Intelligent Energy FCPM, User Manual

Page 1: ...2 4kW UAV Fuel Cell Power Module User Manual Users must read all instructions provided and retain the manual for future reference Document No 10010371 ...

Page 2: ...idereasonableprotectionagainstharmfulinterferenceinaresidential installation Thisequipmentgenerates usesandcanradiateradiofrequency energyand ifnotinstalledandusedinaccordancewiththeinstructions maycause harmfulinterferencetoradiocommunications However thereisnoguaranteethat interferencewillnotoccurinaparticularinstallation Ifthisequipmentdoescause harmfulinterferencetoradioortelevisionreception w...

Page 3: ...te procedure 18 6 7 Configuration update procedure 18 6 8 LED states 18 7 Logging and data connections 19 7 1 SD card formatting 19 7 2 SD card data format 19 7 3 Configuration format 19 7 3 1 Configuration parameter definitions 19 7 4 UART format 20 7 5 CAN format 21 7 5 1 CAN data to FCPM 21 7 5 1 CAN Data sent by FCPM 22 8 Electrical considerations 24 8 1 Battery charge limits 24 8 2 Emergency ...

Page 4: ...mum of 1m3 min of oxygen is required for operation Up to of 20m3 min air is required for cooling FCPM not to be used in dusty smoky or corrosive gas environments Do not use FCPM in rain or snow During integration there is a risk of exposed electrical conductors Pressurised hydrogen present Highly flammable Do not operate the FCPM if the casing is damaged or missing FCPM should be inspected for dam...

Page 5: ...ar 0 25Bar 10PSI 3PSI Hydrogen consumption rate g hr 2 4kW 160 190g hr Hybrid batteries Two default hybrid batteries configurable 2 6S in series Dimensions per battery 130 40 40mm Mass per battery 535g Capacity per battery 3300mAh Environmental operating conditions Startup temperature 5 C to 40 C Operating temperature 5 C to 40 C Storage temperature 10 C to 70 C System warranty 1000hrs Safety feat...

Page 6: ...6 2 Key components 2 2 System diagram Stack Power Module 1 SPM 1 Power Output Module POM FCPM exploded rear view Central Module Power Control Module PCM Stack Power Module 2 SPM 2 ...

Page 7: ... 2 Positive Output 3 Battery Positive 4 FCPM In 5 FCPM Out 6 Battery Diagnostic Module BDM 2 7 Battery Diagnostic Module BDM 1 Start Button Status LED Fuel Cell Power Module FCPM Front view FCPM Top View SPM 2 SPM 1 Central Module Central Module SPM 1 SPM 2 6 3 1 2 7 4 5 ...

Page 8: ...8 HMI UART CAN 9 HMI Digital Analogue 10 Regulator Interface 11 SD Card SPM 1 Electronics Cooling Fan SPM 2 Electronics Cooling Fan Power Control Module PCM FCPM Rear View Bottom View SPM 2 Central Module SPM 1 11 10 9 8 ...

Page 9: ... Ring to Batt and battery negative to common ground GND 4 Connect load positive to PWR and load negative to common ground GND 5 Use the bottom terminal with an M8 button head screw to attach the cable max torque 1 5Nm 6 Feed the cable through the housing battery positive connector 3 7 Use the top terminal with an M8 button head screw to attach the cable max torque 1 5Nm 8 Feed both the battery neg...

Page 10: ...T GND x2 PWR 1 5 N m SPM 2 removed for clarity Steps 1 3 in reverse STEP 3 STEP 1 STEP 2 STEP 4 S BAT GND x2 PWR 1 5 N m SPM 2 removed for clarity 10 3 Assembly 3 1 1 Disconnecting SPMs from central module to allow power connection ...

Page 11: ...STEP 5 Steps 1 3 in reverse STEP 5 Steps 1 3 in reverse 11 3 Assembly 3 1 2 Connecting SPM to central module ...

Page 12: ...mum of two mounting brackets in total Each SPM must have at least one support Recommended mounting points on the system are labelled in the figure below Two optional mounting brackets are included These can be used to aid integration and can be attached to any of the labelled mounting points The 2 4kW unit must be securely attached to the vehicle or test fixture Mounting bracket 2x M4 tapped threa...

Page 13: ...re shown in the diagram below 3 3 Air flow restrictions 3 3 1 Electronics air flow Up to 1m3 min of airflow is required to the power electronics located at the bottom of each SPM Do not cover the vents when mounting airflow must not be blocked when operating the FCPM SPM 1 Power electronics fans Do not cover SPM 2 ...

Page 14: ...atible material with anti static and low hydrogen permeability is required Recommended tubing 6mm OD x 4mm ID anti static polyurethane SMC TAU0604B 20 4 2 Hydrogen specification When installing and operating hydrogen systems hydrogen general safety guidance should be considered ISO TR 15916 basic considerations for the safety of hydrogen systems for more detailed information The hydrogen purity sh...

Page 15: ...connected to an Intelligent Energy FCPM Please refer to the Light Weight LW Regulator user manual for details of how to mount the Regulator to the cylinder The HFLW regulator gas connections are identical to the LW Regulator so may be used for reference https www intelligent energy com uploads product_guides 53527_IE_ _ Lightweight_Hydrogen_Regulator_User_Manual_August_2019 pdf Note Ensure the hyd...

Page 16: ...nection SPM2 Current ports that are not used or are optional for operation are Connection No Description Comments 4 FCPM Out Do not use If connected unit is slave 5 FCPM In Do not use unit is master if not connected 6 Battery diagnostics out Do not use 7 Battery diagnostics in Do not use 8 HMI UART CAN At least one HMI interface must be in place 9 HMI Analogue Digital At least one HMI interface mu...

Page 17: ...However step 6 must be changed to 1 Pull up 3 3V start pins Start 1 and Start 2 on the HMI analogue digital connector for 4 seconds 6 3 Shutdown using the Start button The procedure to shut down the FCPM 1 Press button for 4 seconds 2 Wait until LED stops flashing orange before moving to next step removing battery early will corrupt the micro SD card 3 Disconnect batteries 4 Isolate hydrogen cylin...

Page 18: ...ro SD Card and open IntelligentEnergy folder on the micro SD card 4 Copy the Load Config file and image folder into IntelligentEnergy folder 5 Re insert micro SD card to the FCPM 6 Reconnect batteries 7 Wait for LED to change from rapid amber flashing to rapid green flashing 8 Remove hybrid batteries 9 Configuration update has been completed 6 8 LED states FCPM LED located on top of central module...

Page 19: ...rs Parameter Unit Range Factory Setting 12S Target Output Voltage Volt 40 0 to 70 0 51 4 Battery Charging Current Limit Amp 0 0 to 7 5 7 5 SPM Power Limit Watt 500 to 2000 1500 Customer Serial Port NA NA Debug Serial Port NA NA CAN Data Format NA NA Stop System on Software Fault True False False Stop System on Engineering Fault True False False Wait for Start Command True False False Allow Single ...

Page 20: ...U State NA 7 PCM Error Flags A NA See Section 12 2 1 8 PCM Error Flags B NA 9 PCM Error Flags C NA 10 PCM Error Flags D NA 11 SPM1 Error Flags A NA See Section 12 2 2 12 SPM1 Error Flags B NA 13 SPM1 Error Flags C NA 14 SPM1 Error Flags D NA 15 SPM2 Error Flags A NA See Section 12 2 2 16 SPM2 Error Flags B NA 17 SPM2 Error Flags C NA 18 SPM2 Error Flags D NA Example data output 300 48 7 1600 1700 ...

Page 21: ...harger X Target Output Voltage V 1 X X X X X X X X Regen Voltage Delta V 2 X X X X X X X X Disable Regen 3 X Charge Current Limit A X X X X X X X SPM Power Limit W 4 X X X X X X X X Reserved 5 R R R R R R R R Reserved 6 R R R R R R R R Reserved 7 R R R R R R R R Of the values that are not digital Variable Name CAN message ID Scale units per bit Offset units Bits Maximum Value Transferable Minimum ...

Page 22: ... X X X X X X 7 X X Reserved R R R R R R PCM Flags A 1000 extended d1032 slave ID h408 slave ID 0 X X X X X X X X 1 X X X X X X X X 2 X X X X X X X X 3 X X X X X X X X PCM Flags B 4 X X X X X X X X 5 X X X X X X X X 6 X X X X X X X X 7 X X X X X X X X PCM Flags C 1000 extended d1040 slave ID h410 slave ID 0 X X X X X X X X 1 X X X X X X X X 2 X X X X X X X X 3 X X X X X X X X PCM Flags D 4 X X X X ...

Page 23: ... 3 X X X X X X X X SPM2 Flags B 4 X X X X X X X X 5 X X X X X X X X 6 X X X X X X X X 7 X X X X X X X X SPM2 Flags C 1000 extended d10 slave ID h400 slave ID 0 X X X X X X X X 1 X X X X X X X X 2 X X X X X X X X 3 X X X X X X X X SPM2 Flags D 4 X X X X X X X X 5 X X X X X X X X 6 X X X X X X X X 7 X X X X X X X X Of the values that are not digital Variable Name Update Time ms CAN message ID decima...

Page 24: ... able to supply the current requested by the load source Battery voltage or number of cells must be aligned with the configured voltage of the fuel cell system Battery capacity this will affect how long the battery can discharge for and will directly affect the batteries capability to provide peak or emergency power Typical battery configurations used are 12S 16S LiPo voltage range Note Not correc...

Page 25: ...e still in place and undamaged Hydrogen pipework is still in good condition with no leaks Fans rotate freely In the event of it being stored for more than 60 days the FCPM should be operated at 80 rated capacity for at least 40 minutes 9 2 Recommended storage To maintain the condition of the FCPM between operational usage the FCPM should be stored as follows The FCPM should be stored in a sealed p...

Page 26: ...e Intelligent Energy Product Support Team Either contact your local representative or email product support intelligent energy com Please provide as much detail of the issue as possible including unit serial number and log files When the 2 4kW FCPM or HFLW regulator reaches end of life please contact Intelligent Energy for support with reconditioning or disposal at product support intelligent ener...

Page 27: ... Analogue Digital Port No 9 This connector facilitates communications to and from the FCPM The connector is of the type JST 16CPT B 2A Pin No Description Range 1 12V 0 to12V 2 3 3V 0 to 3 3V 3 Start1 Digital in pull high to simulate button press 4 Start2 Digital in pull high to simulate button press 5 Enable Digital in not used at present 6 Status Digital out not used at present 7 Spare N A 8 Faul...

Page 28: ...s 9600baud 4 UART_Tx UART Comms 9600baud 5 Loop out Connect to pin 6 6 Loop in Connect to pin 5 7 Termination CAN A Complete loop 120Ω 8 Termination CAN B Complete loop 120Ω 9 Cust_CAN_H Customer CAN high 10 Cust_CAN_L Customer CAN low 11 0V 0V 12 Cable shield 0V Filtered 12 1 4 Battery diagnostics module Battery Volts or CVM Port No 6 7 Currently unused 12 1 5 FCPM In Port No 4 Currently unused 1...

Page 29: ...FaultStartFailed Before starting power good not returned from PCM board A 00800000 PomPowerGoodFaultInOperation When running power good not returned from POM board A 00400000 PomPowerGoodFaultStartFailed Before starting power good not returned from POM board A 00200000 BatteryUVCritical Critical Battery Under Voltage 44 3V A 00100000 BatteryUVShutdown Shutdown Battery Under Voltage 45 7V A 0008000...

Page 30: ...ference voltage above limit 3 15V C 00100000 ReferenceVoltageVeryHigh Sensor reference voltage high limit 3 5V C 00080000 ReferenceVoltageVeryLow Sensor reference voltage Low limit 3 0V C 00040000 SerialCustomerRxOverflow Serial Coms Fault C 00020000 SerialCustomerTxOverflow Serial Coms Fault C 00010000 SerialCustomerRxOverrun Serial Coms Fault C 00008000 SerialDebugRxOverflow Serial Coms Fault C ...

Page 31: ...t SPM Coms Fault D 00040000 Spm2RxecodeCrcFault SPM Coms Fault D 00020000 Spm1TxLengthFault SPM Coms Fault D 00010000 Spm1TxEncodeFault SPM Coms Fault D 00008000 Spm2TxLengthFault SPM Coms Fault D 00004000 Spm2TxEncodeFault SPM Coms Fault D 00002000 BadSpmIdentity SPM Coms Fault D 00001000 I2c1AckFailure I2C Fault D 00000800 I2c1ArbitrationLost I2C Fault D 00000400 I2c1BusError I2C Fault D 0000020...

Page 32: ...tart command A 00040000 PcmPwrCtrlLowPower2DenyStart Low power rail 2 is not enabled before start command A 00020000 PcmPwrCtrlSafety1DenyStart Safety 1 is not enabled before start command A 00010000 PcmPwrCtrlSafety2DenyStart Safety 2 is not enabled before start command A 00008000 FanPulseLoadOverTemperature Hardware over temperature trip detected A 00004000 StackSensor1OverTemperature Hardware o...

Page 33: ...80000 UnexpectedStackOutputCurrent Stack output current above threshold when the DCDC is not enabled 3A B 00040000 FanPulseOverCurrent Current to POC load resistor above threshold 250A B 00020000 UnexpectedFanPulseCurrent POC load resistor current above threshold when the load resistor is not enabled 3A B 00010000 LoadDcdcOutputOverVoltage Output voltage is above threshold 85A B 00008000 LoadDcdcO...

Page 34: ... C 00200000 Not currently in use C 00100000 Not currently in use C 00080000 Not currently in use C 00040000 Not currently in use C 00020000 Not currently in use C 00010000 Not currently in use C 00008000 Not currently in use C 00004000 Not currently in use C 00002000 Not currently in use C 00001000 Not currently in use C 00000800 Not currently in use C 00000400 Not currently in use C 00000200 Not ...

Page 35: ...0 Adc12MonitorLowIrqCount ADC Low fault D 00008000 I2c2DacsAckFailure I2C fault D 00004000 I2c2DacsArbitrationLost I2C fault D 00002000 I2c2DacsBusError I2C fault D 00001000 I2c2DacsIrqCount I2C fault D 00000800 I2c2DacsTimeout I2C fault D 00000400 TurnaroundTimeWarning Coms Fault D 00000200 TurnaroundTimeFault Coms Fault D 00000100 Adc3BufferOverwritten ADC Buffer fault D 00000080 Adc3MonitorHigh...

Page 36: ... change as a result of the constant evolution of Intelligent Energy s business and its technology This publication and its contents do not include all details which may be relevant to particular circumstances and should not be regarded as being a complete source of Information To the fullest extent permitted by law Intelligent Energy offers no warranty as to the accuracy of the content of this pub...