Intelligent Energy Portable Load Unit User manual

Portable Load Unit
and Reconditioning Dongle
User Manual
Users must read all instructions provided and retain the manual for future reference
Document No: 1038842

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· The Portable Load Unit should only be used with compatible
Intelligent Energy fuel cell products.
· The customer is responsible for ensuring all technicians and pilots
are suitably trained, accredited and in compliance with local laws
and health and safety regulations.
· The customer is responsible for ensuring the safe operation of the
Portable Load Unit and Fuel Cell Power Module at all times.
· The Portable Load Unit is not to be used in dusty, smoky or corrosive
gas environments.
· Do not use the Portable Load Unit in rain or snow.
· Do not open or dismantle the Portable Load Unit.
· Do not remove any external covers or cowlings.
· Do not use Portable Load Unit if the unit is damaged.
· The Portable Load Unit should be inspected for damage prior to use.
1 Safety warnings 3
2 Portable Load Unit introduction 4
2.1 Portable Load Unit description 4
2.2 Product specification 4
2.3 Compatible Intelligent Energy products for the
Portable Load Unit 4
3 Portable Load Unit 5
3.1 Reconditioning dongle 5
4 Fuel Cell Power Module reconditioning
setup process 6
4.1 Mechanical setup for reconditioning 6
4.2 Connection of the Portable Load Unit 6
4.3 Connection of the Reconditioning Dongle 6
5 Procedure for reconditioning an FCPM 7
6 Portable Load Unit LED states 7
7 Portable Load Unit troubleshooting 7
8 Contact Intelligent Energy Product Support 7
9 End of life treatment and disposal 8
10 EU Declaration of Conformity 8
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 Fuel Cell Power Modules and the Portable
Load Unit and their usage in connection with all stationary and UAV applications. 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 the operating Fuel Cell Power Module
and the Portable Load Unit 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 stationary and portable power applications, 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. 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 fuel cell system) for any damage caused as a result of the 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.
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
[e-mail]

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4Portable Load Unit introduction Portable Load Unit2 3
Product specification
2.1
2.3
3.1
2.2
Dimensions PLU 205 × 155 × 250 mm
Dimensions RCD 45 × 26 × 10mm (Cable 50mm)
Mass PLU 5000g
Mass RCD 30g
Input Voltage 24V
Operating Temperature +5 to +35°C
Max Altitude 3000m
Certification CE and FCC
Input Electrical Connector XT60 Male
Maximum Power Draw 900W
Status LED
Stop button
Reconditioning Dongle
Power connection point Reconditioning Dongle
Portable Load Unit description
The Portable Load Unit (PLU) should be used with an Intelligent Energy Fuel
Cell Power Module (FCPM) and the Reconditioning Dongle (RCD). The PLU
enables the fuel cell stack to be kept at optimal performance, especially after
periods of non-operation.
To allow the FCPM to be reconditioned to an optimal state, the function of
both the PLU and RCD should be understood. The RCD issues commands to the
FCPM which accelerates the reconditioning process. The PLU allows the FCPM
to deliver maximum power in a controlled manner.
Compatible Intelligent Energy products for the Portable Load Unit
The Portable Load Unit can be used with the following fuel cell products from
Intelligent Energy:
· 650W FCPM
· 800W FCPM
Reconditioning Dongle
Air inlet
Air exhaust
FCPM connection

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6Procedure for reconditioning an FCPM
Portable Load Unit troubleshooting
Portable Load Unit LED states
Contact Intelligent Energy Product Support
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For all other issues and questions please contact your local
Intelligent Energy representative or the Product Support team by email
[email protected]
To carry out a reconditioning cycle, after the components have been connected
to the FCPM, as described in Section 4 above, use the following process. It should
be noted that during reconditioning the FCPM will run loudly and periodically go
silent for a few seconds. In addition the PLU status LED will occasionally flash orange
briefly. This is expected and normal behaviour.
· Start up the FCPM in the normal way (long press, then a short press)
(See FCPM manual for full startup procedure)
· Check that the PLU LED is flashing green (the FCPM LED will be flashing green)
· Verify that the FCPM is running
· Allow the FCPM and PLU to operate for 20 minutes (during Reconditioning the
FCPM will run and the fan will be on high)
· Press PLU Stop button to switch off the PLU
· Hold the FCPM button to switch off the FCPM
· Disconnect PLU and RCD from the FCPM
Fault Cause Action
Red flash Over temperature fault 1. Switch unit off
2. Disconnect FCPM from PLU
3. Wait for 10mins to cool down
4. Restart PLU
5. If the fault persists Contact Intelligent Energy
Product Support
Over voltage on
input fault
LED Colour LED Mode Status
Green Flash Operational, dissipating power
Amber Flash Operational, not dissipating power
Red Flash Fault
Any colour Fast flash Boot loader fault
RCD port
Regulator interface
Micro SD card slot
(supplied)
PLU power
connection
point
FCPM power output
Customer interface
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FCPM reconditioning setup process4
4.1
4.3
4.2
Mechanical setup for reconditioning
The PLU and FCPM should be located on a stable surface for reconditioning. The
Hydrogen source should be secured in accordance with local regulations. There should
be adequate ventilation for operation of the FCPM and cooling air flow of the PLU.
Connection of the Portable Load Unit
The FCPM should be connected from the power out port to the power connection port
on the PLU, using a standard XT60 power cable.
Connection of the Reconditioning Dongle
The Reconditioning Dongle should be connected to the Reconditioning port 1
on the FCPM.
The FCPM will need the hybrid battery and fuel connections as for normal operation.
See FCPM manual.
Note:

© Intelligent Energy Limited 2019. All Rights Reserved.
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
basis of any contractual relationship with a third party. Printed November 2019. 55630-IE-UM-201911
Published by: Intelligent Energy Ltd, Charnwood Building, Holywell Park, Ashby Road, Loughborough LE11 3GB. Tel: [phone]
Document No: 1038842. (Registered in England with company number: 03958217).
T+441509 271 271 [e-mail]
Intelligent Energy Charnwood Building, Ashby Road, Loughborough, LE11 3GB, UK
www.intelligent-energy.com
End of life treatment and disposal
EU Declaration of Conformity
In accordance with EN ISO 17050-1:2010
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Intelligent Energy Limited of
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:
·Portable Load Unit (PLU) Part number: 10009831
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
17 October 2019
A copy of the official version of this certificate duly signed by an authorised
signatory of the manufacturer is available upon request by emailing
[e-mail]
Intelligent Energy Limited, Charnwood Building, Holywell Park, Ashby Road,
Loughborough, Leicestershire, United Kingdom, LE11 3GB
When the PLU reaches end of life please contact Intelligent Energy for support with
disposal at [email protected]om