J.28 FAA Order 6980_36 Maintenance of Hydrogen Fuel Cells.pdf

Distribution: IS0B CLASS C (Web Release Only) Initiated By: AJW-223

U.S. DEPARTMENT OF TRANSPORTATION

FEDERAL AVIATION ADMINISTRATION

Air Traffic Organization Policy

ORDER

JO 6980.36

Effective Date:

08/03/2016

Implementation Date:

01/05/2017

SUBJ: Maintenance of Hydrogen Fuel Cells

This Maintenance Technical Handbook (MTHB) provides the necessary guidance to be used in conjunction with information available in Technical Instruction Books (TIB) and other handbooks, for the proper maintenance of Hydrogen Fuel Cells. It also provides information on special methods and techniques that will enable maintenance personnel to achieve optimum performance from the equipment.

This document requires actions by the Airway Transportation System Specialist (ATSS) at operational facilities with Facility, Service, and Equipment Profile (FSEP) equipment: CLEAN.

Note: This publication is Web Release Only due to budget constraints. A hard copy will not be distributed but may be printed locally. An electronic copy may be accessed by using one of the options in Paragraph 1-3, Where Can I Find this Order, and make copies as necessary.

The field office must keep accurate FSEP records and Logistics Center Support System (LCSS) addresses per Order 6000.5D, Facility, Service, and Equipment Profile (FSEP).

To update FSEP information, visit this link:

https://employees.faa.gov/org/linebusiness/ato/operations/technical_operations/ajw1/ajw1b/fsep/.

To update LCSS information, visit this link: https://lcss.faa.gov/lcss.

FAA Technical Performance Record (TPR) Workbooks will be provided by automated TPR or eTPR based on FSEP records to record required system parameters directly into the National Logging Network (NLN). For DoD sites, TPR forms may be electronically downloaded at https://www.adx.faa.gov/portal/group/non-dod/tprs to record system parameters.

The National Periodic Maintenance/Certification Scheduling (PMS) database is maintained by the Office of Primary Responsibility (OPR). The release of this document notifies the field of an update to the Remote Monitoring and Logging System (RMLS) National PMS database. An RMLS Task Glossary Report will be available on the Technical Library with this MTHB under associated files for cross-referencing the Task Number to the Chapter 4 paragraph in approximately five working days after release of this MTHB.

Users are encouraged to submit recommendations for improvements to 9-AMC-AJW141TechDocServices@faa.gov.

Jeffrey Yarnell Director, Air Traffic Control Facilities / Engineering Services https://employees.faa.gov/org/linebusiness/ato/operations/technical_operations/ajw1/ajw1b/fsep/ https://lcss.faa.gov/lcss https://www.adx.faa.gov/portal/group/non-dod/tprs mailto:9-AMC-AJW141TechDocServices@faa.gov

RECORD OF CHANGES DOCUMENT NO. Order JO 6980.36

CHANGE TO

BASIC

SUPPLEMENTS

OPTIONAL CHANGE TO

BASIC

SUPPLEMENTS

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MM DD YY MM DD YY

An electronic copy of the current Record of Changes (ROC) is available for download and print at https://nas.amc.faa.gov/phoenix/views/technicalDocument.xhtml?view=roc&num=6980.36&pre=H

FAA Form 6000-25 (10/12) Electronic Adobe Version https://nas.amc.faa.gov/phoenix/views/technicalDocument.xhtml?view=roc&num=6980.36&pre=H

08/03/2016 JO 6980.36

iii

Table of Contents

Paragraph Page

Chapter 1. General Information and Requirements

1-1. Purpose ..................................................................................................................... 1-1 1-2. Audience ..................................................................................................................... 1-1 1-3. Where Can I Find this Order?...................................................................................... 1-1 1-4. Certification ................................................................................................................. 1-2 1-5. Aircraft Accidents ........................................................................................................ 1-2 1-6. Maintenance Procedure .............................................................................................. 1-2 1-7. Risks ........................................................................................................................... 1-2 1-8. Implementation Date ................................................................................................... 1-3 1-9. Related Publications ................................................................................................... 1-3

1.10. thru 1-19. Reserved.

Chapter 2. Technical Characteristics

2-1. Purpose ...................................................................................................................... 2-1 2-2. Description .................................................................................................................. 2-1 2-3. Theory ......................................................................................................................... 2-3 2-4. System Descriptions ................................................................................................... 2-4 2-5. System Requirements ............................................................................................... 2-17 2-6. Converters ................................................................................................................ 2-17 2-7. Inverter ...................................................................................................................... 2-18 2-8. Hydrogen Sensors .................................................................................................... 2-18 2-9. thru 2-19 Reserved.

Chapter 3. Standards and Tolerances

3-1. General ........................................................................................................................ 3-1

Section 1. Hydrogen Fuel Cell Model: I-1000®, T-1000® and T-2000® (As Applicable)

3-2. Environmental .............................................................................................................. 3-1 3-3. Fuel Cell Battery Voltage .............................................................................................. 3-2 3-4. Fuel Cell Output ........................................................................................................... 3-2 3-5. Customer Provided Fuel Cell Monitoring Panel (T-1000®/T-2000®) .............................. 3-2 3-6. Cartridge Hydration Cycle ............................................................................................ 3-3 3-7. thru 3-19. Reserved.

Chapter 4. Maintenance Requirements

4-1. General ....................................................................................................................... 4-1 4-2. FAA Form 6000 Series ................................................................................................ 4-1

Section 1. Performance Checks

4-3. Semi-Annual ............................................................................................................... 4-1 4-4. Annual ......................................................................................................................... 4-2 4-5. Biennial (Every Two Years) ......................................................................................... 4-3 4-6. thru 4-19. Reserved.

11/16/2021 JO 6980.36 CHG 2

iv

Table of Contents (Continued)

Paragraph Page

Section 2. Other Maintenance Checks 4-20. Semi-Annual ............................................................................................................... 4-5

Chapter 5. Maintenance Procedures

5-1. General ....................................................................................................................... 5-1 5-2. Remote Maintenance Monitoring (RMM) ..................................................................... 5-1

Section 1. Performance Check Procedures

5-3. Hydrogen Leak Test .................................................................................................... 5-1 5-4. Controller Card Battery................................................................................................ 5-1 5-5. Cartridge Lubrication ................................................................................................... 5-2 5-6. Low Fuel Alarm ........................................................................................................... 5-2 5-7. Fuel Cell Cartridge Hydration ...................................................................................... 5-3 5-8. Door Lock and Filter Check (I-1000®, T-1000®, T-2000®) ............................................ 5-3 5-9. Bleed Vent Check ....................................................................................................... 5-3 5-10. Basic Operation .......................................................................................................... 5-3 5-11. Major Alarm ................................................................................................................. 5-3

Section 2. Other Maintenance Procedures.. ..................................................................... 5-4

5-12. As Required……………………………………………………………………………… ...... 5-4 5-13. thru 5-19 Reserved………………………………………………………………… . ........... 5-4

Appendix A. Certification Requirements ................................................................................ A-1

Appendix B. Manufacturer’s Reference Tables ..................................................................... B-1

Appendix C. Troubleshooting ................................................................................................. C-1

Appendix D. Parts Replacement ............................................................................................. D-1

Appendix E. Copyright Permission and Safety ...................................................................... E-1

Appendix F. Glossary ............................................................................................................... F-1 v

Table of Contents (Continued)

List of Illustrations

Figure Page

2-1. Basic Fuel Cell ................................................................................................................ 2-1 2-2. Proton Exchange Membrane .......................................................................................... 2-2 2-3. PEM Fuel Cell Process ................................................................................................... 2-3 2-4. Power Generation Configuration ..................................................................................... 2-4 2-5. I-1000® fuel Cell Chassis ................................................................................................ 2-5 2-6. Configuration Switches ................................................................................................... 2-6 2-7. Terminal Connections ..................................................................................................... 2-6 2-8. Front Panel I-1000® ........................................................................................................ 2-7 2-9. I-1000® Fuel Cell Back Panel .......................................................................................... 2-7 2-10. Typical Site Back Up Power-Fuel Cell ............................................................................. 2-9 2-11. T-1000® Key Components Location .............................................................................. 2-10 2-12. T-2000® Key Components Location .............................................................................. 2-10 2-13. Controller Card (Blower Light Not Shown) ................................................................... 2-11 2-14. Converter Card ............................................................................................................ 2-11 2-15. Communication Card ................................................................................................... 2-13 2-16. Alarm Card .................................................................................................................. 2-13 2-17. I/O Card ....................................................................................................................... 2-14 2-18. Cartridge ...................................................................................................................... 2-14 2-19. TSCB ........................................................................................................................... 2-15 2-20. Hydrogen Cylinders ..................................................................................................... 2-17 B-1. T-2000® Fuel Cell System Connections for 4KW and 6KW Outdoor Installation .............. B-6 vi

Table of Contents (Continued)

List of Tables

Table Page

B-1. Switch Configuration 24V dc Option ................................................................................ B-1 B-2. Major Alarms (I-1000®) .................................................................................................... B-1 B-3. I-1000® State Codes ........................................................................................................ B-1 B-4. I-1000® Terminal Connection Functions ........................................................................... B-2 B-5. T-1000® Fuel Cell Chassis Electronics Card Layout ........................................................ B-3 B-6. T-2000® Fuel Cell Chassis Electronics Card Layout ........................................................ B-3 B-7. Temperature Conversion Table ....................................................................................... B-4 B-8. Interface Connections to TSCB Unit ................................................................................ B-5 C-1. I-1000® Series Fuel Cell Troubleshooting ........................................................................ C-1 C-2. T-1000® Series Fuel Cell Troubleshooting ....................................................................... C-2 C-3. T-2000® Series Fuel Cell Troubleshooting ....................................................................... C-3 C-4. T-1000® and T-2000® Series Fuel Cell Minor Error Codes ............................................... C-4 C-5. T-1000® and T-2000® Series Fuel Cell Major Error Codes ............................................... C-5 D-1. T-1000® System Components ......................................................................................... D-1 D-2. T-2000® System Components ......................................................................................... D-2

09/24/2018 JO 6980.36 CHG 1

1-1

Chapter 1: General Information and Requirements

1-1. Purpose. This Maintenance Technical Handbook (MTHB) provides guidance and prescribes technical standards, tolerances, and procedures applicable to the maintenance and inspection of Hydrogen Fuel Cells. It also provides information on special methods and techniques, which will enable maintenance personnel to achieve optimum performance from the equipment. This information augments information available in Technical Instruction Books (TIB) and other MTHBs, and complements the latest edition of Order 6000.15, General Maintenance Handbook for National Airspace System (NAS).

This handbook provides system oriented maintenance information and establishes a maintenance program for the following Service Area fielded Hydrogen Fuel Cells.

• ReliOn I-1000® Fuel Cell (J-64) system and enclosures

• ReliOn T-1000® Fuel Cell Systems

• ReliOn T-2000® Fuel Cell Systems

1-2. Audience. This MTHB requires actions by the Airway Transportation System Specialist (ATSS) at operational facilities with Facility, Service, and Equipment Profile (FSEP) equipment: CLEAN.

1-3. Where Can I Find This Order?

a. FAA Personnel. For electronic copies, FAA personnel can use one of the following websites to locate this order.

(1) On the Technical Library website at:

http://nas.amc.faa.gov/phoenix/views/technicalLibrary.xhtml.

(2) On the Directives website at:

https://employees.faa.gov/tools_resources/orders_notices/.

(3) From the My FAA website, select “Tools and Resources” then select 'Orders and Notices'.

(4) On the National Airspace Systems (NAS) Document Distribution Application (DDA) at http://nas.amc.faa.gov/nasdda/.

(5) The ATSS and all administrative personnel must subscribe to the Auto- Notifications Services for electronic library release notifications at http://technet.faa.gov/. This document can be printed for local use as required.

b. Department of Defense (DoD).

(1) All DoD customers must register for an Aeronautical Data Exchange (ADX) website account at https://www.adx.faa.gov. When registering, the user must request access to the NAS Engineering tab of the application. The FAA does not distribute hard copies to DoD customers. For problems accessing the ADX website contact 9-ACT-ADX-PM@faa.gov.

http://nas.amc.faa.gov/phoenix/views/technicalLibrary.xhtml https://employees.faa.gov/tools_resources/orders_notices/ http://nas.amc.faa.gov/nasdda/ http://technet.faa.gov/ https://www.adx.faa.gov/ mailto:9-ACT-ADX-PM@faa.gov

1-2

(2) For DoD customers who have questions related to the maintenance handbook, contact Power Operations Engineering, Nina Agrawal at (405) 954-5133.

1-4. Certification. Refer to Order 6000.15 for general guidance on the certification of systems, subsystems, and equipment. Hydrogen Fuel Cells covered under this handbook do not require certification. This order does not impose any additional certification requirements on other systems.

1-5. Aircraft Accidents. When aircraft accidents or incidents occur, Air Traffic Organization (ATO) Technical Operations personnel are responsible, when requested by the Technical Operations Aircraft Accident Representative (TOAAR) through the appropriate control center, to evaluate and document the technical performance of the facilities which may have been involved (for some facilities, it may also be necessary to remove them from service, and to conduct flight inspections). This requires that facility operational data be obtained and recorded in the maintenance log or eTPR, if eTPR workbooks are available, and/or on a generic 6000-8, Technical Performance Record form where no eTPR workbooks are available. These records are official documents, and may be used by an aircraft accident investigation board in the determination of facility operational status at the time of the accident. Refer to the latest edition of Order 8020.16, Air Traffic Organization Aircraft Accident and Incident Notification, Investigation, and Reporting, for detailed guidance on requirements and activities following an aircraft accident/incident.

1-6. Maintenance Procedure.

a. Order 6000.15, this MTHB, the applicable equipment TIB, and other applicable handbooks are consulted and used together by the maintenance technician in all duties and activities for the maintenance of Hydrogen Fuel Cells. These documents are considered collectively as the single official source of maintenance policy and direction authorized by Technical Operations Services. References located in the appropriate paragraphs of this handbook entitled Chapter 3, Standards and Tolerances, Chapter 4, Maintenance Requirements, and Chapter 5, Maintenance Procedures, indicate to the user whether this handbook and/or the equipment TIB must be consulted for a particular standard, key inspection element or performance parameter, performance check, maintenance task, or maintenance procedure.

b. Refer to Order 6000.15 for shutdown, coordination and scheduling policy.

1-7. Risks.

a. Operational. There are no operational risks associated with this MTHB.

b. Safety. In accordance with Orders 1100.161, Air Traffic Safety Oversight, and JO 1000.37, ATO Safety Management System, the Safety Risk Management (SRM) Report information for this MTHB is available at http://nas.amc.faa.gov/phoenix/views/technicalDocument.xhtml?&file=6980_36_mthb_srmrpt.pdf For further guidance in developing SRM documentation, refer to the latest version of the Safety Management System (SMS) Manual.

c. Security. There are no security risks associated with this MTHB.

d. Refer to Appendix E, Copyright Permission and Safety for applied safety signal words.

http://nas.amc.faa.gov/phoenix/views/technicalDocument.xhtml?&file=6980_36_mthb_srmrpt.pdf

1-3

1-8. Implementation Date. This MTHB must be implemented by 01/05/2017. All facilities nationwide must comply with these changes by the implementation date. The changes may be implemented any time after the effective date, but must be implemented by the implementation date. If the implementation date occurs during a completed task interval window, then follow the new guidance for the certification or maintenance task(s) at the next regularly scheduled interval.

1-9. Related Publications. The following related publications are referenced throughout this handbook.

Note: The nature of this directive requires reference to numerous publications.

To avoid frequent revision, for the purpose of changing references to the latest issue, personnel shall consider all references as the most recent edition.

a. FAA Order 8020.16, Air Traffic Organization Aircraft Accident and Incident Notification, Investigation, and Reporting

b. FAA Order 6000.15, General Maintenance Handbook for National Airspace System (NAS) Facilities

c. FAA Order 6032.1, National Airspace System Modification Program

d. FAA Order 1100.161, Air Traffic safety Oversight

e. FAA Order JO 1000.37, ATO Safety Management system

f. FAA order JO 6980.31, Maintenance of Direct Current (DC) Bus Power System

g. FAA Order JO 6000.5, Facility Service and Equipment Profile

h. ReliOn I-1000®, Fuel Cell Operations and Maintenance Manual 102836R4

i. ReliOn T-2000®, Operator’s Manual 64E-106858R4

j. ReliOn T-1000®, Operator’s Manual 64E-106854R6

k. ReliOn User Interface Manual, 640-108262R2

l. NFPA Article 70 National Electric Code

m. NFPA 55 Standard for the Storage, Use, and Handling of Compressed Gases and Cryogenic Fluids in Portable and Stationary Containers, Cylinders, and Tanks, 2005.

n. Configuration Control Decision (CCD) No. N34569, Maintenance Technical Handbook for Fuel Cells

1-10. thru 1-19. Reserved.

1-4

This page intentionally left blank.

2-1

Chapter 2: Technical Characteristics

2-1. Purpose or Function. The Hydrogen Fuel Cell systems are designed to augment the direct current (dc) power being provided to NAS equipment. This chapter describes the specific types of equipment that have been or will be deployed within the FAA Field sites. It describes I-1000® and the greatly improved T-1000® and T-2000® models.

2-2. Description.

a. A fuel cell (figures 2-1 through 2-3), is a device that converts the chemical energy of a fuel (for example, hydrogen, natural gas, and methanol) and an oxidant (air or oxygen) directly into electricity. Hydrogen is the current fuel of choice. The following is a list of characteristics of a fuel cell:

Figure 2-1. Basic Fuel Cell

• Operates electrochemically like a battery, but does not run down or require recharging.

• Its run time is determined by the availability of the energy source.

• Uses an electrolyte.

• It has no moving parts.

• Named by type of electrolyte it has.

• Hydrogen is the current fuel of choice for most fuel cells.

• Much more efficient than fuel combustion.

2-2

Figure 2-2. Proton Exchange Membrane

b. The following are characteristics of Hydrogen Gas:

• Colorless, odorless and has no taste.

• Non-toxic.

• Environmentally friendly.

• Flammable from 4% - 75% in air (LFL = 40,000ppm).

• Comparison: propane 2.2% - 9.6%; gasoline 1.0% – 7.6%.

• Burns with a pale blue flame.

2-3

Figure 2-3. PEM Fuel Cell Process

2-3. Theory. The I-Series or T-Series fuel cell is a modular system. Each 1kW or 2 kW system may be combined in a parallel configuration with up to three or four other systems for a maximum power output of up to 10kW. The I-Series system cannot be combined with the T-series system due to incompatibility of parts. The I-1000® is a modular 1KW fuel cell, may be combined with four other I-1000® to produce a maximum output power. Fuel Cell technology provides clean, quiet, and reliable dc power for back up applications. As figure 2-4 illustrates, in a typical operating configuration, the fuel cell is supplied with standard industrial grade hydrogen gas. The fuel cell provides regulated dc power at a nominal 24, 48 or 125V dc.

2-4

Figure 2-4. Power Generation Configuration

Note: Specific safety rules and precautions shall be followed per manufacturer’s instructions when operating the fuel cell and/or handling the hydrogen cylinder.

2-4. System Descriptions.

a. ReliOn I-1000® Fuel Cell. This section provides a brief description of I-1000® fuel cell;

see figure 2-5, and its operation. For details, refer to ReliOn I-1000® Fuel Cell Operations and Maintenance Manual 102836R4

(1) The outdoor enclosure consists of two compartments: (1) the Equipment Bay houses the fuel cell modules, System Controls Box (SCB) Input/output (I/O) connections, and the bleed/purge system; and (2) a hydrogen storage enclosure: one hydrogen storage enclosure houses six hydrogen (99.95% industrial grade or better) cylinders (at 261 cu ft. each) for a total of 48 KWh of fuel.

(2) The I-1000® fuel cell systems nominally provide 1000W and are powered by six ReliOn hot-swappable cartridges (see the ReliOn I-1000® Fuel Cell Operations and Maintenance Manual102836R4 for more information). The system control box input/output provides a single point from which to monitor alarms and controls the fuel cell systems.

(3) When running, the fuel cells use a hydrogen gas purge cycle to periodically remove excess water and any inert gases that may be present. This bleed system provides an avenue to remove inert gases and residual water evacuation by purging hydrogen gas. The bleed system is preinstalled and is comprised of heated and insulated piping assembled with flexible hoses running from the fuel cell systems. The bleed system allows the purge hydrogen gas to be evacuated through the enclosure roof exhaust to the atmosphere.

(4) The I-1000® fuel cell modules installed in the enclosure provide dc power to a DC distribution block located in the equipment enclosure. This is the termination point from the fuel cell power output to the facility's DC BUS standby power. The system control box input/output provides power to the enclosure fan, AC run relay, and the heat cable for the bleed system. The enclosure 24 V dc fan(s) only run to cool the enclosure when a temperature set point is reached.

2-5

Figure 2-5. I-1000® Fuel Cell Chassis

(5) The bleed system heaters are temperature controlled and will draw approximately 15W per I-1000® from the DC BUS if the internal enclosure temperature drops below 46° F (8° C), while the fuel cells are running.

(6) The outdoor enclosure utilizes ac power for a 120V convenience outlet and for a detection of "Loss of AC power". Also, this power is used to heat the equipment cabinet to maintain a minimum internal temperature of 50°F (10°C). A thermostat-controlled 930W convective heater is installed in the base of the enclosure. In the event of loss of ac power, the heaters are no longer necessary, as the fuel cells produce their own heat during operation.

(7) Configuration Switches, see figure 2-6. There are four switches. Switch 1 is for ReliOn use only. Switch 2 controls whether the fuel cell is in RUN or PROGRAM mode. Default is RUN mode. Switch 3 is divided into four sub switches (1, 2, 3, and 4). Switch 3-1 is for remote start up (not used by FAA). Default is OFF position. Switch 3-2 enables low voltage start up (FAA Preferred Startup Mode), monitors external battery voltage and starts-up once this voltage has fallen to or below the selected threshold value selected by the site. Default is OFF position. (See Appendix B, Table B-1, Switch Configuration 24V dc Option).

2-6

Figure 2-6. Configuration Switches Figure 2-7. Terminal Connections

(8) Terminal Connections. These connections facilitate integrating single or multiple units into specific customer applications. On the back panel of an I-1000® are terminals labeled “1” through “20” (figures 2-8 and 2-9). Refer to Appendix B, Table B-4, I-1000® Terminal Connection Functions. Terminals 1-12 are used to provide the following functions:

• Remote start terminals

• Emergency stop Input/output

• Dry Contact Alarms

Terminals 13-20 are used to provide auxiliary input and output.

2-7

Figure 2-8. Front Panel, I-1000® Figure 2-9. I-1000® Fuel Cell Back Panel

(9) Operations. Front panel controls are shown in figure 2-8. The display screen shows the system State and RUN-TIME (HHH: MM:SS), system voltage, current, power output, alert messages and other data pertinent to the function of the fuel cell. The front panel has an alert light, an ON/OFF/Remote Switch, unit ON light, load breaker, and emergency stop button. (Refer to the ReliOn I-1000® Fuel Cell Operations and Maintenance Manual 102836R4).

Note: For operation, verify that load and/or battery bank is attached, and the LOAD breaker is in the ON position. The I-1000® system is designed to perform a minimum of three restarts to achieve full operations.

(a) The I-1000® systems can be configured to activate on two conditions: "Loss of AC Power" and "Low Battery Voltage Sensing". See Appendix B, Table B-1, Switch Configuration - 24V DC Option for I - 1000® switch settings for low battery sensing. The fuel cell system will shut down if any of the conditions below are true:

• The selector switch is turned to the OFF position.

• The E-Stop button(s) are pushed.

2-8

• Continuity is removed from the remote start contact on the fuel cell signal and control box, if the system was started in this manner (see I-1000® manual for more information).

• Abnormal operating condition triggers a major alarm.

(b) AC Loss: The fuel cells will start and run upon loss of ac. When the DC BUS voltage rises above the "Low Battery Start Voltage" level and ac power is present at the site (see I-1000® manual for more information), the system will return to standby mode and wait until it is triggered to start again (unless the E-Stop is pushed, selector switch(es) are turned to the OFF position, or the system is out of hydrogen).

(c) Low Battery Start: Even when ac is present, if the fuel cell detects that the facility battery has dropped below the low voltage start set point the fuel cell will start and supply power to the battery. If the battery voltage rises above the low-battery start voltage the fuel cell will enter into a 20-minute battery charge test cycle. If the system algorithm determines the charge is maintained for 20 minutes, the fuel cell will return to standby status.

(d) The I-1000® system also will perform an auto test. On a 45-day cycle, the system will turn on, assume facility load (by ramping up its output voltage until it reaches the battery float charger) and operate for 45 minutes. This is done to keep the cartridges in a hydrated state and to ensure quicker operation when a power outage occurs. After it is finished with the testing, it will revert back to standby operation.

(e) The I-1000® system installations have a single hydrogen compartment and are configured with simplex hydrogen manifold, pressure regulation and sensing. This configuration will deplete both banks of hydrogen cylinders concurrently. When the pressure in the cylinders drops below 400 psi, a pressure switch (PS-1) will signal to the System Control Box Input/output (I/O) cabinet where a contact closure will appear at the output terminal strip. At that point, there will be approximately 9 kW/h of hydrogen remaining in all the cylinders.

(f) Where applicable, an ac time delay start relay is installed in the enclosure equipment bay. Upon loss of ac power, this relay will cause a field adjustable (initially set for 2 seconds) delay in the start of the fuel cell to prevent nuisance starts when ac power is intermittent. This relay is adjustable up to 12 seconds. In addition, a run time hour meter is installed on the cabinet front to record the run time of the fuel cell. This meter cannot be reset.

(g) ALARMS: See Appendix B, Table B-2, Major Alarms (I-1000®).

(h) Fuel Cell Back up Power System: See figure 2-10.

2-9

Figure 2-10. Typical Site Back Up Power System – Fuel Cell

b. ReliOn T-1000® and T-2000® Fuel Cells. These systems are similar to the I-1000® Fuel Cell with a few improvements. Key components of I-1000 fuel Cell are shown in figure 2-5.

The following components make up the T-Series hydrogen fuel cell DC power generation system (see figures 2-11, 2-12):

(1) Chassis.

(a) The system chassis provides a central path for control signals, electrical power, fuel supply and exhaust, air supply for fuel cell operation and cooling, and heaters for operation in cold environments. The chassis includes a blower incorporating three separate fans, only two of which are required to operate. The blower can be replaced in the field by the user, using standard tools.

(b) The T-2000® chassis has a dual bus architecture. Five cartridges and two converters are dedicated to each bus, identified as Bus A and Bus B. Each bus must have at least one Converter Card and three fuel cell cartridges installed and functioning for the bus to function.

Each cartridge generates up to 200 W net output. The T-1000® chassis uses one bus structure.

(c) The system can function with only one bus operational. Though each bus operates independently, the two buses should be populated equally for optimal performance. Within a bus, the three cartridges do not need to be in any particular slots.

(d) The T-2000® chassis can accommodate two system controllers. The system’s standard configuration uses a single controller card. One controller card operates the entire chassis; it is not dedicated to Bus A or Bus B. When the chassis is populated with two controller cards, one controller card is actively controlling the system, while the second controller card is in reserve in case of a failure.

2-10

Figure 2-11. T-1000® Key Components Location Figure 2-12. T-2000® Key Components Location

(e) The T-1000® / T-2000® chassis, figures 2-11 and 2-12, is labeled to identify the appropriate placements of electronics cards and fuel cell cartridges.

(2) Electronic Cards.

(a) Controller Card. The controller card, figure 2-13, arbitrates all of the fuel cell system’s operations. This controller card also contains a battery to back up memory if power is lost.

The T-2000® system can accommodate two controller cards. When two controller cards are installed, one controller card is active, controlling the system, while the second controller card is inactive. The chassis will call upon the inactive controller card when the active controller card is non-responsive or becomes inactive. The T-1000® has only one controller card.

2-11

Figure 2-13. Controller Card (Blower Light Not Shown) Figure 2-14. Converter Card

Caution: Per manufacturer’s recommendations to avoid damaging equipment, the controller card should never be “hot swapped” or exchanged while the system is running.

(b) Converter Card. The function of the converter card, figure 2-14, is to convert the internal cartridge bus voltage to the system output voltage. The T-2000® chassis slots to the right of the controller cards can house up to four converter cards. The function of the converter cards is to convert the internal system bus voltage to the user’s external dc power bus voltage. Two converters are designated per bus. The two converters on a bus operate in parallel and are redundant. Converter cards 1A and 2A serve Bus A (the left-most five cartridges), while converter cards 1B and 2B serve Bus B (the right-most five cartridges). All installed converter cards must be of the same voltage (24V or 48V) and must match the voltage of the I/O card. Depending on the system configuration, the second converter card on each bus can be installed to provide optional redundancy. The T-1000® chassis can take up to three converter cards with one converter card as optional for redundancy.

2-12

(c) Communication Card, figure 2-15, and Alarm Card (Optional) figure 2-16 - The T-2000®/T-1000® fuel cell system requires the installation of either a communications card, an alarm card, or a blank communications card A blank card is provided as standard equipment.

(d) The Communications Card provides Ethernet 10/100 capability, allowing the system to be monitored remotely over a network. It is recommended that a shielded CAT 5 cable be used for connection to the communications card. The use of a private network is assumed, so only basic username and password security are implemented. Once network connection is established, user interaction with the system is accomplished by running Telnet over the link. In addition to Ethernet connectivity, the communications card provides four Form C contacts for monitoring user-assignable auxiliary alarms. The Form C contacts are accessed by routing signal wires through the front panel of the card and landing them on the removable board-mounted connector. These four auxiliary alarms are referred to as Aux 2, Aux 3, Aux 4, and Aux 5. (Aux 1 is provided as a standard output on the I/O card). Each auxiliary alarm can be assigned to one of eight events via the User Interface.

(e) The alarm card is for installations that do not require network connectivity via Ethernet. The alarm card provides the same four Form C user-assignable contacts as the communication card. The board-mounted connector is the same as the communication card, allowing easy upgrade without requiring re-wiring by removing the connector mate from the alarm card, and plugging it into the communication card.

(f) I/O Card: The I/O card, figure 2-17, determines the fuel cell chassis voltage and provides the interface for several functions. The alarm interface (I/F) contacts are used to interface with the fuel cell from a remote location. A serial I/F port allows field personnel to use the User Interface to program and troubleshoot the fuel cell. The I/O card provides the positive and negative power terminal connection points for the customer’s power supply, such as the DC BUS with rectifiers. The load breaker controls power to the customer-provided circuit breaker and is a safety device.

2-13

Figure 2-15. Communication Card Figure 2-16. Alarm Card

Caution: Do not use the load breaker on the I/O card as an ON/OFF switch. It is only an over-current protection device. If the fuel cell is running, it can power itself, regardless of the position of this breaker. If the breaker is set to OFF, (the breaker is open), while the fuel cell is running, it will continue to run and consume hydrogen, powering itself without delivering power (since the breaker is off).

Caution: Per manufacturer’s recommendations to avoid damaging equipment, I/O cards should never be “hot-swapped”, or exchanged while the system is running.

(3) Special Controller Board (SCB): In the T-2000® fuel cell system a SCB is reserved for future expansion. The SCB slot must be populated with an SCB blank.

(4) Fuel Cell Cartridges. The ReliOn Modular Cartridge Technology® allows customers to add capacity, provides redundancy, reduces single points of failure, and simplifies maintenance. Each fuel cell cartridge is an independent, hot-swappable fuel cell subsystem, with integrated fuel management, air-cooling, and control sensors. Individual cartridges provide up to 200W of power to the load the cartridge, figure 2-18.

(a) The T-2000® fuel cell system uses between three and ten cartridges. When fully configured, the T-2000® fuel cell system will provide up to 2000W. It can be partially configured for smaller loads. Unpopulated cartridge slots are filled with blank cartridges to tell the system what configuration is installed and to properly guide cooling air through the chassis.

Note: The T-1000® fuel cell system uses up to six cartridges and will provide power up to 1200W.

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Figure. 2-17. I/O Card

Figure 2-18. Cartridge

2-15

(b) The term “hot-swappable” refers to the cartridge’s ability to be removed and installed, without special tools, while the fuel cell is operating and delivering power. Though the cartridges are electrically in series, they are managed such that any combination of cartridges can be removed, so long as a minimum of three functioning fuel cell cartridges remain installed.

(c) If any cartridge should fail during operation, the system will take that cartridge off-line and operate at reduced power with the remaining cartridges. For mission-critical applications, this level of modularity, redundancy, and ease of maintenance puts the T-1000®/T-2000® fuel cell system in the same class as other N+1 telecommunications equipment.

(d) The ReliOn fuel cell system cartridges are based on Proton Exchange Membrane (PEM) technology, and as such, they require water to function properly. The ReliOn proprietary design uses the water generated while delivering power to hydrate the cartridges, eliminating the need for external water sources. For proper hydration, fuel cell cartridges should be operated periodically; they have a limited storage period before requiring reconditioning. After 60 days or more of storage, the cartridge needs to be rehydrated. The T-1000®/T-2000® fuel cell system incorporates an automatic exercise cycle, which periodically operates the fuel cell to check all backup system functions and to maintain the hydration of the cartridges.

c. T-Series Signal and Control Box (TSCB), figure 2-19. The TSCB is the signal and alarm aggregation point for multiple fuel cell systems. It is available in a standard three-system configuration. Its primary function is to allow multiple fuel cells to function with a single fuel supply system. In addition to centralizing fuel control, the TSCB aggregates numerous other signals from multiple fuel cells, and provides a single system E-stop, presenting a single connection interface for the user.

Figure 2-19. TSCB

(1) Fuel Control Centralization. The fuel cells’ rear fuel control connector is wired to the unit fuel I/O ports on the TSCB. The TSCB aggregates the fuel control signals from the fuel cells to the fuel control solenoid in the fuel supply manifold, allowing any fuel cell to demand fuel.

The TSCB distributes the pressure transducer signal from the fuel supply manifold to all fuel cells, allowing all fuel cells to monitor fuel pressure.

(2) Alarm Centralization. Major, minor, and auxiliary alarm outputs from the front of the fuel cells’ I/O cards are centralized at the TSCB.

Caution: The TSCB relays will not function if power is lost to the TSCB. The de-energized condition of the relays will indicate a major and a minor alarm are asserted, and all other signals will be de-asserted.

(a) The major and minor alarms for all fuel cells are connected to a set of Form C dry contacts for the entire installation, presenting a single major alarm and a single minor alarm point, regardless of which individual system triggered the alarm. A front panel Light Emitting Diode (LED) is also provided for visual indication of major and minor alarms.

2-16

(b) Auxiliary alarms are presented individually, rather than aggregated, because they can be uniquely assigned to various functions via the serial port’s User Interface. With a full complement of three fuel cell systems, three auxiliary alarms are provided, each on a Form C dry contact. If an alarm card or communication card is installed, four additional unique auxiliary alarms can also be connected to the TSCB, providing a total of up to seven user-definable auxiliary alarms.

(c) Door switches are connected to the TSCB in 4kW and 6kW outdoor enclosures (a TSCB is not used with 2kW outdoor enclosures). The front and rear doors of the fuel cell cabinets are connected to the door alarm in ports on the TSCB. The door switch signal passes through the TSCB to one of the fuel cell systems, enabling the fuel cell to log the event and issue a minor alarm. A separate door alarm contact on the TSCB is provided for the user, freeing an auxiliary alarm for other uses. This is the standard configuration in a 4kW or 6kW outdoor enclosure. Connecting the door alarm in an indoor installation is optional.

(d) In installations with staged fueling (typically, a 12-bottle installation in which one set of six bottles drain first, then the second set of 6 bottles drains), a pressure switch is installed in the fuel system to add additional fuel level monitoring of the first stage. If installed, this pressure switch is connected through the TSCB to maintain a single connection point for the user.

(3) E-stop Centralization. An E-stop button is available on the front panel of the TSCB. Pressing this E-stop button stops all connected fuel cells. There is no provision for remotely asserting a global E-stop, other than pressing the TSCB front panel E-stop button. If required, a remote E-stop signal can be wired directly to pins 1 and 2 of each fuel cell I/O card.

Note: Pressing an E-stop on an individual fuel cell only stops that fuel cell.

(a) Power Inputs. Power to the TSCB is applied via the two connectors on the far right front panel. Either or both connections may be used, at either 24V or 48V, positively or negatively grounded. This allows the TSCB to centralize multiple fuel cells supporting each independent DC BUS operating at different voltages and groundings. For details on the pin out connects and signals, refer to Appendix B, Table B-8, Interface Connections to TSCB Unit.

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(b) Hydrogen Fuel Cylinders (figure 2-20). The most common fuel solution is compressed gaseous hydrogen.

• High-pressure steel or aluminum cylinders which are exchanged like propane tanks for gas grills.

• 2000+ locations in U.S: Air Gas, Air Liquid, Linde, Praxair, Air Products, and Locals.

• Each kilowatt-hour produced requires about 32 cubic-feet of hydrogen gas.

Example cylinder sizes:

6” X 24” 33 cu-ft. 29 lbs. 1.0 kW/h

6” X 37” 80 cu-ft. 65 lbs. 2.5 kW/h

9” X 56” 197 cu-ft. 125 lbs. 6.1 kW/h

9” X 60” 261 cu-ft. 140 lbs. 8.0 kW/h

Figure 2-20. Hydrogen Cylinders

2-5. System Requirements

a. Required External Battery Capacity. For dc backup power systems, the minimum external battery capacity requirement for use with the T-1000®/T-2000®fuel cell system is 40 Ahr per kW for a 24V installation and 20 Ahr per kW for a 48V installation. This ensures protection for the battery string and provides adequate buffering for fuel cell start-up and load fluctuations.

b. To accommodate operation at ambient temperatures above 40º C, the battery capacity should be increased as determined by the following equations:

Nominal Voltage = 24 V dc

Load = 2 kW

Ambient Temperature = 42ºC

Run Time = 8 hours

Minimum Battery Capacity = (40 Ahr) x (2 kW) = 80 Ahr

Battery Capacity Increment = (32 / 24) (2kW) (8hr) (42-40ºC) = 42.6 Ahr

Required Battery Capacity = (80 + 42.6 / 0.80) = 153.25 Ahr

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2-6. Converters

a. T-2000® system uses an internal dual-bus architecture. Each bus is served by up to two converter cards. The T-2000® Operator’s Manual, table 3-3, lists the details of how to correctly populate a T-2000® chassis with converter cards. The T-1000® system has only one bus. Each converter card is rated for 850 W net output (24V or 48V).

b. Converter cards are available in either 24V or 48V. All installed converter cards must be of the same voltage, and must also match the voltage of the I/O card. A converter card mismatch will result in an alarm condition and non-operation of the unit.

c. The converter card has a red FAIL and green STATUS light. When the unit is energized, both lights will strobe once and then turn off unless a fault is detected. In standby mode, the lights will remain off until the T-2000® fuel cell system enters a start-up condition, at which time the green STATUS light will turn on, indicating that the unit is producing power and the converter card is not in a fault condition.

d. If a converter card is in a fault condition, the red FAIL light will turn on. In this situation, the controller card will issue a minor alarm, as long as enough on-line converters are available to maintain power output. If the fuel cell system is unable to operate, a major alarm will be issued and the red FAIL light on the controller card will be lit. For information on correcting a fault or alarm condition, refer to the T-2000®/T-1000® Operator’s Manual, section 6.0 respectively.

2-7. Inverter. Installations with ac inverters as part of the DC BUS load require special attention.

To alleviate current ripple on the DC BUS due to inverter feedback, the external battery capacity requirement calculated in paragraph 204b above should be increased as summarized below:

• If the inverter is up to 20 % of total DC BUS load, no increase in battery capacity is required

• If the inverter is 20% to 50% of total DC BUS load, increase battery capacity by 25%

• If the inverter is 50% to 100% of total DC BUS load, double recommended battery capacity

2-8. Hydrogen Sensors. The T-1000®/T-2000® fuel cell system is equipped with two internal hydrogen sensors, which continually monitor the system for excess residual hydrogen gas. In the event hydrogen gas is detected, an alarm will activate and an interlock will block operation of the system.

2-9. thru 2-19 Reserved.

3-1

Chapter 3: Standards and Tolerances

3-1. General. This chapter prescribes the standards and tolerances for all of the components making up the Hydrogen Fuel Cell standby power system including batteries, as defined in Order

6000.15. The battery standards and tolerances are not covered in this order; use the latest edition of Order JO 6980.31, Maintenance of Direct Current (DC) BUS Power System. Refer to the specific operator’s manual for each model fuel cell and its components manufacturer data for standards and tolerances not covered in this chapter. Some tolerances are made tighter per FAA field technicians’ recommendations.