Spectronik PROTIUM-2500 User manual

PROTIUM-2500
FUEL CELL SYSTEM
USER GUIDE
VERSION 3.0 APRIL 2022

Failure to follow these safety instructions could result in fire, electric shock, other
injuries, or damage to PROTIUM-2500 Fuel Cell System (PROTIUM-2500)or other property.Read
all the safety information below before using PROTIUM-2500.
Handling Handle PROTIUM-2500 with care.It is made of thin sheet metal, graphite, and plastic and has sensitive
electrochemical membrane and components inside.PROTIUM-2500 is not designed for extreme conditions,
rough handling, vibration, shock or drop.Keep PROTIUM-2500 away from heat, flame, strong sunlight, water,
dust, soil or mud.Do not use adamaged PROTIUM-2500.
Repairing PROTIUM-2500 is assembled under high compression.Do not disassemble or tamper with PROTIUM-
2500.Do not troubleshoot, repair or replace any component by yourself.
Hydrogen Use only high purity (99.999%) dry Hydrogen gas with PROTIUM-2500.Hydrogen is acolorless,
odorless and highly flammable gas.It is non-toxic but can cause asphyxiation. Follow all local rules and regulations
for safe handling, storage and usage of Hydrogen gas.Do not smoke when operating PROTIUM-2500.
Ventilation Operate PROTIUM-2500 in awell ventilated environment.Fresh air intake for the fuel cell oxidant
blower, cooling air entry from the front of the protective mask, and hot air exit from the cooling fans shall not be
obstructed or restricted.
Purging PROTIUM-2500 periodically flushes its anode during operation, releasing Hydrogen gas and water from
the Hydrogen gas outlet.Do not block the Hydrogen gas outlet. Do not bring flame or electric spark close to the
Hydrogen gas outlet. It is advisable to attach alonger gas tubing to the Hydrogen gas outlet connector and safely
guide the purge exhaust far away from the fuel cell.
CAUTION: always put the Hydrogen gas outlet tubing behind the cooling fan and never in front of
the fuel cell stack.Purged Hydrogen mixed with air intake into the fuel cell’s cathode channels may
cause fire and irreversible damage to the fuel cell.
Connectors, ports and buttons Never force a connector into a port or apply excessive pressure to a button. If
the connector and port do not join with reasonable ease, they probably do not match.Check for obstructions and
ensure that the connector matches the correct port.
Disposal and recycling As PROTIUM-2500 contains electronic components, it must be disposed of separately
from household waste.When PROTIUM-2500 reaches its end of life, follow local laws and regulations for proper
disposal and recycling options.
High-consequence activities PROTIUM-2500 is a customized system with pending safety tests and
certifications. It is not intended for use where the failure of the system could lead to death, personal injury or
severe environmental damage.
Disclaimer Every effort has been made to ensure that the information in this manual is accurate.This manual
serves to adequately recommend safe operating procedures, but shall not be treated as comprehensive.Do not
use PROTIUM-2500 in any other way than the one recommended in this manual.Spectronik reserves the right to
change system specifications, appearance or discontinue the product at any time.
Warranty Spectronik warrants the included hardware product and accessories against defects in materials and
workmanship for the first 30 days after delivery.Spectronik does not warrant against normal wear and tear, nor
damage caused by accident or abuse.
To obtain service, contact [e-mail]
© 2022 Spectronik Pte. Ltd., All Rights Reserved.
Spectronik, the ‘S’ logo, and PROTIUM are registered trademarks of Spectronik Pte. Ltd.
SAFETY, HANDLING & SUPPORT
WARNING:

CHAPTER 1 | OVERVIEW
1OVERVIEW
1.1 PROTIUM-2500 SYSTEM OVERVIEW
Figure 1.1.1 Top view of PROTIUM-2500
Figure 1.1.2 Bottom view of PROTIUM-2500
ITEM DESCRIPTION
1. Oxidant blower (x2) 5. Cooling fan (x6)
2. Oxidant flow manifold 6. Protective mask
3. Mounting plate (left) 7. Cathode outlet duct
4. Mounting plate (right)
43
1
2
5
6
7
11

CHAPTER 1 | OVERVIEW
ITEM DESCRIPTION
8. Gas pressure sensor 1 13. Gas pressure sensor 2
9. H2 supply valves (right) 14. H2 supply valves (left)
10. H2 gas inlet connector (right) 15. H2 gas inlet connector (left)
11. H2 gas outlet connector (right) 16. H2 gas outlet connector (left)
12. H2 purge valves (right) 17. H2 purge valves (left)
Figure 1.1.3 Right view of PROTIUM-2500
Figure 1.1.4 Left view of PROTIUM-2500
1.1 PROTIUM-2500 SYSTEM OVERVIEW
13
16
17
14
15
8
9
10
12
11 11
Can also be seen more
clearly in Fig 1.1.2

CHAPTER 1 | OVERVIEW
Figure 1.1.5 Front view of PROTIUM-2500
Figure 1.1.6 Back view of PROTIUM-2500
ITEM DESCRIPTION
18. Power/Signal receptacle 20. Stack power output (-ve)
19. Stack power output (+ve)
18 20
19
7
1.1 PROTIUM-2500 SYSTEM OVERVIEW
(Can also be
in Fig 1.1.2)

Figure 1.2.1 Top, Left and Right views of Electronic Controller
CHAPTER 1 | OVERVIEW
ITEM DESCRIPTION
21. Radio telemetry transmitter 28. On/Off push button
22. Mounting hole (x4) 29. Status LED
23. Stack power output (+ve)30. Balance-of-plant (BOP) switch
24. Stack power output (-ve)31. Load connector (XT-90 female)
25. Power/Signal header 32. Telemetry transmitter port
26. Programming port 33. External power supply receptacle
27. P2 sensor port
22
25
21
24
23
26
27
28
29
30 31
32
33
1.2 ELECTRONIC CONTROLLER

CHAPTER 1 | OVERVIEW
Figure 1.3.1 Accessories
ITEM DESCRIPTION
34. Power/Signal extension cable 39. Free-end wires for user’s load
35. Stack power output (+ve) extension cable 40. Load connector (XT-90 male)
36. Stack power output (-ve) extension cable 41. P2 sensor cable
37. Free-end wires for user’s power supply 42. USB connection to PC
38. External power supply header 43. Radio modem receiver
34
35
36
37 38
39 40
42 43
41
1.3 STANDARD ACCESSORIES

CHAPTER 1 | OVERVIEW
1.4 MECHANICAL DIMENSIONS –PROTIUM-2500
A
B
C
D
All dimensions in mm
A94.50 D646.60
B457.60 E343.50
C550.60 F170.00
E
F

CHAPTER 1 | OVERVIEW
1.5 MECHANICAL DIMENSIONS –ELECTRIC CONTROLLER
I
G
J
L
N
O
P
Q
RST
H
K
All dimensions in mm
G163.40 L131.40 Q35.40
H145.00 M113.00 R63.20
I41.00 N43.10 S85.00
J15.00 O68.60 T107.10
K3.20 (4x) P55.60
M

CHAPTER 1 | OVERVIEW
1.6 MECHANICAL DIMENSIONS –STANDARD ACCESSORIES
All dimensions in mm
U1000.00 Y1000.00
V1000.00 Z600.00
W1000.00 AA 1800.00
X1000.00
U
V
W
X
Y
Z
AA

PROTIUM-2500 cannot be mounted in any orientation due to internal routings of the gas streams within the
fuel cell stack. The stack should also be level to ensure water does not get trapped in the Cathode channels,
obstructing the oxidant flow and causing potential performance drop and cell damage. Mount PROTIUM-2500
horizontally in the recommended orientation above, with the protective mask facing downwards and the cooling
fans facing upwards.
For optimal oxidant and cooling airflows, it is also recommended that there is at least 15cm unobstructed
clearance from the protective mask and oxidant blower inlet, and 30cm unobstructed clearance from the
cooling fans’ outlet.
Figure 1.7.1 Recommended orientation of PROTIUM-2500
1.7 MOUNTING AND AIR CLEARANCE
CHAPTER 1 | OVERVIEW

CHAPTER 1 | OVERVIEW
D
All dimensions in mm
A8.00 C150.00
BR3.25 D510.60 (centre to centre)
1.8 MECHANICAL DIMENSION –MOUNTING AND CLEARANCE
Figure 1.8.1 Dimensions of the mounting holes
BA
C

Fuel cell PROTIUM-2500
Type PEM
No. of cells 80
Architecture Closed cathode
Coolant Air cooled
Rated/gross power 2500/3000W
Rated/gross current 52.5/62.5A
Voltage output 48-72VDC
Start-up time 30s
Operating ambient temp. [-10,45]oC
Operating altitude without power derating 1500m AGL
System weight 9,800g
Max dimension 647 x 344 x 170mm
Fuel supply
Hydrogen gas Dry, 99.999% purity
Delivery pressure 0.7bar (10 psig)
Fuel consumption @ rated power 31.5L/min
Gas tubing PU, 8 x 5.5
Supply & purge control Solenoid valves with integrated pressure sensor
Stack leakage checks Automated via integrated pressure sensors
Electronic controller
Processor board FEATHER V1.2
Weight (including casing) 810g
Output connector XT-90
Warning & protections Low voltage, high/low temperature, high/low
pressure, low battery, stack leakage
Communication 868MHz ultra long range radio modem
Data acquisition (DAQ) software PC GUI/ Android app
Remote control Fan speed, blower speed, manual purge,
remote on-off
CHAPTER 2 | SPECIFICATIONS
2SPECIFICATIONS
2.1 PROTIUM-2500 TECHNICAL DATA SHEET

Figure 2.2.1 Nominal polarization curve for a fully conditioned PROTIUM-2500 at its Beginning-of-Life (BOL).
•Ambient temperature: 24oC
•Relative humidity: 60%
•H2supply pressure: 10psig
•Dead-ended operation
•Balance-of-plant (BOP) powered by fuel cell
•Tcell at 2500W: 66oC
0
500
1000
1500
2000
2500
3000
3500
0.0
10.0
20.0
30.0
40.0
50.0
60.0
70.0
80.0
0.0 10.0 20.0 30.0 40.0 50.0 60.0 70.0
Power (W)
Voltage (V)
Current (A)
CHAPTER 2 | SPECIFICATIONS
2.2 VI CURVE
TEST CONDITIONS

CHAPTER 2 | SPECIFICATIONS
2.3 SYSTEM BLOCK DIAGRAM
1. An external power supply is required to initially turn on the electronic controller.
2. By default, the BOP Switch is set to 1. When the system enters “Running Phase” the fuel cell will be able
to power its own BOP, if Fuel cell power OUT voltage is higher than External Power Supply voltage. Tip:
use 15-48V External Power Supply to ensure that it is always lower than the Fuel cell power OUT voltage.
3. By setting the BOP Switch to 0, the External Power Supply will power the BOP at all times including
“Running Phase”.
Fuel cell
power IN
Power output
to LOAD
User Interface
•ON/OFF push button
•Status LED & Buzzer
Communication
•USB or
•Radio telemetry transmitter
External Power Supply
(15 to 90V, 375W)
Fuel cell
power OUT
48-72V
Hybrid Output Source
(optional)
DC-DC converter
(optional)
NOTE
PROTIUM-2500
fuel cell stack
Balance of Plant (BOP)
•Cooling System
•Oxidant System
•Valves
•Sensors
•Communications BOP Switch 1/0
Electronic
Controller

1. Mount PROTIUM-2500 securely in the recommended orientation. Ensure that there is nothing blocking
the cooling air inlet below the protective mask (6),and sufficient unobstructed clearance from the
oxidant blower (2) inlets and cooling fans (5) outlet.
2. There are two Hydrogen gas purge tubing left and right of the fuel cell stack.Ensure that they are
securely connected to the H2 gas outlet connectors (11)and (16). Caution:channel the purge
tubing far away from the oxidant blower (2) inlets.
3. Connect PROTIUM-2500 to the Electronic Controller using the Power/Signal (34),Stack power
output (+ve) (35)and Stack power output (-ve) (36)extension cables.Also connect the P2 sensor
cable (41)from PROTIUM-2500 to the P2 sensor port (27).
4. Connect the Load connectors (31 and 40)and the Free-end wires (39)to your load.Tip:check
that the polarity is correct.It is also advisable to put an ON/OFF switch at your load and
ensure that it is turned OFF at this time.
5. Connect an external power supply (15-90V, 375W) to the external power supply receptacle (33)
using the supplied external power supply cable (37 and 38). Make sure that the external power
supply is OFF at this stage.
6. PROTIUM-2500 has two H2 gas inlet connectors (10 and 15). Connect your Hydrogen gas supply
to both inlets.Make sure that your Hydrogen gas supply is OFF at this stage.Caution:ensure that the
gas is regulated to 0.5-0.7bar gauge.
Reminder:ensure that all gas tubing and electrical wire connections are firm and secure.
The setup is now completed and PROTIUM-2500 is ready to be turned on.
CHAPTER 3 | OPERATING PROCEDURES
3OPERATING PROCEDURES
3.1 SETTING UP PROTIUM-2500

1. Connect the Radio modem receiver (43)to a PC via the USB cable (42). Launch the Spectronik
Data Acquisition Graphic User Interface (DAQ GUI) software. Choose the Com Port, set the Baud Rate
(57600)and click the S logo.Tip:the latest DAQ GUI software and user manual can be
downloaded from the PROTIUM-2500 product webpage.
2. Turn on your external power supply and wait for 5s. A welcome message should appear in the GUI.
Status LED (29)will blink at 10%.
3. Click START.The message <Low H2 Supply> should appear.
4. Turn on your H2 gas supply.Caution:ensure that the gas pressure is regulated to 0.5-0.7bar
gauge.Insufficient delivery pressure may cause cell flooding and drop in performance, while
excessive pressure may rupture the fuel cell membrane, causing dangerous gas leakage
and irreversible cell damage.Ensure that your pressure regulator can provide Hydrogen
gas flow rate of more than 35L/min.
5. PROTIUM-2500 will do aseries of gas purging and internal diagnostic checks.The cooling fans and
oxidant blowers will turn on. If everything is normal, the system will enter its “Running Phase” –indicated
by the message in the GUI and asolid white Status LED.All system parameter values can now be seen in
the GUI.
6. Set the BOP Switch (30)to 0 or 1 as explained in Section 2.3.
PROTIUM-2500 is now ready to power your application.
CHAPTER 3 | OPERATING PROCEDURES
3.2 TURNING ON PROTIUM-2500

1. Turn ON your load and draw power as per normal. Caution: never pull the fuel cell voltage below 48V or
draw power beyond 2500W.
If hybrid battery is connected at the load, PROTIUM-2500 will provide up to its maximum rated output and
the rest is augmented by the battery. The total power available depends on the capacity of the battery. If no
hybrid battery is connected at the load, the following guideline is recommended:
3.3 POWERING YOUR LOAD WITH PROTIUM-2500
CHAPTER 3 | OPERATING PROCEDURES
Mode Range Ramp-rate
Constant Voltage Load Open circuit voltage to 48VDC min or 2500W max -1VDC/second
Constant Current Load 0A to 55A or 2500W max +2A/second
Constant Power Load 0W to 2500W max +100W/second
2. During Running Phase, the following live status of the fuel cell can be monitored from the GUI.
Parameters Description
FCV FC voltage (V)
FCA FC current (A)
FCW FC power (W)
Energy Energy delivered by the fuel cell during this operation (Wh)
FCT1 FC temperature at location 1 (˚C)
FCT2 FC temperature at location 2 (˚C)
FAN Cooling fan duty cycle (%)
BLW Oxidant blower duty cycle (%)
H2P1 H2supply pressure (Barg)
H2P2 H2pressure in FC (Barg)
Tank-P* Gas tank pressure (Barg)
Tank-T* Gas tank temperature (˚C)
DCDCV* Converter voltage (V)
DCDCA* Converter current (A)
DCDCW* Converter power (W)
BattV External power supply voltage (V)
*with purchase of optional Spectronik accessories (gas tank, pressure regulator and DC/DC converter)
3. During Running Phase, you may manually control PROTIUM-2500 by clicking commands in the GUI such as
Purge, increasing/decreasing oxidant blower speed and cooling fans speed.Caution:manual control is
recommended for advanced users only.For optimal performance, remember to reset to AUTO
controls.
4. During operation, it is normal to see water coming out of the Cathode outlet duct (7) and purge tubing.
Ensure that water does not drip to any electrical components. Caution:there might be unreacted
Hydrogen gas coming out of the purge tubing.Keep away from fire and electric spark.Ensure
sufficient ventilation.

1. Turn OFF your load. The cooling fans will turn faster to cool down the fuel cell, before returning to their
minimum speed.
2. In the GUI, click END.Alternatively, press and hold the On/Off push button (28) for more than 2s. The
message <Shutdown Initiated> will appear in the GUI and PROTIUM-2500 will enter its Shutdown Phase by
carrying out aseries of shutdown procedures such as turning off the gas supply valves, cooling fans and
oxidant blowers.
3. The message <System OFF> will appear in the GUI.PROTIUM-2500 is now turned off. Status LED will blink
at 60% on standby awaiting the next start-up command.
4. If you do not intend to restart the system soon, turn OFF your Hydrogen gas supply and remove the
Hydrogen gas tubing from the H2 gas inlet connectors (10 and 15). Caution: some remaining gas in
the tubing will be released into the atmosphere.
5. Turn OFF the external power supply.All the cables can now be disconnected.
PROTIUM-2500 is now ready to be kept for storage.
3.4 SHUTTING DOWN PROTIUM-2500
CHAPTER 3 | OPERATING PROCEDURES

The PROTIUM-2500 comes with in-built firmware control that is optimized to bring out its best performance
over the applicable ambient environment range.In normal use-case scenario, there is no need for user to fine-
tune the parameters. For advanced user who wishes to control the fuel cell manually, the following commands
can be entered via the GUI:
Command PROTIUM-2500 action
start <enter> Starts the system
end <enter> Enters normal shutdown phase
ver <enter> Displays the firmware version
f <enter> Return to automatic cooling fan control
b <enter> Return to automatic oxidant blower control
p <enter> Open the Hydrogen purge valve for 2s. This is useful to remove excess water if
cell flooding is suspected due to decreasing power output.
= (equal) Increase cooling fan speed by 5% (manual control)
-(hyphen) Decrease cooling fan speed by 5% (manual control)
0Increase cooling fan speed by 1% (manual control)
9Decrease cooling fan speed by 1% (manual control)
]Increase oxidant blower speed by 3% (manual control)
[Decrease oxidant blower speed by 3% (manual control)
PROTIUM-2500 has several in-built protections. The LED will flash and error message will appear in the GUI.
Follow the basic troubleshooting guide below.Most errors should be rectified once the suggested corrective
action has been done and the system restarted.
If the error persists, contact [e-mail].
Tip:you may also long press the ON/OFF push button by >2s to turn ON/OFF the system instead of
entering “start” and “end” command via the GUI.
CHAPTER 4 | SYSTEM MONITORING & PROTECTIONS
SYSTEM MONITORING, PROTECTIONS &
MANUAL CONTROL
4
4.1 MANUALLY CONTROLLING THE PROTIUM-2500
4.2 SYSTEM WARNING &PROTECTIONS