/ Battery Charging Systems / Welding Technology / Solar Electronics
EN
HyLOG Fleet 26F
Operating Instructions
Energy cell
42,0426,0162,EN 004-25062013
0
Dear reader,
Introduction Thank you for the trust you have placed in our company and congratulations on buying this
high-quality Fronius product. These instructions will help you familiarise yourself with the
product. Reading the instructions carefully will enable you to learn about the many different
features it has to offer. This will allow you to make full use of its advantages.
Please also note the safety rules to ensure greater safety when using the product. Careful
handling of the product will repay you with years of safe and reliable operation. These are
essential prerequisites for excellent results.
EN
1
2
Contents
Safety rules ................................................................................................................................................ 5
Explanation of safety symbols .............................................................................................................. 5
General ................................................................................................................................................. 6
Proper use ............................................................................................................................................ 7
Safety measures in operation ............................................................................................................... 7
Environmental conditions...................................................................................................................... 8
Safe use................................................................................................................................................ 8
Protecting yourself and others .............................................................................................................. 9
Danger from gases, hazardous materials and suffocation.................................................................... 9
Safety measures in normal operation ................................................................................................... 9
Specific hazards.................................................................................................................................... 10
General information regarding the handling of batteries....................................................................... 10
Danger from batteries ........................................................................................................................... 11
Danger from pressure vessels .............................................................................................................. 11
Warranty and liability............................................................................................................................. 11
Safety inspection................................................................................................................................... 12
Safety symbols...................................................................................................................................... 12
Mark of conformity ................................................................................................................................ 12
Disposal ................................................................................................................................................ 12
Copyright............................................................................................................................................... 13
General ...................................................................................................................................................... 14
Functionality and device concept.......................................................................................................... 14
Advantages........................................................................................................................................... 14
Features................................................................................................................................................ 15
System configuration ............................................................................................................................ 15
Warning notices on the device.............................................................................................................. 16
Control elements and connections............................................................................................................. 18
Safety.................................................................................................................................................... 18
Control elements and connections........................................................................................................ 18
Control panel......................................................................................................................................... 20
Before commissioning................................................................................................................................ 22
Safety.................................................................................................................................................... 22
Proper use ............................................................................................................................................ 22
Before using for the first time ................................................................................................................ 23
Connectors............................................................................................................................................ 23
Start-up ...................................................................................................................................................... 24
Safety.................................................................................................................................................... 24
Preliminary information ......................................................................................................................... 24
Connecting the power interface to the vehicle ...................................................................................... 24
CAN service interface ........................................................................................................................... 25
Warning and driver information interface .............................................................................................. 25
Refuelling.............................................................................................................................................. 26
Operation ................................................................................................................................................... 28
Safety.................................................................................................................................................... 28
Operating conditions............................................................................................................................. 28
Starting energy delivery ........................................................................................................................ 28
Energy delivery ..................................................................................................................................... 29
Stopping energy delivery ...................................................................................................................... 29
Troubleshooting ......................................................................................................................................... 30
Safety.................................................................................................................................................... 30
Fault diagnosis...................................................................................................................................... 30
Displayed service codes ....................................................................................................................... 30
Care, maintenance and disposal ............................................................................................................... 33
Safety.................................................................................................................................................... 33
Minimum maintenance work ................................................................................................................. 33
Once a year / every 1000 operating hours............................................................................................ 34
EN
3
Annual safety inspection ....................................................................................................................... 34
Maintenance work every 1000 operating hours .................................................................................... 34
Disposal ................................................................................................................................................ 34
Technical data............................................................................................................................................ 35
HyLOG Fleet energy cell....................................................................................................................... 35
4
Safety rules
EN
Explanation of
safety symbols
DANGER! indicates immediate and real danger. If it is not avoided, death or se-
rious injury will result.
WARNING! indicates a potentially dangerous situation. Death or serious injury
may result if appropriate precautions are not taken.
CAUTION! indicates a situation where damage or injury could occur. If it is not
avoided, minor injury and/or damage to property may result.
NOTE! indicates a risk of flawed results and possible damage to the equipment.
IMPORTANT! indicates tips for correct operation and other particularly useful information.
It does not indicate a potentially damaging or dangerous situation.
If you see any of the symbols depicted in the "Safety rules", special care is required.
5
General
The device is manufactured using state-of-the-art technology and according
to recognised safety standards. If used incorrectly or misused, however, it can
cause:
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operating company,
- inefficient operation of the device.
According to the extent to which they are operating and using the device, all
users (drivers, service personnel, etc.) must
- be suitably qualified
- be trained
- read and follow these operating instructions carefully.
The operating instructions must always be at hand wherever the device is being used. In addition to the operating instructions, attention must also be paid
to any generally applicable and local regulations regarding accident prevention and environmental protection.
All safety and danger notices on the device
- must be in a legible state,
- must not be damaged,
- must not be removed,
- must not be covered, pasted or painted over.
For the location of the safety and danger notices on the device, refer to the
section headed "General remarks" in the operating instructions for the device.
The following problems can result in safety issues, and must therefore be resolved before the device is commissioned:
- dirty or blocked cooling air inlet
- power connector connected incorrectly
- missing or faulty safety cap on the refuelling opening
This is for your personal safety!
These operating instructions are concerned only with the vehicle's energy delivery system and describe the technical and safety-relevant interfaces on the
vehicle relating to energy delivery.
The overall safety of the system (energy cell, vehicle and its operation in a
working area) is the responsibility of the vehicle manufacturer / system integrator. The vehicle manufacturer / system integrator is the manufacturer of the
logistics vehicle that installs the energy cell in the vehicle and is responsible
for the conformity of the system as a whole. The overall system safety encompasses:
- Weight compensation (driving stability, traction, etc.)
- Information provided to the driver and surrounding area concerning safety-relevant operating states of the energy cell (warning of hydrogen leak,
etc.)
- Analysis of overall system safety and supply of general system user documentation (energy cell and vehicle) adapted for use of the vehicle with
the HyLOG Fleet energy cell.
6
Proper use
The device is to be used exclusively for its intended purpose.
Any use above and beyond this purpose is deemed improper. The manufacturer shall not be held liable for any damage arising from such usage.
Proper use includes:
- ensuring that the device is undamaged and in perfect condition
- carefully reading and obeying all the instructions in these operating instructions, especially the safety rules and all safety and danger notices
- installing the device in accordance with the vehicle manufacturer's operating instructions
- carrying out all the specified inspection and maintenance work *
- observing all instructions of the vehicle manufacturer and the refuelling
system manufacturer
- obeying other relevant national safety rules
Inspection and maintenance work form part of the responsibility of the operator. However, the operator may arrange for the manufacturer of the vehicle or
the fuel cell system to perform inspection and maintenance work (e.g. as part
of a maintenance agreement).
The device must only be operated in rooms with a volume of more than 10 m³
(353.15 ft³) and with an air circulation rate of not less than 0.6/h. With a room
volume of 10 m³ (353.15 ft³), an air circulation rate of 0.6/h means that 6 m³
(211.89 ft³) of air are renewed per hour.
EN
Safety measures
in operation
The device may not be used if any part has been submerged in or flooded with
water. Notify the manufacturer or its representative immediately so that the device can be checked and any affected parts replaced.
The device must not be used in conditions of frost or (condensing) humidity.
Operating the device in frosty or humid conditions can result in damage. Only
use the device in rooms that are free from frost and condensing air. Detailed
information can be found in the "Technical data" chapter.
Remove the device before washing the vehicle. Never clean the device itself
with water, liquid detergents or steam cleaners.
Information on cleaning the device can be found in the "Care, maintenance
and disposal" chapter.
When installing devices with openings for cooling air, ensure that the cooling air can enter
and exit unhindered through the air ducts. Only operate the charger in accordance with the
degree of protection shown on the rating plate. Observe the "Operating conditions" chapter
of the device operating instructions.
7
Environmental
conditions
Operation or storage of the device outside the stipulated environmental conditions will be deemed to be not in accordance with the intended purpose. The
manufacturer shall not be held liable for any damage arising from such usage.
Detailed information on the permitted environmental conditions can be found
in the "Technical data" chapter.
The surrounding air must be clean and free from
- possible ignition sources
-smoke
- naked flames and light
- petrol and other flammable materials in the form of liquids, vapours or
electrically conductive dusts, e.g. metallic powder
- corrosive gases or substances
Can be used at altitudes of up to 1600 m (5249 ft.)
Safe use
The operating instructions are primarily intended for system integrators who
incorporate the device as a component into an overall vehicle. The contents
are therefore intended for qualified personnel.
The user must have received verifiable training from a qualified technician authorised by the manufacturer.
The user must also observe all warning notices of the vehicle supplier and for
the hydrogen refuelling system.
An electric shock can be fatal. Do not perform any actions other than those described in this documentation. All cables and leads must be secured, undamaged, insulated and adequately dimensioned. Loose connections, scorched,
damaged or inadequately dimensioned cables and leads must be immediately
repaired by authorised personnel.
Leaks in the hydrogen supply pose a risk of fire, explosion and suffocation.
The hydrogen refuelling system must therefore be set up in compliance with
the applicable standards and guidelines and operated in accordance with the
manufacturer's instructions. The technical data shown on the rating plate applies.
Maintenance and repair work on the device may only be carried out by trained
personnel authorised by the manufacturer.
It is impossible to guarantee that bought-in parts are designed and manufactured to suit their application, or that they satisfy safety requirements. Use only
original replacement parts (also applies to standard parts).
Do not carry out any modifications, alterations, etc. to the device without the
manufacturer's consent.
Components that are not in perfect condition must be replaced immediately.
8
Protecting yourself and others
Keep unauthorised persons, especially children, away from the device and the
vehicle containing the device during operation. If, however, there are people
in the vicinity,
- make them aware of all dangers associated with use of the device (risk of
a build-up of explosive acids and gases that are detrimental to health,
possible risk of suffocation due to lack of oxygen in the air, danger from
output current, etc.)
- adhere to the permitted operating conditions as specified in the "Operating conditions" section of the "Operation" chapter
Before leaving the vehicle in which the device is installed, make sure that no
injury or damage can occur in your absence.
EN
Danger from gases, hazardous
materials and suffocation
The fuel is supplied in the form of gaseous hydrogen. Hydrogen is a dangerous substance, which requires great care when handling. Further information
on handling hydrogen can be found in the EU RL 91/155 EEC and 93/112 EU
safety data sheets.
Only use the device in well-ventilated areas to prevent the accumulation of explosive gas. Spaces are not deemed to be at risk of explosion if a concentration of hydrogen of less than 4% by volume can be adequately guaranteed by
the use of natural or forced ventilation.
Keep possible ignition sources, fires and naked flames away from the device,
also inflammable materials, liquids and gases.
Using the device in spaces with inadequate ventilation can cause suffocation
with no visible or otherwise detectable warning. This is because of the oxygen
consumption of the device, which can lead to a lack of oxygen in the room if it
is inadequately ventilated. The device must only be operated in rooms with a
volume of not less than 10 m³ and with an air circulation rate of not less than
0.6/h. Example: With a room volume of 10 m³, an air circulation rate of 0.6/h
means that 6 m³ of air are renewed per hour. Other spatial conditions require
an exact calculation of the air circulation rate in consultation with the device
manufacturer.
Safety measures
in normal operation
Only operate the device when all protection devices are fully functional. If the
protection devices are not in full working order, there is a risk of
- injury or death to the operator or a third party,
- damage to the device and other material assets belonging to the operator,
- inefficient operation of the device.
9
Any safety devices that are not functioning properly must be repaired before
switching on the device.
Never bypass or disable protection devices.
Before switching on the device, ensure that no one is likely to be endangered.
Observe the commissioning and operating requirements as set out in the "Before commissioning" and "Commissioning" chapters.
Generally-speaking, the following applies:
- Ensure adequate ventilation of the installation location
- Ensure that the cooling air can flow into and out of the device unhindered
- Refer to the "Care, maintenance and disposal" chapter of the device operating instructions
- Regularly check the device and its accessories for obvious damage and
proper functioning of safety equipment
- Never operate the unit if there is any evidence of damage
- Always use the unit in compliance with
- the "Proper use" section of the "Before commissioning" chapter
- the "Operating conditions" section of the "Operation" chapter
Specific hazards
General information regarding the
handling of batteries
Keep hands, hair, clothing and tools away from moving parts, for example
fans.
Unauthorised opening or tampering with the device will invalidate the guarantee and poses the risk of serious damage to people and property.
The moist outgoing air from the reaction chamber can reach a temperature of
up to 65 °C (149 °F), which can scald.
The unit contains a back-up battery (lithium technology) which requires careful
handling.
- The back-up battery is maintenance-free
- It must not be tampered with by unauthorised personnel
- If external recharging of the back-up battery is required, this must only be
carried out with a battery charging system approved by the manufacturer
(range for charging voltage: 22 - 28.2 V, maximum charging current: 100
A, e.g. Fronius Selectiva Plus 2100, item number 4,010,061. The need to
recharge the battery externally represents a fault that can only occur in
special situations (prolonged shutdown, overuse, etc.)
- Do not expose the back-up battery to excessive heat (e.g. do not leave
the vehicle parked in bright sunlight)
- The back-up battery is equipped with a protective circuit. This protects it
against:
- Overcharging of the cells (explosion hazard)
- Deep discharge of the cells (damages the cells)
- Destruction of cells by short circuit
- Polarity reversal
- Incorrect charging
- Overtemperature
10
Danger from batteries
The unit contains a back-up battery (lithium technology), which requires careful handling. Batteries contain substances harmful to the eyes and skin. These
can only be released in the event of serious damage (e.g. overheating, accident, etc.).
- Substances escaping from batteries must not come into contact with the
eyes, skin or clothes.
- Do not inhale escaping gases or vapours, and make sure premises are
well-ventilated
- Avoid short circuits
- Do not expose the battery to excessive heat or throw it onto an open fire
Further details can be found in the supplementary safety data sheet available
from the manufacturer.
EN
Danger from
pressure vessels
Warranty and liability
The device is fed with hydrogen from an integrated pressure vessel. Ensure
compliance with the safety rules for pressure vessels.
There is a container of pressurised hydrogen in the device, and it must therefore be treated with care. Detailed information on proper use can be found in
the "Before commissioning" section.
Protect the pressure vessel from excessive heat, mechanical impact, naked
flames, sparks and arcs.
Keep pressure vessels away from electrical circuits.
The manufacturer's instructions must be observed as well as applicable national and international regulations for pressure vessels and accessories.
The duration of the guarantee for the device depends on the supply contract.
However, the manufacturer will not accept any liability if the damage was
caused by one or more of the following:
- Use of the charger not in accordance with the intended purpose
- Incorrect operation
- Operating the charger with faulty protection devices
- Non-compliance with the operating instructions
- Unauthorised modifications to the charger
- Catastrophes caused by the activities of third parties and force majeure
11
Safety inspection
A safety inspection must be carried out by a qualified expert
- before using for the first time after installing in the vehicle
- after any changes are made
- after any additional parts are installed, or after any conversions
- after repair, care and maintenance has been carried out
- and at least once every twelve months
The operator is required to carry out a safety inspection of the unit at least
once every 12 months and to have the safety elements on the unit functiontested. Applicable national regulations must be observed.
Maintenance, technical inspections and checks must only be carried out by
qualified personnel (service organisations) who have been trained in the safety and maintenance of these devices. In addition, all repair and maintenance
work must be performed exclusively using original replacement parts. All
changes to the device and the use of parts that are not original replacement
parts may only be made with the approval of the manufacturer.
If these conditions are not met, the dealer cannot guarantee the safety of the
device. Starting up the device without having performed safety-related maintenance work is done at your own risk.
The manufacturer therefore accepts no liability for damage caused by inadequate maintenance carried out by a third party or by the non-performance of
maintenance.
Safety symbols
Mark of conformity
Disposal
Devices with the CE marking satisfy the essential requirements of the applicable European directives. Further information can be found in the "Technical
data" chapter.
The device has been tested on a voluntary basis by TÜV SÜD for compliance
with the requirements of EN 62282-5-1 and has received the marks of conformity for product safety.
Do not dispose of this device with normal domestic waste! To comply with the
European Directive 2002/96/EC on Waste Electrical and Electronic Equipment and its implementation as national law, electrical equipment that has
reached the end of its life must be collected separately and returned to an approved recycling facility. Any device that you no longer require must either be
returned to your dealer or given to one of the approved collection and recycling
facilities in your area. Ignoring this European Directive may have potentially
adverse affects on the environment and your health!
12
Copyright
Copyright of these operating instructions remains with the manufacturer.
The text and illustrations are all technically correct at the time of printing. We
reserve the right to make changes. The contents of the operating instructions
shall not provide the basis for any claims whatsoever on the part of the purchaser. If you have any suggestions for improvement, or can point out any
mistakes that you have found in the instructions, we will be most grateful for
your comments.
EN
13
General
Functionality and
device concept
The HyLOG Fleet energy cell allows operation of transport vehicles for in-house logistics using hydrogen as the energy source.
This eliminates the long breaks in operation
required with normal charging times, as refuelling takes only a few minutes. The result
is higher productivity and lower maintenance costs. Ideally the hydrogen is generated locally from renewable energy
sources. The only emissions from the energy cell are small quantities of pure water.
The key component of the energy cell is the electrochemical unit in the device - the fuel
cell. This generates electrical energy from hydrogen and from oxygen in the surrounding
air. The fuel cell consists of several individual cells connected in series. A digital control
unit supplies it with hydrogen and air in the correct ratio and maintains the operating temperature.
When used correctly, hydrogen is a safe source of energy. The energy cell has a range of
safety features that comply with applicable standards. The explosion protection requirements are covered by precautionary measures integrated into the device to the extent that
no further explosion protection measures are required at the installation location. Care
must be taken to ensure sufficient circulation of air in the operating environment.
Advantages A great economic advantage of the HyLOG Fleet energy cell is that long battery charging
times are replaced by a refuelling process that takes only a few minutes. This results in
greater availability and productivity of the in-house transport vehicles, combined with lower
maintenance costs. The hydrogen tank can be refilled virtually any number of times,
whereas batteries always have a limited service life.
Use of a fuel cell in the energy cell offers a range of other benefits as well:
Water is the only combustion product of the energy cell, which means that it does not produce any pollutants. Another advantage of the cell is that it is quiet and requires practically
no maintenance. In contrast to conventional generators, the energy cell, with the help of
the fuel cell, converts the chemically-bound energy of the hydrogen directly into electrical
power via an electrochemical process. The hydrogen consumption is therefore very low.
Given the finite nature of energy resources and the need for environment-friendly energy
production, HyLOG Fleet sets new standards for energy efficiency and emission reduction.
The overall logistics system is particularly environment-friendly when renewable energy
sources are used, for example:
-Solar
-Wind
- Water
-Biomass
-Biogas
14
The benefits of using the HyLOG Fleet energy cell as the energy source for in-house trans-
Fuel Cell Control Unit
Battery
Power
Control panel
Signal
Refilling
Condensate
Tank
port vehicles can be summed up as follows:
- Long battery charging times of 8 to 10 hours are replaced by a refuelling process that
takes less than 5 minutes
- Lower maintenance costs mean optimum productivity compared with conventional
battery solutions
- Lower operating costs thanks to longer service life of the fuel-cell-based system
- Less space required since there are no battery charging stations
- Absence of poisonous and odorous emissions
-Quiet
- Energy efficiency is roughly 3 times better than that of conventional systems using internal combustion engines
Features - Fuel cell-based generator
PEM type (polymer electrolyte membrane)
- Simple to operate
- Can easily be integrated into existing vehicle designs
- High standard of safety due to safety functions integrated into the device and explosion protection
- High degree of efficiency
- Quiet, low-maintenance operation
- Interface for data communication
EN
System configuration
15
System components
Position Explanation Detailed explanation, specification
Fuel cell Fuel cell Generates electricity via an electrochemical process
from hydrogen and oxygen in the surrounding air ("cold
combustion"). Since there is very little waste heat, the
fuel cell is extremely efficient.
Battery Lithium-ion tech-
nology batteries
Since the fuel cell always works at close to optimum efficiency, it is used primarily to charge the batteries in order to store the energy. If power consumption increases
due to heavy acceleration of the vehicle, this is largely
met by the battery.
On the other hand, when the vehicle is braked, surplus
braking energy is stored in the battery again. The vehicle's drive unit is therefore a highly efficient hybrid system. Once the battery is fully charged, the fuel cell stops.
When the charge drops below a certain level, the fuel
cell starts recharging again at constant power.
The battery also supplies the energy needed to start the
fuel cell.
Tank A steel vessel for
hydrogen gas
with a capacity of
25 litres (6.6 gallons)
Control
Unit
Control and regulation unit
Contains the energy for operating the vehicle in the form
of hydrogen gas. During the refuelling process the hydrogen is compressed to a pressure of 200 bar (2899.74
psi.), resulting in high storage density and long operating
intervals between refuelling stops.
Controls the battery charging process and the related
activity of the fuel cell. The optimum state of charge of
the battery is always adapted to the current vehicle operation.
Warning notices
on the device
The device is fitted with a rating plate and safety symbols. The rating plate and safety symbols must not be removed or painted over.
Type
Art.No.
www.fronius.com
IP20
WARNING:
OPERATE IN VENTILATED AREAS ONLY - min. Room size 10m³
FOR INDOOR USE ONLY. Do not operate outdoors!
CONTAINS LITHIUM BATTERY. Do not operate if damaged!
Pressure Vessel production year: 2011
Ser.No.
UDC
nom.
I
BATT max.
P
EL. nom.
Fuel type
Pressure
Hydrogen Storage
Receptacle
Weight
Ambient temperature
26 V
450 A
2600 W
225 A
Hydrogen Quality 5.0
max. 200 bar
0,35 kg
Type TN1
180 kg
+2°C...+40°C (60°C)
CONTAINS HYDROGEN GAS,
HIGHLY FLAMMABLE
DO NOT JET WASH!
16
Inadequate ventilation increases the risk of fire, explosion and suffocation. Always operate the device
- with protective grilles fitted on the housing openings for the cooling air supply and outlet
- with sufficient ventilation
- in rooms with a volume of more than 10 m³ (353.15 ft³), with an air circulation rate* of at least 0.6/h
- whilst avoiding oxygen depletion of the surrounding air by ensuring adequate room ventilation
Possible sources of ignition, such as fire, sparks and naked lights, must be kept
away from the battery.
Risk of explosion! Oxyhydrogen is generated in the battery during charging.
Protection IP20: For indoor use only. Do not expose to rain.
Ensure an adequate supply of fresh air during charging. Fit device at least 0.5
m (1 ft. 7.69 in.) above the floor.
Do not use the functions until you have fully read the operating instructions.
Do not dispose of used chargers with domestic waste. Dispose of them according to safety rules.
Fire hazard! Ensure that the pressurised hydrogen vessel built into the device is
never exposed to high temperatures, mechanical impact, naked flames or arcs.
There is a container of pressurised gas in the device, and it must therefore be
treated with care. Never use anything other than a dry cloth to clean the device.
Ensure that the device is never exposed to damp conditions.
EN
* Example: With a room volume of 10 m³ (353.15 ft³), an air circulation rate of 0.6/h
means that 6 m³ (211.89 ft³) of air are renewed per hour.
CAUTION! Danger of burns and scalds from moist, hot process exhaust air and
cooling air. The exhaust air can reach a temperature of 65°C (149°F), the cooling
air a temperature of up to 65°C (149°F). During operation
- Do not touch the hot places where process exhaust air and cooling air escape
- Keep away from process exhaust air and cooling air
WARNING! Incorrect handling of the built-in lithium ion battery may result in fire,
explosion or chemical burns. The battery must never be short-circuited, penetrated, thrown into a fire, crushed, immersed in water, forcibly discharged or exposed
to temperatures outside the permissible range for the device. The battery must
never be used if it is in a defective condition.
In the event that electrolyte and gases escape from the battery as a result of improper treatment, you should proceed as follows:
- If anyone breathes in the escaping gases they may experience breathing difficulties:
Immediately provide air from a fan or take the person outside for fresh air, and in more
serious cases summon medical assistance immediately
- If electrolyte comes into contact with skin, irritations may develop:
Wash the affected area of skin thoroughly with soap and water
- If electrolyte comes into contact with eyes, irritations of the eye may develop:
Immediately rinse the eyes thoroughly with water for 15 minutes and then call a doctor
17
Control elements and connections
(7)
(10)
(10)
Safety
Control elements
and connections
NOTE! After firmware updates, you may notice that your device has certain func-
tions that are not described in these operating instructions. Certain illustrations
may also differ slightly from the actual controls on your device, but these controls
function in exactly the same way. If you have any further questions, please contact the manufacturer.
WARNING! Operating the equipment incorrectly can cause serious damage and
injury. Do not use the functions described here until you have thoroughly read and
understood the following documents:
- these operating instructions
- all the operating instructions for the system peripherals (gas supply, battery,
etc.), especially the safety rules
WARNING! Work carried out incorrectly and electric shocks can have fatal results.
- All covers of the device and the housing in general should only be opened or
removed by trained technicians
- Unauthorised opening or tampering with the device will invalidate the warranty and create the risk of serious injury or damage.
The device is intended to be installed in vehicles with side-on battery replacement. The device is symmetrically designed in terms of the provided mechanical fixing elements and can
therefore be mounted on the vehicle turned through 180°. This allows you to choose
whether to have the filler connection on the left or right hand side of the vehicle. This issue
should be addressed by the vehicle manufacturer when installing the device in the vehicle.
(6) (7)
(5)
(4)
(3)
(8)(9)(1)(2)
No. Function
(1) Control panel
For starting and stopping electricity generation and displaying important system
data, such as the hydrogen level, the operational status, any errors and their causes
(2) Equipotential bonding
Connection for static equipotential bonding during refuelling
18
(3) Tank connection 200 bar (2899.74 psi.)
Connector for refilling with compressed hydrogen gas according to ISO 14687-2 /
SAE J2719, connector: WEH TN1 250 bar (3624.68 psi.)
Detailed information can be found in the supplementary document "Refuelling regulations".
(4) Process exhaust air
Exhaust air of the fuel cell process containing water vapour as a combustion product. The volumetric flow is 65 m³/h (2295.45 ft³/h) at a maximum of 60°C (140°F).
and cooling air outlet
Housing openings to allow cooling air to escape. The maximum cooling air temperature is 65°C (149°F)
WARNING! If operation of the device is impaired by blocked process exhaust air openings, there is a risk of suffocation and explosion. Keep all air
openings completely clear.
(5) Power interface
Connection for the electricity produced. Constant power is up to 2.6 kW at 26.4 V
DC, connection socket: REMA 75012-56
(6) CAN service interface
Data interface for service technicians, connection socket: CAN 4-pin
Combined with warning and driver information interface
EN
(7) Cooling air intake
Housing openings for admission of cooling air. The volumetric flow is 500 m³/h
(17,657.33 ft³/h) at an ambient temperature of up to 40°C (104°F)
WARNING! If operation of the device is impaired by blocked cooling air intake openings, there is a risk of suffocation and explosion. Keep all air openings completely clear.
(8) Process air intake
Housing openings for admission of combustion air of the fuel cell process. The volumetric flow is 65 m³/h (2295.45 ft³/h)
WARNING! If operation of the device is impaired by blocked process air intake openings, there is a risk of suffocation and explosion. Keep all air openings completely clear.
(9) Connector for condensate drainage
For draining the collection container for reaction water that occurs as condensate.
Detailed information can be found in the supplementary document "Refuelling regulations".
WARNING! If operation of the device is impaired by a blocked condensate
drainage connector, there is a risk of suffocation and explosion. Keep the
condensate drainage connector completely clear.
(10) Crane holder
for transporting the device with suitable load-carrying equipment
WARNING! Falling devices can cause serious injury and damage. When
transporting with the crane:
Always use chains/ropes of equal length
Attach chains/ropes to all fixing points on the crane holder
Route chains/ropes so they are at the smallest angle possible to the vertical
19
Control panel
(4)
(3)
(2)
Energy Cell
Service
FC ON
Power ON
H2 Tank L evel
Leakage
H
²
Safety Error
Low Battery
System Error
(5)
(6)
(7)
(8)
(9)
ON
No. Function
(1) "ON" button
Pressing the "ON" button starts energy delivery. The energy is available immediately. Initially it is provided only by the back-up battery, which at the same time supplies the energy needed to start the fuel cell. The "Power ON" indicator (2) lights
up. As soon as the fuel cell has powered up, the "FC ON" indicator (3) also lights
up.
(2) "Power ON" indicator
The "Power ON" indicator signals that the device is ready for use. Energy can be
drawn off at any time - the vehicle can be put into operation.
(3) "FC ON" indicator
The fuel cell has powered up and meets the energy demand according to the operating strategy by interacting accordingly with the back-up battery. The hydrogen
in the tank together with the ambient air sucked into the unit is converted into electricity and water as a combustion product. The back-up battery primarily caters for
low loads and peak demand.
The fuel cell operates in its optimal efficiency range and recharges the back-up battery with surplus power. Once the back-up battery is fully charged, the fuel cell is
automatically and temporarily shut down, and the "FC ON" indicator goes off.
(1)
OFF
INFO
(11) (10)
20
(4) "Service" indicator
The "Service" indicator warns that maintenance is due to be carried out soon. A
corresponding signal is also output via the 4-pin CAN connector.
As soon as the "Service" (4) indicator lights up, contact the manufacturer to arrange for the necessary maintenance work to be carried out.
WARNING! Delaying necessary maintenance work poses the risk of fire, explosion or suffocation and can result in serious injuries and damage. As soon
as the "Service" (4) indicator lights up, contact the manufacturer to arrange
for the necessary maintenance work to be carried out.
(5) "H2 Tank Level" indicator
The "H
Tank Level" indicator shows how much hydrogen is left, from 0 to 100% of
2
the available tank capacity.
(6) "H2 Leakage" indicator
The hydrogen sensor inside the device has tripped. This points to a hydrogen leak
in the system. Do not continue to operate the device. The fault must be rectified by
a Fronius-trained service technician.
WARNING! Operating the device while the "H2 Leakage" (7) indicator is lit
poses the risk of fire, explosion or suffocation and can result in serious injuries and damage. Park the vehicle in a well-ventilated environment. Arrange
for the device to be repaired immediately by a Fronius-trained service technician.
(7) "Safety Error" indicator
The "Safety Error" indicator signals a fault in the energy cell's safety system. Do
not continue to operate the device. The fault must be rectified by a Fronius-trained
service technician.
WARNING! Operating the device while the "Safety Error" (8) indicator is lit
poses the risk of fire, explosion or suffocation and can result in serious injuries and damage. Arrange for the device to be repaired immediately by a Fronius-trained service technician.
(8) "Low Battery" indicator
The "Low Battery" indicator warns you that the device's integrated back-up battery
only has a limited charge left. In this case, the back-up battery must be recharged
using a suitable charger.
EN
(9) "System Error" indicator
The "System Error" indicator signals a fault in the device's control system, which
can also affect the energy cell's safety system. If the indicator does not go off when
you restart the device, contact a Fronius-trained service technician. Do not continue to operate the device.
WARNING! Continuing to operate the device while the "System Error" (10)
indicator is lit poses the risk of fire, explosion or suffocation and can result in
serious injuries and damage. If the "System Error" (10) indicator does not go
off after a restart, turn off the device immediately and have it repaired by a
Fronius-trained service technician without delay.
(10) "INFO" button
If any of the indicators (6) to (9) lights up, press the "Info" button to obtain further
information about the indicator in question. The relevant information is displayed
as a code via the "H
Tank Level" (5) display. An explanation of the code can be
2
found in the "Troubleshooting" chapter.
(11) "OFF" button
Pressing the "OFF" button stops energy delivery. At the same time the energy cell
is shut down and put into a safe state. In the safe state, all the hydrogen valves that
can be activated by the energy cell are closed.
21
Before commissioning
Safety
Proper use Responsibility for operation of the device rests with the user. The overall safety of the ve-
hicle (energy cell, vehicle and its operation in a working area) is the responsibility of the
vehicle system supplier. The vehicle system supplier must ensure that all safety issues relating to the integration of the device into the vehicle have been clarified with the device
manufacturer.
The device is intended exclusively for the generation of electrical energy from hydrogen
with oxygen from the air and may only be used in a suitable transport vehicle for in-house
logistics, and for production of the electrical energy for driving such vehicles.
In-house transport vehicles are deemed to be suitable if the following conditions are met:
- Analysis of overall system safety and supply of general system user documentation
- Information provided to the driver and surrounding area concerning safety-relevant
- Weight compensation, if required due to the fact that the energy cell is lighter than a
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here until you have thoroughly read
and understood the following documents:
- these operating instructions
- all operating instructions of the vehicle, the refuelling system and other system components, particularly the safety rules
(energy cell and vehicle) adapted for use of the vehicle with the HyLOG Fleet energy
cell.
operating states of the energy cell (warning of hydrogen leak, etc.)
battery (driving stability, traction, etc.)
Any use above and beyond this purpose is deemed improper. The manufacturer shall not
be held liable for any damage arising from such usage.
Proper use includes:
- ensuring that the device is undamaged and in perfect condition
- verifiable training of users before using for the first time
- carefully reading and obeying all the instructions in these operating instructions, especially the safety rules and all safety and danger notices
- installing the device in accordance with the vehicle manufacturer's operating instructions
- carrying out all the specified inspection and maintenance work
- observing all instructions of the vehicle manufacturer and the refuelling system manufacturer
- obeying other relevant national safety rules
WARNING! Improper operation, maintenance or transportation can result in serious injuries and damage. There is a container of pressurised hydrogen in the device, and it must therefore be treated with care. The regulations on proper use
must be observed.
22
WARNING! If operation of the device is impaired due to the device coming into
contact with water, there is a risk of suffocation and explosion.
The device may not be used if any part has been submerged in or flooded with
water. Notify the manufacturer or its representative immediately so that the device
can be checked and any affected parts replaced.
Remove the device before washing the vehicle. Never clean the device itself with
water, liquid detergents or steam cleaners.
WARNING! If operation of the device is impaired due to use in frosty or humid
conditions, there is a risk of suffocation and explosion.
Do not use the device in frosty or humid conditions. Operating the device in frosty
or humid conditions can result in damage. Only use the device in rooms that are
free from frost and condensing air. Detailed information can be found in the
"Technical data" chapter.
Remove the device before washing the vehicle. Never clean the device itself with
water, liquid detergents or steam cleaners.
Information on cleaning the device can be found in the "Care, maintenance and
disposal" chapter.
EN
Before using for
the first time
1
2
3
4
Connectors The device is designed for the output voltages indicated on the rating plate. The hydrogen
refuelling system must be suitable for this connector. The necessary design of the hydrogen refuelling connector is described in the "System Configuration" section of the "General" chapter. If connectors, lines or valves are not attached to your version of the appliance,
fit these components so that they conform to the relevant national standards. The setup
examples are merely recommendations and do not necessarily comply with national standards.
WARNING! If operation of the device is impaired by blocked material flows, there
is a risk of suffocation and explosion. Keep all air openings and the condensate
drainage connector completely clear.
Check that there are no obstructions to the following flows:
- Cooling air inlet
- Process air inlet
- Process air outlet
- Hydrogen supply
- Condensate drain
Install the necessary warning signs and driver information notices
Ensure that the user has received verifiable training from an authorised person
If necessary, charge the battery using a suitable battery charger
CAUTION! Inadequately dimensioned installations and consumers can cause
serious damage. Consumers connected to the device must conform to the output
voltages of the device. The technical data shown on the rating plate applies.
WARNING! Leaks and escaping hydrogen during the refuelling process carry the
risk of fire, suffocation and explosion. The refuelling system must be configured
according to the applicable standards and the "Technical data" chapter. Refuelling must only be carried out by properly trained personnel. The technical data
shown on the rating plate applies.
23
Start-up
Safety
WARNING! Faulty installation can cause serious damage and injury. Installation
may only be carried out by suitable trained experts in an in-house transport vehicle suitable for that purpose, in accordance with the "Proper use" section of the
"Before commissioning" chapter.
When installing the device, make sure that all material flows are unobstructed, in
accordance with the "Before using for the first time" section of the "Before commissioning" chapter. Only operate the charger in accordance with the degree of
protection shown on the rating plate. Observe the "Operating conditions" of the
"Operation" chapter.
WARNING! Work carried out incorrectly and electric shocks can have fatal results.
- Covers and the housing in general should only be opened or removed by the
manufacturer's trained technicians
- Unauthorised opening or tampering with the device will invalidate the warranty and create the risk of serious injury or damage.
- Do not carry out any modifications, alterations, etc. to the device without the
manufacturer's consent.
WARNING! An electric shock can be fatal. If the device is electrically connected
to the integrated back-up battery during installation, there is a risk of serious injury
and damage. Do not carry out any work on the connectors, unless the device
- is electrically isolated from the integrated back-up battery
- is turned off and in the safe state. For detailed information about the "Safe
state", refer to the "Control panel" section of the "Control elements and connections" chapter
Preliminary information
Connecting the
power interface to
the vehicle
The overall safety of the vehicle (energy cell, vehicle and its operation in a working area)
is the responsibility of the vehicle system supplier. The vehicle system supplier must ensure that all safety issues relating to the integration of the device into the vehicle have been
clarified with the device manufacturer.
Integration of the device into the vehicle is vehicle-specific and requires in-depth knowledge of all safety issues and operation-relevant factors associated with the type of vehicle
in question. The following instructions do not therefore address the integration of the device into the vehicle, but only with the connection and actual start-up of the device.
WARNING! Operation with excessive power consumption can result in serious
injuries and damage. The power consumption of the vehicle must not exceed the
power delivery of the device.
NOTE! Careless handling of plug connectors can cause damage. When connecting the plug connector for the vehicle's power supply, do not kink, catch or strain
the cables. Renew faulty cables and plug connectors.
24
(1)
1
Connect the power interface (1) on top
1
of the housing with a suitable plug for
the vehicle's power supply
EN
CAN service interface
(1)
for operation of the vehicle and therefore
does not have to be used.
NOTE! Careless handling of plug connectors can cause damage. When connecting the plug connector for the CAN service interface, even if it is not used, do not
kink, catch or strain the cables.
Connect the 4-pin CAN connector (1) on top of the housing with a suitable plug for the
vehicle electronics
The CAN service interface is not required
Warning and driv-
1
er information in-
1
terface
2
2
(1)
3
Pin 1
Pin 0
Pin 2
Vehicle Earth
3
4
4
5
5
6
6
*
Earth
HyLOG Fleet Chassis
25
WARNING! A faulty electrical connection may cause serious injury and damage
and also lead to a risk of explosion. The electrical connection for equipotential
bonding (* see illustration on right) must be tested in accordance with national installation regulations.
WARNING! Electrostatic discharge may lead to a risk of explosion. The vehicle's
chassis should be electrically connected with the energy cell via connector (1)
such that equipotential bonding results.
The interface (1) allows connection of a signal lamp and a signal horn with the following
function:
The signal lamp flashes at intervals:
- Tank is empty
Signal lamp flashes continuously:
- Energy cell is overheated
- General fault on energy cell
After pressing the "INFO" button, the exact error code is shown on the "H
Tank Level"
2
display.
- Safety-critical fault: The overtemperature or overvoltage limits have been reached or
the safety check has detected a malfunction
The energy cell shuts down and can only be restarted by switching off and on again.
After 10 attempts, the device is completely locked:
- Contact the device manufacturer with a detailed description of the fault
Refuelling
The signal lamp flashes continuously and the signal horn sounds:
- A safety-critical fault has occurred: Hydrogen is escaping - for safety reasons you
must close the tank valves
- Do not continue to operate the device. Contact the device manufacturer with a de-
tailed description of the fault
Interface specifications:
- Connectors: AMP Superseal 1.5 6-pin
- Conductors fitted with wire-end ferrules
- Conductor cross-section at least 0.75 mm² (AWG 19)
- Maximum cable length on the vehicle side 2 m (6 ft., 6.74 in.)
WARNING! Leaks in the hydrogen supply pose a risk of fire, explosion or suffocation. The hydrogen refuelling system must therefore be approved by the manufacturer, set up in compliance with the applicable standards and guidelines and
operated in accordance with the manufacturer's instructions. Refuelling must only
be carried out by suitably trained personnel. The technical data shown on the rating plate applies. The additional instructions in the supplementary data sheet "Refuelling" must be observed.
WARNING! Overfilling the hydrogen tank poses a risk of explosion and can result
in serious injuries and damage. The hydrogen tank is considered to be "full" when
a pressure of 200 bar (2899.74 psi.) has been reached.
26
Press the "OFF" button to shut down the energy cell and place it in the safe state
1
Connect the condensate drain
2
Connect the filler coupling of the hydrogen refuelling system to the filler connection in
3
accordance with the refuelling system manufacturer's instructions
Carry out the refuelling process in accordance with the refuelling system manufactur-
4
er's instructions
Once the hydrogen tank has reached a pressure of 200 bar (2899.74 psi.), the hydro-
5
gen refuelling system automatically stops the refuelling process
EN
27
Operation
Safety
WARNING! Operating the equipment incorrectly can cause serious injury and
damage. Do not use the functions described here until you have thoroughly read
and understood the following documents:
- these operating instructions
- all operating instructions of the vehicle, the refuelling system and other system components, particularly the safety rules
WARNING! Using the device in spaces with inadequate ventilation poses a risk
of explosion and suffocation with no visible or otherwise detectable warning. This
is mainly because of the oxygen consumption of the device. However, it is also
possible that a combustible gas mixture will gradually accumulate in the surrounding air. Therefore, the device must only be operated in rooms with a volume of not
less than 10 m³ (353.15 ft ³) and with an air circulation rate of not less than 0.6/h.
Example: With a room volume of 10 m³ (353.15 ft³), an air circulation rate of 0.6/
h means that 6 m³ (211.89 ft³) of air are renewed per hour. Other spatial conditions require an exact calculation of the air circulation rate in consultation with the
device manufacturer.
WARNING! Operating and storing the device under environmental conditions different from those specified here can cause serious injury and damage. The surrounding air must be clean and free from
-smoke
- open flames and fire
- petrol and other inflammable materials, such as liquids, vapours and dust
- corrosive gases or substances
Operating conditions
Can be used at altitudes of up to 1600 m (5249 ft)
Detailed information on the permitted environmental conditions can be found in
the "Technical data" chapter.
This device is designed to be operated within a temperature range of between +2°C
(+36°F) and +60°C (+140°F). Below approx. +2°C (+36°F), the device is operated exclusively with the integrated back-up battery, provided it has sufficient charge.
If the device is started at an ambient temperature of between +2°C (+36°F) and +20°C
(+68°F), the nominal output will not be available until the required process temperature is
reached.
If the device is operated at high ambient temperatures, or with inadequate heat dissipation,
derating occurs in order to prevent an overload.
The device may not be operated for more than 30 minutes in an ambient temperature
range between +40°C (+104°F) and +60°C (+140°F). Premature degradation of the device
can also occur following operation at very high temperatures.
A maximum relative humidity of 85 % (non-condensing) is permissible.
Starting energy
delivery
28
WARNING! Operating the device outside the permitted temperature range can
result in serious injuries and damage. The permitted ambient temperature range
is from +2°C to +60°C (+36°F to +140°F).
Energy is available as soon as you switch on the device. Initially it is provided only by the
ON
1
2
OFF
1
2
Power ON
3
back-up battery, which at the same time supplies the energy needed to start the fuel cell.
Start energy delivery as follows:
Press the "ON" button
EN
Energy delivery
Stopping energy
delivery
Power ON
FC ON
The fuel cell meets the energy demand according to the operating strategy by interacting
accordingly with the back-up battery. The hydrogen in the tank together with the ambient
air sucked into the unit is converted into electricity and water as a combustion product. The
back-up battery primarily caters for low loads and peak demand.
The fuel cell operates in its optimal efficiency range and recharges the back-up battery.
Once the back-up battery is fully charged, the fuel cell is automatically and temporarily shut
down, and the "FC ON" indicator goes off.
The operating strategy for interaction of the back-up battery and fuel cell can be adapted
to the operating cycle. Contact the manufacturer for further details.
To turn off the energy cell and stop energy delivery:
The "Power ON" indicator lights up - the energy for operating the
vehicle is available immediately
As soon as the fuel cell is generating energy, the "FC ON" indicator
also lights up.
Press the "OFF" button
FC ON
Once the energy cell has been switched off, it is in the "safe state". This means that all
valves for the hydrogen supply that can be activated by the energy cell are closed. In the
event that the device is not used for a prolonged period, an automatic safeguard ensures
that it does not consume any energy.
The "FC ON" indicator goes off - the fuel cell is shut down
The "Power ON" indicator goes off - the energy for operating the
vehicle is immediately turned off
29
Troubleshooting
Safety
WARNING! Work carried out incorrectly and electric shocks can have fatal re-
sults.
- All covers of the device and the housing in general should only be opened or
removed by trained technicians
- Unauthorised opening or tampering with the device will invalidate the warranty and create the risk of serious injury or damage.
If the covers of the device or the housing are opened by trained personnel, the following
warnings apply:
WARNING! An electric shock can be fatal. Do not touch any components in the
housing interior before the integrated back-up battery has been electrically isolated from the device and electrically charged components (e.g. capacitors) have
been discharged. Before opening the device:
- Stop energy delivery by pressing the "OFF" button
- Wait until the "Power ON" and "FC ON" indicators have gone off
WARNING! An electric shock can be fatal. Do not touch any components in the
housing interior before the integrated back-up battery has been electrically isolated from the device and electrically charged components (e.g. capacitors) have
been discharged. After opening the device
- Electrically isolate the integrated back-up battery from the device
- Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
- Using a suitable measuring instrument, ensure that electrically charged parts
(e.g. capacitors) have been electrically discharged
Fault diagnosis Contact:
Fronius International GmbH
4600 Wels-Thalheim, Günter-Fronius-Straße 1, Austria
E-mail: energycell@fronius.com
http://www.fronius.com
The unit does not function
Cause: The device's integrated battery is flat
Remedy: Recharge the battery using a suitable battery charging system
Displayed service
codes
Basic service messages are displayed on the control panel via appropriately labelled indicators. If any of the indicators lights up, press the "Info" button to obtain further information
about the indicator in question. The relevant information is displayed in the form of a code.
(Voltage range: 22 - 28.8 V, maximum current 100 A)
(e.g. Fronius Selectiva Plus 2100, item number 4,010,061)
30
Energy Cell
3
3
Service
FC ON
Power ON
H2 Tank Level
a
b
c
d
e
f
Leakage
H
²
Safety Error
Low Battery
System Error
Inform the service technician of the lowercase letters that are shown alongside the illuminated indicators, as illustrated.
EN
ON
OFF
INFO
WARNING! Ignoring service messages poses the risk of fire, explosion or suffocation and can result in serious injuries and damage. Arrange for the device to be
repaired immediately by a Fronius-trained service technician.
If an error message that is not described here appears on the displays, proceed as follows
to resolve the problem:
Stop energy delivery by pressing the "OFF" button
1
Wait until the "Power ON" and "FC ON" indicators have gone off
2
Start energy delivery by pressing the "ON" button
Wait until the "Power ON" indicator lights up
4
If the error occurs again despite several attempts to eliminate it, or if the troubleshooting
measures listed here are unsuccessful:
Make a note of the error message displayed
1
Note the configuration of the device
2
Contact the device manufacturer with a detailed description of the fault
"Service" indicator lights up
Cause: Important maintenance is due soon.
Remedy: Contact the manufacturer immediately to arrange the necessary maintenance
WARNING! Delaying necessary maintenance work poses the risk of fire, explosion or suffocation and can result in serious injuries and damage. As soon as the
"Service" indicator lights up, contact the manufacturer to arrange for the necessary maintenance work to be carried out.
"H2 Leakage" indicator lights up
Cause: The hydrogen sensor inside the device has tripped. This points to a hydrogen
leak in the system. Do not continue to operate the device.
Remedy: Park the vehicle in a well-ventilated environment. Contact the manufacturer
immediately to arrange the necessary repairs.
WARNING! Operating the device while the "H2 Leakage" indicator is lit carries
the risk of fire, explosion or suffocation and can result in serious injuries and damage. Arrange for the device to be repaired immediately by a Fronius-trained service technician.
31
"Safety Error" indicator lights up
Cause: The "Safety Error" indicator signals a fault in the energy cell's safety system.
Do not continue to operate the device.
Remedy: Contact the manufacturer immediately to arrange the necessary repairs.
WARNING! Operating the device while the "Safety Error" indicator is lit carries
the risk of fire, explosion or suffocation and can result in serious injuries and damage. Arrange for the device to be repaired immediately by a Fronius-trained service technician.
"Low Battery" indicator lights up
Cause: The "Low Battery" indicator warns you that the device's integrated back-up
battery only has a limited charge left.
Remedy: Recharge the integrated back-up battery using a suitable battery charger.
"System Error" indicator lights up
Cause: The "System Error" indicator signals a fault in the device's control system,
which can also affect the energy cell's safety system. If the indicator does not
go off when you restart the device, contact a Fronius-trained service technician. Do not continue to operate the device.
Remedy: Contact the manufacturer immediately to arrange the necessary repairs.
WARNING! Continuing to operate the device while the "System Error" indicator
is lit carries the risk of fire, explosion or suffocation and can result in serious injuries and damage. If the "System Error" indicator does not go off after a restart,
turn off the device immediately and have it repaired by a Fronius-trained service
technician without delay .
32
Care, maintenance and disposal
Safety Under normal operating conditions, the device requires only a minimum of care and main-
tenance. However, it is vital to observe some important points to ensure the device remains
in a usable condition for many years.
WARNING! Work carried out incorrectly and electric shocks can have fatal results.
- All covers of the device and the housing in general should only be opened or
removed by trained technicians
- Unauthorised opening or tampering with the device will invalidate the warranty and create the risk of serious injury or damage.
If the covers of the device or the housing are opened by trained personnel, the following
warnings apply:
WARNING! An electric shock can be fatal. Do not touch any components in the
housing interior before the integrated battery has been electrically isolated from
the device and electrically charged components (e.g. capacitors) have been discharged. Before opening the device:
- Stop energy delivery by pressing the "OFF" button
- Wait until the "Power ON" indicator has gone off
EN
WARNING! An electric shock can be fatal. Do not touch any components in the
housing interior before the integrated battery has been electrically isolated from
the device and electrically charged components (e.g. capacitors) have been discharged. After opening the device
- Electrically isolate the integrated back-up battery from the device
- Put up an easy-to-understand warning sign to stop anybody inadvertently
switching it back on again
- Using a suitable measuring instrument, ensure that electrically charged parts
(e.g. capacitors) have been electrically discharged
WARNING! Work that is carried out incorrectly can cause serious injury or damage. Maintenance, technical inspections and checks must only be carried out by
qualified personnel. All repairs and maintenance work must be performed exclusively using original replacement parts.
Any changes to the device or the use of parts that are not original parts requires
the approval of the manufacturer.
If these conditions are not met, the manufacturer cannot guarantee the safety of
the device.
WARNING! Starting up the device without having performed safety-related maintenance work can cause serious injury or damage and is done at your own risk.
The manufacturer accepts no liability for damage caused by inadequate maintenance or the non-performance of maintenance.
Minimum maintenance work
WARNING! A poorly-maintained unit can result in serious injury or damage. For
the unit to operate safely, the specified maintenance tasks MUST be carried out.
33
The following points must always be observed to ensure safe, problem-free operation of
the device:
- Never use anything other than a dry cloth to clean the device. Ensure that the device
is never exposed to damp conditions
- Keep all air inlets and outlets free of obstructions at all times
- Check cables and connectors for signs of damage
- Observe any additional servicing and maintenance instructions provided by the manufacturer
Once a year / every 1000 operating
hours
Annual safety inspection
Maintenance
work every 1000
operating hours
WARNING! A defective gas supply system can cause serious injury and damage.
Inspect the gas supply system in accordance with the applicable national regulations.
WARNING! A poorly-maintained unit can result in serious injury or damage. For
the unit to operate safely, the specified maintenance tasks MUST be carried out.
A safety inspection is required at certain intervals, as is the maintenance specified below.
A safety inspection is required once a year. The safety inspection must be carried out by
a Fronius-trained service technician and includes checking all the safety features of the device.
Maintenance must be performed every 1000 operating hours, or earlier if operating conditions dictate (e.g. dusty environment). The maintenance operations are carried out by authorised service technicians and are designed to preserve
- the satisfactory condition of the device
- its performance
- the warranty requirements
Disposal Dispose of in accordance with the applicable national and local regulations.
34
Technical data
EN
HyLOG Fleet energy cell
Input data
Fuel (ISO 14687-2 / SAE J2719) Hydrogen 5.0
(3.0 available on request)
Tank capacity, mass and nominal pressure of the hydrogen contained
Air inlet < 600 m
Fuel cell data
DC continuous output power 2.6 kW
System voltage 26.4 V DC
Fuse protection of the power interface 225 A, 550 A short-time
System efficiency > 47 %
Data relating to the integrated back-up battery
High-performance lithium-ion rechargeable battery utilising the latest lithium iron phosphate technology
Working voltage 26.4 V DC
Nominal charging capacity approx. 40 Ah
23 l, 0.35 kg, 200 bar
6.08 gal., 0.77 lb., 2899.74
psi.
3
/h
< 21188.8 cfh
LiFePO
4
Output data
Concentration of hydrogen in the process exhaust air
(instantaneous value)
Air outlet < 600 m³/h at max. 65 °C
Reaction condensate (pure water, completely desalinated)
General data
Data interface CAN
Degree of protection IP 20
Marks of conformity CE, TÜV Süd Fuel Cell Safety
Safety standard IEC EN 62282-5 1
Dimensions l x w x h 786 x 310 x 630 mm
Weight 180 kg
Permitted ambient temperature
(at 85% relative humidity)
< 25 % of the lower explosive
limit LEL
< 21188.8 cfh at max. 149 °F
< 1.6 l per tank
< 0.423 gal per tank
30.94 x 12.2 x 24.8 in.
396.83 lb.
2 °C to 60 °C
35.6 °F to 140 °F
35
General data
Permitted storage temperature
(at 85% relative humidity)
Altitude above sea level max. 1600 m
Must be set up horizontally
* Derating takes place in the range 40 °C to 60 °C (104 °F to 140 °F). This means that
the output power is reduced as far as necessary.
Connections
Tank connector and connector for equipotential bonding
via electrical connection with vehicle earth potential
Condensate drainage connector Detailed information can be
Power interface REMA 75012-56
Warning and driver information interface 26.4 V
CAN service interface CAN terminal 4-pin
2 °C to 50 °C
35.6 °F to 122 °F
max. 5249.34 ft.
WEH TN1
found in the separate document "Refuelling regulations".
1 A
36
EN
37
Fronius Worldwide - www.fronius.com/addresses
Fronius International GmbH
4600 Wels, Froniusplatz 1, Austria
E-Mail: pv@fronius.com
http://www.fronius.com
Under http://www.fronius.com/addresses you will find all addresses of our sales branches and partner firms!
Fronius USA LLC Solar Electronics Division
6797 Fronius Drive, Portage, IN 46368
E-Mail: pv-us@fronius.com
http://www.fronius-usa.com
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