h2 E3 Test Station Version 1 Om Manual

Fuel Cell Test Station
Operation and Maintenance Guide
Prepared by Schatz Energy Research Center

as part of the
Hydrogen Energy in Engineering Education (H2E3) project
2009 Schatz Energy Research Center
Preface
This manual is provided by Schatz Energy Research Center to assist users of our fuel cell
test stations developed as part of the Hydrogen Energy in Engineering Education (H2E3)
project. These test stations include many of the features and capabilities found in our
research-grade test stations. However, the H2E3 test stations are intended only for short-
term (e.g. single three-hour lab period), attended operation. Users are responsible for
reading and understanding this manual in its entirety before operating the test stations.
Acknowledgements
The H2E3 project and the development of this fuel cell test station are supported in part by
a grant from the U.S. Department of Energy.
Contact Information
If test station users have any questions or problems regarding this equipment, please
contact the Schatz Energy Research Center:
tel: (707) 826-4345
fax: (707) 826-4347
email: serc@humboldt.edu
web: www.schatzlab.org
Table of Contents
I. Test Station Description

II. Test Station Software
III. Test Station Operation
IV. Troubleshooting
V. System Maintenance
VI. Safe Practices for Test Station Users
Appendices
Test Station Subsystem Diagrams
Data Acquisition and Control Input/Output List and Calibrations
SERC Software Read Me.pdf file
Hydrogen Material Safety Data Sheet
Component Documents
Operations and Maintenance Manual Chapter I
H2E3 Fuel Cell Test Station Test Station Description
Chapter I: Test Station Description
This PEM Fuel Cell Test Station (hereinafter simply referred to as the test station) was
designed and built by the Schatz Energy Research Center (SERC) as part of the
Hydrogen Energy in Engineering Education (H2E3) project, jointly funded by the U.S.
Department of Energy and SERC. The test stations intended purpose is to allow
undergraduate engineering students to gain hands-on experience in testing proton
exchange membrane (PEM) fuel cell stacks.
This compact test station emulates many of the features found on research-grade test
stations built by SERC and others, while emphasizing simplicity and safety for
inexperienced operators. The test station is designed only for attended operation over
short periods, not to exceed a three-hour lab period. The test station is designed to
accommodate low pressure, dead-ended hydrogen fuel cells at a maximum power of 500
W. It is designed specifically for operation with an eight-cell, 300 cm2 stack made by
SERC and provided with the test station. To ensure safety and to preserve the equipment,
please consult with SERC before operating other fuel cells on this test station. The test
station is shown in Figure I-1.
I-1
Figure I-1. Test Station
The purpose of this chapter is to provide an overview of the test station and its major
components, and to describe the support resources and infrastructure necessary to operate
the test station and the fuel cell supplied by SERC. The test station consists of eight
integrated systems mounted on a portable test bench. The systems include:
A. Air System. The oxygen in air acts as a reactant with the hydrogen in the fuel
cell, producing water and releasing electrical energy. This system provides air
from a high-pressure cylinder through a mass flow controller and into the stack.
B. Hydrogen System. Hydrogen is the fuel that powers PEM fuel cells. The
hydrogen system stores hydrogen in a high-pressure cylinder and reduces the
pressure to a level appropriate for delivery to the fuel cell stack.
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C. Water System. Water is used as a heat transport medium in the test station to
either heat or cool the fuel cell using electric resistance heating and a heat
exchanger with fan. Water also circulates through the internal humidification
section of the stack to humidify the incoming air stream.
D. Electrical System. AC and DC electric power are used to operate the test
stations instrumentation. The electrical system also includes an electronic load
used to absorb and control power produced by the fuel cell stack.
E. Fuel Cell Stack. The station comes equipped with an eight-cell, 300 cm2 fuel cell
stack. The stack is internally humidified and uses dead-ended hydrogen feed.
F. Monitoring and Control Hardware. Analog and digital data acquisition
hardware is used to monitor and control the test station in combination with a
user-supplied laptop computer.
G. Test station Software. Test station operation is controlled and monitored using
custom LabVIEW-based software loaded on the users computer.
H. Safety Control System. A number of hardware and software controlled safety
shutdowns ensure safe operation of the test station.
A detailed description of each system is given below. Detailed specifications for the test
station and schematic drawings of the individual systems are included in Appendix A.
Specification sheets and user manuals for individual test station components are also
provided.
The system must have continuous adequate ventilation when operating. Ideally a
ventilation hood should be installed above the test bench. If the hydrogen sensor is
triggered, the test station safety circuit disconnects all AC powered devices.
The user supplies air, hydrogen and water to the test station. The user must also provide a
safe method to handle the exhaust air, water drainage and vented hydrogen from the test
station. The stack exhaust air, water drain and overflow from the water system, and water
from the hydrogen purge knockout can be either routed to a floor drain or collected in a
reservoir or bucket behind the bench. The hydrogen gas vented from the purge system
must exhaust to an appropriate ventilation exhaust system or be directed outdoors through
an open door, window, or other penetration to outdoors.
A. Air System
Located on the right hand side of the bench, the air supply system supplies high purity air
from a high-pressure Compressed Gas Association-approved Size 44 cylinder to the fuel
cell stack.
The high-pressure air from the cylinder enters a two-stage regulator set to deliver air at
60 psig. The air then passes via a flex hose to a mass flow controller, which controls the
desired flow rate to the stack up to 50 slm. A display module mounted on the controller
provides local flow indication. Downstream of the controller is a 3-way supply solenoid
valve that determines when air is directed to the stack. When closed (or de-energized) the
solenoid valve is positioned to port any air that may have leaked by the mass flow
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controller and vent it out the brass port to the atmosphere. A pressure gauge (0-60 inches
of water column) provides local indication of fuel cell air backpressure. Air flows from
the plumbing system through a hose and connects to the air inlet fitting on the stack.
See Figure I-2 for a photo of the air supply system.
Figure I-2. Air Supply System
B. Hydrogen System
The hydrogen system supplies hydrogen gas from a high-pressure cylinder to the fuel cell
stack, reducing the gas pressure to an appropriate level along the way. Hydrogen system
plumbing is located on the back left side of the bench. A cylinder rack attached to the left
side of the test station bench is designed to hold Compressed Gas Association-approved
Size 44 cylinder.
The high-pressure gas from the cylinder enters a two-stage regulator set to deliver gas at
100 psig. The gas then passes via a flex hose to a mass flow meter, which senses flow
over a 0-20 slm range. A display module mounted on the meter provides flow indication.
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Gas supply pressure is then reduced from header line pressure to 2.7 - 5.0 psig by a
single-stage low-pressure regulator. A pressure relief valve is built into the regulator and
provides downstream overpressure protection for the fuel cell. The relief valve is
designed to discharge at 3.8 to 12.5 psig above the outlet pressure setting. After passing
through the regulator, flow to the fuel cell is controlled by a supply solenoid valve. A 0-
15 psig pressure gauge provides local indication of fuel cell gas pressure.
When a fuel cell stack is running, periodic purges of the hydrogen gas remove water
accumulated on the anode side of each cell in the stack. The purge section of the
hydrogen system is located on the outlet of the fuel cell and includes a purge solenoid
valve and a purge drum. The purge drum is mounted to the test station below and behind
the bench and has a manual drain valve and a vent line that is always open to the
atmosphere. During a purge, hydrogen gas flow increases rapidly and pushes water from
the fuel cell through the purge solenoid valve and into the purge drum. Liquid water
separates from the gas stream and hydrogen is vented through the low-pressure vent line.
The water accumulates in the drum and should be drained using the manual valve on the
drain line when necessary. See Figure I-3 for a photo of the hydrogen delivery plumbing.
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Figure I-3. Hydrogen Delivery System
C. Water System
Deionized (DI) water enters the test station water header through a blue-handled manual
valve. Water addition to the water circulation system is accomplished using an automatic
solenoid valve that is triggered by a float switch in the water reservoir. Water is
circulated in a closed loop system to control the temperature of the water exiting the fuel
cell stack. When temperature control is enabled, the system will either heat or cool the
water based on the fuel cell temperature set point. An inline heater will heat the water or
a cooling fan mounted to the heat exchanger will cool the water before it enters the fuel
cell stack.
The water flow rate can be manually throttled with a valve located at the pump outlet.
Flow indication is provided by a rotameter downstream of the throttle valve. If water
circulation is too low or stops completely while the stack is running, stack temperature
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will rise and the cooling fans will run. If the fans are unable to prevent the fuel cell
temperature from rising, the system will shut down on high fuel cell temperature.
Excessive operation of the cooling fan may indicate a problem with cooling flow.
A deionizing cartridge removes unwanted ions from the circulating water prior to
entering the fuel cell. Both the deionizing cartridge and its housing are rated for water
temperatures up to 70C. A water conductivity testlight provides water quality indication,
letting the operator know when the resin cartridge needs replacement. If conductivity
exceeds 200 kOhms-cm, the light will not be lit and the deionizing cartridge will require
replacement. A 0-15 psig pressure gauge provides local indication of water supply
pressure. Abnormally high pressure may indicate excessive water flow or improper quick
connect connection. See Figure I-4 for a photo of the water system plumbing seen from
the front of the test station. Figure I-5 shows additional components of the water system
plumbing as seen from the rear.
Figure I-4. Water System Plumbing (front view).

Arrows show direction of water circulation
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Figure I-5. Water System Plumbing (rear view)

Arrows show direction of water circulation
D. Electrical System and Electronic Load

Power is provided to the test bench via a 15A, 120VAC standard connector. A single 15
amp input breaker located on the front of the test station, adjacent to the hydrogen alarm
indicator panel, controls 120VAC test station power. (See Figure I-6).
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Figure I-6. Hydrogen Alarm Panel and Main Power Switch

A 120VAC 15A (minimum) standard wall outlet provides the test stations incoming AC
power. The electrical components include an over current protection breaker and fuses,
solid-state relays, bench-mounted AC outlets, a 24V DC power supply, a water pump,
water heater, heat exchanger cooling fan, electrically operated solenoid valves, sensors,
and an electronic load. Note that the bench-mounted AC outlets are overcurrent-
protected by a 6A fuse. These outlets are intended to power a laptop computer or desktop
computer and monitor and should not be used as utility outlets for loads in excess of ~500
W.
The system provides electric power to the pump, heater, fan, solenoids and sensors that
are integrated within the hydrogen, air, and water subsystems. The other electrical
components are mounted on the shelf beneath the benchtop. Key electrical components
include several DIN-rail mounted devices (See Figure I-7) and solid state relays (see
Figure I-8). The relays are individually labeled to show which load they control.
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Figure I-7. DIN-Rail Mounted Devices
Figure I-8. Solid State Relays
The fuel cell stack is connected to an electronic load module, configured to operate at
600W maximum power with a maximum current of 160 amps (See Figure I-9). The
electronic load is mounted on the left side of the test station on the shelf beneath the
benchtop directly behind the hydrogen alarm. The electronic loads operating modes
include Constant Current, IV Curve, and Load Profile. The load is equipped with an
internal high temperature shutdown. The electronic load is controlled using an analog
output voltage control signal and an active feedback control algorithm. Note that the load
is protected by a set of -A fuses. If a fuel cell stack is connected with reversed polarity,
these fuses will blow and need to be replaced; contact SERC for assistance.
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Figure I-9. Electronic Load
E. Fuel Cell Stack

The test station includes an 8-cell, 300 cm2 fuel cell stack built by Schatz Energy
Research Center. See Figure I-10. The stack operates at low air and hydrogen pressure
and has an internal air humidification section located on the right end of the stack. See
Chapter III (Test Station Operation) for a detailed description of the stack and its
connections to the test station.
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Figure I-10. Fuel Cell Stack
F. Monitoring and Control Hardware

An end-user-supplied laptop computer running Windows and equipped with National
Instruments Measurement and Automation Explorer (MAX) driver software and supplied
test station software and connected to the test station via a USB port is used to monitor
and control the test station. The data acquisition and signal conditioning system
incorporates analog and digital inputs and outputs.
One multi-function analog I/O device handles all data acquisition and control signals
except for four thermocouples, which are read by a second I/O device. Most analog
signals are conditioned in software; thermocouple signals are conditioned and cold
junction compensated by Omega thermocouple transmitters or National Instruments
DAQ hardware. Digital outputs are actuated via TTL-activated, isolated solid-state relay
modules. Figure I-11 shows the data acquisition modules mounted on the middle shelf.
I-12
Figure I-11. Data Acquisition Modules
G. Test Station Software

LabVIEW, produced by National Instruments Corporation, is the programming
language used to write the software that controls and monitors the test station. In order to
operate, maintain and modify the test station software, it is necessary to have some
understanding of the LabVIEW programming environment.
LabVIEW programmers interact with two different interfaces, namely the front panel
and the block diagram. The front panel is the operator interface used to control and
monitor the test station. A test station operator need only interact with the front panel. A
hardware state, configurable parameter, or safety condition can be manipulated using the
controls on the front panel, and physical phenomena are measured and displayed using
indicators and graphs on the front panel. The controls and indicators are organized by
subsystem and arranged by color. Figure I-12 is a screen shot of the test station software
front panels along with the location of the controls and indicators for each subsystem.
The right-hand portion of the front panel consists of a set of tabs with associated displays
corresponding to the cooling/heating, hydrogen, air, load, and safety subsystems and data
file operations. The top right-hand portion of the front panel includes tabs corresponding
to real-time fuel cell data display, voltage taps display (voltages of individual cells or cell
blocks), a continuously updated graph of cell voltage vs. time, and an A vs. B tab that
allows any two listed variables to be graphed against one another.
I-13
Figure I-12. Software Front Panel
H. Safety Control System

The test stations safety control system consists of a hydrogen alarm that will
automatically shut down power to the station if triggered, and a set of software-controlled
safeties that will shut down the station in the event of a fault such as high fuel cell
temperature or low fuel cell voltage. The test station is designed to be intrinsically safe
but nevertheless should never be operated without the software safeties enabled.
The software handles all faults other than hydrogen leak detection. The test station
operator can select whether a low-level fault is enabled and the threshold for triggering
the fault in the SAFETY SETTINGS (see Chapter II). If a low-level fault occurs, the control
system opens individual solid-state relays, thereby placing all hardware in a safe state
(solenoid valves closed, heater and pump off, etc.)
In the event of a problem during test station operation, the operator has two options for
shutting the station down:
1. Normal Shutdown
During a normal shutdown of the test station, initiated by pressing the PROGRAM
SHUTDOWN button on the software front panel, all hardware for that test station will be
placed in a safe state (solenoid valves closed, heater and pump off, etc.).
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2. Emergency Shutdown
Should an emergency arise, turning off the main power breaker (on the left front of the
test station, beneath the benchtop) will shut off all power supplied to the test station.
Caution: Know the location of the building circuit breaker for the outlet used to power
! the test station and make sure you have access to it. Should a condition arise that inhibits
your access to the test station, such as a fire, turn off power to the test station from the
building circuit breaker panel.
Caution: The bench-mounted AC outlets, the water conductivity sensor, 24V DC power,
! and the hydrogen alarm itself remain powered on in the event that the hydrogen sensor
triggers a test station shutdown.
IMPORTANT: Cutting all power to the test station will not necessarily
power down a laptop computer, as it has an internal battery.
I. System Requirements
The test station requires 1) air supply and exhaust, 2) hydrogen gas supply and venting,
3) deionized water supply and drainage and 4) power. Fuel cell requirements are given in
terms of pressure, flow, temperature, and hydrogen-oxygen stoichiometry as discussed
below.
IMPORTANT: If test station users make any changes to the configuration of
! the test station or its constituent systems, they need to understand the
importance of maintaining air and water quality and the integrity of all
plumbing, especially the hydrogen supply and venting system.
1. Test Station Requirements
Air Supply and Exhaust

The test bench is equipped with a cylinder rack mounted on the right side of the bench
along with a cylinder regulator and flex hose. The user must supply the air cylinder with
the appropriate purity. Commercially available compressed air is generally of sufficient
purity, but make sure the gas is free of metals and sulfur and that carbon monoxide (CO)
and total hydrocarbon (THC) levels do not exceed 1 part per million (ppm). The cylinder
with a regulator and flexible hose is used to supply air to the plumbing system. The
cylinder regulator should be adjusted to deliver gases at 60 psig. A 1 hose exits the stack
carrying warm exhaust air and water to the back of the bench. The end of the exhaust
hose should be directed into a floor drain or alternatively into a bucket filled with water
up to a level a few inches above the open end of the hose. Excessive water levels should
be avoided to minimize backpressure in the air system.
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Hydrogen Gas Supply and Venting

The test bench is also equipped with a cylinder rack mounted on the left side of the bench
along with a cylinder regulator and flex hose. The user must supply the hydrogen
cylinder with the appropriate purity, at least 99.95%. A cylinder with a regulator and
flexible hose for hydrogen can be used to supply gas to the hydrogen plumbing. The
cylinder regulator should be adjusted to deliver gases at 100 psig. A vent hose or
tubing is used to vent gas from the hydrogen system. The line carries purged hydrogen
from the purge drum and from the hydrogen supply pressure regulator relief valve. The
vent line must be vented to an appropriate ventilation system or to the outdoors by the
most direct route feasible.
Deionized Water Supply and Drainage

The test station user must provide a treatment system that delivers filtered deionized
water to the test station. The water must be particle-free and have a conductivity of 5 S
or less. The supply line should be connected to the blue-handled makeup water manual
valve at the back of the test station. A 3/8 drain hose from the DI water system is
located on the back of the bench. The hose from the water system drain valve and
reservoir overflow should be directed into a floor drain or the same bucket used for air
exhaust.
Power Supply
Power must be provided to the test bench from a 15A, 120 VAC, 60 Hz circuit in the
buildings electrical service.
2. Fuel Cell Requirements

To safely operate the fuel cell stack provided, adhere to the following recommendations.
IMPORTANT: Operate the stack at steady-state temperature at least once a
! month. This will maintain hydration of the stacks membrane electrode
assemblies (MEAs), which may significantly extend stack lifetime.
Air Supply
As noted above, commercially available compressed air is generally of sufficient
purity, but make sure the gas is free of metals and sulfur and that carbon monoxide
(CO) and total hydrocarbon (THC) levels do not exceed 1 part per million (ppm).
Air inlet pressure must not exceed 6 psig.
The air temperature upstream of the fuel cell should be kept above 0C at all times.
During continuous operation the airflow should be maintained at 200% to 350%
stoichiometry (2 to 3.5 * 0.01659 slm/(Amp-cell)).
The airflow rate must always exceed 0.5 slm/cell when fuel cell current exceeds 0
Amps.
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Hydrogen Supply
Hydrogen supplied to the test station must be industrial grade (min. 99.95% pure).
Hydrogen must be free of carbon monoxide, hydrogen sulfide, hydrocarbons and
other catalyst poisons.
The hydrogen delivery pressure must not exceed 6 psig.
Hydrogen purges of approximately 1 second duration must be provided at 1 to 20
minute intervals, depending on current density.
Water Circulation/Temperature Control

The water flow rate must be between 0.2 and 0.4 gpm, depending on stack power and
water pressure.
Water temperature should be controlled to 50 to 65C.
The water temperature at the fuel cell inlet must be higher than 5C.
Fuel cell stack temperature must not exceed 65C when using a SERC stack.
Water pressure at fuel cell inlet must not exceed 3 psig.
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Operations and Maintenance Manual Chapter II
H2E3 Fuel Cell Test Station Test Stand Software
Chapter II: Test Station Software

This chapter describes the test station control software that is used to control and monitor
the test station sub-systems and fuel cells.
A. Software Description
LabVIEW, produced by National Instruments Corporation, is a programming language
used in industrial and laboratory automation. The test station software is written in the
LabVIEW programming environment and compiled as a stand-alone application
program. The application requires LabVIEW Runtime Environment 7.1.1 and NI
Measurement and Automation Explorer (NI-MAX) version 8.6 or later to operate.
Experience with LabVIEW is not required to operate the test station software.
The test station user will need to install the software on the user-supplied computer used
with the test station. See the SERC Software Read Me.pdf file provided on the supplied
software disc (and reproduced in the appendix to this manual) for full instructions on
installing the software.
1. Control Software Interface
The screen is divided into four main areas. The upper left panel is the data display
section, with indicators for viewing real-time fuel cell operating parameters, including
stack voltage, current, power, and temperatures; gas flow rates; cumulative fuel cell run
time and amp-hours generated; and individual cell block voltages. The lower right panel
is the control section, consisting of a set of tabs where settings can be made for the water,
air, and hydrogen systems; the load; the safeties; and the data files generated during
testing. The upper right panel is the data visualization section, consisting of tabs for a
continuously updated time chart showing cell block voltages, an x-y graph displaying any
pair of user-selected variables, and a table of raw numeric data as well as any calculated
data parameters. The bottom left panel constitutes a safety section that includes a
PROGRAM SHUTDOWN button and controls for clearing faults and enabling/disabling
safeties. See Figure II-1 for a sample screen shot.
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Figure II-1. Software Front Panel
Air System
Table II-1 lists the controls, indicators and settings for the air system.
Table II-1. Air System Controls, Indicators, and Settings

Controls Indicators Settings
Air Supply Stoich. Setpoint (%) Air Flow Mode (Stoichiometric or
Forced Air Surge Actual Stoichiometry (%) Fixed)
Air Flow (slm) Minimum Airflow (slm)

Air Stoich. Set Point (%)
Surge Factor (x Flow)
Fixed Flow Rate (slm)
Figure II-2 is a screen shot of the AIR system tab with controls and settings.
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Figure II-2. Air System Tab
There are two different air flow modes: stoichiometric and fixed. The AIR FLOW MODE is
selected in the AIR settings tab control. If FIXED FLOW is chosen, the operator can set a
constant air flow rate using the FIXED FLOW RATE control. If STOICHIOMETRIC FLOW is
selected, the operator can set a minimum flow rate using MINIMUM AIRFLOW and a
setpoint, or target, stoichiometry using AIR STOICH. SET POINT. The stoichiometric flow
delivered to the stack is dependent upon the setpoint stoichiometry, the number of cells in
the stack, and the amount of current drawn from the stack as described by:
slm Air S
flow (slm) = 0.0166 I N
cell Amp 100
Where: S = Air stoichiometry (%)
I = Stack current (Amps)
N = Number of cells in stack
In the STOICHIOMETRIC airflow mode, the greater of either the minimum flow or the
stoichiometric flow is delivered to the stack.
Under the AIR system tab, the AIR SUPPLY control enables and disables the air supply to
the stack. Setting AIR SUPPLY to OPEN, energizes the air supply solenoid and enables the
software to send a voltage control signal to the air mass flow controller. Setting the AIR
SUPPLY control to CLOSED de-energizes the air supply solenoid and sends a 0 volt control
signal to the mass flow controller. Note that when the air supply solenoid is de-energized
the air supply is shunted to the atmosphere; this is to prevent pressure build-up or spikes
due to leak-by of the mass flow controller or sudden changes in setpoint. Additional
controls allow the operator to manually initiate a FORCED AIR SURGE and to select a
SURGE FACTOR, set as a multiple of the normal airflow level.
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Hydrogen System
Table II-2 lists the controls, indicators, and settings for the hydrogen system.
Table II-2. Hydrogen System Controls, Indicators, and Settings
Hydrogen Supply Open Hydrogen Flow (slm) Purge Period (min)
Automatic Purge Enable Purge Duration (sec)
Manual Purge
Figure II-3 is a screen shot of the HYDROGEN system tab with controls and settings.
Figure II-3. Hydrogen System Tab
The HYDROGEN SUPPLY button in the HYDROGEN system control box is used to control
the gas supply solenoid valve that is located upstream of the stack. The hydrogen
AUTOMATIC PURGE and MANUAL PURGE buttons control the purge solenoid valve, which
is located downstream of the stack. When the fuel cell is running under normal operation,
the supply solenoid is open and the purge solenoid is closed (except for purging as
described below).
Because the hydrogen pressure delivered to the stack is regulated, opening the purge
solenoid valve greatly increases the hydrogen flow through the stack (the regulator is
trying to maintain the desired delivery pressure while the pressure exiting the hydrogen
system is at atmospheric pressure). This rapid increase in hydrogen flow, while both the
supply and purge solenoid valves are open, is referred to as purging. Automated purging
of the stack is controlled in the HYDROGEN settings tab control. Automatic purging can be
enabled or disabled using the AUTOMATIC PURGE toggle switch. Purges last for the time
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designated by PURGE DURATION and the time interval between purges is specified by
PURGE PERIOD. A manual purge can be performed at any time by using the MANUAL
PURGE control in the HYDROGEN system control box. When the purge button is pressed
the purge solenoid is opened and remains open until the PURGE button is released.
Manual purges will not affect the automatic purge sequence (will not reset the purge
timer or affect the purge period or duration).
Water System
Table II-3 lists the controls, indicators, and settings for the water system.
Table II-3. Water System Controls, Indicators, and Settings
Pump TFC Water Power Section Out [TFC] (C) Set Point (C)
Temperature Control [0] High Dead Band (C)
Auto Fill TFC Air Power Section Out (C) [1] Low Dead Band (C)
Manual Fill TFC Water Power Section In (C) [2]
TFC Water Humidification Section Out
(C) [3]
TFC Air Humidification Section Out (C)
[4]
Ambient Temperature (C) [5]
Figure II-4 is a screen shot of the WATER tab with controls and settings.
Figure II-4. Water System Tab
The water pump circulates water from the water reservoir to the fuel cell and back to the
reservoir. The water is heated or cooled to maintain a desired water temperature, as
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measured by the TFC WATER POWER SECTION OUT (aka TFC) thermocouple, within the
CIRCULATION TEMPERATURE SET POINT range. TFC WATER POWER SECTION OUT is
measured in the water manifold as water is leaving the power section. Controls under the
WATER tab allow enabling of the pump, temperature control and automatic or manual
filling of the reservoir with makeup water.
The pump is directly controlled using the PUMP control in the WATER tab. However, the
TEMPERATURE CONTROL button does not provide direct control over the heaters or fans.
When the TEMPERATURE CONTROL button is enabled the temperature measured at TFC
WATER POWER SECTION OUT determines whether the heaters or fans are on.
Water heating is accomplished using an inline heater just upstream of the stack water
inlet. Cooling is achieved using fans mounted to the heat exchanger. The SET POINT
temperature will be maintained within the tolerances selected using the HIGH and LOW
DEAD BANDS selected in the FC WATER tab.
Depending on the heat output of the fuel cell, the water circulation loop can either heat or
cool the water circulating through the fuel cell. When heating, the heater is controlled
using pulse width modulation. When the temperature is below the setpoint minus the
LOW DEAD BAND the heater is continuously on; when it is above the setpoint plus the
HIGH DEAD BAND the heater is off. When the temperature is between the LOW and HIGH
DEAD BAND temperatures the heater is pulsed.
When cooling the stack, the fan is on when the temperature exceeds the value of the SET
POINT plus the HIGH DEAD BAND, and the fan is off when the temperature is below the
value of the SET POINT minus the LOW DEAD BAND.
Reservoir water level is maintained using a float switch and fill solenoid valve. When the
AUTO FILL control is enabled and the water level drops the float to its low setting, the
float switch closes and the water fill solenoid valve is opened. The water fill solenoid
valve will remain open until the float switch opens and then remain open for another two
seconds. Pressing the MANUAL FILL button will directly open the water fill solenoid valve
and fill the reservoir for as long as the button is depressed.
Safety System
Table II-4 lists the controls and settings for the test station safeties.
Table II-4. Safety Controls and Settings
Controls Settings
Fuel Cell Voltage Minimum Cell Voltage (mV/cell)
Safety Enable Maximum FC Temperature (C)
H2 Flow Safety Max H2 Flow (slm)
Enable
Max FC Current (Amps)
Water Fill Safety
Enable Water Fill Minimum Spacing (sec)
Water Fill Time Limit (sec)
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Figure II-5 is a screen shot of the safety controls and settings.
Figure II-5. Safety Tab
The safety settings, which are accessible in the SAFETY tab, are for low-level/software
faults. In the SAFETY tab both checkboxes and thresholds are used to set fault parameters.
The variable of interest will be compared to the threshold setpoint. If the variable goes
beyond the set point, a low-level/software shutdown will occur. When a software fault
occurs, the test station is placed in a safe state (solenoid valves closed, signal outputs set
to 0V, etc.). Less-critical software safety checks can be disabled by unchecking the
corresponding ENABLE box.
The MINIMUM CELL VOLTAGE safety prevents the fuel cell from running under load if a
cell voltage is less than the set limit. The MAXIMUM FC TEMPERATURE safety ensures that
the fuel cell operating temperature remains below the maximum temperature limit. An
EXCESSIVE H2 FLOW fault will occur if hydrogen flow exceeds the set limit, which may
indicate a hydrogen leak; this feature, however, may incorrectly generate faults, so it is
disabled by default. MAXIMUM FC CURRENT protects against excessive stack current.
WATER FILL MINIMUM SPACING is used to ensure that the reservoir is not filled too often
and MAXIMUM WATER FILL TIME ensures the reservoir fill solenoid does not remain open
too long. These safeties can be disabled by unchecking the WATER FILL SAFETY ENABLE
checkbox.
In summary, to generate a low-level fault: the safeties must be enabled, the appropriate
safety setting enable checkbox must be checked, and one of the conditions monitored
must fall outside of the specified range. For example, assume the minimum cell voltage is
set at 500 mV. If VTap 4 falls to 480 mV, a low-level fault will be triggered if the CELL
VOLTAGE enable box in the SAFETY settings is checked and the SAFETIES are enabled.
II-7
WARNING: During normal operation, all of the software safeties should be

! enabled. Following system startup, the test station should be operated with
the CELL VOLTAGE SAFETY enabled as soon as the cell voltages are above the
minimum threshold.
Electronic Load
Table II-5 lists the controls, indicators, and settings for the electronic load.
Table II-5. Load Controls, Indicators, and Settings
Load Enable Profile Running Load Mode (Constant, IV Curve,
Start IV Curve Interval Current Load Profile
Open Load Profile Interval Time Load Setpoint (Amps)

Remaining Constant Mode (Constant Current,
Constant Power)
Activation End Current (Amps)
Increment in Act. Region (Amps)
Cell Block End Voltage (mV)
Increment in Ohmic Region (Amps)
Time at Each Step (s)
Figure II-6 is a screen shot of the LOAD tab set for constant current mode. In normal
operation, the current flowing through the load is monitored, and the output signal is
adjusted continuously to maintain the desired setpoint.
Figure II-6. Load Tab: Constant Current Mode
II-8
There are three MODES that the load can operate in: CONSTANT CURRENT, IV CURVE and
LOAD PROFILE. The mode that the load runs in is set using the LOAD MODE control. The
LOAD ENABLE controls a power relay that supplies power to the load and its fan.
The second level tab under LOAD settings is used to set the limits and conditions under
which the load operates. Figure II-6, above, displays the LOAD settings under the
CONSTANT tab during CONSTANT CURRENT operation. The LOAD SETPOINT can be used to
set the desired current or power value, depending on which mode the test station is in.
The CONSTANT MODE control allows selection of either constant current or constant
power operation.
Figure II-7 displays the setting for performing a polarization (IV) curve. During an IV
curve the current is varied while the cell voltages, and other variables, are monitored.
WARNING: The OHMIC END CURRENT should never be great enough to
! reduce the lowest cell voltage below 500mV or result in mass transport
limitation. The SAFETIES should always be enabled while IV curves are being
conducted.
Figure II-7. Load Tab: IV Curve Mode
The IV CURVE settings are split into two regions: activation and ohmic resistance. Under
the IV CURVE tab, the START IV CURVE button will begin the generation of an IV curve.
The ACTIVATION END CURRENT should be set to a value just beyond the activation
region. The INCREMENT IN ACT. REGION determines the current increments throughout
the activation region. The CELL BLOCK END VOLTAGE sets a minimum cell voltage at
which the IV curve stops. The INCREMENT IN OHMIC REGION controls the current
increment for the ohmic resistance portion of the curve. The TIME AT EACH STEP control
is used to determine the amount of time that each increment in current will last.
II-9
For example, if the end of the activation region occurs at approximately 12 Amps, the
ACTIVATION END CURRENT should be set to 15 Amps. The INCREMENT IN ACTIVATION
REGION should be set to a small value because small changes in current cause relatively
large changes in the cell voltages in this region of the IV curve. Based on stack
performance and the testing objectives, the CELL BLOCK END VOLTAGE and the
INCREMENT IN OHMIC REGION can be set. The test station is rated for 150 A and 600 W;
the maximum current or power may not be reachable depending on the performance of
the fuel cell stack. Current increments of 5 Amps in the Ohmic region are satisfactory.
The TIME AT EACH STEP should take into consideration the response time of the
instruments you are controlling. Specifically, the air mass flow controller takes some time
to reach steady state flow after each current change. The time period should be at least 2
seconds to enable the MFC to stabilize after each change, up to 5 seconds if a more
precise stoichiometry value is desired.
Using the IV Curve settings provided the IV curve will progress as follows. When the
START IV CURVE button is depressed, a separate data file will be opened. The current will
increase from 0 to 16 Amps, in 2 Amp increments, pausing for 5 seconds at each step.
After remaining at 16 Amps for 2 seconds, the current will increase to 20 Amps and
continue increasing in 5 Amp increments every 2 seconds until the cell with the lowest
measured Vtap voltage is below 500 mV. Alternately, if the current reaches the150 A
limit before the voltage reaches the set cutoff, the test will end. The IV Curve will stop,
the IV curve data file will close, and standard testing w ill resume.
Figure II-8 displays the tab for accessing the LOAD PROFILE interface.
Figure II-8. Load Tab: Load Profile Mode

Under the LOAD PROFILE tab, the OPEN LOAD PROFILE INTERFACE button will open a
separate window that allows a load profile to be set up and run. Within the Load Profile
interface are three tabs, shown in Figures II-9, II-10, and II-11. For information on the
II-10
use of the Load Profile interface, see the INSTRUCTIONS tab or hover the mouse over
individual buttons and refer to the tool tip pop-ups. When a load profile is in progress
the PROFILE RUNNING indicator will light, and the INTERVAL CURRENT and INTERVAL
TIME REMAINING indicators will show at a glance the active step in the profile in
progress. A red indicator to the top right of the profile table indicates unsaved changes in
the profile; it will be grey if there are no unsaved changes.
Figure II-9. Load Profile Interface: Profile Manipulation Tab
Figure II-10. Load Profile Interface: Profile Execution Tab
II-11
Figure II-11. Load Profile Interface: Instructions Tab

File Settings
There are two interfaces for manipulating data files: the FILE SETTINGS tab control and a
DATA FILE dialog box included during startup. The FILE SETTINGS are used to control
how the data files are written, whereas the DATA FILE dialog is used to control the
contents of the data files. For a detailed description of the DATA FILE dialog refer to the
Software Startup and Shutdown section of this chapter.
Table II-6 lists the settings for all the data files.
Table II-6. File Controls, Indicators, and Settings
New File at 0:00 Hard Drive Full Comments
Close Data File Warning Number of VTAPs
Number of Cells
Membrane Type
Area
Stack Name
Max Lines in File
Collect Data After Fault
for (sec)
Min Write Time (ms)
Max Write Time (sec)
Figure II-12 shows the FILE settings tab control. The upper half of the FILE tab provides
fields to enter a description of the test being performed: COMMENTS, NUMBER OF VTAPS,
II-12
NUMBER OF CELLS, MEMBRANE TYPE, AREA, and STACK NAME. The lower half of the
FILE tab contains controls: MAX LINES IN FILE, COLLECT DATA AFTER FAULT FOR, MIN
WRITE TIME, and MAX WRITE TIME.
Figure II-12. File Tab
Data Panel
Table II-7 lists the indicators used to monitor the fuel cell in the left side of the screen
Table II-7. Fuel Cell Data Indicators
Fuel Cell Air Temperature Hydrogen
VTAPS (up to 8) Stoichiometric TFC Water Power Hydrogen
FC Current (A) set point (%) Section Out [TFC] Flow
Actual (C) [0]
FC Voltage (V)
Stoichiometry TFC Air Power
FC Power (W) (%) Section Out (C)
Current Density Total Air Flow [1]
(mA/cm2) (SLM) TFC Water Power
Power Density Section In (C) [2]
(mW/cm2) TFC Water
FC Hours Humidification
FC Amp Hours Section Out (C)
[3]
TFC Air
Humidification
Section Out (C)
[4]
Ambient
Temperature (C)
[5]
II-13
Figure II-13 contains a diagram of the fuel cell indicators.
Figure II-13. Front Panel Data Indicators
Individual cells or cell blocks are monitored with up to 8 voltage taps (Vtaps). If, for
example, a 24-cell stack were monitored, 8 voltage taps could be placed on the stack, one
on every third cell, such that each tap monitored the total voltage across a set of three
adjacent cells. The Vtap displays on the front panel would indicate the average cell
voltages for each three-cell block being monitored. The total stack VOLTAGE, CURRENT,
and POWER are also displayed along with the stack CURRENT DENSITY and POWER
DENSITY.
The Stoichiometry value displayed will turn red if it deviates significantly from the set
value. This is normal during the few seconds after the load current changes, until the air
mass flow controller has had time to react to the change in desired airflow. Of the six
available temperature probes, note that only probe #0, TFC WATER POWER SECTION OUT,
II-14
is used as a control parameter by the software when controlling the heating/cooling loop.
Temperature probes 1 through 5 are only used for experimental data collection.
Total FC Run Hours displays the number of hours the stack has run under load. Total FC
Amp Hours displays the cumulative number of amp-hours the stack has produced. These
counters are stored individually for each stack used on the test station, as selected during
startup.
Figure II-14 shows the TIME CHART tab.
Figure II-14. Time Chart Tab

Under the TIME CHART tab, a continuously updated time chart shows VTAP voltages in
mV vs. time. Both the CHART BUFFER (minutes of data held in memory; not necessarily
displayed on the front panel) and DISPLAY WIDTH (minutes of data visible on the graph)
can be adjusted by the operator.
When the CHART BUFFER value is changed, the entire buffer is cleared of data, and the
buffer size is set to the new value. Setting DISPLAY WIDTH to a value different from
CHART BUFFER will result in displaying only part of the data stored in the buffer, if a
smaller value is entered, or a chart that is only partially filled, if a larger value is entered.
Because of this, the operator can temporarily set the amount of data displayed to a lower
value to zoom in on the latest portion of the chart without clearing the buffer.
The EDIT CHANNELS button will bring up a dialogue where analog input channels other
than the default 8 vTaps can be selected for display on the graph. Note that changing the
displayed channels will clear the buffer.
II-15
Figure II-15 Shows the A VS B tab.
Figure II-15. Y vs X Chart Tab
Under the Y vs X tab, a Cartesian set of axes allows x-y graphing of any pair of the
following set of variables.
VFC
IFC
Hydrogen Flow
Air Flow
TFC Water Power Section Out [TFC]
TFC Air Power Section Out
TFC Water Power Section In
TFC Air Humidification Section Out
Ambient Temperature
Program Run Hours
Fuel cell power
Fuel cell power density
Fuel cell current density
Fuel cell hours
Fuel cell amp-hours
II-16
Buffer control allows the operator to select how many minutes of data are displayed on
the graph at any given time. Changing the buffer size or displayed channels will clear the
buffer.
Additional Data
The ADDITIONAL DATA tab is mainly intended for troubleshooting; it displays a table of
the raw analog input values with a large number of significant figures. It also displays
the values read on the two extra analog input channels.
Error Status
If a software initiated fault occurs, the cause of the fault will be displayed in the ERROR
STATUS region at the lower left corner of the front panel, shown in Figure II-16.
Figure II-16. Error Status display

Once a software fault has occurred, the condition persists until manually cleared by a test
bench operator to ensure that the operator is aware that the unsafe condition occurred.
When a software fault occurs, the system is immediately placed in a safe state, with all
outputs disabled, and both the error status text box and the CLEAR SAFETY FAULT button
appear. The CLEAR SAFETY FAULT button must be pressed before the system can be run
again. For a detailed description of the procedures used during shutdowns, refer to the
Startup and Shutdown section of Chapter IV.
II-17
Combined Read Write Configuration (available only at system start-up)

The Combined Read Write Configuration allows the user to specify which Analog Input
parameters will be written to the data log. The screen is divided into three sections:
ANALOG IN FILE PARAMETERS This table allows the user to specify which Analog Input
parameters will be written to the data log, the labels for column headers, and thresholds
for how large a change must occur in the parameter for the system to do an asynchronous
write to the data log. Note that Vtap values are automatically written to the data file based
on the fuel cell stack configuration, so they are not selected here. See Figure II-17.
CALC DATA FILE PARAMETERS This table allows the user to specify which Calculated
Data parameters will be written to the data log, the labels for column headers, and
thresholds for how large a change must occur in the parameter for the system to do an
asynchronous write to the data log. See Figure II-17.
Figure II-17. Read Write Configuration

CONFIGURATION FILES This section allows the user to create, delete, read, and write the
configurations of the specified AI file Parameters and to specify the Directory Path for
storage of the configuration files. DATA FILE PATH sets the location where the data log
files will be written. See Figure II-18.
II-18
Figure II-18. Configuration Files

The Analog Input parameters that the operator can select are:
VFC
IFC
Hydrogen Flow
Air Flow
TFC Water Power Section Out [TFC]
TFC Air Power Section Out
TFC Water Power Section In
TFC Air Humidification Section Out
Ambient Temperature
The Calculated Data parameters that the operator can select are:
Program Run Hours
Fuel cell power
Fuel cell power density
Fuel cell current density
Fuel cell hours
Fuel cell amp-hours
Current Stack Info (available only at system start-up)

The Current Stack Info display allows the operator to specify the characteristics of the
fuel cell stacks that are being used. The values set can be viewed in the Data tab while the
program is running.
Parameters that the user must specify are:
Number of Cells
Cells Per vTap
Cell Area (cm2)
The system is provided with an 8-cell, 300 cm2 stack.
II-19
Optional parameters are:

Membrane Type
Comments
The operator can:

Add a new stack
Select stack to use
Modify stack parameters
Delete a stack
Save stack settings
Reset stacks in use (used after an unexpected software shutdown or computer crash)
See Figure II-19.
Figure II-19. Current Stack Info
II-20
Operations and Maintenance Manual Chapter III
H2E3 Fuel Cell Test Station Test Station Operation
Chapter III: Test Station Operation

This chapter explains the procedures for operating the test station including connecting a
fuel cell stack to the test station. Step-by-step instructions are provided for powering the
test station up and down and for initiating stack tests, ending tests, and re-starting tests
after a fault shutdown.
A. Fuel Cell Stack Connections

The test station includes an 8-cell, 300 cm2 fuel cell stack built by Schatz Energy
Research Center. The stack operates at low air and hydrogen pressure and has an internal
air humidification section located on the right end of the stack.
Electrical and Instrumentation
The electrical connections are made on the front of the stack. The positive (red) cable is
connected tightly to the right bus plate and the negative (black) cable is tightly connected
to the left bus plate. Note that the convention is to refer to the end of the stack where
hydrogen is supplied (on your left when looking at the stack from the side where bus
plate connections are made) as the left endplate, and the endplate where air is supplied is
called the right endplate.
A multi-wire cable with individually numbered alligator clips referred to as the Vtaps is
used to monitor individual cell voltages. The VTaps connections start with tap 0 (ground)
at the hydrogen (left) bus plate graphite tab and the numbers increase toward the air
(right) bus plate. Figure III-1 shows the Vtaps connected to the rear of the fuel cell stack.
Figure III-1. Rear View of Stack Showing Connected VTaps
III-1
The stack is equipped with five thermocouples that monitor temperatures of the air and
water streams in various manifolds in the stack (see Figure III-2). The water temperature
is monitored in three locations: water into the power section (labeled in Figure III-2 and
on the thermocouple connector as 2: Wat PS In), water out of the power section and into
the humidification section (0: Wat PS Out), and water out of the humidification section
(3: Wat Humid Out). The two air thermocouples measure air temperature out of the
humidification section (4: Air Humid Out) and air exiting the power section (1: Air PS
Out). Note that the temperature monitored by thermocouple 0 (Wat PS Out) is also
referred to as TFC or FUEL CELL TEMPERATURE. It is the parameter that you are
controlling when you enable TEMPERATURE CONTROL and select a temperature set point
in the WATER tab in the user interface. A sixth temperature sensor located under the
bench monitors ambient air temperature and is used as the source for the stack air inlet
temperature.
Figure III-2. Thermocouple Placement with Respect to

Water and Air Flows in Fuel Cell Stack
The thermocouples are part of the stack and should not be removed unless necessary.
Each thermocouple wire is equipped with a quick connect located under the benchtop.
These quick connects can be used when installing or removing the fuel cell stack from
the test bench. If the thermocouple must be removed from the stack, loosen the endplate
fitting nut and slide the probe out of the fitting. The only exception is the TFC
thermocouple. All but the very tip of the TFC thermocouple probe has been insulated
with shrink wrap. The wrap insulates the bare probe and prevents an electrical short from
one cell to another. When removing the TFC thermocouple, the entire fitting (not just the
III-2
nut) must be unthreaded from the endplate. If the thermocouple is removed by pulling the
probe out of the fitting, the shrink wrap will slide off the probe and fall into the manifold.
WARNING: When installing the TFC thermocouple, make sure the probe is insulated.
! Failure to insulate could result in an electrical short from one graphite plate to another.
Air, Gas and Water

Flexible plastic tubing running from the various subsystems is used to supply all liquids
and gases to the stack. Figure III-3 shows the locations of the plumbing and
thermocouple connections on the right end plate. A 1/2 flexible hose runs from the air
plumbing system and connects to the air inlet fitting on the back bottom corner of the
right endplate.
Figure III-3. Locations of Right Endplate Stack Connections (SERC 300)

At the front bottom corner of the right endplate is the water outlet connection. Water
from the stack exits through a 3/8 hose and returns back to the water reservoir. The hose
connection to the stack is an in-line quick connect with positive shutoff. The quick
connect minimizes any water leaking onto the benchtop during installation or removal
and also allows the stack to be isolated from the water system when the test bench is
III-3
shutdown. At the top of the right endplate is an air bleed line that allows any air in the
waterside of the humidification section to vent back to the water reservoir.
The left endplate connections are shown in Figure III-4 below. Air exits the stack from
the 1 elbow fitting in the back bottom corner. Hydrogen gas enters through the upper
3/8 fitting and leaves, when purged, out of the 1/2 fitting on the front bottom corner of
the left endplate. Water enters the stack through the connection above the purge fitting.
The quick connect provides a means to isolate the stack from the water system when the
system is shutdown.
Figure III-4. Locations of Left Endplate Stack Connections (SERC 300)

WARNING: The Swagelok fittings connected to the stack should be
! securely tightened with a wrench. Use the minimal amount of force necessary
to prevent leaks. Keep in mind that all connections are for low pressure
systems. Make sure the air exhaust hose is not kinked or blocked, as this
could result in a harmful overpressure condition in the stack.
III-4
B. Startup and Shutdown

The following procedures should be used when running the test station. A complete test
station power-up is required when the system has been shut down and all AC power is
disconnected from the bench. Normal startups and shutdowns occur in between tests.
Test Station Power-Up

1. Check that all subsystem hoses, electrical cables, VTaps and thermocouples are
connected to the stack as described in section III.A of this chapter. You will
normally need to uncap the air inlet fitting on the right end plate and attach the air
supply hose, and you will need to attach the quick-connect water circulation hose
fittings at both the stack inlet (left end plate) and stack outlet (right end plate).
The air inlet and water inlet and outlets are normally disconnected when not
operating the stack to keep water from draining out of the stack.
2. Plug test station into a 120VAC, 15A, GFCI-protected outlet.
3. Connect the two USB cables between the computer and the USB box on the right
side of the bench.
4. Turn the test station on using the MAIN POWER switch (15A circuit breaker)
located on the front of the bench. Wait approximately 10 seconds for the DAQ
system to initialize. The hydrogen alarm will sound briefly once or twice at
startup; this is normal and can safely be ignored.
5. Turn the computer on.
6. Ensure the air and hydrogen cylinder and regulators are installed and the delivery
flex hoses are securely connected to the plumbing systems.
7. Perform a valve line-up on the test station subsystems as follows:
a. Air Supply System
i. Open the air cylinder valve and set the delivery regulator to 75 psig
ii. Place the stack air exhaust hose in an appropriate drain or reservoir
iii. Make sure that the air exhaust hose is not kinked or otherwise
obstructed in any way; this could cause high air pressure and
damage the stack
b. Hydrogen System
i. Open the hydrogen cylinder valve and set the delivery regulator to
100 psig
ii. Close the hydrogen purge drum drain valve
iii. Install a hydrogen vent hose and route the outlet to an appropriate
vent or open window at or above the level of the test station to
ensure gas flow. Make sure there are no kinks or blockages in this
hose
c. Water System
i. Route reservoir overflow hose to an appropriate drain or reservoir
ii. Install a deionized water supply hose to the DI water supply valve
iii. Open the DI water supply valve
iv. Close the water system drain valve
III-5
v. Crack open the air bleed valve
WARNING: Before opening any valves, either manually or remotely from

! the control software, the operator should have a complete understanding of
what the normal system response should be. If a water, gas, or air leak is
detected or any unexpected system response occurs, immediately close the
valve and correct the problem.
8. The test station is ready for fuel cell testing.
NOTE: Do not obstruct the orifice on the front of the air solenoid valve; this can
vent air under pressure under some circumstances. The air mass flow controller is
equipped with an internal shut-off valve. However, if the air delivery pressure is
lower than 60psi, the valve may not seat fully and a small amount of air will leak
past through the orifice on the front of the solenoid valve; this is normal.
Normal Startup
(Note: suggested values for the 300 cm2 fuel cell stack supplied with the system are
shown in brackets.)
1. Launch the test station program, or click the RUN arrow button at the top of the
interface window to start if the program is already launched.
2. In the CURRENT STACK INFO window, select the stack you wish to use from the
menu [H2E3] and click USE THIS STACK.
3. Set the analog input (AI) and calculated data file parameters. See Figure III-5 for
an image of the file parameter entry screen. Further instructions and notes on
using the parameters are provided in the interface (lower right corner). Note that
unless changed these values will default to those last used, so can usually be left
as-is.
III-6
Figure III-5. Data Log File Parameter Entry Screen

4. Check all the connections to the fuel cell stack, including the fluids (air,
hydrogen, and DI water), power cables, Vtaps, and thermocouples.
5. Click on the WATER tab and perform the following steps:
Enable AUTO FILL
Turn the pump on and verify flow at rotameter. Adjust if necessary using
throttling valve
If reservoir or stack was previously drained, allow the pump to run until the
system has filled with water before continuing
Set the fuel cell temperature setpoint and dead bands [60 +1/-1 deg C]
Enable TEMPERATURE CONTROL
6. Allow the water and stack temperature to warm up to desired temperature; this
can take up to 30 minutes
7. Click on the AIR tab and perform the following steps:
Set the air flow mode, stoichiometry, and minimum flow rate [stoichiometric,
325%, 10 slm]
Enable air supply and verify desired flow rates in the data display panel (note
that depending on the minimum airflow setpoint and load current the actual
stoichiometry may be a very large value)
III-7
8. Click on the HYDROGEN tab and perform the following steps:

Enable supply solenoid valve
Manually purge hydrogen through the system to establish open circuit
voltages
Select purge period and duration and enable auto purge
9. Click on the SAFETY tab and perform the following steps:
Verify setpoints for safeties
Enable CELL VOLTAGE SAFETY in the safety panel
10. Enable the safeties in the display section of the front panel
11. Click on the LOAD tab and perform the following steps:
Select load mode
Select the tab corresponding to the chosen load mode
For CONSTANT CURRENT or CONSTANT POWER mode, enable load and enter
setpoint. Check that the load fan is running and that the LED indicators on the
load are on.
For IV CURVE mode, enable load and select desired setpoints under the IV
CURVE tab. Click START IV CURVE to start the IV curve. The IV curve can be
stopped prematurely by disabling the load.
For LOAD PROFILE mode, enable load and click OPEN LOAD PROFILE
INTERFACE under the LOAD PROFILE tab, and enter desired load profile
settings following the directions given under the INSTRUCTIONS tab. Select the
PROFILE EXECUTION tab and click on EXECUTE to start load profile.
12. Refer to Table III-1 to verify the system parameters are within their normal range
of operation.
Table III-1. Normal Values for Test Station Operating Variables
System Indication/Parameter Monitored at Normal Range

Air Stoichiometry Set Point front panel 200 400 %
Stoichiometry (actual) front panel 200 400 %
Air Regulator pressure gauge 75 - 100 psig
Air Pressure gauge < 50 H2O
Regulator pressure gauge 75 - 100 psig

Hydrogen
H2 Pressure gauge 2.7 - 5 psig
III-8
Water flow rate rotameter 0.25 - 0.6 gpm

Water pressure gauge 0-3 psig
Water conductivity light conductivity Illuminated when
Water sensor conductivity is in
acceptable range
(<200 kOhms-cm)
FC Temperature front panel 60 1 deg C
Startup after Software Fault

When a software fault occurs, the program remains running but the test station
components turn off or are disabled.
1. Read the fault message box to determine the cause of the shutdown. If the fault is
easily corrected the system may be started back up. Refer to the Troubleshooting
section as necessary.
2. Press the Clear Fault button.
3. Follow steps in the Normal Startup Procedure.
Startup after a Safety Fault
1. One of the following two conditions occur during a Safety Fault. Both are
generated by the hydrogen leak detector alarm. There are three indicators on the
blue and red front panel. Pilot, Alarm 1, and Alarm 2. Alarm 1 indicates a
detected leak of > 10% of the lower explosive limit (LEL) of hydrogen in air.
Alarm 2 indicates a detected leak of > 30% LEL.
a. An alarm siren is activated but the system continues to operate. This indicates
that the hydrogen alarm has detected a gas leak greater than or equal to 10%
LEL but not greater or equal to 30% LEL. This can be verified by checking
the front panel of the hydrogen leak detector for an Alarm 1. This would be
a good time to check for hydrogen leaks with a handheld instrument.
b. An alarm siren is activated and the system power has shut down. This
indicates that the hydrogen alarm has detected a gas leak greater than or equal
to 30% LEL. This can be verified by checking the front panel of the hydrogen
leak detector for an Alarm 2 condition. At this time the hydrogen supply is
turned off. Check the hydrogen plumbing for loose fittings before attempting
to restart the system and check for leaks with a handheld instrument
immediately after re-opening the hydrogen supply.
2. Follow the Normal Startup Procedures above.
Normal Shutdown
1. Set the load to 0 and disable the load.
2. Press the software PROGRAM SHUTDOWN button.
III-9
3. Disconnect the air supply hose from the stack and cap the air inlet fitting to keep
the stack from drying out.
4. Disconnect the water inlet and outlet hoses from the stack to keep stack water
from draining out.
Test Station Power-Down
1. Perform Normal Shutdown.
2. Close the air and hydrogen cylinder valves and the DI water supply valve.
3. Close the LabVIEW program and turn off the computer.
4. Turn off the test station via the circuit breaker located on the front panel.
Low Pressure Regulator Adjustment

The hydrogen low pressure regulator for dead-ended operation can be adjusted to deliver
gas at pressures ranging from 2.7 to 5.5 psig. The hydrogen fuel cell pressure is
nominally 3.0 psig. The regulator can be adjusted during fuel cell operation (preferred) or
while shut down using nitrogen. If adjusted during operation, make small changes and
allow time for the regulator to respond and prevent a pressure surge. When the regulator
is adjusted while shut down, the 3-way supply valve is lined-up for nitrogen service, the
hydrogen supply solenoid valve must be open to provide pressure indication (via the
pressure gauge) and gas must flow through the regulator. A pressure relief valve is built
into the regulator and has a non-adjustable relief setpoint at 5.9 psig.
WARNING: Note that the regulators built-in relief valve relieves gas into
! the housing where the adjustment screw is located. If the relief valve lifts
with the access plug out or loose, hydrogen will vent into the atmosphere
through the open port and not through its designated vent line. Be sure the
access plug is tight when pressure adjustment is complete.
The low-pressure hydrogen regulator adjustment procedure is as follows:
1. Remove the black plastic access plug by turning counter-clockwise.
2. Using a flat-bladed screwdriver, turn the adjustment screw to change the delivery
setpoint. Turn the nut clockwise to increase the pressure and turn counter-clockwise
to decrease the pressure.
3. Once the desired pressure is reached, replace the access plug and tighten snugly.
4. If necessary, return the test station to a normal shutdown condition.
III-10
Operations and Maintenance Manual Chapter IV
H2E3 Fuel Cell Test Station Troubleshooting
Chapter IV: Troubleshooting

The purpose of this chapter is to help test station users identify and correct common
problems that may occur in using the test station. The flow chart below provides a
recommended procedure for using this chapter to troubleshoot problems. If you are
unable to troubleshoot a problem using this chapter, please contact SERC.
Does the Hardware fault

hydrogen sensor YES
indicate a fault? See Section IV.A.
NO
Is there a
software YES Software fault
fault
displayed See Section IV.B.
on-screen?
NO
Is the stack YES Fuel Cell problem

malfunctioning? See Section IV.C.
NO / DONT KNOW
Other problem
See Section IV.D.
IV-1
Caution: Fault conditions do not shut off power to the computer, DC power supply,
! or safety devices. You must disconnect the test station from AC power before
servicing it.
The most likely problems to occur in using the test station will be associated with safety
faults. There are two kinds of faults that will cause an automated test station shutdown:
A hydrogen leak, which is known as a hardware fault. The hydrogen sensor is
wired to bypass the control computer and directly shut off power to the test station
AC subsystems.
Less critical faults are known as software faults. These are faults that, if
uncorrected, could result in damage to the fuel cell or test station components but
do not pose an immediate threat to personnel or the facility.
Both of these fault types are discussed in greater detail below, as well as fuel cell faults
and other test station problems that may occur.
A. Hardware Faults
A hardware fault triggered by the hydrogen detector will cause a loss of AC power to the
test stations internal devices (i.e. heaters, pumps, fans, solenoids, etc.).
If the hydrogen detector senses a leak 10% of hydrogens lower explosive limit (LEL)
in air near the sensor, the Alarm 1 LED on the hydrogen monitor detector will light, but
the system will continue to operate normally. If the hydrogen detector senses 30% of
hydrogens LEL, the Alarm 2 LED on the hydrogen monitor detector will light, the
hydrogen monitors audible alarm will sound, and a hardware fault will be triggered. The
hydrogen monitors audible alarm will only continue to sound while the hydrogen sensor
detects hydrogen 30% of LEL.
Another type of hardware fault that can occur is failure of the electronic load. The load is
protected by a temperature switch that will disable the load if it senses a load temperature
above 90C. If this occurs, the user need only wait a few minutes for the load to cool off
before resuming testing. However, the user should first determine and address the cause
of the overheat condition, which may be high ambient temperature or extended periods of
running near maximum load conditions.
Note that it is possible to temporarily exceed the power limit on the load without
exceeding either the voltage or current limits; however, running at high power for
extended periods will eventually cause the load to shut down due to high temperature
conditions. The load fan will keep running in order to cool the load off under a high
temperature load shutdown. If the fan does not run when you have the load enabled, the
load fan or load relay may need to be repaired or replaced.
1. Hydrogen Detector
The hydrogen detector consists of a transmitter and sensor. The sensor mounted on an
armature above the fuel cell and detects the concentration of hydrogen in air. Use the
following procedures if a hydrogen alarm is triggered:
IV-2
Close the hydrogen 3-way valve.
Look at the hydrogen detector lights located behind the electronic load under the
bench and determine the alarm level (Alarm 1 or Alarm 2).
If Alarm 2 is lit and the audible alarm sounds, indicating 30% LEL, leave the room
and notify facility safety personnel.
If Alarm 1 is lit, complete a visual inspection of the hydrogen plumbing following the
procedures outlined in the Leak Check section (VI.A.3) of the Maintenance chapter.
You will not be able to restart the test station and pressurize the system downstream
of the hydrogen supply solenoid until the concentration decreases below 10% of LEL.
You may need to complete several iterations of pressurizing and depressurizing the
system until the percentage of hydrogen in air is consistently below 10% LEL while
the system is under pressure.
2. Emergency Stop
If any dangerous conditions are detected, (e.g. smoke, fire, sparking, etc.) immediately
turn off the power switch on the front of the test station, leave the building and notify
appropriate personnel of the potential hazard.
B. Software Faults
All software faults result in a software-controlled shutdown that places the stations
hardware in a safe state and keeps the test station program running. The setpoint and
enabling boxes for each software initiated fault are set within the SAFETY settings, with
the exception of the HARDWARE ERROR fault. The software-initiated faults are:
A LOW CELL VOLTAGE fault will occur if the lowest cell voltage falls below the
MINIMUM CELL VOLTAGE. To determine why a particular Vtap (cell or block)
voltage is performing poorly, refer to the Fuel Cell Faults section of this chapter.
A HIGH FC TEMPERATURE fault occurs if the operating temperature of the fuel cell
water cooling system exceeds the fault temperature setpoint. The operating
temperature setpoint, measured where cooling water leaves the fuel cell power
section, is set in the COOLING settings.
A HIGH FC CURRENT fault will occur if the load is drawing excessive current from the
fuel cell. Extended operation at high current output may damage the fuel cell stack.
A HIGH H2 FLOW fault occurs if the hydrogen flow exceeds the fault setpoint. This is
a leak indication.
A FC WATER FILL TOO FREQUENT-CHECK FOR LEAKS fault indicates that the reservoir
float switch is initiating a reservoir fill more often than is permitted by the setpoint
selected in the SAFETY settings. This may indicate a leak in the water circulation loop.
A FC FILL TOO LONG fault indicates that the fuel cell reservoir fill solenoid is
remaining open longer than is permitted by the setpoint selected in the SAFETY
IV-3
settings. This may indicate a major leak in the reservoir, a fill solenoid stuck in the
closed position, the float becoming stuck prior to reaching the reset point or that the
water fill valve has been left closed.
STACK VOLTAGE GREATER THAN 50V: Cannot be disabled individually.
Table IV-1 describes some of the possible reasons that a software fault might occur and
what corrective action(s) should be taken. If a fault shutdown does not occur when a
known fault condition exists, ensure the fault is selected in the SAFETY Settings and the
ENABLE SAFETIES button is selected.
Table IV-1. Troubleshooting Software Faults
Fault Possible Reasons Corrective Action
Input/Output Error Communication failure Restart main DAQ unit
between DAQ units and
Disconnect and reconnect
computer
USB cables
If two above steps dont help,
restart computer
Low Cell Voltage Inadequate supply of H2 Verify H2 pressure and
and/or air to FC. airflow. Open H2 supply valve
and check proper operation of
solenoids and blowers as
necessary.
Anode and/or cathode is Refer to the Fuel Cell Faults
flooded. section of this chapter
High FC Stack is producing more Check that the fault setpoint
Temperature heat than can be removed temperature is not set too low.
by the FC water cooling Usually the stack should run
system. near 60C and shut down near
65C.
Make sure the heat exchanger
fan(s) are on and heater is off.
Inadequate cooling water Open water throttle valve,
flow. ensure water flow 0.2 gpm.
Rule of thumb: 0.04 gpm per
100 W with minimum of 0.2
gpm
Check Tygon tubing for kinks
or pinches.
Drain water system and inspect
plumbing for obstructions
IV-4
Obstruction in water Adjust throttling valve
plumbing.
or pinches.
Pump is cavitating, (pump Manually cycle pump a few

is operating but not times to remove any trapped
pumping water). air in pump head
Repair or replace pump
Thermocouple reading Ensure operating temperature
incorrect. thermocouple is plugged into
the socket behind the bench.
Ensure the analog input signal
is being read by the computer
and scaled properly.
High FC Current Fuel cell short circuit Ensure no conductive materials
are shorting stack or in contact
with stack, electronic load or
current shunt.
Ensure proper installation of
fuel cell stack thermocouples,
can cause internal short circuit
FC Water Fill Too Major leak in reservoir Inspect for leaks and repair
Frequent and/or water plumbing.
FC Fill Too Long Possible leak in water Inspect water system for leaks
circulation loop. and repair
Water reservoir filling too Open throttle valve slightly to
slowly due to restricted allow adequate fill rate
flow/inadequate fill flow.
Obstruction in water Adjust throttling valve
plumbing.
or pinches.
Stack Voltage A stack with over 50V Stack too large for system.
Greater Than 50V open circuit voltage has
been placed on test station.
IV-5
C. Fuel Cell Faults

Fuel cell faults can present themselves in numerous ways. From anode flooding to cross-
leaks, there are a number of reasons a stack may perform poorly either temporarily or
permanently.
1. Troubleshooting
The operator should continuously monitor fuel cell stack performance during
experimental testing. Poor performance is typically defined by relatively low cell voltage
at a given current density. The more the system parameters (load, air stoichiometry, purge
frequency and duration, etc.) are changed, the more likely an operational problem will
occur. A summary of the symptoms that may be observed during stack operation is
provided in Table IV-2. The symptoms are used to identify fuel cell problems and thus
help to determine the possible root causes of the problem.
Table IV-2. Troubleshooting Fuel Cell Stack Failures

Problem Symptom Root Cause
Anode flooding Voltage decreases during purge and Hydrogen delivery
recovers immediately after purge system cannot provide
enough flow/pressure
during purge.
Inadequate purge
duration and period.
Unusually wet purges Broken separator or
cooling plate
After purge, voltage recovers, then decays Inadequate purge
after a period of time duration and period
Water leaks from any of the bottom four Loose stack bolts,
stack bolts broken separator or
cooling plate
Cathode Voltage rises sharply w/ air surge Inadequate air
flooding stoichiometry
Loss of GDM
hydrophobicity
Voltages not stable at normal air Incorrect Airflow
stoichiometries (250-300%) Source calibration,
Unusually wet air exhaust Broken separator or
cooling plate
Water leaks from stack or stack bolts Loose stack bolts
IV-6
Humidification High and/or fluctuating air pressure Torn humidification
cross-leak membrane
Power Section Water collecting in the Air Inlet line when Torn humidification
cross-leak the stack is not being operated. membrane
Cell does not pass cross-leak check, section Hole or tear in
V.C.2 membrane
MEA damage Voltage rises when H2 pressure is removed. Porous or broken
separator/cooling plates
Sniffer indicates H2 in air exhaust. Hole or tear in
membrane
Porous or broken
separator/cooling plates
Loose stack bolts
Lack of above symptoms. Catalyst contamination
Voltage forced above
1.8 V/cell
Water connected to Air
or H2 fittings
Restricted Voltage rises sharply with air surge with Mechanical blockage
airflow out signs of flooding.
2. Cross Leak Check

To determine if a cell in the stack has developed a cross-leak due to a puncture in the
membrane, pervious separator/cooling plates, or loose stack bolts, use the following
procedures:
1. Place the load at open circuit by setting the load to 0 Amps and disable the load.
2. Open the HYDROGEN SUPPLY SOLENOID and supply at least 4 slm air.
3. Wait until the open circuit cell voltages are relatively stable.
4. Disable the air supply and open the FC air inlet vent valve.
5. Observe the cell voltages over time using the display graph.
If a cell voltage rapidly decays after removal of the air supply, note which cell crashes
first. The first cell to crash is usually the cell that has a punctured membrane or is
adjacent to a cracked graphite plate. A rapid decrease in cell voltage is a sign of a
significant cross-leak. If a cell voltage holds strong initially but begins to degrade within
30 seconds, a lesser but still significant leak may be present. If all cell voltages stay
above 800 mV for longer than 30 seconds, the cells do not have a significant cross leak.
IV-7
! WARNING: Notify the fuel cell supplier if a cross leak is suspected.
D. Other Test Station Problems

Test station problems may occur that cannot be classified as hardware faults, software
faults, or fuel cell faults. Table IV-3 lists a number of such miscellaneous problems and
suggests possible solutions.
Table IV-3. Troubleshooting Other Test Station Problems
Symptom Possible Causes Things to Check/Solutions
Test station will No AC power Confirm that the main power switch
not power up is on and that the test station is
plugged into a functioning outlet
H2 Detector Tripped If the H2 detectors power indicator is

lit, confirm that it is not in alarm state
All data shows 24V power supply Check power supply internal and
zero values, I/O problem external fuses. A blown external fuse
not functioning. will have a lit indicator.
Some data Bad signal connections Check connections and signal
looks random voltages at BNC connections on DAQ
unit on middle shelf
Check thermocouple connections.
Overloaded or Check power supply voltage. Check
malfunctioning 24V fuses. A bad fuse has a lit neon
power supply indicator
Malfunctioning Check output voltages of hardware
measurement hardware associated with the bad data
Some data Incorrect software Confirm that scales listed in in

looks inaccurate scaling (due to hardware Measurement and Automation
change or drift) Explorer (MAX) match the values
outlined in the manual
Check hardware outputs at BNC
connectors on DAQ unit on middle
shelf, compare w/ scales listed in
Measurement & Automation Explorer
Malfunctioning Check output voltages of hardware
measurement hardware associated with the bad data
Hydrogen sensor has Check alarm lights on hydrogen alarm
been tripped panel
IV-8
No cell voltage No hydrogen or air Check hydrogen and air system
or voltages valves
crash
Voltage tap not Check voltage taps, reconnect if
connected needed
No hydrogen or air Check air plumbing
Voltage tap not Check voltage tap clips on the stack
connected
Purge drum full Drain purge drum
Bad fuel cell stack Replace or repair, contact SERC
Power Outage Wait for power to return
Computer Test station software Resolve cause of error and clear fault
beeping fault
Windows crash Reboot Windows
No water flow Reservoir empty Check that program is actually

running and safety circuit is enabled
Visually check water level
Check throttle valve Check the throttle valve
Pump is off Enable circulation pump in software
Pump is cavitating Manually cycle pump a few times to
(operating but not remove any trapped air in pump head
pumping water).
Repair or replace pump
Software Program is in fault state Check program fault indicator
controls have
no effect
Conflicting software Some software controls require
states certain conditions to operate; for
example, temperature control will
only work when the circulation pump
is enabled
Program is not actually Make sure the arrow at the top of the
running program window under the menu bar
is black; if it is white, the program is
open but not actually running, and
must be started; click the white arrow
to start program
Computer has frozen Check to see if the Start menu
functions
IV-9
Program has frozen Check to see if buttons change color
in response to being clicked; if they
do not, the program is frozen and
must be force quit (Control-Alt-
Delete to bring up process manager)
Program error If the program appears to be running
properly but will not control hardware,
there may be a bug in the software, but this
is unlikely; stopping and restarting the
program will reset it to a default state
Alarm is Hydrogen detected Sounds like a single high-pitched beep;
sounding check alarm indicator lights on blue
hydrogen detector box
Load not Load overheated, Set load to 0 (but leave enabled to keep fan
working triggering high running), wait a few minutes for load to
temperature cutout cool off and switch to reset, and try
switch (fan will keep enabling load again. Investigate and correct
running if load enabled) cause of overheating
Load and/or load fan Contact manufacturer/vendor to repair or
failed (fan not running replace load
when load enabled)
Software fault Cell voltage too low
Fuel cell thermocouple

Check onscreen fault display for source of
temperature too high
error, refer to stack troubleshooting
Fuel cell current too high
Water filled too long or
too frequently
IV-10
Operations and Maintenance Manual Chapter V
H2E3 Fuel Cell Test Station System Maintenance
Chapter V: System Maintenance

The purpose of this chapter is to explain routine preventative maintenance procedures
that should be carried out in order to avoid test station malfunctions and ensure a long,
safe operating lifespan for the test station. Detailed maintenance instructions for many
off-the-shelf test station components are provided in the manufacturers literature
provided with the test station.
Important: When performing any maintenance, tag the test station as out of service to
! avoid unsafe operation of the test equipment by other persons.
A. Air, Hydrogen and Water Systems Maintenance

Common maintenance tasks for the three subsystems include visual inspections, pressure
relief valve setpoint checks, and system leak checks. Other procedures are for specific
tasks such as deionization cartridge changeout.
1. Visual Inspection
The operator should make a periodic visual inspection of all system components
including gauges, hoses and vent line exits. The components should be inspected for
cleanliness and integrity in order to identify potential failures. When testing is in
progress, the operator should check the water levels in the hydrogen knockout drum.
2. Leak Checks
The most important maintenance task to be performed, especially on the hydrogen
plumbing, is periodic leak checking. Leak checks should be performed every 3 months
and after any system maintenance, whether corrective or preventive. System operators
can perform leak tests with a portable gas detector (hydrogen system) or Snoop-type
leak-checking fluid (all systems) while the system is running and fully pressurized. A
pressure drop test (all systems) can be done while the system is shut down; however, this
test will only determine whether a leak exists and not identify its location.
The recommended leak check methods are a combustible gas detector for the hydrogen
system, small amounts of leak-checking fluid for the air system, and a visual inspection
of the water system.
If the leak is from a component or section of the system that cannot be fixed or
retightened, that section or component must be replaced. The system must be
depressurized before the leak can be fixed.
! Note: Never attempt to tighten a leaky fitting while under pressure!
Most likely the leak is from a loose Swagelok fitting. As stated in the Swagelok Tube
Fitters Manual, these connections can be disconnected and re-tightened many times. The
same reliable, leak-proof seal can be obtained every time the connection is remade. To
tighten the fitting, apply the appropriate size wrench to the Swagelok nut and the fitting
it screws on to. While holding the fitting stationary, turn the Swagelok nut clockwise
until tight. Pressurize the system again and recheck for a leak.
V-1
3. Valve and Regulator Cross-Leak Checks

A valve or regulator cross leak can cause improper system operation. While performing
routine operation and maintenance procedures, the operator should closely monitor
system response to valve manipulations and watch for symptoms that may indicate a
cross leak problem. Early detection of a cross leak will allow repair and/or replacement
of the defective part before further damage occurs.
4. Deionization Cartridge Changeout

The water conductivity light will remain lit during test station operation as long as
conductivity is below 200 kOhms-cm. If conductivity exceeds this level, the light will
shut off, indicating that the resin cartridge should be replaced.
In order to inspect and/or replace the resin cartridge, the test station must be shut down
and the water circulation system isolated and depressurized. Prior to changing out the
cartridge, perform all the corrective actions presented in the troubleshooting section.
The procedure is as follows:
1. Ensure the test station is shut down.
2. Close the blue-handled DI water supply valve on the back of the bench.
3. Cover the electronics shelf with a plastic tarp or large bag to prevent any water from
spilling onto the electrical components.
4. Open the blue-handled water system drain valve. The valve is located below and to
the left of the pump as viewed from the front of the bench.
5. Once the system is drained, the sump can be removed. Place a bucket under the
cartridge housing. While supporting the weight of the water-filled sump, loosen the
sump with a sump housing wrench by turning counterclockwise.
6. Remove the sump carefully so as not to spill water onto nearby components or wires.
Dispose of the water and cartridge and rinse the sump clean. The resin cartridge is not
hazardous and can be disposed in a regular waste receptacle.
! 7. Check the condition of the o-ring inside the sump. Caution: If the O-ring appears
damaged or crimped it should be replaced.
! 8. Place a new cartridge in the sump and screw the sump onto the cap until hand tight.
Caution: Do not overtighten.
9. Close the drain valve and open the water supply valve.
10. Start the test station software and open the reservoir fill solenoid valve.
11. Once full, start the circulation pump to remove air from the system.
12. Check the cartridge housing for water leaks and tighten the sump if necessary.
13. Monitor the water conductivity light.
V-2
B. Hydrogen Detector Maintenance

The manufacturers of the hydrogen detector recommend yearly testing and calibration.
To calibrate the sensor, refer to the sensor manual. It is also recommended that the sensor
be tested every year for proper performance as part of the test stations safety system. To
test the sensor:
1. Use the appropriate startup procedures outlined in Chapter III to get the test station
online.
2. Enable hydrogen supply to the stack, then immediately disable the hydrogen supply.
This will fill the hose between the hydrogen supply solenoid valve and the stack inlet
with a small amount of hydrogen, sufficient for testing the detector.
3. Loosen and detach the hydrogen supply fitting at the stack inlet and quickly direct the
open end of the hose toward the hydrogen sensor mounted above the stack. This
should immediately result in an Alarm 2 condition, shutting down test station
power.
4. Follow Normal Startup procedures as described in Chapter III to restart the station.
C. Transducer Maintenance and Calibration

To ensure that all transducers are properly maintained and calibrated, follow the
specifications given for each instrument in the manufacturers literature.
D. Control and Monitoring Hardware Maintenance

The control and monitoring hardware should not require special procedures for
maintenance. To ensure that the equipment functions properly, use the following
guideline.
1. Check Integrity and Condition of Visible Wiring

Periodically, a visual inspection should be made of any electrical wiring that can be
easily accessed. Check for damage to wire insulation and gently tug on the wires to make
sure they are not loose.
2. Keep Components Clean

Periodically all easily accessed electrical components should be inspected and cleaned as
needed. Do not allow dirt, dust and debris to accumulate around electrical components.
Vacuum these areas as needed.
V-3
Operations and Maintenance Manual Chapter VI
H2E3 Fuel Cell Test Station Safety
Chapter VI: Safety

In addition to the safety information given in this chapter and elsewhere in this manual,
please also read the safety information found in the manufacturers literature for
individual test station components, provided with the test station.
We also provide a list of recommended reading material at the end of this chapter that
covers hydrogen system safety, as well as proper hydrogen gas system design and
operation.
A. Safety Orientation
This chapter addresses safety issues that all personnel working with the test station need
to be aware of. The system, while designed for maximum safety and fully compliant with
all applicable safety codes and regulations, can be hazardous if not operated correctly.
The primary potential hazards associated with the test station include:
high-pressure gas accidents,
fire, and
electric shock.
After studying this section of the Operations and Maintenance Manual, system operators
should understand these hazards and be prepared to respond to any foreseeable hazardous
situation that may arise in a manner that will protect personnel in the vicinity while also
avoiding or minimizing harm to the facility and equipment.
WARNING: Never work at the fuel cell test station alone. At least two
! people should be in the room at all times when the test station is operating.
Only authorized, trained personnel or students working under the direct
supervision of authorized, trained personnel who are present in the room
should operate the fuel cell test station.
1. Properties of Hydrogen Gas

Hydrogen has an undeserved reputation as a highly dangerous substance. In reality, in
some situations it can be safer to work with hydrogen than with other fuels we commonly
use (such as gasoline, methane/natural gas and propane); in other situations it can be
more hazardous. Therefore, prior to operating the system, personnel should have a basic
understanding of hydrogen gas properties and associated hazards.
The principal hazard presented by hydrogen systems is the uncontrolled combustion of
accidentally released hydrogen. For hydrogen to combust, two additional elements are
required: an oxidizer and a source of ignition. Hydrogen is combustible over a wide range
of concentrations in air, and a variety of common physical processes (open flames, hot
surfaces, friction, electrical spark, static discharge) can serve as sources of ignition. Some
important characteristics of hydrogen are discussed in more detail below, and Table VI-1
compares some of hydrogens physical properties with those of methane, the chief
constituent in natural gas. The NFPA 704 Rating for hydrogen gas is: Health:0, Fire: 4,
Reactivity: 0, Special: None
VI-1
Table VI-1. Some Physical Properties of Hydrogen and Methane

Hydrogen Methane
Autoignition temperature 520 C 630C
Heat of combustion (lower
120 MJ/kg 50 MJ/kg
heating value)
Lower flammable limit (in air) 4% by volume 5.3% by volume
Upper flammable limit (in air) 75% by volume 17% by volume
29.5% by
Stoichiometric mixture (in air) 9.5% by volume
volume
Density (20C, 100kPa) 0.0827 kg/m3 0.6594 kg/m3
Diffusion coefficient (in air) 0.61 cm2/s 0.16 cm2/s
Viscosity (20C, 100kPa) 8.814 Pa-s 11.023 Pa-s
Flame temperature (in air) 2045C 1957C
Minimum ignition energy (for 0.017 mJ
0.274 mJ
stoichiometric mixture in air)
Propensity to Leak
The low viscosity and small molecular size of hydrogen gives it a greater propensity to
leak than other common gaseous fuels. For the same pressure and hole size, hydrogen
would leak approximately 2.8 times faster than natural gas and 5.1 times faster than
propane on a volumetric basis. However, because the energy density of hydrogen is so
much lower than that of methane or propane, the energy leakage rate for hydrogen would
only be 0.88 times that of methane, and 0.61 times that of propane.
It is nearly impossible, unless you use all welded joints, to build a gaseous hydrogen
plumbing system that is truly leak free. However, building a system that is as tight as
possible and minimizes hydrogen gas leaks is obviously desirable. In addition, adequate
ventilation in the vicinity of the hydrogen system is a must.
Dispersion
Hydrogen is more diffusive and more buoyant than gasoline, methane and propane, and
therefore tends to disperse more rapidly. For low momentum gaseous hydrogen leaks,
buoyancy affects gas motion more significantly than diffusivity. For high momentum
leaks, which are more likely in high pressure systems, buoyancy effects are less
significant, and the direction of the release will determine the gas motion. Localized air
currents due to wind or ventilation will also affect gas movement. At low concentrations
the effect of buoyancy becomes less significant because the density of the hydrogen-air
mixture is similar to that of air.
VI-2
As a consequence of these dispersion properties, hydrogen gas tends to disperse readily

and form an ignitable mixture with air. However, in an unconfined atmosphere this
mixture will quickly dilute to levels below the lower flammability limit. So, although the
rapid mixing properties of hydrogen lead to a more rapid formation of a combustible
mixture, they also lead to a faster dispersal and generally shorter duration of a flammable
hazard than for other fuels on an equal volume basis.
Hydrogen Gas and Flame Detection
Hydrogen is a colorless, odorless and tasteless gas. Its presence cannot be detected by
human senses. In addition, the unique characteristics of a hydrogen fire make it difficult
to perceive with the human senses. In contrast to hydrocarbon fuels, which radiate most
of their energy as visible light and heat, a hydrogen flame radiates significantly less heat
and virtually no visible light. Instead, significant energy from a hydrogen flame is
radiated in the ultraviolet region. As a result, hydrogen burns with a pale blue, almost
invisible flame that is almost visually imperceptible in artificial light or daylight. Equally
important, human physical perception of the heat from a hydrogen fire doesn't occur until
direct contact with the combustion gases.
Flammability and Ignition
Hydrogen has a much wider range of flammability in air (4% to 75% by volume) than
methane (5% to 17% by volume), propane, or gasoline, and the minimum ignition energy
(for a stoichiometric mixture) is about an order of magnitude lower (1/16th that of
methane).
These characteristics would tend to indicate that flammability is a greater risk for
hydrogen than for other fuels. However, these comparisons may not be as significant as
they appear. In many accidental situations the lower flammable limit (LFL) is more
important. The LFL for hydrogen is similar to that of methane, about twice that of
propane and four times that of gasoline. In addition, the minimum ignition energy for
hydrogen at the LFL is also similar to that of methane. Weak ignition sources, such as an
electrostatic spark, are often noted as being sufficient to ignite a combustible hydrogen-
air mixture. However, a weak electrostatic spark from the human body releases about
0.10 Joules, enough energy to ignite methane, propane, gasoline and other fuels as well.
Combustion Characteristics
Hydrogen-oxidizer mixtures can combust either as a fire at a fixed point, a deflagration,
or a detonation. Depending on the rate of release of hydrogen from the source, fires can
produce outputs ranging from that of a small candle to a high-pressure jet. At a fixed
point hydrogen gas can burn as a jet flame, with combustion taking place along the edges
of the jet where it mixes with sufficient air. In a stationary mixture in the open with no
confinement, a flammable hydrogen mixture will undergo slow deflagration. Deflagration
refers to a flame that relies on heat- and mass-transfer mechanisms to combust and move
into areas of unburnt fuel.
If the flame speed is accelerated, perhaps due to extreme initial turbulence or turbulence
induced by obstacles or confinement, the result is an explosion. In the extreme case the
flame speed becomes supersonic and results in detonation. Once initiated, detonation is
self-sustaining (no further turbulence or confinement is required) as long as the
VI-3
combusting mixture is within the detonatable range. A detonation explosion is capable of

causing much greater physical damage due to the significantly higher pressure that is
generated (as great as 20 times the initial stoichiometric pressure versus about 8 times the
initial pressure for a deflagration).
The lower radiation from a hydrogen flame makes the flame itself hotter than a
hydrocarbon flame, and objects engulfed by a hydrogen flame tend to heat faster.
However, the lower radiation of heat from the flame means that there is less heat
transferred to objects or people outside the flame.
The heat of combustion of hydrogen per unit weight is higher than any other material, but
hydrogen has a relatively low heat of combustion per unit volume. Thus the combustion
of a given volume of hydrogen will release less energy than the same volume of either
natural gas or gasoline.
Hydrogen Embrittlement and Material Compatibility
Prolonged exposure of some high strength steels to hydrogen can cause them to lose their
strength, eventually leading to failure. This is known as hydrogen embrittlement and
occurs when hydrogen permeates into the lattice structure of the material, reacting with
carbon atoms in the steel to form methane. Sensitivity to hydrogen embrittlement is
influenced by numerous parameters, including plastic deformation, cyclic loading,
hydrogen purity, temperature, and pressure. Hydrogen embrittlement is a particular issue
for ferritic steels, and occurs at ambient temperatures and elevated pressures. The
problem is exacerbated when the steel is subjected to mechanical stresses. The processes
take place on freshly exposed metallic surfaces that are likely to form at surface defects
or other stress raisers as a result of stress-induced local plastic deformation processes.
Suitable metals for gaseous hydrogen service include austenitic stainless steel with
greater than 7% nickel (such as 304, 304L, 308, 316, 321, 347), copper and its alloys
(such as brass, bronze and copper-nickel), and aluminum and its alloys. Non-metallic
materials that can be used in gaseous hydrogen service for valve seats, gaskets, etc.
include Buna-N, Viton, Kel-F, and Teflon.
Physiological Hazards
Hydrogen is non-toxic, but it can cause asphyxiation in a confined area due to
displacement of oxygen. Smoke inhalation, a primary cause of injury due to fires, is
considered less serious in the case of hydrogen because the sole product of combustion is
water. However, secondary fires can produce smoke and other combustion products that
present a health hazard.
2. Handling Compressed Gases

The test station is designed to receive hydrogen at a maximum inlet pressure of 90 psig.
A combustible gas such as hydrogen can be hazardous at this pressure level. Greater
pressure hazards may exist elsewhere in the facility where hydrogen used on the test
station is stored and conveyed at higher pressures. The following information has been
adapted from the Compressed Gas Associations pamphlet P-1, Safe Handling of
VI-4
Compressed Gases in Containers and Lawrence Livermore National Laboratorys

Environmental Safety and Health Manual, Volume II, Part 18.1: Pressure.
Note: Only authorized, trained personnel should work with compressed gases.
General Precautions
Secure both ends of gas hoses with a hose restraint to prevent whipping in the event
the hose or fitting fails. For systems in occupied areas, support and secure the hose
and tubing at least every 7 ft.
Do not use an open flame to leak-check a gas cylinder, piping, or fittings; use
soapsuds or a leak detection solution.
Remove the talc and dust from a new hose before connecting it.
Never interchange regulators and hose lines with one type of gas for another.
Explosions can occur if flammable gases or organic materials come in contact with
oxidizers (e.g., oxygen) under pressure.
Before using equipment (regulators, pressure gauges, gas hoses, etc.) in a pressurized
gas system, make sure that the equipment is adequately rated to meet system pressure
requirements.
Never leave pressure on a hose or line that is not being used. To shut down a system,
close the cylinder valve and vent the pressure from the entire system.
B. Test Station Safety Features

The fuel cell test station is equipped with features to ensure safe system operation. These
features include: hydrogen gas alarm, pressure relief devices, main power switch (which
can be used as an emergency shutdown switch), software-controlled safety shutdowns,
and intrinsic safety design (i.e. if electrical power is lost, all relays, solenoid valves and
power contactors will revert to a safe condition). These hardware and software safety
features are described in detail in Chapters I and II.
Test station users should also be familiar with and have access to the circuit breaker that
provides test station power at the main electrical panel. This provides an additional means
to cut power to the test station in the event that the switch on the station cannot be
accessed safely.
C. Safety Equipment and Guidelines

The following instructions and guidelines will help system operators to use the facilitys
safety equipment effectively.
1. Fire extinguishers
Fire extinguishers must be located in the fuel cell test station area. See guidelines later in
this chapter (Hazard Identification and Response: Fire and Combustion Hazards) on
controlling hydrogen fires and other types of fires. Fire extinguishers need to be clearly
labeled according to the class of fire they are suitable for. These codes, as given in NFPA
10, are:
VI-5
Class A Fires in ordinary combustible materials such as wood, cloth, paper,

rubber, and many plastics.
Class B Fires in flammable liquids, oils, greases, tars, oil-base paints, lacquers and
flammable gases.
Class C Fires that involve energized electrical equipment where the electrical
conductivity of the extinguishing medium is of importance; when electrical
equipment is de-energized, extinguishers for class A or B fires may be safely used.
Class D Fires of combustible metals such as magnesium, titanium, zirconium,
sodium, lithium and potassium.
Fire extinguishers must be kept in their designated locations and in plain sight. Operators
should notify the appropriate safety officer of any discharged, partially discharged,
missing or mislocated fire extinguishers.
Fire extinguishers at the site should be of type A:B:C. Only Halon fire extinguishers
should be used on a fire involving personal clothing. The materials from other
extinguisher types can cause asphyxiation by cutting off oxygen to a person surrounded
by the cloud of chemicals.
In order to effectively operate a fire extinguisher, one should remember P-A-S-S.
P -- Pull the fire extinguisher pin
A -- Aim the hose at the base of the fire
S -- Squeeze the handle
S -- Sweep the hose back and forth
2. Hydrogen Gas Detection

A portable hydrogen gas or combustible gas detector can be used to check for hydrogen
leaks at the fuel cell test station. Such a device can be a useful diagnostic tool when
trying to locate a leak in the hydrogen system plumbing.
3. Hydrogen Flame Detection

The unique characteristics of a hydrogen fire make it difficult to perceive with the human
senses. The flame is nearly invisible, especially in daylight, and perception of the heat
from a hydrogen fire doesn't occur until direct contact with the combustion gases. A dry
straw broom can be used to detect small hydrogen fires by holding the broom out in front
of you while approaching the area where the hydrogen fire is suspected. Alternatively, a
portable UV detector can be used to detect hydrogen fires.
4. Safety Glasses
Operators should wear safety glasses whenever working in the fuel cell test station lab or
performing any operations involving the hydrogen plumbing or hazardous substances. In
order to ensure proper eye protection is used, eyewear should be comfortable, fit snugly
over the eyes and around the face, and not impede the wearers movement. To maintain
optimal safety, eye protection should be kept clean and in good condition.
VI-6
5. Hearing Protection
When performing tasks with high pressure gases, such as testing pressure relief devices,
it is a good idea to wear hearing protection. If a fitting or component in the high pressure
gas system were to rupture, there would be a loud noise capable of causing hearing
damage.
6. Fire Blanket
The fuel cell test station area should be equipped with a fire blanket. This can be used to
extinguish a fire involving somebody's clothing or hair. The appropriate procedure for
extinguishing such a fire is to have the victim stop, drop and roll on the floor with the
blanket wrapped around their body.
D. Hazard Identification and Response

The primary potential hazards associated with the test station include:
high-pressure gas accidents,
fire, and
electric shock.
This section of the O&M Manual discusses these hazards and the appropriate response to
hazardous incidents.
1. High Pressure Hazards

Any gas can be dangerous to handle at high pressure, flammable or not. Hazards
associated with gas leaks in the high-pressure hydrogen system include: injury from
projectiles associated with a catastrophic failure of high pressure plumbing, fire and
explosion hazards, asphyxiation via oxygen displacement, hose whipping, gas
entrainment in the blood system due to direct contact of a high pressure gas stream with
the skin, and hearing damage due to a loud noise associated with a high pressure gas
system rupture.
Hydrogen is provided to the test station at a maximum pressure of 100 psig. The pressure
is further reduced to a low level of only 3 to 5 psig before the hydrogen gas reaches the
fuel cell.
Note: Only authorized, trained personnel should work with compressed
! gases.
RESPONSE:
A hydrogen gas leak or high pressure rupture has the potential for fire and/or explosion.
Rapid response is the best way to prevent or minimize equipment damage and personnel
injury. If a hydrogen gas system leak or rupture occurs, perform the following steps:
a. Shut down the fuel cell test station by placing the main power switch in the OFF
position or by tripping the circuit breaker that provides test station power at the main
VI-7
electrical panel (whichever is safer). An emergency shutdown will close all solenoid
valves and shut off power to all components except the DC power supply,
datalogger, water conductivity sensor, and the AC outlets provided for the control
computer. Shutting down will slow and eventually stop the leak unless the gas is
leaking upstream of the test stations hydrogen supply solenoid valve. If the leak is
from upstream of the solenoid valve and it is safe to do so, close the hydrogen tank
valve to stop the gas flow.
b. Isolate the area to prevent personnel injury.
c. If the gas leak has been stopped and adjacent equipment or structures have
caught on fire, put out the fire using an extinguisher or call the fire department.
d. Post warning signs and isolate the area until the high pressure or gas leak hazard
has been resolved.
2. Fire and Combustion Hazards

Hydrogen gas constitutes the single greatest fire hazard on the fuel cell test station. See
Section A.1 of this chapter (Properties of Hydrogen Gas) for a description of the basic
properties of hydrogen gas. Hydrogen gas under pressure, as in this system, can be a
special fire hazard because pressurization allows the storage of large quantities of fuel in
a relatively small space.
RESPONSE:
Hydrogen fires are nearly invisible, especially during daylight hours. If you have any
suspicion that a hydrogen fire may be burning in a particular area, it is best to stay away
from that area. If you must enter the area, do so cautiously and slowly with a combination
ultraviolet/infrared (UV/IR) detector to check your path in front of you. Do not proceed if
the UV/IR detector shows a significant heat source in your path. If UV/IR detector is not
available, hold a broom extended in front of you. If the broom scorches or catches fire, do
not proceed.
Guidelines for Extinguishing Hydrogen Fires

The only safe way to extinguish a flammable gas fire is to stop the flow of gas. If the
flow cannot be stopped, allow the entire contents of the cylinder to burn. Cool the
cylinder and surroundings with water from a suitable distance. Do not extinguish the fire
if you are unable to stop the flow of hydrogen doing so may increase the hazard by
permitting the formation of ignitable or explosive mixtures with air. These may propagate
to a source of ignition.
Excessive pressure may develop in gas cylinders exposed to fire. This can result in
explosion regardless of cylinder contents (initial pressure or gas type). Cylinders with
pressure relief devices (PRDs) may release their contents through such devices when
exposed to fire. Cylinders without PRDs have no provision for controlled release and are
therefore more likely to explode if exposed to fire.
VI-8
Small Fires: Use one of the fire extinguishers located in the fuel cell test station area.
Large Fires: Evacuate the premises and contact the fire department immediately (dial
911).
Stop the flow of gas if at all possible. This is the top priority. To do this, shut down
the fuel cell test station by placing the main power switch in the OFF position or by
tripping the circuit breaker that provides test station power at the main electrical panel
(whichever is safer). An emergency shutdown will close all solenoid valves and shut
off power to all components except the DC power supply, datalogger, water
conductivity sensor, and the AC outlets provided for the control computer. Shutting
down will slow and eventually stop the leak unless the gas is coming from upstream
of the solenoid valve. If the leak is from upstream of the solenoid valve and it is safe
to do so, close the hydrogen tank valve to stop the gas flow.
Shut off all electrical power to the test station and surrounding areas by tripping the
circuit breakers in the main electrical panel.
Approach the fire from an upwind position, as the flame can flash downwind very
easily.
Extinguish the fire by aiming the fire extinguisher hose at the base of the fire,
squeezing the handle and sweeping the hose back and forth.
If necessary, allow the fire to burn itself out. This should happen quickly if the flow
of hydrogen is stopped, as hydrogen disperses rapidly.
Provided all electrical power in the area has been disconnected, spray flammable
materials near the fire with a water mist or soak the materials in some other manner to
prevent the fire from spreading.
If there is a chance that pure oxygen or compressed air is mixing with the burning
hydrogen, the flow of oxygen or compressed air should be shut off immediately.
Post warning signs and isolate the area until the fire and combustion hazard has been
resolved.
3. Electric Shock Hazards

The fuel cell test station UPS is supplied 120 VAC single phase power. A two-gang side-
mounted outlet on the test station supplies 120 VAC single-phase power to the control
computer or other external user-supplied instrumentation (up to a maximum of 5 Amps
total for both outlets). A 24 VDC power supply provides power for the test stations DC
devices. In addition, the test station is equipped to handle DC power output from a fuel
cell ranging from 0 to 160 Amps DC and 0 to 50 VDC, up to a limit of 600W maximum
power. The 120 VAC power can produce a shock resulting in injury or death. It is
imperative that system operators follow standard electrical safety procedures when
working with these components (see the lockout/tagout procedure below).
Remember that circuits on the test station may be energized even when the system is in
standby mode. In addition, even when power to circuits has been disconnected, stored
electrical energy (i.e. in capacitors or batteries) may maintain high voltages on particular
electrical components. Before performing maintenance on or near any electrical
components, the technician should check for high voltages on electrical circuits using a
voltmeter.
VI-9
Water and electricity are both present on the fuel cell test station. Together, water and
electricity can be a deadly combination. System operators must use special caution when
working at the test station if water or other liquids have been spilled or have leaked in the
vicinity of the test station. If you notice that water has leaked onto or near to the stations
electrical components, shut down the station, disconnect AC power to the station, and
clean up the spill. Find and correct the cause of the spill or leak before you proceed with
further test station operations.
Note: Only authorized, trained personnel should work with the fuel cell test station
! electrical system.
RESPONSE:
If a person receives an electric shock, take the following steps:
1. Do not touch the victim if there is any possibility that they are still in contact with a
live electrical circuit.
2. If necessary, use a plastic or wooden implement such as a broomstick (something that
is NOT electrically conductive) to push the victim away from the live electrical
circuit.
3. Once the victim is safely separated from the electrical circuit, check for breathing and
a pulse. If the victim is not breathing, administer rescue breathing. If the victim does
not have a pulse, administer cardiopulmonary resuscitation (CPR).
4. Call 911.
5. Keep the victim warm.
6. The victim should not eat or drink until he or she has been seen by a doctor.
7. If an electrical shock hazard is still present at the test station, turn off the main power
switch. If the switch is not accessible, shut off electrical power to the test station by
tripping the circuit breaker that provides test station power at the main electrical
panel. This will shut off power to all components on the test station.
8. Post warning signs and isolate the area until the electrical hazard has been resolved.
E. Safety Policies
System operators must adhere to the following safety policies when operating the fuel
cell test station:
Only trained, authorized personnel should be allowed to operate and maintain the fuel
cell test station.
Personnel working with high pressure gases, flammable gases and/or electrical
systems must have adequate training and experience.
Use appropriate personal safety equipment on the job. Wear safety glasses at all times
when working in the fuel cell test station area or working with high pressure gases.
Wear hearing protection when working with high pressure gases.
Use the buddy system (work with at least one other researcher present and ready to
assist in case of an accident or emergency) when performing any operation,
maintenance or troubleshooting tasks on the fuel cell test station. Never perform
system operation, maintenance or repair tasks alone.
Be familiar with facility-wide safety policies.
VI-10
Tagout/Lockout Procedure
When any component on the fuel cell test station is being serviced or repaired, operators
must use the following tagout or lockout procedures to ensure personnel safety and avoid
accidental restarting of equipment during service procedures. The purpose of a tagout is
to provide clear notification to all personnel that the system or a system component is
being serviced and must not be operated. A lockouts purpose is to physically prevent
operators (or anyone else) from starting the system or system component while it is being
serviced. Devices used for tagout/lockout must meet requirements found in 29 CFR
1910.147, The Control of Hazardous Energy (Lockout/Tagout), and 29 CFR 1910.333,
Selection and Use of Work Practices (Electrical Safety-Related Work Practices). If a
piece of equipment is tagged out but not locked out, one additional safety anti-start
measure must be employed, such as opening of a circuit disconnect or physical blocking
of mechanical equipment. All new or temporary operators or operators assistants must
be shown these lockout/tagout procedures before working with the fuel cell test station.
Notify all personnel who operate or work in the vicinity of the equipment that a
tagout or lockout is being implemented, and which piece or pieces of equipment will
be affected.
Make sure that the person performing the tagout or lockout is familiar with the
equipment being serviced and knows how to tagout or lockout the equipment properly
and safely.
If the equipment to be serviced is in use, shut down the fuel cell test station.
Isolate any electrical equipment to be serviced from the electrical system by
disconnecting its source of power. Make sure that no residual energy (e.g. capacitors)
presents a safety threat.
Depressurize the hydrogen gas system if any gas system equipment is to be serviced.
Tagout or lockout the opened electrical disconnects, electrical power plugs or closed
gas system valves that have been used to isolate the equipment being serviced.
Check that no personnel are working on or near the equipment to be serviced, then
test that the electrical disconnect tagout/lockout is in effect by trying to start the
equipment. If the equipment starts, it has not been isolated correctly. If the equipment
does not start, proceed with servicing.
When servicing is completed, make sure all personnel are clear of the equipment,
remove tagout/lockout devices, close the electrical disconnect(s), and re-start
equipment as appropriate.
F. Material Safety Data Sheets (MSDS)

A Material Safety Data Sheet (MSDS) for hydrogen is included as an appendix of this
manual. MSDSs provide safety information on any potentially hazardous or toxic
substances. An MSDS is required to provide the following information:
Product and company information
Composition/ingredient information
Hazards identification
First aid measures
VI-11
Fire fighting measures

Accidental release measures
Handling and storage
Exposure controls
Personal protective equipment
Physical/chemical properties
Stability and reactivity
Toxicological information
Ecological information
Disposal considerations
Transport information
Regulatory information
G. Additional Information Resources

SERC recommends that test station users consult the following documents for more
detailed information on working safely with hydrogen.
National Aeronautics and Space Administration, Glenn Research Center Safety Manual,
Chapter 6: Hydrogen.
www.nfpa.org/assets/files/PDF/CodesStandards/HCGNASAHydrogenCh06.pdf
International Standards Organization. Basic Considerations for the Safety of Hydrogen
Systems. ISO/PDTR 15916. 2002.
Air Products Corporation, Safetygram #4, Gaseous Hydrogen.
http://www.airproducts.com/nr/rdonlyres/3c6d640e-93c5-4bd0-8f21-
8f7344c66554/0/safetygram4.pdf
Compressed Gas Association Documents:
CGA AV-1, Safe Handling and Storage of Compressed Gases (video)
CGA G-5, Hydrogen
CGA G-5.4, Standard for Hydrogen Piping Systems at Consumer Locations
CGA S-1.3, Pressure Relief Device Standards - Part 3 - Stationary Storage
Containers for Compressed Gases
CGA G-5.5, Hydrogen Vent Systems
CGA P-1, Safe Handling of Compressed Gases in Containers
National Fire Protection Association, NFPA 50A Standard for Gaseous Hydrogen
Systems at Consumer Sites.
VI-12
Test Station Subsystem Diagrams
Air System
Hydrogen System
Water System
AC Electrical Schematic
Safety Shutdown Circuit
Electronic Load Schematic
Air from
cylinder
regulator
(~50 psig)
Air MFC
Mass Flow Meter
(0 - 50 slm)
S
to vent
Pressure
Gauge
(0-60"WC)
H2 Air
Title: SCHATZ Drawn By: G. Chapman Date: 12/19/08

Portable Test Station ENERGY
File Name: H2E3 Air System
RESEARCH
Comments: CENTER Scale: None Revision:
Hydrogen flex hose
Supply
(80-100 psig)
3/8" tubing Vent

up to inlet
of LPR
Mass Flow
MFM
Meter
(0-20 slm)
Low Pressure
Regulator relief line
1/2" tubing/hose from FC
Supply outlet to atmosphere
S
Solenoid
Valve Purge
Solenoid
Fuel Valve
Cell
Pressure S
Gauge
(0-15 psig)
Purge Drain
Drum Valve
Title: Portable Test Station Hydrogen System SCHATZ Drawn By: G. Chapman Date:08/27/09
ENERGY
RESEARCH File Name: H2E3 H2 System
Comments: CENTER Scale: Revision:
Heat 120 V AC in
Exchanger controlled by
(Thermatron digital output
Manual Fill Solenoid 730 SLM1)
Valve (ASCO SC8262G226)
Overflow Drain
S
Make-up water
from DI water
system
Float Switch - digital input
120 V AC in (Cole-Parmer
Rotameter
controlled by HW-07187-04)
(Omega FL46302)
digital output Reservoir
(Cole-Parmer
3 - Wat Humid Out* HW-29820-10)
(FC Water Temp Throttle valve
exiting
stack)
0 -Wat PS Out*
(FC Water Circulation
Temp @ T T Pump
Power/Humid Water System
(March Drain Valve
Section AC-2CP-MD)
Transition)
120 V AC in
Fuel Cell
controlled by
digital output Key
500 W Max
Resistivity
Indicator = hose
(Cole-Parmer C-01504-37)
T2 - Wat PS In* = hard pipe

(FC Water Temp T Auxiliary
entering stack) Digital Input Drain
Stack Water
600 W Inline Heater DI Sump
Pressure Gauge
(Omega AHPF-081) (Lang Engr 158003 w/
Omega
cartridge PCL-2411)
* All 3 Thermocouples PGM-63L-15PSI
(Omega TMTSS-062U-6) - analog inputs 120 V AC in controlled by digital output
Title: Temperature Control System SCHATZ Drawn By: Engel w/ props to Chapman, Reis Date:03/02/09
H2E3 Test Stations ENERGY
RESEARCH File Name:H2E3 Water System1.vwx
Comments: Based on Auburn System Drawing CENTER Scale:None Revision: 2
HOT
15A
A Power IO - 25 amp SSR part# HDA-3V25
B Opto22 - 10 amp SSR part# 120D10
C Opto22 - 3 amp SSR part# 120D3
A
6A 6A
6A 6A 6A
Safety
Relay
B C C C C C C B
Hydrogen
DO0 DO1 DO2 DO3 DO4 DO5 DO6 DO7
Alarm
0 1 2 3 4 5 6 7
ELoad
12VDC
Power
Relay
24VDC
Power
H
Supply F F P
0 1 2 3 4 5 6 6 7
N
Hydrogen Hydrogen Water Heat
120VAC H2 AC Conductivity DC 600W Air Supply Electronic Water
Alarm Outlets Probe Power Water Supply Purge Fill Exchanger Load Pump
15A Solenoid
Heater Solenoid Solenoid Solenoid Fan
Title: H2E3 Test Station 1 AC Electrical Schematic SCHATZ Drawn By: Scott Rommel Date: 8-14-09
ENERGY
File Name:
RESEARCH
Comments: CENTER Scale: Revision: A
Safety
Relay
AC Power In AC Power Bus
Alarm 2
N
RKI PS-2
Hydrogen
Monitor and
Alarm
24VDC
N Power +-
Supply
Functionallity -
When the RKI detects hydrogen in air at 10% of lower explosive limit (LEL) an
alarm will sound and the Alarm 1 light will come on. At 30% of LEL, Alarm 2 will
be activated and the contacts powering the Safety Relay will open. This will power
down the following AC devices:
H2, Air, H2 Purge, and Water Fill Solenoids
Heat exchanger fan
Water pump
Water heater
Electronic load cooling fan and DC power to the electronic load modules
This effectively powers down the entire test station except :

Hydrogen alarm
24VDC power supply
AC outlet to the conductivity indicator
AC outlet intended for use by the PC or laptop used to run the system.
Title: TS1 and TS2 Safety Shutdown Circuit

File Name: SCHATZ Designed By: Scott Rommel
Comments: H2E3 ENERGY Date: 8-20-09
TS1 and TS2 Safety Shutdown Circuit.vwx RESEARCH
CENTER Scale: Revision: A
+12VDC
Module A connector Module B connector
Thermal top view top view
Switch 1/4A 20 19 1/4A 20 19
90 C
+
Control 0-4 V = 0-160 A
Signal -
Polarizing Key Polarizing Key

1/4A 1/4A
2 1 2 1
GND
Title: SCHATZ Drawn By: Scott Rommel Date: 3-12-09

H23E Electronic Load Schematic ENERGY
File Name: Electronic Load Schematic v1.3.vwx
RESEARCH
Comments: CENTER Scale: none Revision: 1
Data Acquisition and Control Input/Output List and Calibrations
Digital Output (USB-6229)

Channel Name Device Controlled Physical Channel SSR Max Current
TS_DO_Heater Inline Heater port0/line0 25A
TS_DO_Air Solenoid port0/line1 10A
TS_DO_H2 Solenoid port0/line2 10A
TS_DO_Purge Solenoid port0/line3 10A
TS_DO_WaterFill Solenoid port0/line4 10A
TS_DO_Fan Fan port0/line5 10A
TS_DO_LoadEnable Load Relay and fan port0/line6 10A
TS_DO_Pump Pump port0/line7 25A
Digital Input (USB-6229)

Channel Name Device Read Physical Channel
TS_DI_Float Float switch port0/line8 (inverted)
Analog Output (USB-6229)

Channel Measurement Type Physical Units Calibration
Name Channel
TS_AO_Air Air MFC Signal AO0 slm 05 = 0-50
TS_AO_Load Load Setpoint Signal AO1 A 0-4 = 0-160
Analog Input (USB-6229)

Name Channel
TS_Vtap1 Cell 1 voltage AI0 mV 5 = 5000
TS_AirFlow Air Flow (MFC) AI16 slm 0-5 = 0-50
TS_H2Flow Hydrogen Flow (MFM) AI17 slm 0-5 = 0-20
TS_Current Load current shunt AI18 A y = 3005.6x 0.695
TS_Temp4 Temperature 4 (type T TC AI19 C 0-10 = 0-100
on Omega transmitter)
TS_Ambient Ambient Temp (type T TC AI21 C 0-10 = 0-100
on Omega transmitter)
TS_VFC Stack total voltage (2:1 AI22 V 5 = 10
voltage divider)
Analog Input (USB-9211A)

Name Channel
Temperature_0 Temperature 0 (type T TC) AI0 C Type T
Note: The four temperatures should be configured as an NI-DAQmx Task named
TS_Temperatures, using built-in CJC source and configured as 1 Sample (On Demand)
SERC Portable Fuel Cell Test Station Software Installation Instructions
Automated Install Instructions
1. Install NI-DAQmx version 8.8 or later (either from supplied discs or downloaded
from NI.com), selecting options for NI-DAQmx with LabVIEW 7.1 support, and
Measurement and Automation Explorer. Note that this installation may require
up to 7GB of available hard drive space to complete, and will take some time.
2. Launch the installer by opening Setup.exe in the Installer directory on
the software distribution disc. Follow onscreen directions to complete the
installation process.
3. Reboot the computer with the test station DAQ units connected via USB and the
test station powered on. Confirm that the devices are recognized and functioning
correctly.
Manual Install Instructions
1. Install NI-DAQmx version 8.8 or later (either from supplied discs or downloaded
from NI.com), selecting options for NI-DAQmx with LabVIEW 7.1 support, and
Measurement and Automation Explorer. Note that this installation may require
up to 7GB of available hard drive space to complete, and will take some time.
2. Copy the SERCPortableFCTestStation.exe application from the
Manual Install folder of the distribution disc to the desired location on the
hard drive; it does not require being installed in any specific location.
3. Launch NI-MAX (Measurement and Automation Explorer). Select Import
from the File menu within NI-MAX. Select the SERC_PTS.nce configuration
file in the Manual Install folder of the distribution disc as the file to import;
click Next and follow the prompts to import the configuration.
4. Reboot the computer with the test station DAQ units connected via USB and the
test station powered on. Confirm that the devices are recognized and functioning
correctly.
`
MATERIAL SAFETY DATA SHEET

SECTION 1. PRODUCT IDENTIFICATION
PRODUCT NAME: Hydrogen, compressed

CHEMICAL NAME: Hydrogen FORMULA: H2
SYNONYMS: None
MANUFACTURER: Air Products and Chemicals, Inc.
7201 Hamilton Boulevard
Allentown, PA 18195-1501
PRODUCT INFORMATION: 1-800-752-1597
MSDS NUMBER: 1009 REVISION: 4
REVISION DATE: June 1994
SECTION 2. COMPOSITION/INFORMATION ON INGREDIENTS
Hydrogen is sold as pure product >99%

CAS NUMBER:1333-74-0
EXPOSURE LIMITS:
OSHA: None ACGIH: Simple asphyxiant
SECTION 3. HAZARD IDENTIFICATION
EMERGENCY OVERVIEW
Hydrogen is a flammable, colorless, odorless, compressed gas packaged in cylinders at
high pressure. It poses an immediate fire and explosive hazard when concentrations
exceed 4%. It is much lighter than air and burns with an invisible flame. High
concentrations that will cause suffocation are within the flammable range and must not be
entered.
EMERGENCY TELEPHONE NUMBERS

(800) 523-9374 Continental U.S., Canada, and Puerto Rico
(610) 481-7711 other locations
POTENTIAL HEALTH EFFECTS INFORMATION:

INHALATION: Asphyxiant. It should be noted that before suffocation could occur,
the lower flammability limit of hydrogen in air would be exceeded possibly causing
both an oxygen-deficient and explosive atmosphere. Exposure to moderate
concentrations may cause dizziness, headache, nausea and unconsciousness.
Exposure to atmospheres containing 8-10% or less oxygen will quickly bring about
unconsciousness without warning leaving individuals unable to protect themselves.
Lack of sufficient oxygen may cause serious injury or death.
MSDS# 1009 HYDROGEN Page 1 of 5

PUB # 310-406
EYE CONTACT: None
SKIN CONTACT: None
CHRONIC EFFECTS: None
OTHER EFFECTS OF OVEREXPOSURE: None
EXPOSURE INFORMATION:
ROUTE OF ENTRY: Inhalation
TARGET ORGANS: None
EFFECT: Asphyxiation (suffocation)
SYMPTOMS: Exposure to an oxygen-deficient atmosphere (<19.5%) may cause dizziness,
drowsiness, nausea, vomiting, excess salivation, diminished mental alertness, loss of consciousness,
and death.
MEDICAL CONDITIONS AGGRAVATED BY OVEREXPOSURE: None
CARCINOGENIC POTENTIAL: Hydrogen is not listed by NTP, OSHA or IARC.
SECTION 4. FIRST AID

INHALATION: Persons suffering from lack of oxygen should be removed to fresh air. If victim is not
breathing, administer artificial respiration. If breathing is difficult, administer oxygen. Obtain prompt
medical attention.
SKIN CONTACT: None
EYE CONTACT: None
INGESTION: None
NOTES TO PHYSICIAN: None
SECTION 5. FIRE AND EXPLOSION

FLASH POINT: AUTOIGNITION: FLAMMABLE LIMITS:
Flammable gas 565.5_C (1050_F) LOWER: 4% UPPER: 74%
EXTINGUISHING MEDIA: CO2, dry chemical, water spray or fog for surrounding area. Do not extinguish
until hydrogen source is shut off.
HAZARDOUS COMBUSTION PRODUCTS: None
SPECIAL FIRE FIGHTING INSTRUCTIONS: Evacuate all personnel from danger area. Immediately
cool container with water spray from maximum distance, taking care not to extinguish flames. If flames
are accidentally extinguished, explosive re-ignition may occur. Stop flow of gas if without risk while
continuing cooling water spray.
UNUSUAL FIRE AND EXPLOSION HAZARDS: Burns with a pale blue, nearly invisible flame.
Hydrogen is easily ignited with low-ignition energy, including static electricity. Hydrogen is lighter than air
and can accumulate in the upper sections of enclosed spaces. Pressure in a container can build up due
to heat, and it may rupture if pressure relief devices should fail to function.
SECTION 6. ACCIDENTAL RELEASE MEASURES

Evacuate immediate area. Eliminate any possible sources of ignition, and provide maximum explosion-
proof ventilation. Shut off source of hydrogen, if possible. If leaking from cylinder, or valve, call the
Air Products' emergency phone number. The presence of a hydrogen flame can be detected by
approaching cautiously with an outstretched straw broom to make the flame visible.

PUB # 310-406
SECTION 7. HANDLING AND STORAGE
STORAGE: Specific requirements are listed in NFPA 50A. Cylinder storage locations should be well-
protected, well-ventilated, dry, and separated from combustible materials. Cylinders should never
knowingly be allowed to reach a temperature exceeding 125 _F (52 _C). Cylinders of hydrogen should be
separated from oxygen cylinders or other oxidizers by a minimum distance of 20 ft., or by a barrier of
noncombustible material at least 5 ft. high having a fire resistance rating of at least _ hour.
Cylinders should be stored upright with valve protection cap in place and firmly secured to prevent falling
or being knocked over. Protect cylinders from physical damage; do not drag, roll, slide or drop. Use a
suitable hand truck for cylinder movement. Post "No Smoking or Open Flames" signs in the storage
areas. There should be no sources of ignition. All electrical equipment should be explosion proof in the
storage and use areas. Storage areas must meet national electric codes for class 1 hazardous areas.
HANDLING: Do not "open" hydrogen cylinder valve before connecting it, since self-ignition may occur.
Hydrogen is the lightest gas known and may collect in the top of buildings with out proper ventilation. It
may leak out of a system which is gas-tight for air or other gases. Leak check system with leak detection
solution, never with flame. If user experiences difficulty operating cylinder valve, discontinue use and
contact supplier. Use only approved CGA connections. DO NOT USE ADAPTERS. Never insert an
object (e.g., wrench, screwdriver, pry bar, etc.) into valve cap openings. Doing so may damage valve,
causing a leak to occur. Use an adjustable strap wrench to remove over-tight or rusted caps. Never
strike an arc on a compressed gas cylinder or make a cylinder a part of an electrical circuit.
SPECIAL PRECAUTIONS: Use piping and equipment adequately designed to withstand pressures to be
encountered. Use a check valve or other protective apparatus in any line or piping from the cylinder to
prevent reverse flow.
SECTION 8. PERSONAL PROTECTION/EXPOSURE CONTROLS

ENGINEERING CONTROLS: Provide natural or explosion-proof ventilation adequate to ensure
hydrogen does not reach its lower explosive limit of 4%.
RESPIRATORY PROTECTION:
General Use: None
Emergency Use: Air supplied respirators are required in oxygen-deficient atmospheres. Before
entering area you must check for flammable or oxygen-deficient atmospheres.
PROTECTIVE GLOVES: Work gloves are recommended when handling cylinders.
EYE PROTECTION: Safety glasses are recommended when handling cylinders.
OTHER PROTECTIVE EQUIPMENT: Safety shoes are recommended when handling cylinders.
SECTION 9. PHYSICAL AND CHEMICAL PROPERTIES

APPEARANCE AND STATE: Colorless gas at normal temperature and pressure.
ODOR: Odorless
MOLECULAR WEIGHT: 2.016
BOILING POINT (1 atm) : -423.0 _F (-252.8 _C)
SPECIFIC GRAVITY (Air =1): 0.06960
FREEZING POINT/MELTING POINT: -434.5 F (-259.2 _C)
VAPOR PRESSURE (at 70 F): Not applicable
GAS DENSITY (At 70 F (21.1 C) and 1 atm): 0.00521 lb/ft3 (0.08342 kg/m 3)
SOLUBILITY IN WATER (Vol/Vol at 60 F (15.6 C)): 0.019
SPECIFIC VOLUME (At 70 F (21.1 C) and 1 atm): 192 ft3/lb (11.99m3/kg)

PUB # 310-406
SECTION 10. REACTIVITY/STABILITY
CHEMICAL STABILITY: Stable
CONDITIONS TO AVOID: None
INCOMPATIBILITY (Materials to Avoid): Oxidizing agents. Some steels are susceptible to hydrogen
embrittlement at high pressures and temperatures.
REACTIVITY:
A) HAZARDOUS DECOMPOSITION PRODUCTS: None
B) HAZARDOUS POLYMERIZATION: Will not occur.
SECTION 11. TOXICOLOGICAL INFORMATION

Hydrogen is a simple asphyxiant.
SECTION 12. ECOLOGICAL INFORMATION

No adverse ecological effects are expected. Hydrogen does not contain any Class I or Class II ozone
depleting chemicals (40 CFR Part 82). Hydrogen is not listed as a marine pollutant by
DOT (49 CFR Part 171).
SECTION 13. DISPOSAL

WASTE DISPOSAL METHOD: Do not attempt to dispose of residual or unused product in the cylinder.
Return to supplier for safe disposal.
Residual product within process system may be vented at a controlled rate, to the atmosphere through a
vent stack that discharges to an elevated point. This stack should be in an isolated area away from
ignition sources.
SECTION 14. TRANSPORTATION

DOT/IMO SHIPPING NAME: Hydrogen, compressed
HAZARD CLASS: 2.1 (Flammable Gas)
IDENTIFICATION NUMBER: UN1049
PRODUCT RQ: None
SHIPPING LABEL(s): Flammable gas.
PLACARD (When required): Flammable gas.
SPECIAL SHIPPING INFORMATION: Cylinder should be transported in a secure upright position in a
well ventilated truck. NEVER TRANSPORT IN PASSENGER COMPARTMENT OF A VEHICLE.
Shipment of compressed gas cylinders which have not been filled with the owner's consent is a violation
of Federal law (49 CFR Part 173.301 (b)).
SECTION 15. REGULATORY INFORMATION

U.S. FEDERAL REGULATIONS:
EPA - ENVIRONMENTAL PROTECTION AGENCY
CERCLA: Comprehensive Environmental Response, Compensation, and Liability Act of 1980
(40 CFR Parts 117 and 302):
Reportable Quantity (RQ): None

PUB # 310-406
SARA: Superfund Amendment and Reauthorization Act
SECTION 302/304: Requires emergency planning on threshold planning quantities (TPQ) and
release reporting based on reportable quantities (RQ) of EPA's extremely hazardous substances
(40 CFR Part 355).
Extremely Hazardous Substances: None
Threshold Planning Quantity (TPQ): None
SECTIONS 311/312: Require submission of material safety data sheets (MSDSs) and chemical
inventory reporting with identification of EPA defined hazard classes (40 CFR Part 370). The
hazard classes for this product are:
IMMEDIATE: No PRESSURE: Yes
DELAYED: No REACTIVITY: No
FLAMMABLE: Yes
SECTION 313: Requires submission of annual reports of release of toxic chemicals that appear in
40 CFR Part 372.
Hydrogen does not require reporting under Section 313
40 CFR PART 68: Risk Management for Chemical Accidental Release. Requires the development
and implementation of risk management programs at facilities that manufacture, use, store, or
otherwise handle regulated substances in quantities that exceed specified thresholds.
Hydrogen is not listed as a regulated substance. However, any process that involves a
flammable gas on site in one location, in quantities of 10,000 pounds (4,553 kg) or greater, is
covered under this regulation.
TSCA: Toxic Substance Control Act: Hydrogen is listed on the TSCA inventory.
OSHA - OCCUPATIONAL SAFETY AND HEALTH ADMINISTRATION:
29 CFR 1910.119: Process Safety Management of Highly Hazardous Chemicals. Requires
facilities to develop a process safety management program based on Threshold Quantities (TQ) of
highly hazardous chemicals.
Hydrogen is not listed in Appendix A as a highly hazardous chemical. However, any process
that involves a flammable gas on site in one location, in quantities of 10,000 pounds (4,553 kg)
or greater is covered under this regulation unless it is used as fuel.
SECTION 16. OTHER INFORMATION

OTHER INFORMATION:
NFPA RATINGS: HMIS RATINGS:
HEALTH: =0 HEALTH: =0
FLAMMABILITY: = 4 FLAMMABILITY: = 4
REACTIVITY: =0 REACTIVITY: =0
SPECIAL: = SA (CGA recommends this to designate simple asphyxiant)

PUB # 310-406

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Fuel Cell Test Station

Operation and Maintenance Guide

Prepared by Schatz Energy Research Center

I. Test Station Description

Chapter I: Test Station Description

Figure I-1. Test Station

Figure I-2. Air Supply System

Figure I-3. Hydrogen Delivery System

Figure I-4. Water System Plumbing (front view).

Figure I-5. Water System Plumbing (rear view)

D. Electrical System and Electronic Load

Figure I-6. Hydrogen Alarm Panel and Main Power Switch

Figure I-7. DIN-Rail Mounted Devices

Figure I-8. Solid State Relays

Figure I-9. Electronic Load

E. Fuel Cell Stack

Figure I-10. Fuel Cell Stack

F. Monitoring and Control Hardware

Figure I-11. Data Acquisition Modules

G. Test Station Software

Figure I-12. Software Front Panel

H. Safety Control System

1. Test Station Requirements

Air Supply and Exhaust

Hydrogen Gas Supply and Venting

Deionized Water Supply and Drainage

2. Fuel Cell Requirements

Water Circulation/Temperature Control

Chapter II: Test Station Software

1. Control Software Interface

Figure II-1. Software Front Panel

Table II-1. Air System Controls, Indicators, and Settings

Air Flow (slm) Minimum Airflow (slm)

Figure II-2. Air System Tab

Figure II-3. Hydrogen System Tab

Figure II-4. Water System Tab

Figure II-5 is a screen shot of the safety controls and settings.

Figure II-5. Safety Tab

WARNING: During normal operation, all of the software safeties should be

Open Load Profile Interval Time Load Setpoint (Amps)

Figure II-6. Load Tab: Constant Current Mode

Figure II-7. Load Tab: IV Curve Mode

Figure II-8. Load Tab: Load Profile Mode

Figure II-9. Load Profile Interface: Profile Manipulation Tab

Figure II-10. Load Profile Interface: Profile Execution Tab

Figure II-11. Load Profile Interface: Instructions Tab

Figure II-12. File Tab

Figure II-13 contains a diagram of the fuel cell indicators.

Figure II-13. Front Panel Data Indicators

Figure II-14. Time Chart Tab

Figure II-15 Shows the A VS B tab.

Figure II-15. Y vs X Chart Tab

Figure II-16. Error Status display

Combined Read Write Configuration (available only at system start-up)

Figure II-17. Read Write Configuration

Figure II-18. Configuration Files

Current Stack Info (available only at system start-up)

The system is provided with an 8-cell, 300 cm2 stack.

Optional parameters are:

The operator can:

Figure II-19. Current Stack Info

Chapter III: Test Station Operation

A. Fuel Cell Stack Connections