PowerCell PS-5 User manual

PS-5 Fuel Cell System
Instruction Manual

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WARNING! FIRE OR EXPLOSION HAZARD
Failure to follow safety warnings exactly could result in serious injury, death or property
damage.
•Do not store or use gasoline or other flammable vapours and liquids in the vicinity of this or any
other appliance.
•Installation and service must be performed by a qualified installer, service agency or the gas
supplier.
IMPORTANT!
Carefully read all instructions in this manual before attempting to install, prepare, operate,
or service the equipment.
Follow the safety precautions and all warning statements given in the instructions.
Keep the manual for future reference.

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Table of Contents
1Safety precautions ................................................................................................................ 4
1.1 Warning symbols ..................................................................................................................... 4
1.2 General safety.......................................................................................................................... 4
1.3 Stopping the PS-5..................................................................................................................... 6
1.4 Hydrogen gas safety................................................................................................................. 8
1.5 Electrical safety........................................................................................................................ 9
1.6 Disposal.................................................................................................................................... 9
1.7 Field Support............................................................................................................................ 9
2Introduction.........................................................................................................................10
2.1 Type selection guide .............................................................................................................. 10
2.2 Disclaimer............................................................................................................................... 10
2.3 About this manual.................................................................................................................. 10
2.4 Definitions and abbreviations................................................................................................ 11
3System description...............................................................................................................12
3.1 Overview................................................................................................................................ 12
3.2 Fuel cell module..................................................................................................................... 12
3.3 Cooling module...................................................................................................................... 14
3.4 Power and electronics module (PE)....................................................................................... 15
4Installation ..........................................................................................................................16
4.1 Tools and Materials................................................................................................................ 16
4.2 Pre-installation requirements................................................................................................ 16
4.3 Electrical connections ............................................................................................................ 21
4.4 Lifting instruction................................................................................................................... 21
4.5 Internal system connections.................................................................................................. 23
4.6 External system connections ................................................................................................. 24
4.7 Pre-Start Testing .................................................................................................................... 26
4.8 First Start................................................................................................................................ 26
4.9 Optional External Component ............................................................................................... 26
5Operation ............................................................................................................................27
5.1 Quick Guide............................................................................................................................ 27
5.2 User interface......................................................................................................................... 29
5.3 Remote Control Mode ........................................................................................................... 33
6Troubleshooting...................................................................................................................34
6.1 Alarm Stop........................................................................................................................... 34
6.2 Alarm Shutdown ................................................................................................................. 36
6.3 Warnings................................................................................................................................ 38
7Service and Maintenance .....................................................................................................39
7.1 Service intervals..................................................................................................................... 39
7.2 Cleaning.................................................................................................................................. 39
7.3 Changing coolant ................................................................................................................... 40
7.4 Replacing the air filter............................................................................................................ 40
7.5 Replacing fuses ...................................................................................................................... 41
7.6 Hydrogen sensor replacement............................................................................................... 41
8Replacement and additional parts ........................................................................................42
8.1 Coolant................................................................................................................................... 42
8.2 Filter....................................................................................................................................... 42
8.3 Fuses ...................................................................................................................................... 42

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8.4 Cabinet fan............................................................................................................................. 43
8.5 Hydrogen sensor.................................................................................................................... 43
Appendices .................................................................................................................................44
A Technical data........................................................................................................................ 44
B CAN configurations ................................................................................................................ 45
C Connection details ................................................................................................................. 51
D Menu system layout .............................................................................................................. 55
E Declaration of Conformity ..................................................................................................... 56
1 Safety precautions
The PS-5 has multiple layers of protection to reduce the risk and minimise the consequence of any
foreseeable hazard that the system will present. However, external factors to the PS-5, such as
improper use or a faulty installation, can present hazards that the PS-5 cannot control. Read this
manual carefully and follow all instructions and pay attention to the external requirements that the
end user must provide for the installation, found in Section 0. Any deviation from the instructions in
this manual will result in the cancellation of the system warranty.
1.1 Warning symbols
The following symbols are used in this manual:
WARNING
Potentially hazardous situation which could result in severe
personal injury, death, or severe damage to property, if the
instructions are not followed.
CAUTION
Potentially hazardous situation or unsafe practice that could
cause minor personal injury or damage to property, if the
instructions are not followed.
NOTE
Important additional information and recommendations.
1.2 General safety
The following list indicates the general safety points related to the PS-5. Keep in mind that the PS-5 is
a power generation system and should be treated with the same caution as any other electrical
generator system. The end user should think about who will have access to PS-5 and may want to
secure the area to prevent any unauthorised access to the system.
The area surrounding the PS-5 must be kept clear and free of combustible materials,
gasoline, and other flammable vapours and liquids. In addition, no ignition sources
should be present around the PS-5 system.

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Do not block or obstruct the air openings on the PS-5, air openings communicating
with the area in which the PS-5 is installed, or the required spacing around the PS-5.
The air exhaust from the PS-5 is depleted due to part of the oxygen being consumed
in the electrochemical reaction in the PS-5. Unless the air exhaust is properly
ventilated, conditions around the PS-5 may become asphyxiating.
The PS-5 shall never be operated without its protective covers securely attached in
their correct places.
Do not use the PS-5 if any part has been under water. A flood-damaged fuel cell is
potentially dangerous. Attempts to use the PS-5 can result in fire or explosion. A
qualified service agency should be contacted to inspect the PS-5 and to replace all gas
controls, control system parts, electrical parts that have been wet.
When changing any of the serviceable parts of the PS-5, follow all instructions given
in this manual. Failure to do so may result in personal injury or death and may
irreversibly damage the PS-5.
The environmental conditions in which the PS-5 is installed must be pollution degree
2 or better (i.e. office environment) such that there is only non-conductive pollution
in the environment.
If any liquids spill from the PS-5, allow sufficient time for them to cool down before
cleaning them up as internal temperatures can reach 90°C and can present a burn
hazard.
The PS-5 uses an ethylene glycol based coolant which is moderately toxic when
consumed. Do not allow animals or children near coolant spills as ethylene glycol has
a sweet taste and so may taste like food.
Carefully examine the PS-5 installation and make sure that all intake and exhaust
openings are clear and free of obstructions, there are no cracks or gaps in rack that
the PS-5 is mounted in, and that there are no obvious signs of deterioration of
the PS-5.
The PS-5 must be located away from sources of refrigerant gasses or silicone vapors
as these can damage the fuel cell stack and gas sensing equipment.

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1.3 Stopping the PS-5
The PS-5 has three OFF states and five ON states as described in the table below.
System OFF states
System ON states
OFF
All internal actuators are
unpowered and have their control
signal turned off. In this state, no
component can turn on.
ENABLED
The system is in an idle state
but it can automatically start
to generate power if the start
conditions are triggered.
IDLE
Internal components are powered
and may turn on through deliberate
user actions.
STARTUP,
DRYOUT,
SHUTDOWN
In these states, the system is
running but not generating
power.
FAILSAFE
A critical error has been detected
and has shut the system down. This
is equivalent to the OFF state.
RUN
In this state, the system is
running and outputting power
to the battery(s).
1.3.1 Immediate stop:
If a situation arises that requires the PS-5 to be immediately stopped, the switch on the front panel of
the device can be switched to the OFF position. This will switch the system to the OFF state and
immediately stop all internal components, close both fuel supply valves and disconnect the fuel cell
stack from the battery(s).
If the system is in the RUN, SHUTDOWN, or DRYOUT states when stopped, the normal
shutdown procedure will be skipped which can increase the degradation of the fuel
cell stack and decrease future performance.
Local
Off
Remote
Ethernet
ok

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1.3.2 Normal stop:
The stop trigger depends on if the system has been started locally (s
) and the system configuration:
Local start:

Menu Auto-.
Remote start, hardware start configuration:
If the system is configured to have a remote hardware start trigger, the system is turned off by
disconnecting the hardware start signal through the means that the user has installed.
Remote start, CAN configuration:
If the system is configured to receive commands through CAN, the system is stopped by changing the
v (0).
If the system is in the ENABLED state, it will immediately switch to the IDLE state,
otherwise the system will run through, or finish, the normal shutdown procedure
before switching to the IDLE state.
BACK
>
>
>
SETTINGS
CONFIGURATION
FAILSAFE & SERVICES
SYSTEMSTATUS
MAIN MENU
>
BACK
W
W
Idle
0
5000
Output Power limit
Output Power
System State
Auto-start
SYSTEM STATUS
Disabled

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1.4 Hydrogen gas safety
Hydrogen is a highly flammable gas that can release a vast amount of energy in a very short amount
of time. The main hazards of hydrogen are related to hydrogen leaks building up in contained areas
which can be effectively mitigated through simple precautionary actions. The first and foremost action
is to ensure that all pipes transporting hydrogen are leak tight and cannot be damaged in any
foreseeable event, the area around and above these pipes is properly ventilated, and that there are
no sources of ignition. Be aware that there may be local or national regulations on the storage and use
of hydrogen gas. It is recommended to install the PS-5 according to IEC standard 60079-10.
Hydrogen gas is highly flammable and when contained, it can be explosive. Avoid
ignition sources around and above the PS-5 to reduce the risk of fire or explosion in
case of a fuel leakage.
Hydrogen flames are invisible and emit little radiant heat so can be hard to detect. If
there is a suspected hydrogen fire, do not approach the PS-5, instead turn off the
supply of hydrogen and contact the local emergency service.
A large hydrogen leak in a contained area can deplete the atmosphere of oxygen and
so create an asphyxiation hazard. In the case of a large leak, do not approach the PS -5
or enter any small enclosed areas. Contact the local emergency service.
Hydrogen is incompatible with many materials. A common example is embrittlement
in metals, where the metal becomes fragile and can crack. Ensure that all pipe work
and tubing, including any seals, are compatible with hydrogen.
Hydrogen is very buoyant and rapidly disperses in an open environment. The major
hazards of a hydrogen leak can be mitigated by avoiding locations where hydrogen
can easily accumulate, such as an unventilated roof space, and ensure adequate
ventilation around the PS-5.

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1.5 Electrical safety
The PS-5 can produce highvoltages and should not be used without its protective covers which prevent
direct contact with the internal electrical components. There may be local or national regulations
regarding the connections between the PS-5 and the battery bank(s) which require the wiring to be
carried out or certified by a registered electrician.
High voltages can be present inside the PS-5 or its output terminals. This voltage can
be sustained even after the hydrogen fuel supply is stopped. Make sure the PS-5 has
no electrical potential between the power terminals before any work is carried out.
Do not perform any service activities on the PS-5 while it is connected to the batteries.
Always disconnect the batteries before starting to service the system.
The fuel cell stack can sustain a high voltage for several hours after the fuel supply has
been stopped. Do not attempt to access the fuel cell stack or the electronics circuit
boards at the rear of the PS 5 as these can remain energized.
1.6 Disposal
The PS-5 should be disposed of at an authorised disposal centre. Apart from the coolant which is
discussed below, there are no components that require specific treatment for disposal; however, there
may be local or national regulations on the disposal of the fuel cell stack itself.
The PS-5 coolant is ethylene-glycol based and is treated as anti-freeze which typically must be disposed
of at an authorised hazardous material recycling centre.
1.7 Field Support
To request field support for items not included in the User Manual, please contact PowerCell or refer
to your service agreement:
PowerCell Sweden AB
Ruskvädersgatan 12
SE-418 34
Göteborg
Sweden
[phone]
[email protected]

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2 Introduction
The main application for the PS-5 system is for it to be a float voltage or controlled power battery
charger that can monitor one or two battery banks. The PS-5 will continuously monitor the battery
voltage and when it detects a low voltage it will automatically start up and charge the battery to a set
voltage and then turn itself off. When configured to output to two battery banks, the PS-5 will treat
each output independent of the other so it can charge a single battery bank or both at the same time,
and the batteries can be held at different voltages.
The PS--5 can be setup with
a radiator to reject waste heat to the environment, or a heat exchanger which can recover the heat
and use it for heating at the installation location.
2.1 Type selection guide
PS5 - - - - - -
Maximum power (kW) Internal Hydrogen Sensor
1.6, 3.3, 5 1 = Installed, 0 = Not installed
Battery voltage (VDC) Cooling Option
24, 48 HEX = Heat exchanger, RAD = Radiator
Fan mounting direction
U = Upwards, B = Backwards
*PS5 5 24 variants are not available.
*PS5 5 RAD variants have a limitation on the ambient temperature.
2.2 Disclaimer
PowerCell takes no responsibility for any damage or injury caused by improper use of the PS-5 or from
user actions that are not expressly stated in this manual.
2.3 About this manual
This manual contains all information required to install, operate, and maintain the PS-5 system. No
special qualifications are required to operate or maintain the PS-5, but there may be local and/or
national regulations on its installation such as requiring the electrical connections to be performed by
a qualified electrician. It is the responsibility of the end user to comply with all applicable regulations
regarding, but not limited to, the installation, operation, and disposal of the PS-5.