Manual for Schunk Fuel Cell Stacks

FC-42/HLC

Schunk Bahn- und Industrietechnik GmbH

Manual for Schunk Fuel Cell Stacks

Table of contents
1 Preliminary remarks ......................................................................................... 6 1.1 1.2 2 2.1 2.2 2.3 2.4 2.5 2.6 2.7 2.8 3 3.1 3.2 3.3 3.4 3.5 3.6 4 4.1 4.2 4.3 4.4 4.5 4.6 5 5.1 5.2 6 Nomenclature ............................................................................................. 6 General ....................................................................................................... 6 Installation.................................................................................................. 7 Hydrogen .................................................................................................... 7 Electrical connections ................................................................................. 8 Cooling water ............................................................................................. 8 Products created ......................................................................................... 9 Temperatures ............................................................................................. 9 Overpressure .............................................................................................. 9 Further information .................................................................................... 9 General points .......................................................................................... 10 Hydrogen .................................................................................................. 10 Air ............................................................................................................ 10 Water cooling............................................................................................ 11 Media connections .................................................................................... 11 Power connection ..................................................................................... 14 Anode supply............................................................................................ 14 Cathode supply ......................................................................................... 15 Critical operating states ............................................................................ 15 Monitoring ................................................................................................ 16 Switching on ............................................................................................. 17 Switching off............................................................................................. 17 Storage of one individual fuel cell ............................................................. 18 Storage / long-term switching-off of a complete system .......................... 18

Safety instructions ........................................................................................... 7

Media supplies and power connection ............................................................ 10

Operating the fuel cell .................................................................................... 14

Storage .......................................................................................................... 18

Transport ...................................................................................................... 19

Manual for Schunk Fuel Cell Stacks

7 Notes fr system integrators .......................................................................... 20 7.1 7.2 7.3 7.4 7.5 8 8.1 8.2 8.3 8.4 8.5 8.6 8.7 8.8 8.9 General ..................................................................................................... 20 Electrical circuitry ..................................................................................... 20 Avoidance of open-circuit voltage mode ................................................... 22 Operating methods, mounting and installation position ............................ 22 Minimal system configuration ................................................................... 24 High-current mode ................................................................................... 25 Throttling of the cathode air ..................................................................... 25 Humidifying of the cathode air.................................................................. 25 Humidifying of the anode gas ................................................................... 26 Regulating of the quantity of air ............................................................... 26 Purging cycles........................................................................................... 27 Anode gas recirculation ............................................................................ 27 Cathode air recirculation ........................................................................... 27 Media reversal .......................................................................................... 27

Methods for optimizing the efficiency ............................................................. 25

8.10 External humidification ............................................................................. 27 8.11 Manual drying of the fuel cell .................................................................... 28 9 Data log and operating proof ......................................................................... 28 10.1 External leakage of the reaction gases ...................................................... 29 10.2 External leakage of the cooling medium ................................................... 29 10.3 Internal leakage of the reaction gas .......................................................... 29 11 Disposal ........................................................................................................ 30 12 Optional extras .............................................................................................. 30 13 Faultfinding and remedies .............................................................................. 31 14 Standards (selection) ...................................................................................... 33 15 Literature ....................................................................................................... 34 16 Data sheet ..................................................................................................... 35 10 Searching for leaks......................................................................................... 29

Manual for Schunk Fuel Cell Stacks

List of figures
Fig. 1: Connection schematic for FC-42 fuel cells, example: 360 Watt module. ...... 12 Fig. 2: Connection schematic for FC-42 fuel cells, example: 1080 Watt module. .... 13 Fig. 3: Different configurations of electrical circuitry.............................................. 20 Fig. 4: Prescribed installation positions for the fuel cell ......................................... 23 Fig. 5: The most important components for the operating of a fuel cell ................. 24 Fig. 6: Ideal air stoichiometry. ............................................................................... 26 Fig. 7: Carrier for FC-42 fuel cells ......................................................................... 30 Fig. 8: U/I characteristic curve for Schunk FC-42 fuel cells .................................... 37

List of tables
Table 1: Different configurations of the output bundling ....................................... 21 Table 2: Faults and remedies ................................................................................. 31 Table 3: Standards (seletion) ................................................................................. 33 Table 4: Data sheet for Schunk fuel cells ............................................................... 35

Manual for Schunk Fuel Cell Stacks

List of ecronyms
DOE EMV FAQ FC-42 HLC OCV PA PE PEFC PP ppm department of energy electromagnetic compatibility frequently asked questions Fuel Cell with 42 single cells Hydrogen, Liguid Cooled open circuit voltage polyamide polyethylene polymer electrolyte fuel cell polypropylene parts per million

Manual for Schunk Fuel Cell Stacks

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1.1

Preliminary remarks
Nomenclature
The Schunk fuel cell stack is designated with the following nomenclature: FC-42/HLC: Fuel cell stack with 42 cells for hydrogen operation and liquid cooling.

1.2

General
In this document the term "fuel cell" stands for the Schunk fuel cell stack including the attachment parts needed for the supplying of media and cooling water. General statements on the water supply for and the operating characteristics of PEM fuel cells in the relevant literature are also applicable for the Schunk fuel cell. It is explicitly recommended that the literature listed below is read to supplement the information in this manual.

Fuel Cell manual (DOE Department of energy, 2004) Fuel Cell Systems explained (Larminie, Dicks, 2006) Brennstoffzellen Entwicklung, Technologie, Anwendung (Heinzel/Mahlendorf/Roes, 2006) With the fuel cells of the type FC-42, it is a matter of PEFCs with a proton-conducting membrane. The fuel cells are designed for use with pure hydrogen on the anode side and air on the cathode side. They are cooled by liquid and can be used in a temperature range of 5 to 70 C. The fuel cell requires no maintenance provided that the parameters stated in the data sheet are maintained.

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2.1

Safety instructions
Installation
The fuel cell may only be operated indoors when there is an adequate air change rate1 and/or there is an extraction system and an approved hydrogen sensor has been installed. In operation FC-42 fuel cells consume oxygen and accordingly may not be used in closed rooms. It must be ensured that the ambient temperature around the fuel cell is below the spontaneous ignition temperature of hydrogen and that no sparks can occur at the place of installation. The relevant standards are to be maintained2. For permissible temperatures at the place of installation see the data sheet in the appendix. The fuel cell should be installed in such a way that the air and hydrogen outlets are at the lowest point so that the process water created can flow out3. If when it is being operated the fuel cell is not in a housing that provides protection against contact, then all the metal parts of the fuel cell that are located externally with the exception of the two electric contact poles - must be carefully earthed; see here also IEC 60529.

2.2

Hydrogen
The installation of the hydrogen supply must be carried out in accordance with the relevant standards .
4

For further information on handling hydrogen see the EU safety data sheet in accordance with EU directive 91 / 155 EEC and 93/112 EU.

1 The air change rate stated takes account of the consumption of oxygen by the fuel cell as well as of the maximum amount of hydrogen and of moisture release to the room. 2 For references to a selection of these standards see section 13: Standards 3 See recommended installation layout in section 7.4 4 For references to a selection of these standards see section 13: Standards

Manual for Schunk Fuel Cell Stacks

Hydrogen is / has: a colourless and odourless gas, easily inflammable, subject to igniting spontaneously if it flows out at high speeds, lighter than air, asphyxiating at high concentrations, an explosion range (in air) of 4 - 77 %, and an ignition temperature of 560 C. It is recommended that the working area in which hydrogen is used is equipped with safety systems, (e.g. hydrogen sensor, forced ventilation etc.)

2.3

Electrical connections
If two or more fuel cells are connected together electrically in series, then the opencircuit voltage is greater than 50 V and there is the risk of a fatal electric shock. The relevant standards are to be observed.

It is essential that short circuits are avoided (to prevent risk of sparks and explosions!). The electrical connections are to be executed in such a way that o o o o reliable electrical contact is ensured under all circumstances, the connections cannot become loose in an unintended manner, they are protected against corrosion, and contact with the ambient surroundings is not possible.

The relevant EMC prescriptions are to be observed.

2.4

Cooling water
Additives5 (e.g. anti-freeze) added to the cooling water can be poisonous. Contact with and/or drinking/swallowing of the cooling water is to be avoided. Common cooling water additives contain as a rule corrosion protection agents and anti-fouling additives which can be harmful to the health. Accordingly please observe the warning instructions on the containers of the additives used.

5 See section 3.4 - water cooling

Manual for Schunk Fuel Cell Stacks

2.5

Products created
The water that is created in the course of the process (hereafter process water) may be discharged into the sewer system without any misgivings. It does not contain any substances that are harmful to the environment. Nevertheless the process water should not be drunk / swallowed. The system for leading away the process water should be dimensioned in such a way that the quantity that is discharged (see data sheet) can be led off in a reliable manner.

2.6

Temperatures
The surfaces of the FC-42 can reach temperatures in excess of 60 C. The installation must be executed in such a way that contact is prevented (risk of burns!). The materials used are such that safe and reliable operation of the fuel cell is only ensured within the range of temperatures stated in the data sheet. If the temperature of the fuel cell exceeds or falls below this range of temperatures (even once), then it is possible that the fuel cell is no longer operationally safe and accordingly should then be checked by an expert before being used again.

2.7

Overpressure
If the values specified (see appendix) for the maximum pressure on the cathode and also on the anode sides are exceeded (even once), then it is possible that the fuel cell is no longer operationally safe and accordingly should be checked by an expert before being used again.

2.8

Further information
Further information in particular on safety strategies for fuel cell systems is published in IEC 62282-2 Fuel cell technologies, Part 2: Fuel cell modules.

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3
3.1

Media supplies and power connection

General points
The materials selected for the media supply systems should be selected carefully. It must be ensured that no metallic ions get on to the membrane on the anode or the cathode sides. It must be ensured that no particles can get into the fuel cell. Pipe cross-sections and pressures (see data sheet) are to be dimensioned in such a way that undersupplying of the fuel cell is not possible under any operating states. It must be ensured that no oxygen gets on to the anode side during operating of the fuel cell since oxygen can damage the catalyst on the membrane. (This can occur in particular if and as soon as the stock of hydrogen available for the fuel cell is used up so that at purging air instead of hydrogen is drawn in. This does not represent a problem if the fuel cell is ventilated in a currentless state. The materials selected for use must be such that they are resistant to / stable at a temperature at least 20 C (safety margin) above the maximum intended working temperature of the fuel cell system but in any case to a temperature of at least 80 C. If plastic hoses are used, then care must be taken that these cannot kink (observe minimum permissible bending radius).

3.2

Hydrogen
Hydrogen of a purity of at least 3.0 is to be used (without proportions of CO). If doubt exists on the composition of the hydrogen, then the statement of purity of 3.0 is not enough. It must be ensured that the contamination present consists exclusively of nitrogen, inert gases, fully saturated hydrocarbons and residual moisture. Typical, known "poisons" for catalysts, e.g. compounds containing sulphur, must be at levels of < 0.1 ppm; all other contamination < 5 ppm. The piping has to be in accordance with the current standards.

3.3

Air
The air fed in may not contain any organic solvents, oil aerosols, smoke gases or other contamination. The use of a dust filter (class F4) as well as a filter for organic and inorganic compounds is advisable.

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3.4

Water cooling
Normal mains water, to which an anti-freeze agent (in the ratio 3 : 1) and an antifouling additive (prevents biological contaminating of the cooling water) have been added, serves as the cooling medium. In no case may distilled or deionized water be used since this could attack the material of the fuel cell or fuel cell system components. (For quantities, pressure and connection see the data sheet). Examples of suitable anti-freeze agents:

Glysantin ProtectPlus / G48 GlycoShell Mobil 3+ Important: The use of an anti-freeze agent in the cooling circuit does NOT mean that the fuel cell stack may be used at a temperature < 0 C. Its use serves merely to provide protection against corrosion and decay. A measurement of temperature in the coolant is only meaningful when the flow of coolant is at least 5 % of the standard value. Care is to be taken that there are no bubbles of air in the cooling circuit. Bubbles of gas can be effectively separated off with a compensating reservoir in the cooling circuit.

3.5

Media connections
By reason of the connection facilities on the two end platens of the module, the supplying of the stack with hydrogen, air and cooling water can be carried out in a number of different ways. However it is explicitly recommended that the media are fed in or, as the case may be, led off in accordance with the following diagrams. The connection holes which are not needed for the particular case are to be closed in a gastight manner with suitable plugs (G 1/4" and G 3/8", of plastic - PA, PP or PE). All the screw plugs and blank plugs needed in accordance with the images below are contained in a plug kit available as an optional extra (see section 12).

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Fig. 1: C Connection sc chematic for FC-42 fuel cells, example: 360 Watt module (not the positio of the te on power lug g).

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Fig. 2: Connection s schematic for FC-42 fuel cells, example: 1080 Wa module (n o att note the position of wer the pow lug).

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3.6

Power connection
At each end of the fuel cell there is an M5 female screw thread for the power connection. Suitable, low-corrosion cable lugs (e.g. nickel-plated, silver-plated, gold-plated) are to be used for the power connection and secured to prevent them from coming loose. The fact that the connection cables are adequately insulated and are of dimensions suitable for the intensity of current must be ensured at all times. Important: The screws may not be screwed in too far since otherwise they will contact the collector and press this into the final graphite platen. The fuel cell can be destroyed in this way. The length of the thread (from the upper edge of the end adapter) may not exceed 10 mm. Tightening torque: maximum 2 Nm. The threads of the power lugs are not suitable for carrying high mechanical loads, e.g. for the situation that they are used for holding the fuel cell in a housing).

Operating the fuel cell

General information is given in this section on the operating of the FC-42 fuel cell. In part the information has been taken from publications and is intended to represent a starting basis for the development work carried out by the system integrator.

4.1

Anode supply
Pressure-led (dead-end): In this mode a constant level of pressure (see data sheet) is maintained at the anode inlet. The anode outlet is kept closed by a valve except when it is opened periodically in pulses in order to "purge" the anode. Cycle times and pulse duration must be laid down in accordance with the particular mode of operation. Typically the valve is kept closed for 60 s and is opened for 1 s.

Flow-led: Hydrogen flows through the fuel cell continuously on the anode side. Here the quantity of flow depends on the current generated and must be set so that it is overstoichiometric at all times. If the supply is understoichiometric, the fuel cell absorbs air via the anode side whereby this can lead to irreversible damage to the catalyst. In certain circumstances a purging process in which the mass flow is significantly increased can also be necessary in flow-led mode in order to drive out condensate that has formed effectively.

Moistening of the anode gas: In both the afore-mentioned modes moistening of the anode gas can lead to an increase in efficiency.

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4.2

Cathode supply
The cathode can be operated exclusively in flow mode since the air consists to approx. 80 % of inert gas and contains only approx. 20 % oxygen. The quantity of air needed for stable operating of the fuel cell depends on the current generated and must at the same time fulfil the conditions necessary to maintain the water balance. At low operating temperatures a higher quantity of air is necessary than at higher operating temperatures in order to permit the process water created to be absorbed. The air stoichiometry measured at the cathode outlet can lie between 1.2 and 1.4. In addition it can be necessary to drive out the condensate arising during operating of the fuel cell by periodically increasing the air flow. If the fuel cell is operated at a cathode outlet temperature of > 55 C, active humidification of the cathode gas offers advantages in respect of the output and service life of the fuel cell.

4.3

Critical operating states

These operating states lead to irreversible damaging of the fuel cell even if they act only for a very short time and must be avoided in all circumstances:

1.

Depletion of the fuel under load as caused, for example, by throttling or shutting off of the hydrogen supply.

2.

Presence of air on the anode side. This operating state can be caused by "open anode" mode (i.e. not "dead-end mode") coupled with an inadequate supply of hydrogen. The fuel cell then sucks in air via the anode outlet. This causes the catalyst on the anode side to be oxidized and thereby permanently damaged.

3.

Overheating of the fuel cell stack. At T > 75 C (in operation), the membranes can be destroyed if there is inadequate humidification. The temperature of the cathode exhaust air should always be kept below 75 C.

4.

Short circuit or, as the case may be, very low total voltage (below 75 % of the nominal voltage). In this operating state it is very probable that a number of cells change their polarity. Such a "pole-changing" leads to permanent damage to the fuel cell. Operating states at < 75 % of the nominal voltage may only be set for a restricted period. At the same time care must be taken that the fuel cell is not thermally overloaded and that the individual cell voltage does not fall below 0.3 V.

Manual for Schunk Fuel Cell Stacks

Further disadvantageous operating modes, which can lead to a reduction in service life / output, are: OCV (open circuit voltage) mode Frequent switching operations in which the maximum current (see data sheet) is exceeded Inadequate or excessive humidification Unfavourable installation position resulting in the flowing out of the condensate being hindered All substances which damage the membranes or catalysts6 Important: If permanently damaged, the pole-changed cell will generate not electricity but hydrogen (electrolysis). In such a case hydrogen can be detected in the cathode exhaust gas during operating of the fuel cell even though the FC-42 continues to be tight from the anode side to the cathode side. In this case the fuel cell is no longer operationally safe and must be sent back to the manufacturer for disposal.

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4.4

Monitoring
During operating of the fuel cell the following values should be monitored at all times:

Voltage of the fuel cell (in the case of bundling the total voltage of a bundle) Current of the fuel cell (in the case of bundling the current of each individual cell stack) Difference in temperature between return flow and outward flow of the cooling liquid Temperature of the fuel cell measured in the cathode exhaust air, directly at the outlet of the stack Consumption of hydrogen If one of the values as measured lies outside the particular permissible range (see data sheet), the fuel cell is to be switched off immediately and separated from the load. Please check that all the connections with the fuel cell are in good order and that the fuel cell is being supplied with all operating media; in addition check your

If a suitable filter (see section 3.3) is installed where the cathode air is drawn in, no contamination from the environment can reach the cells.

Manual for Schunk Fuel Cell Stacks

system for malfunctions. The consumption of hydrogen should lie within 5 % of the calculated value in one interval. Note: The hydrogen consumption is calculated from the number of individual cells and the current. The following holds good: Mass H2 needed in order to generate a current of 1 A for one hour at one cell: 0.03765 g (i.e. mH2 = 23.72 g/h with 42 cells and 15 A). Under conditions close to the ambient pressure and temperature the consumption of hydrogen is: 7 ml/min/cell/A.
7

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4.5

Switching on
When switching on the fuel cell the following sequence is to be followed:

1. Switch on cooling 2. Switch on air supply 3. Switch on hydrogen supply 4. Purge anode with hydrogen 5. Check the open-circuit voltage (should be > 35 V) 6. Switch on electrical load

4.6

Switching off
When switching off the fuel cell the following sequence is to be followed:

1. Disconnect electrical load 2. Shut off hydrogen feed 3. Open anode outlet (purge valve) 4. Shut off supply of air (fuel cell is now depressurized) 5. Switch off cooling (switching off the cooling in a time-delayed manner may be advisable)

See FAQs and Service questionnaire at www.schunk-fuelcells.com

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Storage
In general one has to differentiate between the storing of one individual fuel cell and the storing of a system in which the fuel cell is installed.

5.1

Storage of one individual fuel cell

If the fuel cell is not to be operated for more than 5 days, care must be taken that no microorganisms move in. Accordingly before storing it at room temperature the fuel cell should be heated up briefly to 75 C without electrical operation and then blown through with dry (40 % R.H. at 20 C 5 C) air that is free of oil and dust (for approx. 20 minutes, approx. 50 l/min) in order to dry it. Finally the media inlets and outlets should be closed with suitable blind plugs (e.g. from the plug kit available as an optional extra).

5.2

Storage / long-term switching-off of a complete system

Before a complete system is stored, the cathode is to be ventilated and thus depressurized. A filter mounted on the inlet side (see section 3.4) prevents contamination being able to get into the fuel cell. On the outlet side it must be ensured by means of a suitable mechanism that no coarse contamination from the ambient surroundings (chemical compounds, dust, insects) can get carried in. In general it is sufficient when the system is closed with a simple flap. Gastight sealing of the cathode is not necessary. Before the system is switched off and depressurized, anode and cathode should be freed of condensate by means of a suitable purging process (e.g. relatively long purging or postrunning of the cathode blower). After this the anode is depressurized via a valve. Ideally before the system is switched off permanently the anode should be subjected to controlled ventilation by the cathode blower until the open-circuit voltage has fallen to zero. If the fuel cell has not been in operation for > 5 days, it must be assumed that it will have to be operated for approx. 5 minutes until the full output is achieved through self-humidification. Approx. 50 - 60 % of the full output is to be reckoned on immediately after switching on.)

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Transport
If a fuel cell is transported in a moist state, it must be ensured that it is not subjected to temperatures in excess of or below the permitted temperatures (see data sheet). Ideally the fuel cell should be dried and protected against frost. A check can be made with the aid of appropriate temperature recording devices (e.g. "FreezeWatch" from 3M) as to whether the temperature fell below 0 C. The instructions given in section 5 (storage) should be followed in particular with extended transportation (> 5 days). The position of the fuel cell during transportation is optional but it should be packed with good padding to reduce the effect of impacts and high accelerations; acceleration sensors on the packing or on the fuel cell itself (e.g. "Shockwatch") can be fitted to display what acceleration the fuel cell was subjected to. Important! There can be residues of coolant in the fuel cell which should be removed (blown out) before transport. In addition it is recommended that all media connections are closed with blank plugs.

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7
7.1

Notes fr system integrators

General
The PEM fuel cells of type FC-42 are designed as a modular system and can be bundled together in a variety of ways in order to achieve the outputs and operating voltages desired. The desired constellation must be stated when ordering since the fuel cells are supplied bundled together in a turnkey state.

7.2

Electrical circuitry
The possibility of electricity being fed back into a FC-42 fuel cell (e.g. from other fuel cells in a module or from batteries in a hybrid system) must be reliably excluded. This can be achieved by means of, for example, a Schottky diode with a punchthrough voltage that is as low as possible (< 500 mV) and a load current that is as low as possible in the shut-off direction. In addition it is recommended that the fuel cell is isolated completely electrically with a suitable relay prior to extended "off" phases. Alternatively the individual overall voltage and the individual overall current can be monitored with a monitoring circuit and an individual load-shedding process activated in the case of a malfunction. Different levels of direct current and different classes of output can be achieved by bundling the fuel cells together in series or parallel in accordance with the circuit variants shown in the sketches.

Fig. 3: Different configurations of electrical circuitry (parallel / in series / parallel and in series)

Manual for Schunk Fuel Cell Stacks

There are 4 different operating modes: Voltage led: The voltage of the fuel cell is led in a forced manner and the current sets itself in accordance with the characteristic curve. In this mode overloading of the fuel cell is easy to avoid and an undervoltage can be easily excluded. Feeding back into the fuel cell must always be excluded. Current led: The current that is drawn from the fuel cell is set externally. Here care has to be taken that the voltage does not fall below the minimum working voltage of the fuel cell (see data sheet). Here too feedback into the fuel cell must be excluded. Output led: The desired output is set externally for the fuel cell. Here voltage and current set themselves dynamically in accordance with the characteristic curve. It must be ensured that current and voltage remain in the permitted working range and that no feedback into the fuel cell takes place. Resistance led: With a pure Ohmic load, current, voltage and the output supplied set themselves in accordance with Ohm's law and the dynamic characteristic curve. Current and voltage must lie in the permitted working range. Here a feedback from the load is not possible. Important: Even if an electrical feedback from the load is not possible, such a feedback can result from the coupling together of a number of fuel cell modules.

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Table 1: Different configurations of the output bundling

Voltage / V 24 48 72 96

Current / A Wattage, W and in brackets the number of FC-42 basic modules 15 30 45 60 360 (1) 720 (2) 1080 (3) 1440 (4) 720 (2) 1440 (4) 2160 (6) 1080 (3) 2160 (6) 1440 (4)

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7.3

Avoidance of open-circuit voltage mode

A situation in which the fuel cell remains in a state above 85 % of the open-circuit voltage for periods of more than 10 minutes has an unfavourable effect on its service life and efficiency. Accordingly in a hybrid system (battery / fuel cell) it is advantageous for the fuel cell to be switched off completely if the output falls below approx. 20 % of the nominal output. If the load is thrown off, the fuel cell should be changed to a zero-potential state. A cyclic operating mode with OCV mode (e.g. OCV - 0.5 V/cell - OCV) should also be avoided (i.e. to avoid frequent switching on and off of the fuel cell). The fuel cell can be discharged electrically with a low current (1 - 5 % of the nominal current) by, for example, putting a resistance into circuit.

7.4

Operating methods, mounting and installation position

Different operating methods are possible and the particular ones that are advantageous depend on the ambient conditions, system configuration and installation position of the stack.The standard counterflow configuration is the configuration with which good results are achieved in an unhumidified system (see Fig. 6). Other flow directions, which are matched to the particular operating conditions of the fuel cell, are possible. With all configurations care must be taken that the condensate created during operating is carried out completely and does not run back into the cell stack. (Standing condensate generally makes its present noticeable by a gentle "gurgling" sound). Accordingly only the following two installation positions are to be recommended:

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1. The fuel cell is stood on one of the cooling plates angled at 0 - 5 to the

horizontal.

2. The fuel cell is stood on one of the consumers (short face side) angled at

0 - 5 to the horizontal.
Fig. 4: Prescribed installation positions for the fuel cell (1. = left, 2. = right)

05

05

With both installation positions it is to be recommended that the cooling water flows upwards, i.e. from the bottom to the top, through the fuel cell whereas the outlets for air and hydrogen should be at a low point if possible (c.f. section 3.5 - media connections). Important: In no case may the fuel cell be secured by using the M5 holes in the end adapters. The forces acting through the use of these for securing can damage the fuel cell irreversibly. Instead a tensioning or clamping mechanism should be provided which surrounds the fuel cell and holds it firmly in position. The use of the M5 tapped hole on the face of the fuel cell for the mounting of light system components (e.g. diodes for the electrical isolation of the individual fuel cell stacks) does not represent a problem.

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7.5

Minimal system configuration

Fig. 5: The most important components for the operating of a fuel cell with and without cathode humidifier

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8
8.1

Methods for optimizing the efficiency

High-current mode
While being operated, FC-42 modules may be electrically "short-circuited" at intervals of not less than two minutes for a maximum of 200 ms. Such a high-current operation should be realized with a semiconductor relay (e.g. CRYDOM D1D40) or a MOSFET (e.g. MOSFET FQP85N06) since the contacts of a mechanical relay would fuse (the fuel cell is a capacitor with a high capacitance!). The brief high-current pulse can bring about an increase in efficiency of some 5 - 15 %.

8.2

Throttling of the cathode air

A brief (less than 500 ms) throttling down of the incoming stream of air when the fuel cell is under load can bring about an increase in efficiency of some 10 %. This procedure should be followed not more often than once every 2 minutes. In general the efficiency of PEM fuel cells is superior when they are operated dynamically rather than under constant conditions.

8.3

Humidifying of the cathode air

At temperatures in excess of approx. 50 C more water is removed from the fuel cell via the cathode exhaust air than is created by the reaction. As a result the membrane dries out and its efficiency falls. By humidifying the cathode air the water equilibrium can be kept stable over a wide temperature range. For a closed humidifying circuit it is necessary that the process water, that is contained in the cathode exhaust air to a large extent, is transferred to the flow of incoming air. A membrane exchanger can be used for this purpose. In analogous fashion the condensed and purified process water can be sprayed in via nozzles or injected in in the form of a mist with ultrasound. At the same time the spraying/injecting in of the water brings about a considerable cooling effect. With active feeding back of water it must be ensured that only pure, ionfree water is being recirculated.

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8.4

Humidifying of the anode gas

At high levels of output water is transported from the anode to the cathode by electro-osmosis. This can lead to the membrane drying out on the anode side so that the efficiency falls. Humidifying of the anode gas to a dew point of approx. 5 K below the cell stack temperature can lead to an increase in efficiency.

8.5

Regulating of the quantity of air

The moisture content balance of the fuel cell can be optimized by regulating the quantity of air as a function of the current and the temperature. In particular one can prevent thereby the cathode being flooded with excess water. This state is very critical at low temperatures. At high temperatures an excess of air can lead to the membrane drying out very rapidly.

Fig. 6: Ideal air stoichiometry for different levels of moisture content of the ambient air, plotted via the stack temperature (measured in the air flow of the cathode outlet).

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8.6

Purging cycles
At periodic intervals the anode must be purged in order to remove and carry out inert gases and/or condensate. The purging of the anode can be carried out by, for example, arranging that the outlet valve for the hydrogen is opened every 60 s for approx. 0.5 - 2 s at a preset primary pressure (e.g. 250 mbar).

8.7

Anode gas recirculation

Here the anode gas is transported from the anode outlet to the anode inlet with the aid of a gastight pump (e.g. a membrane pump). The ratio between the fresh gas fed in and the recirculated gas should be approx. 1:1. If recirculation is carried out in this way the purging intervals can be extended very considerably. It must be explicitly stated that the pump is resistant to hydrogen and water vapour.

8.8

Cathode air recirculation

A homogeneous distribution of moisture and efficient removal of condensate without drying out of the stack is achieved if a proportion of the cathode outlet air is fed back to the cathode inlet.

8.9

Media reversal
If the electrodes have become contaminated by, for example, contaminated reaction gases, a "cleaning" of the fuel cell can be brought about with the aid of a media reversal. In addition this operating mode is to be recommended in order to humidify the fuel cell uniformly in the situation that it has previously become too moist on the cathode side.

8.10 External humidification

If the fuel cell is being used for the first time following a relatively long period of storage, one must reckon on a period of time elapsing before the fuel cell has humidified itself and can produce its full output. This process can be accelerated by means of an external humidification system. With the aid of a conventional steam generator the fuel cell can be subjected to a throughflow of vapour from distilled water (!!!) via the existing media connections for approx. 2 - 3 minutes. When operating of the fuel cell is commenced thereafter, the full output will be available at an earlier stage.

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8.11 Manual drying of the fuel cell

If the electrodes of the fuel cell become too moist as a result of, for example, an inadequate flow of air or a too low temperature, then the fuel cell must generally be dried manually in order to restore its full efficiency again. To be recommended here is the use of the cathode blower in combination with an external power source. A Ypiece connection can be used in order to dry both cathode and anode at the same time. When drying the fuel cell care must be taken that the maximum pressure never exceeds 300 mbar.

Data log and operating proof

Should it be wished to advance a claim under warranty, then proof must be presented that the fuel cell was not being operated under pathological conditions (e.g. excess temperature, undervoltage, hydrogen deficiency, contamination etc.). The proof is to be presented in the form of a data log without gaps of the fault scenario whereby the log should include the period prior to the occurrence of the fault, this period to be > 15 minutes and whereby it should include the following measurement parameters: Sampling rate 1 Hz for all measurement parameters Voltage at the power lugs of the fuel cell Current at each individual stack of the fuel cell Temperature of the return-flow cooling water Temperature at the outlet from the cathode In view of the very considerable burden recording of the above data places on the fault-recording memory, it should be noted that recording of merely the minimum and maximum values of the above parameters is sufficient to prove that the fuel cell was not operating / being operated properly. Similarly proof must be presented that the anode was supplied exclusively with hydrogen of the required quality (c.f. section 3.2). For the supply of air to the cathode proof must be presented that filters were installed that were capable of absorbing to an adequate extent all the organic and inorganic contamination.

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10 Searching for leaks

10.1 External leakage of the reaction gases
In order to prove whether the fuel cell is leaking into the ambient surroundings (external leak) from the anode or the cathode, the following quantitative method can be used: Close both the anode and cathode outlets (e.g. with suitable blank plugs) in a gastight manner Subject anode and cathode via a common pressure line (e.g. with a T-piece) to a test pressure of 100 mbar, using air as the testing medium. Close the common pressure line in a gastight manner (by clamping or with the aid of a suitable shut-off valve). Measure with a pressure gauge and a stopwatch the time that elapses for the pressure in the closed space to fall from 100 mbar to 50 mbar. This time should be longer than that stated in the data sheet.

10.2 External leakage of the cooling medium

In order to prove whether the cooling circuit is leaking into the ambient surroundings (external leak), the following quantitative method can be used: Close the coolant outlet (e.g. with a suitable blank plug) in a gastight manner. Subject the cooling system to a test pressure of 100 mbar, using air as the testing medium. Close the pressure line in a gastight manner (by clamping or with the aid of a suitable shut-off valve). Measure with a pressure gauge and a stopwatch the time that elapses for the pressure in the closed space to fall from 100 mbar to 50 mbar. This time should be longer than that stated in the data sheet.

10.3 Internal leakage of the reaction gas

In order to prove whether the reaction gas can leak from the anode side to the cathode side, the following quantitative method can be used: Close the anode outlet (e.g. with a suitable blank plug) in a gastight manner. The cathode should be left open to the ambient surroundings.

Manu for Schunk Fuel Cell Stac ual cks

Subject the anode side to a tes pressure of 100 mbar, using air as the testing S e st e g medium. ine in a gastight man nner (by cla amping or with the aid of a sui r a itable Close the pressure li alve). shut-off va Measure w with a press sure gauge and a sto e opwatch th time tha elapses for the he at f pressure in the close space to fall from 100 mbar to 50 mbar. This tim should be n ed o r me longer tha that stat an ted in the d data sheet.

30

11 D Dispos sal
The fuel ce is to be returned to the man ell e nufacturer for dispos sal.

12 O Option extr nal ras

In addition to the fuel cell itself, the follo n owing acce essories may be obta ained on request: Plug kit: T kit contains all th screw pl The he lugs (in a r rapid-conn nection for of rm execution) and blank plugs needed for the closing of the me ) k edia connec ctions on a an FC-42 tha are not n at needed. Carrier: Th device c he carrier hold FC-42 fuel cells w ds f with capacities between 360 and 1440 Watt in the op ts ptimum ins stallation position an permits the fuel cell to be p nd s c reliably mo ounted in a complete system. The scope of delivery includes a screw-in kit e T y n specially m matched to the carrie permitting space-saving inst o er tallation.
Fi 7: Carrier for FC-42 fu cells ig. r uel

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13 Faultfinding and remedies

Table 2: Faults and remedies
No Fault description No potential cause No Measures / checks Check that the cathode blower is generating an adequate volumetric flow taking into account all pressure losses (pipe system, filter, fuel cell etc.) Check that the cathode supply system is free of condensate Check that the regulating of the quantity of air is taking place properly. Notes / further measures

1 1 Supply of air inadequate

2 3

For production of a suitable air supply see sections 3.3 and 4.2 and the data sheet

1 2 Supply of hydrogen inadequate

2 3 1

Check that the hydrogen supply is generating an adequate volumetric flow taking into account For production of a all pressure losses suitable hydrogen Check that the pressure level of the hydrogen supply see sections 3.2 supply lies in the given working range. and 4.1 and the data sheet Check that the anode is being adequately purged, i.e. to ensure removal of condensate and inert gas Check that the air supply is sufficient to prevent condensate forming Check that the fuel cell is mounted in the optimum installation position. For installation position see section 7.4

The electrodes are too moist

2 3 4 1

The output of the fuel cell is too low 4 The electrodes are too dry

Check that the fuel cell is reaching an adequate working temperature Dry the fuel cell, e.g. with the aid of the cathode See section 8.11 blower Is the supply of air to the fuel cell so high that it is drying out? Is the working temperature of the fuel cell too high? Humidify the fuel cell before commissioning it after an extended period of storage with the aid of a steam generator Check that the current being drawn from the fuel cell is not too high Check that the fuel cell is not being operated at a working voltage that is too low Check the mechanical connecting of the electrical contacts. Check that the electrical connection is not generating heat during operating. Check that the electrical connection is not showing a voltage drop. Check that no corrosion is visible on the electrical contacts. Check that the hydrogen being supplied is of adequate purity. Check that there is no contamination in the cathode air. Carry out a media reversal in order to clean the electrodes

2 3

See section 8.10

The electrical working point is unsuitable

1 2 1

The electrical connection is inadequate

2 3 4 1

For further information on the electrical connecting see section 7.2

See section 3.2 See section 3.3 See section 8.9

The electrodes are contaminated

2 3

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No

Fault description

No

potential cause There is a parasitic electrical load on the fuel cell Supply of air is inadequate Supply of hydrogen is inadequate The electrical connection is inadequate The electrodes are contaminated

No 1 2 1 1

Measures / checks Check that the fuel cell is completely separated from all consumers. Check the electrical connections for creepage and short circuits See above (measures under 1.1) See above (measures under 1.2)

Notes / further measures

2 3

See sections 3.3 and 4.2 See sections 3.2 and 4.1

4 The fuel cell does not reach the specified open-circuit voltage

See above (measures under 1.6)

See section 7.2

1 1

See above (measures under 1.7) Check whether the fuel cell generates heat without being under load Check the time for the voltage to decrease under separated load compared with the figure in the data sheet Check the electrical connections for creepage and short circuits Check whether the fuel cell generates heat without being under load Check the time for the voltage to decrease under separated load compared with the figure in the data sheet Check the time for the pressure at the anode to decrease in comparison with the figure in the data sheet Operate the fuel cell in the given voltage range Operate the fuel cell in the given current range Check the load profile in respect of time Check that the coolant pump supplies an adequate volumetric flow that takes account of the given pressure losses of the complete pipe system, of the fuel cell and of the cooler Check that there is no contamination in the cooling system Check that the coolant being used is suitable Check that the coolant pump is not sucking in air Vent the cooling circuit Check that the coolant pump is not sucking in air Check the piping system for leaks Check the fuel cell for internal leaks Check the piping system for leaks. Check the fuel cell for internal leaks

See section 8.9

The fuel cell has an internal short circuit

2 3 1

If an internal short circuit is established, then the fuel cell must be replaced

The fuel cell has an internal leak

3 The electrical working point selected is not suitable 1 2 3

If an internal leak is established, then the fuel cell must be returned to the manufacturer for repair or to be exchanged.

1 The supply of coolant is too low / the temperature of the coolant is too high

2 3 The fuel cell becomes too hot

2 3 4

See section 3.4

There are inclusions of air in the cooling circuit Hydrogen is getting to the cathode Air is getting to the anode

1 2 1 2 1 2

See section 10.3

See section 10.3

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No

Fault description

No

potential cause Only a low electrical output is being taken from the fuel cell

No 1

Measures / checks Increase the electrical output being drawn Improve the insulation of the system Reduce the cooling output; in certain circumstances it may be necessary to put a bypass to the heat exchanger into circuit Check that the media is flowing around the sensors Measure the temperatures at the cathode outlet and in the coolant circuit Reduce the cooling output; in certain circumstances it may be necessary to put a bypass to the heat exchanger into circuit

Notes / further measures

2 3 1 2

The fuel cell remains too cold

The measurement of temperature is faulty The cooling output is too high

14 Standards (selection)

Table 3: Standards (seletion)

IEC 62282-2 IEC 60079 (alle) IEC 60352 (alle) IEC 60529

Fuel cell technologies, Part 2: Fuel cell modules Electrical apparatus for explosive gas atmospheres Solderless connections Degrees of protection provided by enclosures

An overview on all the standards to be applied is given in IEC 62282-2.

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15 Literature
Mrz 2006 James Larminie; Andrew Dicks, Fuel Cell Systems explained, second edition,

Heinzel, Angelika; Mahlendorf, Falko; Roes, Juergen, Brennstoffzellen Entwicklung, Technologie, Anwendung, 3. Aufl., Heidelberg 2006 U.S. Department of Energy, Fuel Cell Handbook Seventh Edition by EG&G Technical Services, Inc., 2004

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16 Data sheet
Table 4: Data sheet for Schunk fuel cells

Ambient conditions Storage temperature (dry unit) Ambient temperature during operating Relative humidity of ambient air (operating and storage) Operating conditions Operating temperature (not humidified) Operating temperature (humidified, dew point approx. 5 - 10 K below stack temperature) Max. temperature of the surfaces Electrical properties Nominal current * Nominal voltage * Nominal output * Minimum voltage (briefly, 5 s) Open-circuit voltage Service life ***** Mechanical properties Mass Dimensions LxWxH Interfaces Electrical connection Max. tightening moment Media Purity of hydrogen Hydrogen consumption Max. pressure drop, anode * Max. pressure drop, cathode * Process water generated at full load * Max. inlet pressure, anode Oxygen content of feed air Air consumption 99.99 0-4 15 30 180 300 20 - 30 0 - 40 %, no Co l/min mbar mbar g/h mbar Vol.-% l/min M5-female screw thread 2 Nm 2100 188 x 130 x 53 g mm 15 24 360 15 36 - 42 > 1500 A V W V V h 75 C 5 - 50 < 70 C C -10 bis +50 5 - 70 40 - 95, not condensing C C %

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Media (continuation) Max. inlet pressure, cathode Max. pressure difference, anode/cathode Max. gas temperature at inlet **** Minimum gas temperature at inlet **** Max. gas temperature at outlet **** Gas leakage, anode to cathode ** Gas leakage to outside *** Leakage, coolant system to outside *** Cooling medium Coolant throughput Max. pressure drop, coolant Max. temperature difference, return flow outward flow in the coolant Max. coolant pressure
* ** *** **** Can vary by 15 % Time for the cathode-anode pressure difference to change from 100 mbar to 50 mbar with air as testing medium; see also leak rate measurement further below. from 100 mbar to 50 mbar with air as testing medium. Holds good for anode and cathode. Time for the cathode and anode pressure difference vis vis ambient surroundings to change

300 300 65 5 75 > 300 > 900 > 600 water/ glycol >0,5 300 5 1

mbar mbar C C C s s s l/min mbar K bar

*****

After the specified time the output is at least 90 % of the nominal output. The precondition for the validity of this statement is that the fuel cell has not been operated under pathological proof of this is to be kept up with a complete data log (see section 12 - data log). conditions (e.g. excess temperature, undervoltage, hydrogen depletion, contamination etc.). The

****** The voltage drop is measured on the basis of the current OCV.

Important: All statements in the data sheet are typical average values and are based on measurements made under ideal conditions. The values stated are guide-line values and are not guaranteed.

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Fig. 8: U/I characteristic curve for Schunk FC-42 fuel cells

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The manual is protected by copyright. The rights justified thereby and in particular the rights in connection with the manual of translating, printing, removing figures therefrom, transmitting by remain reserved. radio, reproducing by photo-mechanical or similar means and storing in data processing systems

If a new version of this manual is published, then all earlier versions lose their validity. Each and every liability of the supplier is excluded for damage or loss that results from improper operation or unprofessional installation.

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Rev 2.0 [eng] (04/2008)

Schunk Bahn- und Industrietechnik GmbH Hauptstrae 97 35435 Wettenberg www.schunk-sbiw.com fuelcellstacks@schunk-group.com