Heliocentris Commercial Confidential 1

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Integration of Industrial Fuel Cells in Technical
Applications Using the NEXATraining System
Dr. Claus Fischer Ralph Schanz HELIOCENTRIS
Energiesysteme GmbH Berlin / Germany
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Heliocentris

• Founded in 1995
• Pioneer in fuel cell education
• Based in Berlin (Germany) / office in Vancouver
• Leading supplier of fuel cell training systems
  toUniversities, Research Institutes and Science
  Centres with over 35.000 units sold to 50
  countries

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Heliocentris - An educational company

• Post secondary education
• Lab products
• Training systems
• Fuel cell and hydrogen components
• System integration service

• School education
• Science kits
• Lesson material
• Outreach programs

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Todays Challege on Fuel Cell Integration

• Rapidly emerging industry using fuel cells as
  replacement of conventional batteries (vehicles,
  off-grid power supply)
• High demand of RD, particularly in fuel cell
  integration
• Lack of experience on industrial fuel cell
  systems (kW)
• Training necessary to improve implementation
  skills for fuel cells in own applications

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The NEXA Training System
Based on an industrial 1.2 kW Fuel Cell Module
(NEXA)
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Fuel Cell Module

• Nexa Power Module 1.2 kW
• Unregulated DC output 22..48 V / Nominal 24 V
• Rated Current 46 A
• Pressure 0.7- 17 bar (10..250 PSIG)
• Quick coupler integrated flow meter

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Fuel Cell Module
Advantages of the NEXA Power Module

• Start-up kit included ready to use
• In-built system control
• Complete safety monitoring
• Easy system integration
• Long life time at extended run times
• Reliable operation (No. 1 fuel cell in
  universities)

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NEXA Accessories
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Energy Management Module

• DC/DC converter (24 V)
• Battery charger with Start- and Back-up
  Batteries
• Batteries 24 V (2 different capacities plus
  external battery option)
• DC/AC Inverter (230 V)

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DC Electronic Load

• Max Power 1500 W
• Fully computer programmable adjust load profiles

Computer, Monitor Training Software
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The NEXA Training System
Learn step by step

• The stable conditions for operation
• Which fuel cell size is requested
• How to optimize the battery capacity vs. hydrogen
  capacity
• How climatic conditions effect fuel cell
  operation
• How the system responds on a selected load
  profile
•  

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• Flow Chart
• Power Chart
• Time Chart

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• Flow Chart
• Power Chart
• Time Chart

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Real time Monitoring FC-Voltage FC-Current H2 /O2
-Concentration Hydrogen consumption Temperature Pr
essure H2 Battery-Voltage Mass flow
O2 FC-Temperature Voltage Purge Cells Run Time
FC-System Run Time Fuel Cell

• Flow Chart
• Power Chart
• Time Chart

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Versatile in Use Four Examples
The NEXA Training System

• Electrical Engineering
• Physical / Mechanical Engineering
• Energy Engineering
• Application Engineering
• Product and Prototype Development

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1) Evaluation of Suitable Power Electronics

• Need for power electronics
• Set up a hybrid system
• Analyse the design
• Adapt to special applications

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2) Evaluation Design of a Battery Power
Management
The NEXA Training System

• Need for batteries
• Charging and discharging
• Selection of battery types
• Optimize the parameters

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3) Design of an Off-grid Power Supply
The NEXA Training System

• Set-up and operation of a fuel cell hybride (2
  kWpeak/1 kWcont)
• Ohmic and inductive loads
• Power quality analyses
• Final prototype design

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4) Development of Fuel Cell Powered Vehicles
The NEXA Training System

• Design and construction of a car
• Proper Selection and adjustment of a suitable
  motor, buffer battery etc.
• Optimizing the power management
• Improve interaction of all system components

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Conclusion and Outlook

• The Nexa Training System is a valuable tool for
  complex fuel cell engineering tasks and for fuel
  cell integration.
• The system response on various load profiles of a
  fuel cell hybrid system can be investigated.
• Electrical components of an own application can
  be defined and optimized (ideal for prototype
  design).

• Further information and contact
• www.heliocentris.com

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Instructor
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Instructor the Fuel Cell Stack System for
Training

• 50 watts fuel cell stack
• Safe hydrogen supply solutions (Gas cylinders,
  hydride storage tanks or electrolyser solutions)
• Complete educational material included
  (Experimentation handbook, experimentation and
  display software, interactive CD-ROM with
  learning modules)

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Instructor
Hydrogen supply - Hydrogen connection - Pressure
reducer - Pressure gauge - Safety magnet valve
Fuel Cell System - H2 connection and flow
meter - 50 W air cooled fuel cell stack -
Temp. sensor - Single cell control - Purge magnet
valve

• DC/DC-converter
• DC/DC converter
• -Start battery

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Instructor
Parameter Control and Set Mode
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Instructor
Parameter Monitoring Mode
Voltage
Temperature
Current
H2-Consumption
Fan Power
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Instructor
Experiment 1 Factors effecting the
characteristic curve
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Instructor
Experiment 2 Usable Power
Input Power 77 W Stack Power 40 W
Usable Power 26 W ?Stack 0,52 ?System 0,34
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Tessekürler
  INVITATION Please visit us at HANNOVER
FAIR 21-25 April in Germany (Hall 13, Stand
E40/1). Large Fuel Cell Exhibition