manual is accurate and disclaims liability for any

inaccuracies or omissions that may have occurred.

4Lightweight Hydrogen Regulator2

Product speciﬁcation

2.1

2.2

Hydrogen Regulator Mass 250g

Maximum regulator (cylinder) pressure 300 Bar/4350 PSI

Output pressure 0.5 Bar ± 0.25 Bar/7 PSI ± 3 PSI

PRV set pressure 2 Bar/29 PSI

Burst disc set pressure 450 Bar/6500 PSI

Cylinder interface M18 ×1.5 or 5/8" UNF thread

Maximum cylinder mass 10kg

Product Overview

The Lightweight Hydrogen Regulator has been designed for use with the

Intelligent Energy UAV FCPMs. It is intended to provide control and safety

features on a lightweight cylinder to allow use on UAVs. It is controlled from an

Intelligent Energy UAV FCPM. The Regulator has been designed to meet relevant

safety standards. It is designed to operate with compressed gaseous hydrogen.

Lightweight Hydrogen Regulator2

Main components2.2

PRV cap

Low pressure PRV

Fill port - 8mm PCP

quick connect

On/oﬀ solenoid valve

control to FCPM

Hydrogen out -

proprietary

connector to FCPM

High pressure

burst disk

Hydrogen in -

cylinder interface

M18 or 5/8" UNF

Pressure

transducer

to FCPM

Prior to operation the cylinder will need to be purged to remove

air impurities.

Once the regulator is ﬂush, apply a maximum torque of 58Nm (42.8ft.lb).

Always conduct a leak check on the completed assembly.

Assembly and connection3

Assembly of regulator to cylinder3.1

By hand, carefully thread the

regulator assembly into the cylinder.

Tighten the regulator until it is mated

ﬂush to the neck of the cylinder.

· Take the cylinder and regulator and inspect for physical damage or debris,

reject if visible to the eye.

· Inspect the mating threads for damage or debris, reject if visible to the eye.

Assembly and connection3

3.2

3.3

Filling of cylinder

Only qualiﬁed technicians trained in high pressure and ﬂammable gases can carry

out ﬁtting of regulators and ﬁlling of cylinders, and do so in accordance with local

laws and Health and Safety (H&S) regulations.

A leak check must be conducted after ﬁlling the cylinder.

Consult local H&S / facilities management for guidance on storage of cylinders and

advisable safety equipment.

Hydrogen fuel

When installing and operating hydrogen systems, hydrogen general safety guidance

should be considered, for more detailed information see:

ISO/TR 15916 – Basic considerations for the safety of hydrogen systems

Hydrogen purity is an important consideration for fuel cell performance, it should

comply with the speciﬁcation in the table below for best performance:

For more details about hydrogen quality see the user manual for your FCPM

or contact Intelligent Energy Product Support, see Section 6

Fuel Characteristics Fuel Requirements

Hydrogen concentration > 99.90 %

Nitrogen, Helium, Argon < 0.10%

Oxygen < 50 ppm

Carbon Dioxide < 2 ppm

Carbon Monoxide < 0.2 ppm

Ammonia < 0.1 ppm

Sulphur containing compounds < 4 ppb

Max particle concentration < 1 mg/kg

Max particle diameter < 75 µm

8Assembly and connection3

3.4 Hydrogen connection

The Lightweight Hydrogen Regulator is designed to be connected to an

Intelligent Energy FCPM, please refer to the FCPM user manual for details of how

to make the hydrogen connection to that unit.

Ensure the hydrogen cylinder and FCPM are securely mounted

before proceeding.

Verify that the connector O-rings are in place and free from damage or debris.

Align the hose connector path with the regulator pins.

Push the hose connector and twist anti-clockwise. It will click when located.

Refuelling4

Symptom Reason(s) Action

High H2pressure fault Gas pressure

regulation fault

Contact Intelligent Energy Product Support

Low H2pressure fault No hydrogen supplied

from cylinder

Cylinder is empty

Gas pressure

regulation fault

1. Check cylinder pressure, reﬁll if needed

2. Inspect the solenoid valve cable

Replace if damaged

If the steps above do not resolve the issue,

contact Intelligent Energy Product Support,

see Section 6

Loss of cylinder pressure Leak between cylinder

and regulator

Leak from the regulator

1. Place cylinder and regulator in a well-

ventilated space, preferably outdoors

2. Purge the gas from the cylinder by lifting

the cap of the PRV, see diagram in section 2.2

3. When the cylinder is empty. A person trained

in the use of pressurised gas should remove

the regulator from the cylinder and inspect

the sealing o-ring. Replace if damaged

4. Reassemble and reﬁll the cylinder

5. Check for leaks

If the steps above do not resolve the issue,

contact Intelligent Energy Product Support,

see Section 6

Troubleshooting5

There are multiple ways to ﬁll cylinders and Intelligent Energy has application notes

available for some ﬁll options. Contact Intelligent Energy Product Support for details,

see Section 6.

10 Contacting Intelligent Energy Product Support6

For all other issues and questions please contact your local

Intelligent Energy representative or the Product Support team by email

[email protected]

End of life treatment and disposal

When the Lightweight Hydrogen Regulator or cylinder reaches end of life

please contact Intelligent Energy for support with reconditioning or disposal

at [email protected]

EU Declaration of Conformity

In accordance with EN ISO 17050-1:2010

Intelligent Energy Limited

Charnwood Building, Holywell Park, Ashby Road, Loughborough, Leicestershire,

United Kingdom, LE11 3GB

In accordance with the following Directive(s):

· 2014/30/EC The Electromagnetic Compatibility Directive

· 2014/95/EU General Product Safety Directive

Hereby declares that:

· 650W/800W Fuel Cell Power Module + Lightweight Pressure Regulator

Part number: 10005518

Is in conformity with the applicable requirements of the Directives set out above and the

following standards documents:

· EN 61000-6-2:2005 Electromagnetic compatibility (EMC) –

Generic standards – Immunity for

industrial environments

· EN 61000-6-4:2007+A1:2011 Electromagnetic compatibility (EMC) –

Generic standards – Emission standard

for industrial environments

A copy of the oﬃcial version of this certiﬁcate duly signed by an authorised

signatory of the manufacturer is available upon request by emailing

sales@intelligent-energy.com

Intelligent Energy Limited, Charnwood Building, Holywell Park, Ashby Road,

Loughborough, Leicestershire, United Kingdom, LE11 3GB

25th June 2018 Document Ref. No. 263-DOC-001

The information contained herein is the intellectual property of Intelligent Energy Ltd and it may not be copied or reproduced in any format.

The information contained in this publication is intended only as a guide and is subject to change as a result of the constant evolution of Intelligent

Energy’s business and its technology. This publication and its contents do not include all details which may be relevant to particular circumstances and

should not be regarded as being a complete source of Information. To the fullest extent permitted by law, Intelligent Energy oﬀers no warranty as to

the accuracy of the content of this publication, shall not be liable for the content of this publication and no element of this publication shall form the