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HyLOG Fleet
24015F
Operating Instructions
EN
Energy cell
42,0426,0271,EN 003-22112018
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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
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Contents
Safety rules ................................................................................................................................................ 7
Explanation of safety symbols .............................................................................................................. 7
General ................................................................................................................................................. 7
Proper use ............................................................................................................................................ 8
Safety measures in operation ............................................................................................................... 9
Environmental conditions...................................................................................................................... 9
Safe use................................................................................................................................................ 9
Protecting yourself and others .............................................................................................................. 10
Danger from gases, hazardous materials and suffocation.................................................................... 10
Safety measures in normal operation ................................................................................................... 10
Specific hazards.................................................................................................................................... 11
General information regarding the handling of batteries....................................................................... 11
Danger from batteries ........................................................................................................................... 11
Danger from pressure vessels .............................................................................................................. 11
Warranty and liability............................................................................................................................. 12
Safety inspection................................................................................................................................... 12
Safety symbols...................................................................................................................................... 12
Disposal ................................................................................................................................................ 12
Copyright............................................................................................................................................... 13
General ...................................................................................................................................................... 14
Functionality and device concept.......................................................................................................... 14
Advantages ........................................................................................................................................... 14
Properties.............................................................................................................................................. 15
System configuration ............................................................................................................................ 15
Warning notices on the device.............................................................................................................. 16
Control elements and connections............................................................................................................. 18
Safety.................................................................................................................................................... 18
Controls and connections ..................................................................................................................... 18
Control panel......................................................................................................................................... 20
Before commissioning................................................................................................................................ 23
Safety.................................................................................................................................................... 23
Proper use/intended purpose................................................................................................................ 23
Before using for the first time ................................................................................................................ 24
Connections .......................................................................................................................................... 24
Start-up ...................................................................................................................................................... 26
Safety.................................................................................................................................................... 26
Advance information ............................................................................................................................. 26
Connecting the power interface to the vehicle ...................................................................................... 26
Pin assignment for the vehicle connection............................................................................................ 27
Specification for the vehicle connection................................................................................................ 27
Potential Equalization ........................................................................................................................... 28
Application example for the vehicle connection .................................................................................... 28
Refuelling ................................................................................................................................................... 29
Safety.................................................................................................................................................... 29
General ................................................................................................................................................. 29
General refuelling.................................................................................................................................. 29
Time-optimised refuelling...................................................................................................................... 30
Pressure tolerances .............................................................................................................................. 32
Refuelling process ................................................................................................................................ 32
Operation ................................................................................................................................................... 33
Safety.................................................................................................................................................... 33
Operating conditions ............................................................................................................................. 33
Starting energy delivery ........................................................................................................................ 34
Stopping energy delivery ...................................................................................................................... 34
Troubleshooting ......................................................................................................................................... 35
Safety.................................................................................................................................................... 35
Fault diagnosis...................................................................................................................................... 35
Displayed service codes ....................................................................................................................... 36
Care, maintenance and disposal ............................................................................................................... 38
Safety.................................................................................................................................................... 38
EN
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Minimum maintenance work ................................................................................................................. 39
Once a year / every 1000 operating hours............................................................................................ 39
Annual safety inspection ....................................................................................................................... 39
Maintenance work every 1000 operating hours ....................................................................................40
Service life ............................................................................................................................................ 40
Pressure equipment.............................................................................................................................. 40
Disposal ................................................................................................................................................ 40
Technical data............................................................................................................................................ 41
HyLOG Fleet 24015F............................................................................................................................ 41
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Safety rules
EN
Explanation of
safety symbols
DANGER!
Indicates immediate and real danger.
If it is not avoided, death or serious 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.
General
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" chapter, special care is required.
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 operator,
- 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.
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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
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 (HyLOG Fleet device, 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.
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.
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.
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Remove the device before washing the vehicle. Never clean the device itself with water,
liquid detergents or steam cleaners.
Safety measures
in operation
Environmental
conditions
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.
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.
Additional 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
EN
Safe use
Can be used at altitudes of up to 1600 m (5249 ft.)
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, in combination with an ignition source, pose a risk of fire and
explosion. 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).
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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.
Protecting yourself and others
Danger from gases, hazardous
materials and suffocation
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 (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.
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 safety data sheet of the hydrogen supplier.
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
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Only operate the device if all of its 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
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 device(s)
- 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
EN
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 unit contains a back-up battery (NiMH-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 (maximum charging current: 35 A, e.g. Acctiva Professional 35A, item number 4,010,335,874. 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 (damages the cells)
- Deep discharge of the cells (damages the cells)
- Destruction of cells by short circuit
- Polarity reversal
- Incorrect charging
- Overtemperature
Danger from batteries
Danger from
pressure vessels
The unit contains a back-up battery (NiMH-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.
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.
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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.
Warranty and liability
Safety inspection
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
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 function-tested. 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 manufacturer 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 Devices with the CE marking satisfy the essential requirements of the applicable European
directives. Further information can be found in the "Technical data" chapter.
Disposal Do not dispose of this device with normal domestic waste! To comply with the European
Directive 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!
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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
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General
Functionality and
device concept
The HyLOG Fleet device allows transport
vehicles for internal logistics to be operated
with 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 HyLOG Fleet are small
quantities of pure water.
The key component of HyLOG Fleet 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 HyLOG Fleet is that long battery charging times are re-
placed 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, within
the intended product life cycle of 10 years, whereas batteries always have a limited service
life.
Use of the fuel cell offers a range of other benefits as well:
Water is the only combustion product of the fuel cell, which means that it does not produce
any pollutants. Another advantage of the fuel cell is that it is quiet and requires practically
no maintenance. In contrast to conventional generators, the fuel cell electrochemically converts the chemically-bound energy of the hydrogen directly into electrical power. 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
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