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Pro 12000 Duo

EFOY Pro 12000 Duo Operation And Installation Manual

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Contents
Contents
Contents ..................................................................................................... 1
1 Introduction ...................................................................................... 4
1.1 Foreword ..................................................................................... 4
1.2 Contact details ............................................................................. 4
2 Safety Information ............................................................................ 5
2.1 Explanation of safety alert signal words ...................................... 5
2.2 General safety instructions .......................................................... 6
2.3 Safety instructions for methanol ................................................. 8
2.4 Correct use ................................................................................ 10
2.5 Certification ............................................................................... 11
2.6 Warranty .................................................................................... 12
2.7 Disposal and Transportation ...................................................... 13
3 Configuration .................................................................................. 14
3.1 Standard equipment .................................................................. 14
3.2 Connections ............................................................................... 15
3.3 Specifications ............................................................................. 18
4 Installation...................................................................................... 21
4.1 Installation space requirements ................................................ 21
4.2 Mounting the fuel cell ................................................................ 25
4.3 Off-heat ...................................................................................... 26
4.4 Connecting the exhaust hose ..................................................... 27
4.5 Fill in EFOY Initial Start Fluid ..................................................... 29
4.6 Electrical connection ................................................................. 31
4.6.1 Electrical connection to the battery ................................. 32
4.6.2 Combination with other energy sources .......................... 34
5 Operation ........................................................................................ 35
5.1 Operation via the operating panel .............................................. 35
5.1.1 Buttons and symbols on the operating panel ................... 35
5.1.2 Initial start ........................................................................ 37
Contents
Page 2
5.1.3 Info screen ....................................................................... 39
5.1.4 Main menu ........................................................................ 42
5.1.5 Expert menu ..................................................................... 44
5.2 Remote control via computer .................................................... 53
5.3 Fuel cartridges .......................................................................... 54
5.3.1 Connecting the fuel cartridge ........................................... 54
5.3.2 Selecting a fuel cartridge ................................................. 57
5.4 Operating modes........................................................................ 59
5.4.1 Automatic ......................................................................... 59
5.4.2 Manual On ........................................................................ 60
5.4.3 Manual Off ........................................................................ 61
5.4.4 External control ............................................................... 62
5.4.5 Hybrid ............................................................................... 63
5.5 Automatic antifreeze mode ........................................................ 64
5.6 Shutdown ................................................................................... 65
5.6.1 Switching off the fuel cell ................................................. 65
5.6.2 Removing the EFOY fuel cartridge ................................... 65
5.6.3 Secure transportation and storage procedure ................. 65
5.6.4 Detaching the charge line and data line ........................... 66
5.6.5 Detaching the exhaust hose ............................................. 66
6 Maintenance ................................................................................... 67
6.1 Service ....................................................................................... 67
6.2 Long term storage ..................................................................... 67
6.3 Firmware update ....................................................................... 68
6.4 Cleaning ..................................................................................... 68
7 Troubleshooting ............................................................................. 69
7.1 Safety ......................................................................................... 69
7.2 Errors and solutions .................................................................. 70
7.2.1 Error message on the display .......................................... 70
7.2.2 Display Warnings.............................................................. 72
7.2.3 Errors without display messages ..................................... 73
7.3 Adding EFOY recovery fluid ........................................................ 74
8 Data Interface and Optional Accessories ........................................ 75
Contents
8.1 Data interface functionality........................................................ 75
8.2 Communication Protocols.......................................................... 77
Data interfaces ............................................................................... 77
8.2.1 Modbus RTU ..................................................................... 78
8.2.2 SIO / Plain text .................................................................. 88
8.3 GSM-Modem .............................................................................. 89
8.4 Fuel cartridge sensor FS1 ......................................................... 90
8.5 Cluster Controller CC1 .............................................................. 91
8.6 DuoCartSwitch DCS 1 ................................................................. 93
9 Appendix ......................................................................................... 94
9.1 Installation Checklist ................................................................. 94
9.2 U-I and U-P characteristic ......................................................... 95
9.3 Output power characteristic ...................................................... 96
Introduction
Page 4
1 Introduction
1.1 Foreword
Thank you for choosing an EFOY Pro fuel cell from SFC Energy AG. We hope you enjoy using your new energy supply system.
Before you use the fuel cell for the first time, please read this user manual and follow the installation instructions.
Please contact your distributor in case you have questions about installation or operation.
Copyright by SFC Energy AG 2017. All rights reserved. Subject to change without notice.
1.2 Contact details
SFC Energy AG Eugen-Saenger-Ring 7 85649 Brunnthal Germany Hotline: +49 89 / 673 592 555 Freecall*: 00800 / 732 762 78 eMail: service@sfc.com Web: www.efoy-pro.com
*Calls can be placed free of charge from the landline from: Germany, Belgium, Denmark, France, Great Britain, Italy, the Netherlands, Norway, Austria, Sweden, Switzerland and Spain.
Safety Information
DANGER!
Indicates an imminently hazardous situation, which, if not avoided, poses a high risk of death or serious physical injury.
WARNING!
Indicates a potentially hazardous situation, which, if not avoided, poses a medium risk of death or serious physical injury.
CAUTION!
Indicates a hazardous situation, which, if not avoided, poses a slight risk of mild or moderate physical injury or damage to property.
INFO:
Important information for the operator or user of the system.
2 Safety Information
2.1 Explanation of safety alert signal words
Safety Information
Page 6
For Indoor use only. Use the EFOY Pro fuel cell only in housings with protection against water and dust.
The EFOY Pro fuel cell must not be opened.
The EFOY fuel cartridge must not be opened or refilled using excessive force.
Modifications to the device constitute a safety hazard and may result in the loss of your operating license and nullify your warranty and guarantee.
Use original EFOY accessories only.
EFOY Pro fuel cells and EFOY fuel cartridges must not be stored and operated at temperatures over +50 °C / +122 °F.
Protect from heat and direct sunlight.
Operate the EFOY Pro fuel cell only as specified in the installation instructions, and in a well-ventilated space.
Keep EFOY Pro fuel cells that have been switched off in frost-free storage or use the automatic antifreeze feature.
Do not smoke in the vicinity of the EFOY Pro fuel cell or EFOY fuel cartridge. Protect from heat and ignition sources. Methanol is highly flammable!
Keep all EFOY Pro fuel cells and EFOY fuel cartridges out of reach of children, even when empty or only partly full.
2.2 General safety instructions
Read the user manual before commissioning the fuel cell, and keep the user manual close to the device at all times.
Follow all of the instructions in this user manual.
Safety Information
WARNING!
In exceptional cases, the exhaust gases emitted by the device may contain substances that are harmful to health!
Do not inhale exhaust gases directly for prolonged periods. Instead, use the exhaust tube provided to route the exhaust gas into the open air.
WARNING!
Damage in the event of an accident; risk of injury!
EFOY Pro fuel cells and EFOY fuel cartridges must be securely fastened to prevent damage in the event of an accident.
WARNING!
EFOY Pro fuel cells must not be used in potentially explosive atmospheres.
CAUTION!
Burn Hazard.
Hot surfaces. In operation temperature up to +65 °C / +150 °F at heat exchanger possible. Do not touch.
CAUTION!
The EFOY Pro fuel cell is not water-tight!
Ensure that no water can enter the fuel cell.
CAUTION!
Improper use or improper connection to other electrical equipment may lead to damage.
Safety Information
Page 8
INFO:
There is no risk of you coming into contact with methanol provided that you handle the device and fuel cartridges in accordance with the instructions.
DANGER!
Leakage of methanol fumes poses a fire hazard! Do not smoke when replacing the EFOY fuel cartridge and do not expose it to other ignition sources! Protect EFOY fuel cartridges from temperatures exceeding +50 °C / +122 °F.
Leakage of a small quantity of methanol will evaporate, leaving no residue. Do not touch leaked methanol.
WARNING!
Methanol is highly flammable!
You receive methanol in safe, tested EFOY fuel cartridges, which prevent the contents from escaping if used correctly.
The storage and transport of methanol may be subject to statutory regulations.
For more information, refer to the safety data sheet on methanol, available on our website at http://www.efoy-pro.com.
WARNING!
Methanol is toxic when inhaled, swallowed or allowed to come into contact with the skin. Inhaling and swallowing methanol, or allowing it to come into contact with your skin carries a serious risk of irreversible damage.
Call a doctor immediately if you have direct physical contact with the substance, in the event of an accident, or if you feel unwell, and show the doctor the fuel cartridge label or the methanol safety data sheet.
2.3 Safety instructions for methanol
Safety Information
CAUTION!
Impurities in methanol!
Original EFOY fuel cartridges contain methanol that has been approved by SFC. Even slight impurities or foreign particles in commercially available methanol may cause irreversible damage to the device, and may nullify the warranty or guarantee.
Use only original EFOY fuel cartridges!
Safety Information
Page 10
2.4 Correct use
The EFOY devices produced by SFC Energy AG are automatic charging devices for 24 V or 48 V lead accumulators (batteries) or SFC qualified lithium iron phosphate batteries (LiFePO4). Please note the following:
The devices must only be used to charge lead accumulators (batteries)
that conform to the technical specifications of the device (see chapter
3.3 “Specifications” on page 18).
The devices can be used according to the technical specifications for
stationary and mobile operation in vehicles (see chapter 3.3 “Specifications” on page 18).
The devices must only be operated with original EFOY fuel cartridges.
Damaged fuel cartridges may not be used.
The devices are not intended to be used as an emergency power supply
for medical or life-sustaining systems.
Connecting several devices in parallel to increase the charging current
is permitted.
Connecting several devices in series to increase the voltage is not
permitted.
Devices with a defective or damaged housing must not be operated. The devices are intended for industrial use.
Safety Information
SFC Energy AG, Eugen-Saenger-Ring 7, 85649 Brunnthal, Germany, hereby declares that the EFOY Pro 12000 Duo conform to the provisions of the EC Directive on electro-magnetic compatibility (2004/108/EC). The following harmonized norms apply:
DIN EN 61000-6-1:2007, DIN EN 61000-6-3:2007 + A1:2011
Radio Frequency Interference (RFI) (FCC 15.109)
This equipment has been tested and found to comply with the limits for Class B digital devices pursuant to Part 15 of the FCC Rules. These limits are designed to provide reasonable protection against harmful interference in a residential environment. This equipment generates, uses, and can radiate radio frequency energy, and if not installed and used in accordance with the instruction manual, 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 and correct the interference by one or more of the following measures:
Reorient or relocate the receiving antenna. Increase the separation between the equipment and the receiver. Consult the dealer or an experienced radio/TV technician for help.
Labeling Requirements (FCC 15.19)
This device complies with Part 15 of 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.
Modifications (FCC 15.21)
Changes or modifications to this equipment not expressly approved by SFC Energy AG may void the user’s authority to operate this equipment.
2.5 Certification
Declaration of conformity
Safety Information
Page 12
Industry Canada Compliance Statement
This digital apparatus does not exceed the Class B limits for radio noise for digital apparatus set out in the interference–causing equipment standard entitled: “Digital Apparatus”, ICES–003 of Industry Canada.
Cet appareil numérique respecte les limites de bruits radioélectriques applicables aux appareils numériques de Classe B prescrites dans la norme sur le matériel brouilleur : “Appareils numériques”, NMB–003 édictée par Industrie Canada.
The devices have been tested for electro-magnetic compatibility in accordance with ECE Regulation No. 10, and have been approved for use in motor vehicles.
Approval number: E24 10R-051962
The devices have undergone voluntarily testing by TÜV SÜD AG for conformity with the basic requirements of IEC 62282-3, and have been awarded the seal of approval for product safety.
This product is intended and certified for Canada and the USA. The product was voluntarily tested according to the safety requirements:
UL 60950-1:2007/R2014-10; CAN/CSA C22.2 No. 60985-1:2007/A2:2014-10; ANSI/CSA FC 1:2014; CAN/CSA-C22.2 No. 62282-3-100-15
Seals of approval
2.6 Warranty
The warranty period begins with the purchase of a new device. You can use your sales receipt as proof of this date. Please keep these documents safe. Our warranty services are based on the warranty conditions of SFC Energy AG that are valid for the relevant country at the time of purchase. Please note the attached conditions of warranty.
Service
Please contact our EFOY hotline in relation to any technical questions about EFOY Pro fuel cells. The contact details are provided in chapter 1.2
“Contact details” on page 4.
Safety Information
WARNING!
Plastic wrapping and cardboard boxes pose a risk of suffocation!
Please keep all packaging out of reach of children.
2.7 Disposal and Transportation
Packaging
Your new device was packaged to ensure that it reached you safely. All materials used in the packaging are environmentally friendly and can be re-used.
We recommend that you keep the packaging in case it is needed for winter storage.
However, if you wish to dispose of the packaging, please help our planet by disposing of it in an environmentally responsible way and in accordance with the applicable local regulations.
Please note the instructions provided by SFC Energy AG when transporting the device. For information on this, refer to our website or contact the EFOY hotline. The contact details are provided in chapter 1.2 “Contact details” on page 4.
Fuel cartridges
Completely empty fuel cartridges can be disposed of with your plastic waste. Dispose of partly full fuel cartridges or damaged fuel cartridges in the same way as other hazardous waste, such as solvents and paint.
Old devices
Old devices are more than just worthless rubbish! Environmentally responsible disposal can reclaim valuable raw materials, while protecting the environment.
Old electronic devices must not be disposed of in your household rubbish. Observe the local regulations.
For advice on returning old devices, please contact the EFOY hotline. The contact details are provided in chapter 1.2 “Contact details” on page 4.
Configuration
Page 14
Part number
Description
Qty
-
Device EFOY Pro fuel cell
1
500 904 001
Insulated exhaust hose EH2
1
500 903 001
EFOY Initial Start Fluid 1.5l
1
500 903 002
EFOY Recovery Fluid 0.5 l
2
500 901 001
User manual EFOY Pro 12000 Duo
1
500 078 013
Ferrite communication
1
WARNING!
Use original EFOY accessories only! Use of unauthorized parts compromises safety and renders the warranty null and void.
3 Configuration
3.1 Standard equipment
The EFOY Pro fuel cell SET includes the following equipment:
A complete list of accessories and spare parts is available at www.efoy-pro.com.
Configuration
Front view
1.
Operation panel (see detail view)
2.
Opening screw for EFOY fluids
3.
Data interface (see detail view)
4.
Connector #1 for EFOY fuel cartridge
5.
Connector #2 for EFOY fuel cartridge
6.
Outlet screw for internal fluid (for transport), bottom side
7.
Air supply for cooling air
Back view
8.
Off-heat from heat exchanger
9.
Data interface reverse side (see detail view)
10.
Electrical connection (see detail view)
11.
Connection for exhaust hose
8
9
10
11
7
1 2 3 4 5 6 7
3.2 Connections
Configuration
Page 16
Detail view – Operation panel
1.
Switch EFOY Pro fuel cell on/off
2.
[menu]
Display the main menu.
3.
[]
Scroll back one level in the menu.
4.
[]
Scroll up one line in the display.
5.
[]
Scroll down one line in the display.
6.
[ok]
Open the selected menu. Confirm a selection.
7.
Red LED lights up to indicate a fault.
Detail view – Data interface front side
Remote Control
Data Interface
1.
DuoCartSwitch (10 VDC)
1.
DuoCartSwitch (10 VDC)
2.
TxD (Operation panel OP2)
2.
TxD (RS232 Data)
3.
RxD (Operation panel OP2)
3.
RxD (RS232 Data)
4.
GND, Ground
4.
GND, Ground
5.
+12 VDC
5.
+12 VDC
6.
Fuel Cartridge Sensor (10 VDC)
6.
Fuel Cartridge Sensor (10 VDC)
7.
Remote On
7.
Remote On
8.
M/S (Master/Slave) & Hybrid
8.
M/S (Master/Slave) & Hybrid
1 2 3 4 5
6
7
1…8 1...8
Remote Control
Data Interface
Configuration
Detail view – Electrical connection
1.
Connection sense line +
2.
Connection power line +
3.
Connection power line -
4.
Connection sense line –
5.
Connection earth line
Detail view – Data interface reverse side – I/O
A
RS485
B
RS485
1.
RS232 GND
1 - 1 - 2.
RS232 TxD
2 - 2 - 3.
RS232 RxD
3 - 3 - 4.
MODBUS ISOCOM
4
RS485 MODBUS B
4
RS485 MODBUS B
5.
MODBUS B
5
RS485 MODBUS A
5
RS485 MODBUS A
6.
MODBUS A
6 - 6 - 7.
-
7 - 7 - 8.
-
8
MODBUS ISOCOM
8
MODBUS ISOCOM
9.
-
5
1 2 3 4 1
2
3 … 11
1…8
1…8
Configuration
Page 18
Product
EFOY Pro 12000 Duo
Max. rated output
500 W
Min. power output 3,000 h 1
400 W
Min. power output 4,500 h 1
350 W
Nominal voltage
24 V DC
48 V DC
Voltage range
18.5 V – 32 V DC
34.5 V – 63 V DC
Max. charging current at 500 W
24 V DC: 20.83 A
48 V DC: 10.42 A
Min. charging current at 400 W1
24 V DC: 16.67 A
48 V DC: 8.33 A
Recommended min. battery capacity2
24 V DC: 80 - 200 Ah
48 V DC: 40 - 100 Ah
Switch-on voltage for automatic battery charging at 24 V / 48 V DC 3
24.4 V
48.8 V
Switch-off voltage for automatic battery charging at 24 V / 48 V DC 3
28.8 V
57.6 V
Required starting voltage at 24 V / 48 V DC
20 V
36 V
Max. battery voltage at 24 V / 48 V DC
31 V
(Anti freeze mode up to
32 V)
62 V
(Anti freeze mode up to
63 V)
Nominal consumption 4
0.9 l/kWh / 0.2 gallons/kWh
Quiescent power consumption at 24 V / 48 V DC
75 mA
40 mA
3.3 Specifications
Performance data
1
Nominal power varies by ±10 %, decreases linear with the operation hours. Specification valid
within warranty period.
2
Depends on battery type and application - bigger batteries possible if charging current
sufficient for battery (e.g. solar batteries).
3
Factory setting - can be modified at operation panel or interface adapter and PC.
4
Effective consumption depends on operating conditions.
All technical data at temperatures of +20 °C / +68 °F.
Configuration
Product
EFOY Pro 12000 Duo
Number of fuel cartridges (with DCS1)
2
(4)
Length fuel connector
70 cm / 27.6 in
Sound pressure level at a distance of 1 m / 7 m (3.3 ft / 23 ft)
62 dB(A) / 45 dB(A)
Weight
32 kg / 70.6 lbs
Dimensions (LxWxH)
With 19“ bars:
Without 19“ bars:
640 x 482.4 x 310 mm / 25.2 x 19 x 12.2 in
640 x 441 x 310 mm / 25.2 x 17.3 x 12.2 in
Warranty
See chapter 2.6 "Warranty" on page 12.
Space requirement (LxWxH)
Minimum:
1000 x 482.6 x 355.6 mm / 39.4 x 19 x 10.1 in
International protection class (IP-class)
IP 20
Inclination along the direct axis
Permanent: 10°
Temporary (<10 minutes): 45°
Inclination along the quadrature axis
Permanent: 10°
Operating temperature 1
-20 °C to +50 °C / -4 °F to +122 °F
Starting temperature
+3 °C to +50 °C / +37.4 °F to +122 °F
Storage temperature
+1°C to +50 °C / +34 °F to +122 °F
Recommended altitude 2
Up to 4,000 m / 13,000 ft
INFO:
All technical data tested under standard conditions. The specifications are subject to change without notice.
General data
Installation requirements
1
At temperatures above +40 °C / +102 °F the power output can decrease.
2
During operation above 3,000 m / 9,842 ft the power output can decrease.
Configuration
Page 20
Operation
Via operating panel with text display or via operating panel OP2 with text display
Data-Interface
RS232 RJ-45 plug for accessories (e.g. interface adapter)
Data-Interface Modbus RTU
RS485 RJ-45 plug and terminal block (A, B, GND)
Electrical interface Power
Terminal plus (+) and minus (-): min. 10 mm² / 0.4 in²
Electrical interface Sense
Terminal plus (+) and minus (-): min. 2 mm² / 0.08 in²
Electrical interface Earth
Terminal: min. 2 mm² / 0.08 in²
Fuel cartridges
M10
M28
(only with M28
adapter)
MT60
Volume
10 liters /
2.64 gallons
28 liters /
7.4 gallons
60 liters /
15.85 gallons
Weight
8.4 kg / 18.5 lbs
23.4 kg / 51.6 lbs
55 kg / < 121 lbs
Energy capacity
11.1 kWh
31.1 kWh
60 kWh
Dimensions
(L x W x H)
23 x 19 x 32 cm /
9.0 x 7.6 x 12.5 in
42 x 28 x 36 cm /
16.5 x 11.0 x 14.2 in
34 x 39 x 67 cm /
13.4 x 15.4 x 26.4 in
Equipment
Fuel cartridge
Installation
CAUTION!
Solvents may emit fumes during sealing. Ensure that there is sufficient ventilation and follow the instructions for using the sealing compound.
When choosing a location in which to install the fuel cell, please remember that the permitted operating temperature range for the device is -20°C to +50 °C / -4°F to +122 °F.
CAUTION!
If the temperatures in the installation space exceed +50 °C / +122 °F the EFOY Pro fuel cell will shut down and not produce energy.
As soon as the temperature in the installation space fall below +40 °C / +104 °F the EFOY Pro 12000 Duo will start again fully automatic.
CAUTION!
The device requires an air supply and generates off-heat and exhaust gases. The off-heat and exhaust gases must be released into the open air.
4 Installation
4.1 Installation space requirements
Installation should be carried out by trained personnel. Ensure that there is sufficient unoccupied space behind the installation
area before you drill or saw any openings. Please also observe the safety information provided by the tool manufacturers.
Installation
Page 22
Opening at installation space
1
Opening for air supply for installation space
2
Air supply for stack and heat exchanger
3
Separation of air supply and off heat
4
Off-heat from heat exchanger
5
Process exhaust air from stack (see chapter 4.4 “Connecting the exhaust hose“ on page 27)
Space requirement
1 2 2 3 3
4
Installation
The space in which the device is to be installed (including safety
distance) must be at least LxWxH: 1000 x 482.6 x 355.6 mm / 39.4 x 19 x 10.1 in (8HE)
If the fuel cell is installed within a sealed container, provide an
opening for supply air with an opening of at least 600 cm² / 95 in² – at structured openings (fine grid, narrow gap), accordingly more.
The air openings of the installation space need to be protected
against the penetration of water and foreign particles (e.g. using louvered metal sheets and fly screens).
Ensure that there is sufficient ventilation in the installation space to
prevent heat build-up. This can be done with additional openings or an additional temperature-controlled fan.
Separation of air supply and off heat is necessary to prevent
recirculation of waste heat at high temperatures.
The electrical connections, the fill opening for EFOY Recovery Fluid
and the fuel cartridge must be easily accessible.
Install the device in an upright position only.
CAUTION!
Make sure that the device does not exceed the maximum inclination.
Inclination
Permanent: 10°
Temporary (<10 minutes): 35°
Installation
Page 24
CAUTION!
Make sure that the device does not exceed the maximum inclination.
When positioning the fuel cartridge, ensure that it is within reach of
the fuel cartridge connection. Each connection hose is 70 cm / 27.6 in long and must not be kinked or pinched at any point.
The EFOY Pro 12000 Duo each have two 70 cm / 27.6 in hoses. Make
sure that the fuel cartridge is within reach of both connections.
CAUTION!
The connection hose and exhaust hose must not be damaged or replaced by another hose.
Use only original EFOY connection hoses.
Positioning the fuel cartridge
Installation
Select a suitable location for installation as described in chapter 4.1 "Installation space requirements" on page 21.
Observe the dimensions in chapter 3.3 "Specifications" on page 18.
DANGER!
Leakage of methanol poses a fire hazard!
Do not drill or screw into the housing. Components could be harmed and methanol could leak out.
1. Place or position the device at the desired location.
2. With the 19” rail bar the device can be mounted with screws to a
19” rack. Use 4 screws each side for mounting. Optional the device can be mounted in other installation locations.
The fixation in every direction is important for a proper operation.
4.2 Mounting the fuel cell
Installation
Page 26
CAUTION!
Please prove that the off heat of the heat exchanger is not led to the supply air. Separate supply air and off heat.
1. If the fuel cell is installed within a sealed container, provide an
opening for supply air with an opening of at least 600 cm² / 95 in² – at structured openings (fine grid, narrow gap), accordingly more.
2. The air openings of the installation space need to be protected
against the penetration of water and foreign particles (e.g. using louvered metal sheets and fly screens).
3. Ensure that there is sufficient ventilation in the installation space
to prevent heat build-up. This can be done with additional openings or an additional temperature-controlled fan.
4. Separation of air supply and off heat is necessary to prevent
recirculation of waste heat at high temperatures.
5. The electrical connections, the fill opening for EFOY fluids (EFOY
Initial Start Fluid and EFOY Recovery Fluid) and the fuel cartridge must be easily accessible.
4.3 Off-heat
Installation
DANGER!
Within the EFOY Pro fuel cell methanol and oxygen are converted into water and carbon dioxide. This process creates heat, which needs to be con-ducted to the outside together with water vapor, carbon dioxide, and traces of methanol.
Avoid inhaling exhaust gases directly or for extended period, the insulated exhaust hose must be vented outside.
WARNING!
Exhaust gases contain moisture and may exceed +60°C / +140°F during operation.
Let the EFOY Pro 12000 Duo cool down before conducting a service at the unit.
WARNING!
The exhaust hose leads water vapor and water to the outside. At deep temperatures this water can freeze and harm the device.
Install an exhaust hose heater in applications with frequent cold environments below +1 °C / 34 °F to prevent freezing.
4.4 Connecting the exhaust hose
Information regarding exhaust hose heater are available at your service partner or on: www.efoy-pro.com.
Hotline: +49 89 673 592 - 555 Freecall*: 00800 732 762 78
service@sfc.com
It is possible to also collect the generated water in the installation space in a separate, vented water cartridge. Mind sufficient air supply.
Installation
Page 28
1. Remove the protective cap from the
exhaust gas outlet of the EFOY Pro fuel cell. Keep this for winter storage or in case you need to return the fuel cell.
2. Attach the insulated exhaust hose
supplied to the exhaust gas outlet.
3. Take measurements to determine
where to drill the duct opening. The duct opening should consist of a hole with a 18 mm / 0.7 in diameter.
4. Drill a hole for the exhaust hose.
5. Feed the exhaust hose from the
installation space through to the outside.
6. Use a suitable sealant to seal the
hole. Ensure that the exhaust hose has no kinks or blockages and that the exhaust gases can flow freely out of it.
INFO:
Keep the exhaust hose as short as possible. The portion of the hose that penetrates outside should be no longer than 5 cm / 5.9 in. Cut the end of the hose diagonally to prevent drop formation.
The exhaust hose must not be damaged or replaced by another hose.
Take precautions to prevent the exhaust hose from freezing in winter. The exhaust hose must be no longer than 50 cm / 19.7 in. It is essential to use hose insulation in winter. The exhaust hose may be up to 100 cm /
39.4 in long for summer operation and during transitional seasons.
INFO:
Avoid siphoning in the hose as this prevents the passage of the exhaust gas.
To prevent siphoning, ensure that the hose is pointing downwards.
Installation
CAUTION!
Do not get in contact with the EFOY Initial Start Fluid. Wear methanol­resistant gloves and safety goggles when filling in EFOY Initial Start Fluid.
The content of the fluid is 0.5 mol/l dissolution of distilled water and methanol and is not harmful in small amounts.
CAUTION!
Note that liquid can drop out when filling in EFOY initial start fluid.
1. Use a clean pair of scissors to cut off
the tip of the bottle.
2. Put on the filling tube onto the tip.
The EFOY Initial Start Fluid bottle is for one time use only.
3. Unscrew the opening screw for
EFOY fluids (EFOY fluids only) with 6 mm allen key. Keep the screw close for further use.
4. Insert the tube into the connection
nozzle on the device until the mark.
5. Turn the bottle upside down above
the fuel cell and slowly squeeze the entire content into the opening.
4.5 Fill in EFOY Initial Start Fluid
For a secure transport and storage the EFOY Pro 12000 Duo is shipped empty. Therefore it is necessary to fill in EFOY Initial Start Fluid before initial operation. The content of the fluid is 0.5 mol/l dissolution of distilled water and methanol.
Installation
Page 30
6. Use a cloth to wipe away any excess
EFOY Initial Start fluid that may spill over.
7. Bolt the opening screw again.
INFO:
The EFOY initial start fluid can be filled in the EFOY Pro 12000 Duo before installation. The device should not freeze after the EFOY initial start fluid was filled in.
INFO:
The EFOY Initial Start Fluid is required for every initial start.
Be sure to order your next refill of EFOY initial start fluid from your specialist dealer in plenty of time.
Installation
DANGER!
Danger of short circuit.
Connect the EFOY Pro 12000 Duo fuel cell only without voltage to prevent a short circuit.
DANGER!
Danger due to unbalanced charging of batteries.
Always install a battery equalizer in a serial connection of several 12 V batteries for a higher nominal voltage of 24 V DC or 48 V DC.
The responsibility of a proper installation and usage of the application underlie to the user.
WARNING!
All electrical work must only be carried out by qualified electrical technicians in accordance with the relevant legal provisions.
Laying cables incorrectly or using the wrong cable size may result in a fire hazard.
All connected cables must have sufficient insulation and adequate proof voltage, and the connectors must be scoop-proof. The laying of un­insulated cables and pins is not permitted.
CAUTION!
Compare installed circuit breaker tripping characteristics with installed battery parameters.
High battery capacities can cause high inrush currents.
INFO:
The EFOY Pro 12000 Duo must be connected to the battery using a fused circuit. Fuses have to confirm to the maximum currents as specified, see chapter 3.3 “Specifications” on page 18.
Preferably run separate lines for charging (power) and for voltage measuring (sensor) to the battery, otherwise the flow of current will cause false voltage readings.
4.6 Electrical connection
Installation
Page 32
INFO:
The EFOY Pro charges the connected battery and the battery supplies the power to the application or to the electrical loads.
The EFOY Pro must only be used to charge batteries that conform to the technical specifications of the device (see chapter 3.3 "Specifications" on page 18).
The EFOY Pro can charge 24 V and 48 V batteries (Factory settings: lead batteries; Adjustable: LiFePO4).
The charging parameters for automatic mode can be adjusted individually using the expert menu in the operating panel (see chapter
5.1.5 “Expert menu“ on page 44) or using a computer (see the user manual for the interface adapter).
The settings and parameters for LiFePO4 batteries can be found in chapter 5.1.5 “Expert menu“ on page 44.
To protect the battery, the additional use of deep battery protection is recommended to disconnect the load from the battery when the battery voltage is low.
Check polarity before you connect the device.
CAUTION!
The EFOY Pro 12000 Duo needs power to measure the battery voltage as well as to start.
Take care that the EFOY Pro fuel cell is connected directly to the batteries and there is no load throw-off in between.
#
Description
Cable cross-section [mm²]
1
Sense +
0.5 - 16 mm² / 0.02 - 0.6 in²
2
Power +
10 - 25 mm² / 0.4 – 1 in²
3
Power -
10 - 25 mm² / 0.4 – 1 in²
4
Sense -
0.5 - 16 mm² / 0.02 - 0.6 in²
5
Earth
0.5 - 16 mm² / 0.02 - 0.6 in²
4.6.1 Electrical connection to the battery
Installation
CAUTION!
High battery capacities can cause high inrush currents.
Compare installed fuse / circuit breaker tripping characteristics with installed battery parameters.
1.
Device EFOY Pro 12000 Duo
6.
Earth
2.
Cable Sense +
7.
Fuse / circuit breaker Power +
3.
Cable Power +
8.
Fuse / circuit breaker Sense +
4.
Cable Power –
9.
Optional: Emergency switch
5.
Cable Sense –
10.
Battery 24 V DC / 48 V DC
Install a fuse / circuit breaker between the EFOY Pro 12000 Duo and the batteries in the cables sense + and power +. It should be as close as possible to the batteries.
Recommended fuse / circuit breaker Power + line: Type B, rated current at 24 V / 48 V DC: 32 A / 16 A
Recommended fuse / circuit breaker Sense + line: Type B, rated current at 24 V / 48 V DC: 6 A / 6 A
For a direct safety switch-off in terms of service an emergency switch should be installed in the power + cable.
Installation
Page 34
CAUTION!
The EFOY Pro 12000 Duo needs power to measure the battery voltage as well as to start.
Take care that the EFOY Pro fuel cell is connected directly to the batteries and there is no load throw-off in between.
CAUTION!
When connecting a charge controller with temperature compensation please consider the maximum battery voltage of the EFOY Pro fuel cell (see chapter 3.3 "Specifications" on page 18).
INFO:
In the case of a combination with other energy sources it is recommended to adjust the switch-on thresholds of the EFOY Pro so that the device only switches on if solar alone does not provide enough energy (e.g. in winter)
4.6.2 Combination with other energy sources
The EFOY Pro can be combined with other energy sources, which then charge the battery together. The EFOY Pro is often used in combination with a photovoltaic system.
Operation
1. Switch EFOY Pro fuel cell on/off
2.
[menu]
Display the main menu.
3.
[]
Scroll back one level in the menu.
4.
[]
Scroll up one line in the display.
5.
[]
Scroll down one line in the display.
6.
[ok]
Open the selected menu. Confirm a selection.
7. Red LED lights up to indicate a fault.
1 2 3
4 5 6
7
5 Operation
5.1 Operation via the operating panel
5.1.1 Buttons and symbols on the operating panel
Buttons/LEDs
The buttons and LEDs on the operating panel have the following functions:
Operation
Page 36
Current battery voltage.
Current charging current of the EFOY Pro fuel cell.
Fill level of the fuel cartridge.
INFO:
The fuel gauge for the fuel cartridge is just an indicator and calculates the methanol consumption. The FS1 fuel cartridge sensor must be used to measure the actual fill level. The fuel cartridge should only be replaced once it has been completely emptied.
A cluster icon is displayed for EFOY Pro devices that run in parallel (see chapter 8.5 "Cluster Controller CC1" on page 91).
If want to operate the EFOY Pro fuel cell using an external controller, the external control function must be enabled (see chapter 5.4.4 "External control" on page 62). If this is not enabled, a padlock symbol appears (Factory defaults).
If the external control is switched on, an open padlock appears at the bottom right of the display.
If you have switched external control on and the device is in "Remote Control" mode, "RC" (Remote Control) appears at the bottom right of the display.
If the battery type was changed via the expert menu to Lithium iron phosphate (LiFePO4), a LiFe-icon appears top right on the display (see chapter 5.1.5 “Expert menu" on page 44).
The altitude is above 3,000 meter. The icon appears on the right on the display. Air pressure-induced power reduction is possible.
MODBUS RTU was selected as communication protocol. “M”
appears at the bottom right of the display (see chapter 5.1.5 “Expert menu” on page 44, under point communication.
Symbols on the display
The display shows different symbols depending on the operating status and operating mode of the EFOY Pro fuel cell:
Operation
After connecting the EFOY Pro fuel cell to the operating panel for the first time, the intro screen appears on the display.
After a short wait, the language selection appears.
1. Use [][] to select the required language.
2. Press [ok] to confirm your selection.
DANGER!
Danger due to incorrect voltage profile setting.
The selected voltage profile has to confirm to the connected battery voltage.
The responsibility of a proper installation and usage of the application underlie to the user.
5.1.2 Initial start
Fill in EFOY Initial Start Fluid
Consider filling EFYOY Initial Star Fluid into the EFOY Pro 12000 Duo before the initial start. Please follow the descriptions in chapter 4.5 “Fill in EFOY Initial Start Fluid“ on page29.
Switch on
Selecting a language
Select voltage profile
Operation
Page 38
1. Use [][] to select the voltage profile
connected to the EFOY Pro 12000 Duo. Following voltage profiles are available:
- 24 V profile
- 48 V profile
2. Press [ok] to confirm your selection.
1. Following battery types are available in the
"Battery type" menu:
- Lead-acid
- Lead Gel
- AGM
- LiFePO4 (Lithium iron phosphate)
2. Press [ok] to access to select a battery type.
By choosing the LiFePO4 battery type, the Icon
“LiFe” will be shown on the Info screen.
CAUTION!
Incorrectly set battery type may damage the battery. This may nullify your warranty.
Only use the precise values permitted for the battery parameters and battery protection settings (see chapter 5.1.5 “Expert menu" on page
44).
INFO:
The factory defaults for all battery types are based on experience and the parameters for the LiFePO4 batteries are tested and approved only with specific batteries. Please refer to your dealer or follow the advice of the battery manufacturer.
Select battery type
Operation
1. Use [][], to select whether you want to
use a single fuel cartridge or a DuoCartSwitch DCS1 for the relevant connector.
2. Press [ok] to confirm your selection.
INFO:
A detailed description of the DuoCartSwitch DCS1 is available in the respective user manual.
3. Select the relevant fuel cartridge for each
connector.
4. Press [ok] to confirm your selection.
"Connector #1" is displayed first. If you confirm this selection, you can select "Connector #2".
5. Press [ok] to confirm your selection.
Use to access the operating mode. Press [menu] to access the main menu. Press [] to access the system information.
The first line indicates the operating mode selected, e.g., "Automatic" (see chapter 5.4 "Operating modes" on page 59).
Selecting a fuel cartridge
5.1.3 Info screen
During subsequent operation of the device, an info screen appears after switching the device on:
Operation
Page 40
The second line indicates the operating status (see "Operating status" on page 40).
The symbols at the bottom of the display indicate the battery charge condition and the fill level of the fuel cartridge (see "Symbols on the display" on page 36).
1. Press . The operating mode selection
appears.
2. Use [][] to select the operating mode (see
chapter 5.4 „Operating modes“ on page 59).
3. Press [ok] to confirm your operating mode
selection.
Start phase
The EFOY Pro fuel cell undergoes a start phase lasting up to 20 minutes. At the end of this phase, it has reached its full rated output.
Charging mode
The EFOY Pro fuel cell charges the battery.
Standby
As long as the battery charge has a sufficient degree, the EFOY Pro fuel cell remains in standby mode and monitors the battery.
Shutdown procedure
The EFOY Pro fuel cell shuts down charging mode. To protect the components in the device, this procedure may take several minutes to complete.
Antifreeze
The EFOY Pro fuel cell remains active to protect itself from the effects of freezing. For more information, see chapter 5.5 “Automatic antifreeze mode” on page
64.
Battery protection
The EFOY Pro fuel cell charges the battery automatically in order to prevent deep discharge of the battery.
Operating mode
Operating status
Operation
Interruption
Operation is interrupted because the ambient temperature is too high. The EFOY Pro fuel cell switches on again automatically as soon as operation can be resumed.
Error
An error has been detected, and corresponding messages are displayed. For more information, see chapter 7.2 "Errors and solutions" on page 70.
INFO:
During normal operation, the EFOY Pro 12000 Duo briefly interrupts power generation several times each hour for max. 30 seconds. A charging current of 0.0 A is displayed when this occurs.
The energy gap is reproduced during the charging cycle.
1. Press []. The system information is
displayed. The second screen displays information about
the duration of charging cycles in different modes.
Aut: Average charge duration in automatic mode.
Man: Average charge duration in manual mode.
Ext: Average charge duration in remote mode.
The third screen displays operating time and error information. The error messages are explained in chapter 7.2.1 "Error message on the display" on page 70.
Press [] to return to the info screen.
System information
Operation
Page 42
Press [menu]. The main menu appears. Press [][] to select a submenu. Press [ok] to access the selected submenu. Press [] to return to the info screen.
You can select the following menu options in the main menu:
- Operating mode
- Fuel cartridge
- System information
- Language
- System reset
1. Select the connected fuel cartridge.
2. Press [ok] to confirm your selection.
INFO:
If you have not connected a full fuel cartridge, disable the fuel gauge by selecting "Disable fuel gauge" in the menu.
5.1.4 Main menu
Operating mode
For a detailed description, see chapter 5.4 "Operating modes" on page 59.
Fuel cartridge
System information
For a detailed description, see "System information" on page 41.
Operation
1. Press [][] to select the language.
2. Press [ok] to confirm the language selection.
Press [ok] to perform a restart. Press [] to stop the restart and return to
the main menu.
Language
Reset
The reset function allows you to restart the EFOY Pro fuel cell:
Operation
Page 44
CAUTION!
Incorrectly set operating parameters may damage the device. This may nullify your warranty.
Only use the precise values permitted for the battery parameters and battery protection settings (see page 49).
Before installation and operation please check the battery data sheets from the manufacturers permitted battery values.
Press and hold [ok] and [menu] at the same time
for 2 seconds. The expert menu appears.
Press [][] to select a submenu. Press [ok] to access the selected submenu. Press [] to return to the expert menu.
You can select the following menu options in the expert menu:
- Voltage profile
- Battery type
- Battery parameters
- Battery protection
- Communication
- Factory defaults
This option allows you to undo all the settings in the menu “Expert menu”. Press [ok] to confirm or [] to cancel.
CAUTION!
If “Factory defaults” settings are chosen all settings have to be set again, like battery type and voltage profile.
Please be sure that the right settings are set.
5.1.5 Expert menu
Operation
1. Press [][] to select a voltage profile
where the EFOY Pro 12000 Duo is connected to. You can select the following voltage profiles:
- 24 V Profile
- 48 V Profile
2. Press [ok] to confirm the voltage profile.
DANGER!
Danger due to incorrect voltage profile setting.
The selected voltage profile has to confirm to the connected battery voltage.
The responsibility of a proper installation and usage of the application underlie to the user.
1. You can select the following batteries in the
"Battery type" menu:
- Lead-acid
- Lead Gel
- AGM
- LiFePO4 (Lithium iron phosphate)
2. Press [ok] to access to select a battery type.
By choosing the LiFePO4 battery type, the Icon
“LiFe” will be shown on the Info screen.
CAUTION!
Incorrectly set battery type may damage the battery. This may nullify your warranty.
Only use the precise values permitted for the battery parameters and battery protection settings on page 49.
Voltage profile
Battery type
Operation
Page 46
INFO:
The factory defaults for all battery types are based on experience and the parameters for the LiFePO4 batteries are tested and approved only with specific batteries. Please refer to your dealer or follow the advice of the battery manufacturer.
You can select the following options in the "Battery parameters" menu:
- Switch-on delay
- Switch-on voltage
- Switch-off voltage
- Switch-off current
- Absorption time
- Min. charge time
- Max. charge time
- Hybrid (only when external control is on)
- Factory defaults
This option allows you to undo all the settings in the menu “battery parameters”. Press [ok] to confirm or [] to cancel.
CAUTION!
Incorrectly set operating parameters may damage the device. This may nullify your warranty.
Only use the precise values permitted for the battery parameters and battery protection settings (see page 49).
CAUTION!
Adjust the battery settings according to the application.
Check the battery specific characteristic curve to set the battery parameters fitting to the discharge values.
Battery parameters
Operation
Battery parameters
Function
Switch-on delay
The EFOY Pro fuel cell does not start immediately if the switch-on voltage only drops below the set threshold level temporarily. The device only starts automatically if the switch-on voltage is still below this threshold level after the switch-on delay of 60 seconds. For example, with the factory default of 24.4 V / 48.8 V for lead-acid batteries, the switch-on voltage must drop below 24.4 V / 48.8 V for at least 60 seconds in order for the EFOY Pro fuel cell to start.
If loads with a high rate of power consumption are operated temporarily, this value must be set in accordance with the operating times of these loads.
Switch-on voltage
The EFOY Pro fuel cell switches on at the set voltage and charges the battery.
Setting too high a value for the switch-on voltage results in frequent starting of the EFOY Pro fuel cell. Setting too low a value for the switch-on voltage results in damage to the battery. The default value for lead batteries is 24.4 V /
48.8 V, which corresponds to approx. 50% of the battery charge condition.
Switch-off voltage
If the battery voltage reaches the set level, the EFOY Pro fuel cell switches off, provided that the value set for the "Switch-off current" or “Absorption time” parameter has also been reached.
Please note your battery's end-of-charging voltage. Note the charging recommendations provided by the battery manufacturer.
Switch-off current
The EFOY Pro fuel cell switches off if the current drops below the set switch-off current.
If you want the battery voltage to serve as the only switch­off parameter, set the maximum value, as the current is always below this value in EFOY Pro fuel cells.
Absorption time
This function serves as an additional switch-off criterion for EFOY Pro fuel cells if the switch-off current level is not reached within the set time period.
This period is set by default to 180 minutes, but can be changed to any value between 0 and 300 minutes.
Operation
Page 48
Battery parameters
Function
Max. charge time
If the switch-off criteria, voltage and current, have not been satisfied, the EFOY unit will shut down after defined operating hours. Once the switch-on criteria have been satisfied, the EFOY unit will turn on again, which can be immediately after the maximum charge time.
This switch-off criterion prevents unlimited charge cycles caused by various factors like defective batteries.
This criteria can by switched off by setting 0 h.
Min. charge time
The EFOY Pro fuel cell calculates the aver-age duration of a charging cycle. If this duration drops below the present value of 30 minutes, it indicates the error, too old, defective or battery too small. This can equally be an indication that incorrect battery parameters have been selected. A warning is displayed on the operating panel. Several short charging cycles can damage the EFOY Pro fuel cell and/or the battery. Please contact your local dealer to solve the problem.
Hybrid
This battery voltage is the maximum set level in Hybrid and Remote On operation, the EFOY Pro fuel cell will charge up to.
INFO:
The EFOY Pro fuel cell switches off automatically. In order for the EFOY Pro fuel cell to switch off, the voltage must drop below the set switch­off voltage level, and the current must drop below the set switch-off current. The factory defaults for lead batteries are a switch-off voltage of 28.8 V / 57.6 V and a switch-off current of 10.0 A / 5.0 A. This means that the EFOY Pro fuel cell switches off as soon as the battery reaches a voltage of 28.8 V / 57.6 V and the charging current simultaneously drops below 10.0 A / 5.0 A.
Operation
Permitted value ranges for lead batteries (24 V)
Factory defaults
Min.
Max.
User­defined value:
Switch-on voltage
24.4 V
22.0 V
26.0 V
Switch-off voltage
28.8 V
27.0 V
29.4 V
Switch-off voltage (Hybrid)
29.4 V
27.0 V
30.0 V
Switch-off current
10 A
8 A
24 A
Switch-on delay
60 s
2 s
300 s
Absorption time
180 min
0 min
300 min
Max. charge time
24 h
0 h
240 h
Min. charge time
30 min
30 min
180 min
Permitted value ranges for lead batteries (48 V)
Factory defaults
Min.
Max.
User­defined value:
Switch-on voltage
48.8 V
44.0 V
52.0 V
Switch-off voltage
57.6 V
54.0 V
58.8 V
Switch-off voltage (Hybrid)
58.8 V
54.0 V
60.0 V
Switch-off current
5 A
4 A
12 A
Switch-on delay
60 s
2 s
300 s
Absorption time
180 min
0 min
300 min
Max. charge time
24 h
0 h
240 h
Min. charge time
30 min
30 min
180 min
Operation
Page 50
Permitted value ranges for LiFePO4 batteries (24 V)
Factory defaults
Min.
Max.
User­defined value:
Switch-on voltage
25.0 V
24.0 V
26.8 V
Switch-off voltage
29.0 V
27.6 V
29.2 V
Switch-off voltage (Hybrid)
29.0 V
27.0 V
30.0 V
Switch-off current
10 A
8 A
24 A
Switch-on delay
60 s
2 s
300 s
Absorption time
180 min
0 min
300 min
Max. charge time
48 h
0 h
240 h
Min. charge time
30 min
30 min
180 min
Permitted value ranges for LiFePO4 batteries (48 V)
Factory defaults
Min.
Max.
User­defined value:
Switch-on voltage
50.0 V
48.0 V
52.0 V
Switch-off voltage
58.0 V
55.2 V
58.4 V
Switch-off voltage (Hybrid)
58.0 V
54.0 V
60.0 V
Switch-off current
5 A
4 A
12 A
Switch-on delay
60 s
2 s
300 s
Absorption time
180 min
0 min
300 min
Max. charge time
48 h
0 h
240 h
Min. charge time
30 min
30 min
180 min
Operation
CAUTION!
Incorrectly set operating parameters may damage the device. This may nullify your warranty.
Only use the precise values permitted for the battery parameters and battery protection settings.
You can select the following menu options in the "Battery protection" menu:
- Switch-on voltage
- Enable/Disable
- Factory defaults
This option allows you to undo all the settings in the menu “battery protection”. Press [ok] to confirm or [] to cancel.
If you want to switch off the EFOY Pro fuel cell after the battery protection function has started,
press . The function is re-enabled automatically when the device is switched on or is operated in automatic mode.
Battery protection
The EFOY Pro fuel cell has automatic battery protection when the EFOY Pro fuel cell is switched off.
Battery protection is enabled automatically if the battery voltage (Lead­batteries) drops below 22.0 V / 44.0 V for more than 15 minutes. "Battery protection" mode ends as soon as the voltage reaches 26.4 V / 52.8 V. The switch-off voltage in battery protection mode is not adjustable.
The battery protection function provides deep discharge protection for the battery, even when the EFOY Pro fuel cell is switched off and does not take over the charging function.
Operation
Page 52
Factory defaults
Min.
Max.
User­defined value:
Permitted value ranges for lead batteries
Battery protection (24 V)
22.0 V
21.0 V
24.0 V
Battery protection (48 V)
44.0 V
42.0 V
48.0 V
Permitted value ranges for LiFePO4 batteries
Battery protection (24 V)
22.0 V
21.0 V
24.0 V
Battery protection (48 V)
44.0 V
42.0 V
48.0 V
INFO:
Please check your system if the fuel cell repeatedly switches back to battery protection. Either the battery has already been damaged or too much energy has been discharged.
INFO:
Battery protection only works if a full EFOY fuel cartridge is connected.
In the menu ”Communication“ different
communication protocols can be selected. Following protocols are adjustable:
- SIO / plain text (Factory setting)
- MODBUS RTU
Two menus are available:
o MODBUS Address o MODBUS Config
Communication
Operation
Additionally the interface can be chosen:
- RS232 (Front data interface, factory setting)
- RS485 (Data interface back side, only Modbus
RTU)
- Factory defaults
This option allows you to undo all the settings made in the menu “Communication”. Press [ok] to confirm or [] to cancel.
By choosing the MODBUS RTU as communication protocol, an “M“ icon appears at the right bottom of the display.
A detailed description is available in this user manual in chapter 8.2 „Communication Protocols“ on page 77.
5.2 Remote control via computer
You can also control the EFOY Pro using a computer. Remote control is also possible using an optional modem.
The same operating functions available via the operating panel are also available via the data interface (see chapter 5.1 "Operation via the operating panel" on page 35).
A detailed description is available in the user manual for the interface adapter IA1.
Operation
Page 54
CAUTION!
Ensure that a full EFOY fuel cartridge is connected at the initial start of the EFOY Pro fuel cell.
When the fuel cartridge is empty, the yellow LED on the device flashes and the red LED on the operating panel. "Fuel cartridge empty" also appears on the operating panel.
INFO:
Check after every connection of a fuel cartridge the functionality at the EFOY Pro fuel cell via manual on.
WARNING!
Use only original EFOY fuel cartridges!
Please refer to the information about methanol provided in chapter 2 "Safety Information" on page 5.
Keep all EFOY Pro fuel cells and EFOY fuel cartridges out of reach of children, even when empty or only partly full.
5.3 Fuel cartridges
5.3.1 Connecting the fuel cartridge
The fuel cartridge can be changed while the device is in operation. EFOY fuel cartridges are intended for single use only and cannot be
refilled.
Operation
1. Screw the EFOY Pro fuel cartridge
connector (1) directly onto the M10 fuel cartridge (2)
2. Press [ok] on the operating panel so
that the red warning light and error message are no longer displayed.
Select the installed fuel cartridge on the operating panel (see chapter 5.3.2 "Selecting a fuel cartridge" on page 57).
INFO:
For use in vehicles an appropriate fastening has to be used. The installation as well as the safety related inspection has to be done by the user.
The M10 fuel cartridge may also be used on its side in stationary applications. The valve must be on the side at the top for this.
1. Screw the EFOY Pro fuel cartridge
connector (1) to the M28 adapter (2).
2. Screw the M28 adapter (2) onto the
M28 fuel cartridge (3).
3. Press [ok] on the operating panel so
that the red warning light and error message are no longer displayed.
Select the installed fuel cartridge on the operating panel (see chapter 5.3.2 "Selecting a fuel cartridge" on page 57).
INFO:
The M28 fuel cartridge can only be connected using the optional M28 adapter.
For use in vehicles an appropriate fastening has to be used. The installation as well as the safety related inspection has to be done by the user.
The M28 fuel cartridge may also be used on its side in stationary applications. The valve must be on the side at the top for this.
3
2
Connecting the M10 fuel cartridge
Connecting the M28 fuel cartridge
Operation
Page 56
4. Screw the EFOY Pro fuel cartridge
connector (1) directly onto the MT60 fuel tank (2)
5. Press [ok] on the operating panel so
that the red warning light and error message are no longer displayed.
Select the installed fuel cartridge on the operating panel (see chapter 5.3.2 "Selecting a fuel cartridge" on page 57).
INFO:
For use in stationary and vehicle application an appropriate fastening has to be used. The MT60 only should be installed in upright position. The installation as well as the safety related inspection has to be done by the user.
1. Unscrew the fuel cartridge connector
from the empty EFOY fuel cartridge.
2. Remove the empty EFOY fuel
cartridge.
3. Use the screw cap to seal each
EFOY fuel cartridge securely after use.
2
Connecting the MT60 fuel tank
Removing the fuel cartridge
Operation
INFO:
If you have not connected a full fuel cartridge, disable the fuel gauge by selecting "Disable fuel gauge" in the menu.
1. Select an active fuel cartridge to edit it
directly.
2. Press [ok] to confirm your selection..
You can select the following actions in the fuel cartridge submenu:
- Reset:
Resets the counter after the fuel cartridge has been changed to 100%.
- Enable:
Enables the fuel cartridge.
- M10 / M28 / MT60:
Changes the fuel cartridge type for the respective connector.
3. Select a connector to edit the connector and
any associated fuel cartridges.
4. Press [ok] to confirm your selection.
5.3.2 Selecting a fuel cartridge
When you select the "Fuel cartridge" submenu in the main menu, the display shows the fuel cartridges already enabled and the device connectors.
Operation
Page 58
You can select the following actions in the connector submenu:
- Cartridge:
A single fuel cartridge is to be used at the connector. The associated fuel cartridge is displayed at the highest level of the menu.
- DuoCartSwitch:
A DuoCartSwitch is to be used at the connector.
A detailed description of the DuoCartSwitch is available in the respective user manual.
- Deactivate:
Disables the connector.
Operation
INFO:
If the device fails to start, check that the cap is not still attached to the exhaust hose connector. Remove the cap.
INFO:
To ensure optimal battery maintenance, the charging current must not be stopped abruptly when the cut-off threshold is reached. For this reason, the EFOY Pro fuel cell continues charging the battery for up to three hours at a reduced current after the configured cut-off threshold is reached (factory default lead batteries: 28.8 V / 57.6 V). The length of the recharging period depends on the battery voltage and power consumption.
5.4 Operating modes
The EFOY Pro fuel cell can be operated in one of the following modes:
Automatic Manual On Manual Off External control on Hybrid
5.4.1 Automatic
Automatic mode starts as soon as you connect the device to the battery. The device monitors the battery voltage independently.
The EFOY Pro fuel cell switches on automatically if the battery voltage drops below 24.4 V / 48.8 V (Lead batteries). The battery is then charged until the cut-off threshold of 28.8 V / 57.6 V is reached.
When the device is started, it goes through a start phase, which may last up to 20 minutes. It only reaches its full rated output after this phase.
During normal operation, the EFOY Pro fuel cell briefly interrupts power every 20 minutes for maximal 20 seconds. A charging current of 0.0 A is displayed when this occurs. The lost energy will be generated afterwards.
Operation
Page 60
1. Press on the operating panel, or select
"Operating mode" in the main menu. The operating mode selection appears.
2. Select the "Manual On" operating mode.
3. Press [ok] to confirm your selection.
5.4.2 Manual On
You can switch the device on manually if the battery voltage is below 26.4 V / 52.8 V (Lead batteries) or 28.0 V / 56.0 V (LiFePO4). After the start phase, the device is then in "charging mode".
The device operates independently of the configured switch-on voltage, and charges the battery until the cut-off threshold is reached.
(U
>28.8 V / 57.6 V and I
batt
Please note: The EFOY Pro fuel cell can only start if it is connected to an intact battery and a filled fuel cartridge. The EFOY Pro fuel cell does not switch on if the battery is damaged or has been deeply discharged.
< 10.0 A / 5.0 A)
off
Operation
INFO:
To protect the components, the device should not be switched off until it has been running for at least 30 minutes since it was started. If the device is switched off before this period has elapsed, it will continue running for the remainder of the required running time. The message "Shutdown procedure" is shown on the display. Do not disconnect the fuel cartridge or battery during the shutdown procedure.
INFO:
The battery protection and automatic antifreeze functions remain active after the device is switched off.
1. Press on the operating panel, or select
"Operating mode" in the main menu. The operating mode selection appears.
2. Select the "Manual Off" operating mode.
3. Press [ok] to confirm your selection.
4. Wait until the shutdown procedure has
finished and "Shutdown procedure" is no longer displayed on the info screen.
INFO:
Do not disconnect the fuel cartridge or battery during the shutdown procedure.
The shutdown procedure may take some time, to ensure that all protective features are applied.
5.4.3 Manual Off
Operation
Page 62
1. Press on the operating panel, or select
"Operating mode" in the main menu. The operating mode selection appears.
2. Select the "External control on" operating
mode.
3. Press [ok] to confirm your selection.
An open padlock is displayed at the bottom right of the display.
If the controller now receives an external signal "RC" (Remote Control) is displayed at the bottom right of the display.
INFO:
If you have not enabled external control, a closed padlock is displayed at the bottom right of the display when an external signal is being received.
The unit starts disregarded the switch-on voltage and charges the batteries until the set switch-off parameters
5.4.4 External control
You can control the EFOY Pro externally using a switching contact on Pin 7 at the Data Interface plug, e.g. a solar charger. See chapter 3.2 Connections on page 15 for the Pinning.
"External control" operating mode must be enabled.
Operation
CAUTION!
Incorrectly set operating parameters may damage the device. This may nullify your warranty.
Only use the precise values permitted for the battery parameters and battery protection settings.
The EFOY Pro can be set into Hybrid mode by a voltage signal or a software control. In this operation mode all parameters are disabled, like switch-on voltage or battery protection. Only the frost protection mode is an exception.
Activation via voltage signal: Connect Pin 4 (GND, Ground) or the negative
battery pol with Pin 8 (Hybrid) Activation via software control: Send at least every 15 seconds the SIO command
HYBRID or Modbus address 42002 Hybrid to the EFOY Pro fuel cell.
To start and stop the EFOY Pro fuel cell a positive voltage signal must be connected to Pin 7 (Re­mote On) or via software SIO command REMOTE ON/OFF or Modbus address 41030.
INFO:
The battery voltage is deactivated in hybrid mode and is not shown on the display.
The battery voltage will not exceed the set value switch-off voltage (Hybrid). If the voltage signal on pin 7 or the software commands are not removed the EFOY Pro fuel cell will charge the battery continuous in full and part load mode as a constant voltage (CV) charger.
5.4.5 Hybrid
Operation
Page 64
The device has an intelligent automatic antifreeze feature. This operating status switches on automatically as soon as the temperature drops below +3 °C / +37.4 °F. This prevents the device from freezing. If the device is operating in antifreeze mode, the message "Antifreeze" is shown in the second line of the display.
CAUTION!
The automatic antifreeze feature only works when the fuel cell is connected to a filled EFOY fuel cartridge and an intact battery.
INFO:
The battery protection as well as the antifreeze mode is also active when the EFOY Pro 12000 Duo is in switch off mode.
INFO:
The methanol consumption in the antifreeze mode depends on the climatic conditions.
5.5 Automatic antifreeze mode
Operation
INFO:
Protect the fuel cartridge and the fuel cartridge connector on the device from impurities.
Follow the instructions shown on the display:
1. Shut down EFOY Pro 12000 Duo via
”Manual Off“ and let the unit cool down.
2. Press [menu] and [] for at least 3
seconds.
3. Put the resealable 2 liter canister under
the opening screw on the bottom and unscrew the outlet screw.
5.6 Shutdown
5.6.1 Switching off the fuel cell
Switch off the EFOY Pro fuel cell via the operating panel or directly on the device. This is described in chapter 5.4.3 "Manual Off" on page 61.
5.6.2 Removing the EFOY fuel cartridge
This is described in "Removing the fuel cartridge" on page 56.
5.6.3 Secure transportation and storage procedure
For a secure transport and storage the secure transport and storage procedure has to be executed, especially when the EFOY Pro 12000 Duo fuel cell is exposed temperatures below +1 °C / +34 °F.
The following items are required for this procedure:
Resealable canister (2 liter) Isolated hexagon socket screw key (Allen key) Methanol-resistant gloves Safety goggles
Operation
Page 66
4. This procedure can take at least up to 5
minutes. After completing the procedure a message will be shown in the display.
5. Rescrew in the outlet screw and dispose
the fluid under acceptance of national allowance.
INFO:
Store the plugs and cables in a cool, dry place.
CAUTION!
Store the EFOY Pro fuel cell in a cool place, but at a temperature over +1 °C / +34 °F. (See also storage temperature in chapter 3.3 "Specifications" on page 18).
If the EFOY Pro fuel cell is exposed to temperatures below +1 °C / +34 °F without connected batteries and sufficiently filled fuel cartridges, it must be defrosted for approximately 24 hours at room temperature before use.
INFO:
Use a suitable box for storing the EFOY Pro fuel cell, e.g., the box in which it was delivered. The EFOY Pro fuel cell must be stored in an upright position only.
5.6.4 Detaching the charge line and data line
1. Switch off the voltage connection between EFOY Pro and the
battery via the switch off switch.
2. Disconnect the electrical connection afterwards.
5.6.5 Detaching the exhaust hose
Disconnect the exhaust hose. Protect it from impurities and seal the exhaust outlet with the protective cap.
Maintenance
WARNING!
Do not open the EFOY Pro fuel cell! Unauthorized opening of the EFOY Pro fuel cell interferes with safe operation of the device and nullifies the warranty and guarantee. The EFOY Pro fuel cell does not contain any parts that you can maintain or repair yourself.
CAUTION!
Burn Hazard.
Hot surfaces. In operation temperature up to +65 °C / +150 °F at heat exchanger possible. Do not touch.
CAUTION!
Store the EFOY Pro fuel cell in a cool place, but at a temperature over +1 °C / +34 °F. (See also storage temperature in chapter 3.3 "Specifications" on page 18).
If the EFOY Pro fuel cell is exposed to temperatures below 0 °C / 32 °F without connected batteries and sufficiently filled fuel cartridges, it must be defrosted for approximately 24 hours at room temperature before use.
CAUTION!
6 Maintenance
6.1 Service
Under normal operating conditions, the EFOY Pro fuel cell is maintenance­free.
6.2 Long term storage
After long term storage over 6 month SFC recommends to check the functionality of the EFOY Pro fuel cell before installation. For that purpose connect the fuel cell to a battery to run a charging cycle. A charging cycle can last several hours. After successfully passing the charging cycle run the transport lock procedure. Press the [menu] and [] button on the Operating panel at least 3 seconds and follow the instructions on the display.
Maintenance
Page 68
Note that liquid can drop out when running the transport lock procedure.
INFO:
Use a suitable box for storing the EFOY Pro fuel cell, e.g., the box in which it was delivered. The EFOY Pro fuel cell must be stored in an upright position only.
INFO:
For an update with the EFOY Updater the RS232 data interface has to be activated. If RS485 is in use change the communication interface to RS232.
WARNING!
Switch the device off and disconnect the charge line before cleaning.
The device is not water-tight. Please ensure that no moisture can enter the device.
6.3 Firmware update
Be sure to check on a regular basis which updates are available for your firmware.
Simply connect the EFOY Updater to your EFOY Pro fuel cell data interface at the front side to perform the update.
For information on the latest firmware updates and the Updater, please contact your service partner or go to www.efoy-pro.com.
6.4 Cleaning
1. Clean only with a soft cloth dampened with a mild detergent.
2. Reconnect the battery charge line after cleaning so that the
automatic antifreeze feature remains activated (see chapter 5.5 “Automatic antifreeze mode” on page 64).
Troubleshooting
WARNING!
Do not open the EFOY Pro fuel cell! Unauthorized opening of the EFOY Pro fuel cell interferes with safe operation of the device and nullifies the warranty and guarantee. The EFOY Pro fuel cell does not contain any parts that you can maintain or repair yourself.
If you cannot resolve an error using these instructions, please contact the sales partner from whom you purchased the device, or contact our service hotline directly.
7 Troubleshooting
7.1 Safety
Contact details
Headquarters SFC Energy AG Eugen-Saenger-Ring 7 85649 Brunnthal Germany Hotline: +49 89 / 673 592 555 Freecall: 00800 / 732 762 78* eMail: service@sfc.com Web: www.efoy-pro.com
*Calls can be placed free of charge from the landline from: Germany, Belgium, Denmark, France, Great Britain, Italy, the Netherlands, Norway, Austria, Sweden, Switzerland and Spain.
Troubleshooting
Page 70
Error message
Code
Solution
Service is required. Protect device against frost! Please contact EFOY hotline or hotline@sfc.com.
1 10 15 76 83
Please contact your service partner or the hotline. Contact details are provided in chapter 1.2 "Contact details" on page 4.
A restart is required. If the error occurs again please contact EFOY hotline or hotline@sfc.com. Press OK for restart.
13 14 17 70 71 73 75 80 81 84 87
Select the "System reset" option in the main menu to restart the device (max. twice).
If the error still occurs, please contact your service partner or the hotline. Contact details are provided in chapter 1.2 "Contact details" on page 4.
Please make sure the exhaust hose is not blogged, bent or frozen. Press OK for restart.
11 18
Please check the installation of the exhaust hose and position it so that no condensation can gather. Do not bend the exhaust hose. If necessary, clean the exhaust hose and protect the opening from becoming clogged. Shorten the exhaust hose if condensation is gathering in it.
7.2 Errors and solutions
7.2.1 Error message on the display
In the event of interruptions and errors, the operating panel displays warning messages on the display panel, including an error code and instructions on how to resolve the error.
By following these instructions, you can quickly and easily eliminate some of the errors that may occur.
Troubleshooting
Error message
Code
Solution
Fuel cartridge empty. Please replace the fuel cartridge, and press OK.
20 22
See chapter 5.3.1 “Connecting the fuel cartridge“ on page 54.
Please refill EFOY Recovery Fluid. To restart press ok. If this problem occurs again, please contact your service partner.
30 31
Make sure that the off-heat can escape without obstruction and that the ambient temperature is below +50 °C / +122 °F. If the fuel cell is installed within a sealed container, please ensure that the opening for supply air has a cross-section of at least 600 cm² / 95 in². Then refill the fuel cell with EFOY service fluid (see chapter
7.3 "Adding EFOY recovery fluid" on page
74).
Interruption: Cooling insufficient. Please check installation and air supply!
32
The cooling air is insufficient or the ambient air is too warm. Please check whether the room in which the fuel cell is installed has sufficient ventilation, or whether the openings for the air supply in the EFOY Pro fuel cell are blocked.
Interruption: Device frozen. Please defrost device slowly for at least 24h at room temperature.
40
The device was exposed to temperatures below +1°C / +34°F without a connected battery and/or an EFOY fuel cartridge that was not filled sufficiently. It must be allowed to defrost for approx. 24 hours at room temperature.
Interruption: Surroundings too warm. Please wait for the device to cool down.
41
The ambient temperature is too high. The device will start automatically if the temperature drops to below +40 °C / +104 °F.
Troubleshooting
Page 72
Error message
Code
Solution
Battery voltage low. Please check battery connection and load battery.
50 52
Please check the cabling and check whether a suitable battery is connected. Check the battery voltage. If it is too low, please load the battery with a battery charger. Please also check other loading devices for defects, e.g. alternator or charge controller.
Battery voltage high. If applicable, please check additional charging devices.
51 53
Please check the cabling and check whether a suitable battery is connected. Please also check other loading devices for defects, e.g. alternator or charge controller.
Please disconnect fuel cartridge connection, shake cartridge firmly and reconnect. Restart device at most 2 times. Press OK for restart.
72
Check the fuel cartridge connection and, if necessary, check for any contamination and remove it. Then please perform a system reset (max. twice). If the error still occurs, please contact your service partner or the hotline. Contact details are provided in chapter 1.2 "Contact details" on page 4.
Error message
Solution
Interruption: Cooling insufficient. Please check installation and air supply!
The cooling air is insufficient or the ambient air is too warm. Please check whether the room in which the fuel cell is installed has sufficient ventilation, or whether the openings for the air supply in the EFOY Pro fuel cell are blocked.
Battery defective, too small or too old. Please check the battery and the battery parameters. Replace battery if necessary or review battery parameters.
The on-board electrical system including the battery has to be checked. The EFOY Pro has measured charging cycles which were too short. This is an indication of a defective, too old or too small battery. The battery parameters may also need to be reviewed.
7.2.2 Display Warnings
Troubleshooting
Error message
Solution
Note: Supply problem at fuel connector #1.1 #1.2 #2.1 #2.2. Please check fuel connector. If this problem occurs again please contact your service partner.
Check the fuel cartridge connector for contamination and proper fuel cartridge connection. Check the fuel cartridge on functionality and exchange it if necessary. The connector can be reset in the cartridge menu in the operation panel.
Possible cause
Solution
No battery is connected, the battery has not been properly connected, or a deep discharge has occurred.
Check the pins, polarity and cables (see chapter 4.6 “Electrical connection” 31). Connect a charged battery in order to start the device.
Short-circuit has occurred.
Ensure that the polarity of the charge line is correct.
Switch off the device, check the cause of the short circuit or overload, and eliminate the error.
If the problem recurs:
Please contact your service partner or the hotline.
Freecall: 00800 / 732 762 78*
Hotline: +49 89 / 673 592 555
service@sfc.com www.efoy-pro.com
*Calls can be placed free of charge from the landline from: Germany, Belgium, Denmark, France, Great Britain, Italy, the Netherlands, Norway, Austria, Sweden, Switzerland and Spain.
7.2.3 Errors without display messages
Troubleshooting
Page 74
If the internal EFOY fluid level is low, the red LED on the EFOY Pro fuel cell comes on and the message "Please refill recovery fluid" appears on the operating panel display.
WARNING!
If this message is displayed frequently, check that the air supply at the installation location is sufficient. There is no need to add EFOY recovery fluid under normal operating conditions.
Never refill the fuel cell with more than one bottle of EFOY recovery fluid at a time.
Use original EFOY recovery fluid only.
Switch off the EFOY Pro fuel cell before refilling with EFOY recovery fluid. Disconnect the charge line.
Make sure that no dirt or foreign bodies enter the fill opening.
1. Use a clean pair of scissors to cut off
the tip of the bottle.
INFO :
The EFOY recovery fluid bottle is for one time use only.
2. Unscrew the openinig screw for
EFOY fluids (EFOY fluids only) with 6 mm allen key. Keep the screw close for further use.
3. Insert the tip of the bottle into the
connection nozzle on the device and slowly squeeze the entire contents slowly into the opening.
7.3 Adding EFOY recovery fluid
Data Interface and Optional Accessories
4. Use a cloth to wipe away any excess
EFOY service fluid that may spill over.
5. Bolt the openinig screw again.
Tighten the screw hand-tight.
6. When you have finished filling the
device, press [ok]. The message is deleted and the EFOY Pro fuel cell returns to its previous operating status, e.g. automatic mode.
7. Be sure to order your next refill of
EFOY recovery fluid from your specialist dealer in plenty of time.
CAUTION!
The data interface cannot be connected directly to a computer. The interface adapter is required for this.
Connecting the EFOY Pro fuel cell directly to a computer can damage both devices.
8 Data Interface and Optional Accessories
8.1 Data interface functionality
The EFOY Pro data interface enables the connection of:
Computer or modem with the interface adapter IA1 Fuel cartridge sensor FS1 Cluster controller CC1 DuoCartSwitch DCS1
Data Interface and Optional Accessories
Page 76
Pin
Data Interface
1
DuoCartSwitch DCS1
2
RS232 TxD (Transmit Data)
3
RS232 RxD (Receive Data)
4
GND, Ground
5
Battery +
6
Fuel Cartridge Sensor FS1
7
Remote On
8
Parallel/hybrid operation control
A. CAT5 data line B. Interface Adapter IA1 C. PC (COM interface)
The interface adapter IA1 is used to connect the EFOY Pro to a computer or modem via the COM connection.
The USB adapter enables you to connect the interface adapter to the USB connection if no COM connection is available.
When using a communication interface, the supplied ferrite must be mounted to the communication cable. The communication cable must be laid through the ferrite twice
(“loop”). The ferrite must be placed as
close as possible to the EFOY Pro fuel cell.
Data Interface and Optional Accessories
1. Press and hold [ok] and [menu] at the same
time for 2 seconds. The expert menu appears.
2. Press [] to select a submenu
“Communication” and press [ok] to access.
3. Press [][] to select one of the following
communication protocols:
o SIO / plain text o MODBUS RTU
4. Select the required communication protocol
for the RS232 interface and press [ok] to select.
By choosing the MODBUS RTU as communication protocol, an “M“ icon appears at the right bottom of the display.
A. Data interface front side
Data interface: RS232 The description for the data interface can be
found in chapter 3.2 “Connections” on page 15.
A
8.2 Communication Protocols
The communication with the EFOY Pro fuel cells is possible via RS232 and RS485 data connection. Also a direct modem connection for external control and observation is possible.
Following protocols are supported:
- SIO / clear text (RS232, factory settings)
- MODBUS RTU (RS232 and RS485)
The settings can be changed via the Operating panel OP2:
Data interfaces
If MODBUS RTU protocol should be used you have to choose which interface side is in use. You have to activate the interface on the front and back side in the menu “Communication”:
Data Interface and Optional Accessories
Page 78
B. Data interface back side
Data interface: RS485 The description for the data interface can be
found in chapter 3.2 “Connections” on page 15.
1. Press and hold [ok] and [menu] at the same
time for 2 seconds. The expert menu appears.
2. Press [] to select a submenu
“Communication” and press [ok] to access.
- RS232 (Data interface front side, factory settings)
- RS485 (Data interface back side)
3. Select the required data interface and press
[ok] to select.
INFO :
Only the activated interface is ready for use. The deactivated interface is without function
B
8.2.1 Modbus RTU
The EFOY Pro fuel cell enables a MODBUS RTU communication via the RS­232 or RS485 data interface.
Following parameters are set for the MODBUS RTU protocol: Baud rate: 9600 Data bits: 8 Party: Even Parity Stop bits: 1 Display in Operating panel OP2: 9600 8,E,1 The parameters can be changed on demand via Operating panel OP2, PC
or Laptop.
Data Interface and Optional Accessories
1. Press and hold [ok] and [menu] at the same
time for 2 seconds. The expert menu appears.
2. Press [] to select a submenu
“Communication” and press [ok] to access.
3. Select a submenu “MODBUS Config” and
press [ok].
4. Press [][] to select one of the following
MODBUS configurations. Press [ok] to confirm.
Following configurations are available:
Display in Operating panel OP2
9600 8,E,1
(Standard)
9600 8,O,1
9600 8,N, 2
9600 8,N,1
Baud rate
9600
9600
9600
9600
Data bits 8 8 8 8
Parity
Even
Parity
Odd Parity
No Parity
No Parity
Stop bits 1 1 2 1
INFO:
The pre-installed MODBUS Address is the last 2 numbers of the serial number. The EFOY Pro with serial number 123456-1234-56789 has the address 89. In the case where the serial number ends with 00 the address 100 is set.
Via Operating panel OP2:
Via PC or Laptop:
With the SIO command “MODBUS” the configurations can be adjusted as
well as the MODBUS RTU protocol can be activated. A detailed description is available in the user manual for the interface
adapter.
Connection to a RS485 network
An RS485 interface is provided at the data interface back side of the EFOY Pro 12000 Duo.
Data Interface and Optional Accessories
Page 80
CAUTION!
Wrong set addresses can cause conflicts within the communication network!
Make sure that every MODBUS address in an RS-485 network is only given once. If one address is given to several components the network can be disturbed.
1. Press and hold [ok] and [menu] at the same
time for 2 seconds. The expert menu appears.
2. Press [] to select a submenu
“Communication” and press [ok] to access.
3. Select a submenu “MODBUS Address” and
press [ok].
4. Press [][] to select a MODBUS address
between 1 and 247. Press [ok] to confirm.
INFO:
If the EFOY Pro fuel cell is disconnected from the battery the changed MODBUS address will be saved.
Check and adjust the MODBUS address when connecting the EFOY Pro fuel cell to a new network.
The MODBUS address of each EFOY Pro fuel cell can be changed via the Operating panel or with the MODBUS command:
The description for the data interface can be found in chapter 3.2 “Connections” on page 15.
Via operating panel:
Via PC or Laptop:
With the SIO command “MODBUS” the configurations can be adjusted as
well as the MODBUS RTU protocol can be activated. A detailed description is available in the user manual for the interface
adapter.
Data Interface and Optional Accessories
Object
ID
Name
Example
Type
0x00
VendorName
SFC Energy AG
STRING
0x01
ProductCode
400100-1525-00001
STRING
0x02
MajorMinorRevision
19.08
STRING
0x03
VendorUrl
http://www.sfc.com/
STRING
0x04
ProductName
EFOY Pro Series
STRING
0x06
UserApplicationName
Firmware EFOY Pro 12000 Duo V01 19.08I24V/48V QB date 2016-03-24
STRING
Address
Name
Description
Unit
Multiplier
Type
30001
Tst
Stack temperature
°C
0.001
INT32
30005
Twt
Heat exchanger temperature
°C
0.001
INT32
30007
Tdcdc
Periphery temperature
°C
0.001
INT32
30009
Tpcb
Periphery temperature
°C
0.001
INT32
30011
Tres
Periphery temperature
°C
0.001
INT32
30013
Taux
Reservoir temperature
°C
0.001
INT32
30015
Ubat
Battery voltage
V
0.001
UINT16
8.2.1.1 MODBUS RTU functions The EFOY Pro MODBUS protocol is based on following Modbus
specifications: Modbus application protocol V1.1b3
Specific feature: Type RTC (Real Time Clock) Use following bit field definition for decoding RTC types (e.g. system time
and date):
struct { unsigned long second : 6; // seconds 0 to 59 unsigned long minute : 6; // minutes 0 to 59 unsigned long month : 4; // month 1 to 12 unsigned long hour : 5; // hour 0 to 23 unsigned long day : 5; // day 1 to 31 unsigned long year : 6; // year - 2000 (max. 63) };
Read Device Identification (Function code 0x2B)
Read out system information
Input Register (Function code 0x04)
Data Interface and Optional Accessories
Page 82
Address
Name
Description
Unit
Multiplier
Type
30016
Uaus
Output voltage
V
0.001
UINT16
30017
Uklemm
Internal voltage
V
0.001
UINT16
30018
Uper
Internal voltage
V
0.001
UINT16
30020
Ust
Stack voltage
V
0.001
UINT16
30021
Uzell
Internal voltage
mV
0.1
UINT32
30023
ULF1
Internal voltage
V
0.001
UINT16
30024
Uref
Internal voltage
V
0.001
UINT16
30028
Iaus
Output current
A
0.001
INT16
30029
Iper
Periphery current
A
0.001
UINT16
30030
Ist
Stack current
A
0.001
UINT16
30031
Pst
Stack power
W
0.001
UINT32
30033
Pper
Internal power
W
0.001
INT32
30035
FuellSt
Internal filling
%
0.01
UINT16
30036
LastError
Last occurred error
- 1 UINT8
30037
Error
Current error
- 1 UINT8
30038
StBtrb
Operating hours stack
h
0,001
UINT32
30040
SysBtrb
Operating hours system
h
0,001
UINT32
30042
PcStack
Internal value
- 1 UINT8
30043
PcAux
Internal value
- 1 INT32
30045
ResF
Internal value
- 1 UINT16
30046
DHV
Internal value
- 1 FLOAT
30048
DC-DC
Internal value
%
0.01
INT16
30049
AdW
Internal value
- 1 UINT8
30050
FS
Fuel cartridge sensor FS1 status
- 1 UINT8
30051
SysTime
System time
h 1 RTC
30053
Tst1
Temperature of stack 1
°C
0.001
INT32
30055
Tst2
Temperature of stack 2
°C
0.001
INT32
30057
Tst3
Temperature of stack 3
°C
0.001
INT32
30059
Tst4
Temperature of stack 4
°C
0.001
INT32
30065
Twt1
Temperature of heat exchanger 1
°C
0.001
INT32
30067
Twt2
Temperature of heat exchanger 2
°C
0.001
INT32
30069
Twt3
Temperature of heat exchanger 3
°C
0.001
INT32
30071
Twt4
Temperature of heat exchanger 4
°C
0.001
INT32
30077
Tluft
Temperature of intake air
°C
0.001
INT32
30079
Tumg
Ambient temperature
°C
0.001
INT32
30081
Tsys
Internal temperature
°C
0.001
INT32
30083
Tup
Temperature of circulation pump
°C
0.001
INT32
30085
Tzt
Temperature of fluid vessel
°C
0.001
INT32
30089
U12V
Periphery voltage (12V)
V
0.001
UINT16
Data Interface and Optional Accessories
Address
Name
Description
Unit
Multiplier
Type
30099
UUP
Circulation pump voltage
V
0.001
UINT16
30100
Coin
Condition of back up coin cell (available in future release)
-
1.0
UINT8
30102
IstSollCP
Target value for stack current
A
0.001
UINT32
30104
PoutQuer
Averaged output power
W
0.000001
UINT32
30110
PoutSoll
Target value for output power
W
0.000001
UINT32
30113
Eta
Internal value
-
1.0
FLOAT
30118
pumg
Ambient pressure
mba r
0.01
INT32
30120
Tpumg
Temperature of the ambient pressure sensor
°C
0.01
INT16
30121
pumgOK
Function ambient pressure sensor
­1
UINT8
30700
MeOH
Methanol consumption
L 1 UINT16
30702
OnReason
Last switch on reason
n 1 UINT16
30703
OffReason
Last switch off reason
n 1 UINT16
30704
LoadDrops
Number of load disconnections
n 1 UINT16
30705
LastRun
Last operation
- 1 RTC
30707
Modus
Operation mode
n 1 UINT16
30708
Status
Operation state
n 1 UINT16
30709
Warning Bits
Warnings
n 1 UINT16 30711
CumWOut
Cumulated output power
Wh 1 INT32
30713
AvgCycle Auto
Average charging duration in automatic mode
-
1
FLOAT
30715
AvgCycle Manual
Average charging duration in manual mode
h
1
FLOAT
30717
AvgCycle Remote
Average charging duration in remote mode
h 1 FLOAT
30719
LastCycle Auto
Last charging duration in automatic mode
h 1 FLOAT
30721
LastCycle Manual
Last charging duration in manual mode
h 1 FLOAT
30723
LastCycle Remote
Last charging duration in remote mode
h 1 FLOAT 30725
Cart1
Fill level cartridge port #1
l
0.001
INT32 30727
Cart11
Fill level cartridge port #1.1
l
0.001
INT32 30729
Cart12
Fill level cartridge port #1.2
l
0.001
INT32 30731
Cart2
Fill level cartridge port #2
l
0.001
INT32
Data Interface and Optional Accessories
Page 84
Address
Name
Description
Unit
Multiplier
Type
30733
Cart21
Fill level cartridge port #2.1
l
0.001
INT32 30735
Cart22
Fill level cartridge port #2.2
l
0.001
INT32 30737
CartAll
Sum of the fill levels of all connected fuel cartridges
l
0.001
INT32 30800
Rev
Firmware version
- 1 UINT32
Address
Name
Description
Value
Type
41016
Cartridge Reset
Reset fuel gauge of cartridge port to 100 %.
C: Connector DCS1: DuoCartSwitch DCS1
1: C#1 11: C#1 DCS1#1 12: C#1 DCS1#2 2: C#2 21: C#2 DCS1#1 22: C#2 DCS1#2
-1 : All
INT16
41996
Modbus Address
Set Modbus address
1 - 247
INT16
41998
Modbus Config
Set Modbus communication settings.
0: 9600 8,E,1 1: 9600 8,O,1 2: 9600 8,N,2 3: 9600 8,N,1
INT16
42000
Reset
Restart the fuel cell.
-
INT16
42002
Factory Defaults
Set all parameters to default.
-
INT16
42004
Hybrid
Deactivate all parameters for 15 seconds.
-
INT16
42006
Plain text Protocol
Switch device to plain text interface.
-
INT16
42008
Level converter select
Set data interface: Front side RS232, back side RS385
0: RS232 1: RS485
INT16
49999
IDSTATESEL
Select expert setting read property of selected ID. See chapter 8.2.1.2 “Overview ID list” on page
87.
0: Actual value 1: Standard value 2: Min. value 3: Max. value
INT16
Holding register (Function code 0x03)
Data Interface and Optional Accessories
Address
Name
Description
Value
Type
40990
IDSELECT
Select expert setting ID.
See chapter
8.2.1.2 “Overview ID list” on page
87.
UINT16
40991
IDVALUE
Read/write expert setting of selected ID.
See chapter
8.2.1.2 “Overview ID list” on page
87.
INT32 41000
Button
Change operation mode.
0: OFF 1: ON 2: AUTO
UINT16
41002
Cartridge Port 1
Configuration of cartridge port #1.
-1: DCS 0: disabled 1: M10 2: M28 3: MT60
INT16
41004
Cartridge Port 11
Configuration of cartridge port #1.1.
1: M10 2: M28 3: MT60
INT16
41006
Cartridge Port 12
Configuration of cartridge port #1.2.
1: M10 2: M28 3: MT60
INT16
41008
Cartridge Port 2
Configuration of cartridge port #2.
-1: DCS 0: disabled 1: M10 2: M28 3: MT60
INT16
41010
Cartridge Port 21
Configuration of cartridge port #2.1.
1: M10 2: M28 3: MT60
INT16
41012
Cartridge Port 22
Configuration of cartridge port #2.2.
1: M10 2: M28 3: MT60
INT16
Holding register
Data Interface and Optional Accessories
Page 86
Address
Name
Description
Value
Type
41014
Cartridge Select
Activate cartridge port. C: Connector DCS1: DuoCartSwitch DCS1
1: C#1 11: C#1 DCS1#1 12: C#1 DCS1#2 2: C#2 21: C#2 DCS1#1 22: C#2 DCS1#2
INT16
41020
Battery Type
Set battery type.
0: lead acid
1: lead gel 2: AGM
3: LiFePO4
INT16
41022
External Control
Software lock for external control.
0: On 1: Off
INT16
41024
Battery Protect
Battery protection mode.
0: On 1: Off
INT16
41026
Fuel gauge Display
Fuel gauge state on Operating panel OP1.
0: Off 1: On
INT16
41028
Language
Adjust language on Operating panel OP1.
0: German 1: English
2: Italian 3: Spanish
4: French 5: Dutch
INT16
41030
External Remote
External software remote signal.
0: Off 1: On
INT16 41032
Voltage profile
Set voltage profile
0: 24V Profile 1: 48V Profile
INT16
Data Interface and Optional Accessories
Profile
Type
ID
Name
Standard
Min.
Max.
All
All
17
Switch-on delay
60 s
2 s
300 s
45
Absorption time
180 min
0 min
300 min
89
Minimum charging time
30 min
30 min
180 min
Lead
49
Max. output time
24 h
0 h
240 h
LiFePO4
77
Max. output time
48 h
0 h
240 h
24 V
Lead
21
Switch-on voltage
24400 mV
22000 mV
26000 mV
22
Switch-off voltage
28800 mV
27000 mV
29400 mV
23
Switch-off current
10000 mA
8000 mA
24000 mA
47
Battery protection switch-on voltage
22000 mV
21000 mV
24000 mV
75
Switch-off voltage hybrid
29400 mV
27000 mV
30000 mV
LiFePO4
78
Switch-on voltage
25000 mV
24000 mV
26800 mV
79
Switch-off voltage
29000 mV
27600 mV
29200 mV
80
Switch-off current
10000 mA
8000 mA
24000 mA
81
Battery protection switch-on voltage
22000 mV
21000 mV
24000 mV
82
Switch-off voltage hybrid
29000 mV
27000 mV
30000 mV
48 V
Lead
33
Switch-on voltage
48800 mV
44000 mV
52000 mV
34
Switch-off voltage
57600 mV
54000 mV
58800 mV
35
Switch-off current
5000 mA
4000 mA
12000 mA
36
Battery protection switch-on voltage
44000 mV
42000 mV
48000 mV
37
Switch-off voltage hybrid
58800 mV
54000 mV
60000 mV
LiFePO4
38
Switch-on voltage
50000 mV
48000 mV
52000 mV
39
Switch-off voltage
58000 mV
55200 mV
58400 mV
40
Switch-off current
5000 mA
4000 mA
12000 mA
41
Battery protection switch-on voltage
44000 mV
42000 mV
48000 mV
42
Switch-off voltage hybrid
58000 mV
54000 mV
60000 mV
8.2.1.2 Overview ID list
Data Interface and Optional Accessories
Page 88
Command
Description
?
Display command overview.
BATTERY
Select battery type
BATTERYPROTECTION
Control battery protection
BUTTON
Software control of device
CARTRIDGE
Set/view connected fuel cartridges/DuoCartSwitch
CONFIG
Set customized operation parameters
DEFAULT
Apply default operation parameters
ERROR
Show ten most recent errors
FUELGAUGE
Enable/disable fuel gauge
GET
Get customized operation parameter
HYBRID
Switch the device from automatic into hybrid mode for 15s
LANGUAGE
Set language in Operating panel OP2
LIMITS
Show min. and max. values of operation parameters
LOCKED
Lock control contacts
LOG
Show details of current operation state
MODBUS
Settings of MODBUS protocol
PROFILE
Select voltage profile
REMOTE
Remote control via software interface
RESET
Restart the device
Recommended way to read expert setting parameter:
1. Write (command 0x10) desired expert setting ID to MODBUS
Register 40990 (IDSELECT)
2. Use a combined read & write (command 0x17), write setting
property to read to 49999 (IDSTATESEL) and read 40991 (IDVALUE).
Recommended way to write expert setting parameter:
1. Write (0x10) desired expert setting ID to MODBUS register 40990
(IDSELECT)
2. Write desired value to 40991 (IDVALUE) using command.
8.2.2 SIO / Plain text
Following commands are available in the clear text protocol:
Data Interface and Optional Accessories
SERIAL
Show the device's serial numbers
SET
Set customized operation parameter
SFC
Show current operation state
STDVALUE
Show default values of operation parameters
SYSTEM
Display system operation information
VALUE
Show current values of operation parameters
VER
Show version of firmware
A detailed description is available in the user manual.
A detailed description is available in the user manual for the interface adapter IA1.
8.3 GSM-Modem
The optional GSM modem enables you to monitor and control the EFOY Pro fuel cell remotely. It is recommended to use such a solution for autonomous operation of the EFOY Pro.
Functions
Notification if errors occur Notification if fuel cartridge falls below the reserve (with optional fuel
cartridge sensor FS1)
Remote diagnostics Remote control Remote parameter adjustment Firmware update via GSM modem
Data Interface and Optional Accessories
Page 90
You connect the sensor to the EFOY Pro data interface.
The sensor should be combined with a remote monitoring system, e.g. the GSM modem GSM-2-SMS.
You fasten the fuel cartridge sensor to the fuel cartridge holder for M10 fuel cartridges using two screws. You can choose from two different heights to mount the FS1.
A detailed description is available in the user manual “Fuel cartridge sensor FS1”.
8.4 Fuel cartridge sensor FS1
By default, the EFOY Pro does not monitor the actual fill level of the fuel cartridge. The fuel gauge for the fuel cartridge is just an indicator and calculates the methanol consumption. The FS1 fuel cartridge sensor must be used to measure the actual fill level. The EFOY Pro reports a fuel level error if the cartridge is used up.
The optional fuel cartridge sensor FS1 indicates if the fuel level drops below the position of the sensor. This early warning gives the user time to change the cartridge before it is completely empty.
The fuel cartridge sensor FS1 may also be used with fuel cartridges that are partly empty. It sends a signal to the EFOY Pro fuel cell when the fill level falls below the sensor.
Data Interface and Optional Accessories
1. Cluster controller CC1
2. Interface adapter IA1
3. Computer connection
(COM)
4. to fuel cartridge
sensor FS1
A detailed description is available in the user manual for the cluster controller CC1.
Interface splitter:
The cluster controller splits the data interface and provides two sockets to connect the interface adapter and the fuel cartridge sensor together.
INFO :
A power supply is not available at the interfaces.
Parallel operation:
For high power requirements you can connect up to five devices in parallel using the optional cluster controller CC1. The devices switch charging mode on and off together.
Devices running in parallel must all be in the same operating mode (e.g. all in automatic mode) and the "External control" operating mode must be enabled.
All EFOY Pro fuel cells must have the same settings to run in parallel.
8.5 Cluster Controller CC1
The cluster controller combines 3 functions:
1. Interface splitter (provides 2 sockets)
2. Parallel operation of up to 5 EFOY Pros
3. Remote control of one EFOY Pro (Remote-on pin)
Data Interface and Optional Accessories
Page 92
The cluster icon is displayed at the bottom right of the display for EFOY Pro devices running in parallel.
Remote control (remote-on):
The EFOY Pro can be controlled externally using a switching contact on the CC1, which means that the charging mode can be started.
The same function can also be enabled via the computer interface.
If the device is in "Remote Control" mode, "RC" (Remote Control) appears at the bottom right of the display.
If you have not enabled external control, (see chapter 5.4 "Operating modes" on page 59), a padlock appears at the bottom right of the display.
A detailed description is available in the user manual Cluster Controller CC1.
Data Interface and Optional Accessories
The DuoCartSwitch enables you to connect two fuel cartridges to the cartridge connector of one EFOY Pro fuel cell. The switching valve switches automatically from the fuel cartridge in operation to the reserve fuel cartridge. This means that the autonomy of the application can be doubled.
1. Screw the fuel-cartridge connector of
the EFOY Pro on the DuoCartSwitch.
2. Connect one DuoCartSwitch via a port
doubler to each RJ45-plug of the EFOY Pro:
- A: Remote Control plug
- B: Data Interface plug
CAUTION!
Only connect one DuoCartSwitch to each RJ45-plug (Remote Control / Data Interface).
If both DuoCartSwitch are connected to one RJ45-plug the switching of the DuoCartSwitch fuel connectors malfunctions, which might damage the EFOY Pro fuel cell.
3. For activation of the DuoCartSwitch
see chapter 5.1 “Operation via the operating panel” on page 35.
A B
8.6 DuoCartSwitch DCS 1
A detailed description is available in the user manual DuoCartSwitch DCS1.
Appendix
Page 94
Application:
EFOY Pro 12000 Duo S/N:
Date:
Technician:
#
Description
Note
OK
1
Initial Start Fluid filled in completely
Temperatures above +3 °C / +38 °F
2
Fuel cell supplied with voltage
Check battery voltage and compare
3
Language set
Adjustable in main menu
4 Voltage profile set
Adjustable in expert menu
5
Battery type set
Adjustable in expert menu
6
Fuel cartridge and DuoCartSwitch set
Adjustable in main menu
7
EFOY Pro 12000 Duo started manually
Test run successful
8 Air intake and off heat not blocked
9
Exhaust hose not blocked
No kinks
9 Appendix
9.1 Installation Checklist
Appendix
9.2 U-I and U-P characteristic
24 V DC:
48 V DC:
Appendix
Page 96
Copyright by SFC Energy AG 201
8. V14
9.3 Output power characteristic
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