Hybrid Light Trailer Operating Manual - Ensol Systems · Hybrid Light Trailer Operating Manual...

M-HLT-1212

Hybrid Light Trailer Operating Manual

Unit 2 - 5550 Panorama Drive Surrey, BC Canada V3S 1B7

Tel: 604-576-8333 Fax: 604-576-8233

www.ensolsystems.com


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Forward

Thank you for purchasing Ensol System’s Hybrid Light Trailer.

Please read through this reference guide before operating the unit as it contains particular start

up, shut down and disconnection procedures.

If you have any questions or concerns, contact Ensol at:

Ensol Systems Inc.

Unit 2 – 5550 Panorama Drive

Surrey, BC, Canada, V3S 1B7

Tel: 604-576-8333

Fax: 604-576-8233

Email: [email protected]

www.ensolsystems.com


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Table of Contents

Contents

Section 1 – WARNING NOTIFICATIONS .................................................................................................... 4

Section 2 – Quick Startup Procedure........................................................................................................ 5

Section 3 – General Information .............................................................................................................. 6

3.1 Product Introduction...................................................................................................................... 6

3.2 Product Specifications .................................................................................................................... 6

Section 4 - System Setup/Startup ............................................................................................................ 7

4.1 Parking & Leveling the Trailer......................................................................................................... 7

4.2 Raising the Mast ............................................................................................................................ 8

4.3 Activating the System .................................................................................................................... 8

4.4 Methanol Fuel Cell ......................................................................................................................... 9

Section5 Power System Operation ......................................................................................................... 10

5.1 Power System Introduction .......................................................................................................... 10

5.2 Solar System Operation ............................................................................................................... 11

5.3 Fuel Cell Operation ...................................................................................................................... 11

5.4 UN Certified Methanol Fuel Cartridges ......................................................................................... 12

5.5 Operational States ....................................................................................................................... 14

5.6 Default Parameters of cutoff threshold ........................................................................................ 15

5.7 Startup and Shutdown Phases ...................................................................................................... 16

5.8 Anti–Freeze Protection Mode ...................................................................................................... 17

5.9 Operation at the Device ............................................................................................................... 18

5.10 Service Fluid ............................................................................................................................... 19

Section 6 Error Messages....................................................................................................................... 20

6.1 Error Classifications Ranges.......................................................................................................... 20

6.2 Error Types .................................................................................................................................. 20

6.3 Most Common Error Messages .................................................................................................... 20


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Section 1 – WARNING NOTIFICATIONS

ATTENTION: PLEASE FOLLOW THESE WARNING NOTES. FAILURE TO COMPLY MAY RESULT IN

DAMAGE TO THE EQUIPMENT, AND/OR INJURY/DEATH TO PERSONNEL.

1. LOWER THE MAST WHEN WIND SPEEDS EXCEED 80KM/HR

2. NEVER OVER-EXTEND THE WINCHES.

3. ALWAYS ENSURE THE SIDE OUTRIGGERS AND ALL JACKS ARE SET WHEN RAISING THE

MAST.

4. ENSURE THE TRAILER IS PROPERLY LEVELED.

5. NEVER DETACH FUEL CELL FROM BATTERIES OR FUEL WHEN LOCATED IN

TEMPERATURES LOWER THAN 5 °C. FAILURE TO COMPLY WILL FREEZE THE FUEL CELL

AND MAY VOID WARRANTY.

6. REMOVE LIGHTS FROM MAST AND STORE IN THE ENCLOSURE DOORS WHEN

TRANSPORTING THE TRAILER.


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Section 2 – Quick Startup Procedure

This is a quick startup guide. For a more explicatory startup guide, go to Section 3

7. Park trailer at desired location, targeting for the most level ground.

8. Set all jacks and outriggers leveling the trailer according to the front and side spirit levels.

9. Raise the mast from the horizontal position to a vertical position by using the horizontal toggle

switch. Ensure the mast locks in place once horizontal.

10. Next position the lights to the desired location by loosening the locking screw, swiveling the

tower and tightening the locking screw again. Note that the solar panels, if possible, should be

facing south for optimal fuel efficiency.

11. Next raise the mast to the desired height by pushing the vertical toggle switch.

12. Once the trailer and mast are set and secured, open the control panel to start the system up.

13. Ensure the fuel cells are in the Auto mode and if not press the power button on the remotes

until they are.

14. Next turn the switches in the control panel to the right or ‘on’ position. The main power switch

will turn the inverter on and the lights switch will turn the lights on. Note that the lights will

automatically turn off during daylight via the photocell on the mast.


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Section 3 – General Information

3.1 Product Introduction

The Ensol Systems Hybrid Light Trailer offers a clean quiet solution to portable lighting, with virtually no

emissions.

Powered by a hybrid system of photovoltaic cells and a DMFC (Direct Methanol Fuel Cell), these

packages are reliable even in the most remote and harsh environments, and will last for weeks before

needing to be re-fueled.

3.2 Product Specifications

TRAILER:

Mast Stowed Dimension L x W x H 4.32 x 1.98 x 1.83 m (170 x 78 x 72 in)

Maximum Height of Mast 9 m (30 ft)

Width with Side Outriggers Extended 3.84 m (151 in)

Weight 950 kg (2100 lbs)

Axle 3500lb (1588kg) leaf spring axle

Hitch Combo - 2" ball hitch & 2.5" pintle ring

Jacks Four, 2000 lb adjustable leveling jacks

Tires ST205/75R15 – 6 ply (15 in)

Lighting DOT approved tail, side, brake & signal lights

Enclosure 14 gauge steel, polyester powder paint, SST hardware

POWER & LIGHTING:

METHANOL FUEL CELL (QTY 2):

Model EFOY PRO 2200

Power Output 90 Watt (2160 Watt-hrs/day)

SOLAR PANEL (QTY 2):

Model Solartech 130W

Power Output 130 Watts

LIGHTING (QTY 4):

Type LED

Color Cool White (4500K)

Power Consumption 50 Watts

Photopic Lumens 4250 lumens per fixture

Scotopic Lumens 7650 lumens per fixture


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BATTERIES (QTY 4):

Model Powersonic PSG-121000

Type AGM

Nominal Voltage 12 VDC

Capacity 100 Ahr

OPERATIONAL ESTIMATIONS:

Max/Min Days of Operation1,2 29 days / 158 days

Annual Fuel Consumption1,2 711 Litres

Annual Fuel Cost1,2 $5,590

Annual Operating Hours Per1,2 1Estimations based on solar insolation and daylight hour values for Fort Mcmurray, AB, Canada. 2Values will not be accurate if solar panels are not facing south.

Section 4 - System Setup/Startup

4.1 Parking & Leveling the Trailer

When parking the trailer, the operation should try and find the most level ground at the desired point of

installation. This will make it much easier to level the trailer when setting the jacks. To level the trailer,

follow these steps:

1. Ensure the vehicle is in park and that the parking brake is applied.

2. Chock the wheels and raise the front jack to remove the trailer from vehicle.

3. Face all jacks downward, but not yet in contact with the ground.

4. Extend the side outriggers by pulling the spring-loaded pin outwards, and by sliding the

outriggers out until they pin locks in place.

5. Next lower the jacks to raise each side of the trailer ensuring that the trailer is level according to

the front and side spirit levels.

6. Once leveled, you can raise the mast.


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4.2 Raising the Mast

The mast is control by electric winches which will stop automatically via limit switches. Please note that

after a limit switch has killed the power to the winch, the winch may still be operated. OPERATING THE

WINCH PAST THE TOWER’S EXTENTS WILL RESULT IN DAMAGE TO THE SYSTEM AND/OR INJURY/DEATH

TO PERSONNEL.

Take care when operating the mast. To raise the mast safely, follow these steps:

1. Remove the pin which locks the tower to the enclosure. This pin is located at the top back of the

enclosure.

2. Next push the horizontal lift toggle switch to bring the mast in a full upright position ensuring

that the mast locks into the spring loaded tab at the base of the mast. The electric winch will

automatically stop via limit switches once the tower is erect. DO NOT RE-PUSH THE

HORIZONTAL TOGGLE SWITCH IN THE ‘RAISE’ POSITION ONCE THE TOWER IS LOCKED OR THE

SYSTEM MAY DAMAGE. Once locked in place, push the supplied pin into the sliding tab.

3. Next position the lights at the desired location. First turn the handle on the locking screw in a

counter-clockwise position. Once the screw is loosened you can rotate the mast to position the

lights where desired. Note that for optimal fuel consumption efficiency, the solar panels, if

possible, should be facing south. Tighten the locking screw once the mast is in the desired

position.

4. When the tower is locked in place and secured, you can raise the mast to the desired height by

pushing the vertical toggle switch.

5. Follow these steps in revers to lower the mast.

4.3 Activating the System

To activate the system, open the control panel located at the front right side of the trailer. Inside the

control panel are the fuel cell remotes (Figure 1) and the power switches.

First ensure that the fuel cells are on and the remote displays “Auto Mode”. If the remote displays “Off”,

press the power button once and the fuel cells will turn on.


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Figure 1 – Fuel Cell Remote

Once the fuel cells are on, turn the switches in the control panel to the “On” position or to the right. The

first switch activates the inverter, while the second switch activates the lights. The lights will instantly

turn on if the inverter is on and if it is night time. Note that the lights turn off automatically during

daylight hours via the photocell located on the mast.

Close the control panel tightly once the system has been activated.

4.4 Methanol Fuel Cell

The EFOY Pro Fuel Cells will already be mounted, but all their accessories still may need to be

connected.

Connect all accessories in the following order:

• First, connect the methanol fuel cartridges. Screw the M28 cartridge adapter to the cartridges if

not already done so. Then connect the fuel line into the Duo Cart switch located beside the fuel

cell. Next connect the two fuel lines coming from the duo cart switch to each cartridge. Do this

for both fuel cells.

• Second, connect the exhaust tubing line to the EFOY Pro fuel cell’s exhaust port. This is a small

tube stub protruding just next to the fuel line. From there bring it down into the empty M28

cartridge, used for water collection.


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• Third, connect the wiring harness and remote to their respective ports. Ensure that the remote

is plugged into the ‘Remote’ RJ45 port and not the ‘Data’ port.

Section5 Power System Operation

5.1 Power System Introduction

The Hybrid Light Trailer’s power system consists of two methanol fuel cells and two solar panels to

charge a bank of sealed lead-acid batteries. This stored electrical power is then used to run the lights.

The power system is illustrated below in Figure 2.

Figure 2 – Hybrid System


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5.2 Solar System Operation

The solar system is comprised of two 130Watt solar panels. If possible, try to face the panels south

towards the sun. Since the panels are on the mast, the lighting system may need to be located on the

south side of the area desired to be lit, in order to have the panels face south.

5.3 Fuel Cell Operation

The SFC EFOY Pro fuel cell uses a catalytic process to directly convert methanol into electricity (see

Figure 3). The byproduct of this reaction is water, small amounts of CO2 and heat. To eliminate freezing,

the water must be collected internally. The collected water should be changed out at the point in time

that the fuel cartridge is replaced.

Figure 3


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Since the EFOY Pro fuel cell is a ‘smart’ fuel cell, charging and monitoring to the batteries is handled

automatically (example in Figure 4). With the remote which is included, the user can view the charging

mode, battery voltage, charging current, system operating hours and firmware version, and can also

change the charging mode. By pressing the power button on the remote, the user can turn the system

off, put it in automatic or turn the system on for one charge cycle.

Figure 4

Ensol Systems has pre-programmed the fuel cell’s parameters for the installation location. If charging

voltage set points need to be altered, please contact Ensol Systems.

For a full description of the EFOY Pro fuel cell’s operation, please see the manual provided by SFC’s

document 101123_UM_EFOY_Pro_GB_v02.

5.4 UN Certified Methanol Fuel Cartridges

The EFOY Pro uses special plastic fuel cartridges to facilitate ease of use and transport:

• The methanol fuel cartridges are UN certified containers certified for transport on cargo planes.

• The containers are spill resistant and designed to withstand significant impact force.

• Empty cartridges should be recycled.

• 28L cartridges are the largest available size and a cartridge adapter is required to use this

cartridge with the EFOY Pro fuel cell. DO NOT THROW AWAY THE CARTRIDGE ADAPTER!


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• The fuel cell methanol is ultrapure. Do not puncture the cartridge. To avoid contamination, do

not transfer residual methanol from an old cartridge to a new cartridge. DO NOT USE ANY

OTHER METHANOL SOURCE TO FUEL THE EFOY PRO! Impure/contaminated methanol will

severely degrade the performance and life of the EFOY and will VOID WARRANTY.


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5.5 Operational States

• Note that a minimal battery voltage of 9.0V or 18.5 V is required for the EFOY Pro to start.


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5.6 Default Parameters of cutoff threshold

New charging strategy (firmware 9.20 since mid of August 2010):

• Switch on voltage: 12.3 V (11.0 - 13.0 V)

• Switch off voltage: 14.2 V (13.5 - 14.7)

• Switch off current: 2 A / 4 A @ EFOY Pro 2200 (0.5 - 10 A)

• Switch off time: 3 hours (0 - 5 hours)

• This ensures full battery charging and maximizes battery life


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5.7 Startup and Shutdown Phases


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5.8 Anti–Freeze Protection Mode

• Note that the Hybrid Light Trailer is heavily insulated to ensure that the system works in cold

temperatures.

• THE ANTI-FREEZE PROTECTION MODE WILL NOT WORK WITHOUT FUEL! Please ensure that the

fuel cell does not run out of methanol in freezing temperatures. If the fuel cell freezes, 24 hours

will be required for the fuel cell to warm back up and be returned to service.

• The Anti-Freeze Mode will keep the EFOY Pro warm while the temperature is below 5oC (This

will work even when the unit is “OFF”).

• Anti-Freeze Mode requires the connection to a faultless, adequately charged battery and fuel

cartridge.

• Fuel consumption will be dependent upon external temperature differential. Weather,

insufficient insulation, ambient temperature and operating mode can have an impact on fuel

consumption.

• The EFOY Pro does not give the produced energy to a fully charged battery in Anti-Freeze Mode.

Rather, the stack “burns” methanol and supplies the peripheries (pumps, etc…) to heat up the

system. The batteries will not be overcharged.

• Startup temperature (when the Anti-Freeze Mode has not been activated) is 5 oC.


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5.9 Operation at the Device

Remote Control:


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5.10 Service Fluid

• If service fluid is low the yellow light will turn on at the EFOY Pro and the message “Please refill

service fluid” will appear at the control panel display.

• Normally, there is no need to add service fluid prior to the initial start-up.

• Note that the fuel cell produces its own service fluid during operation. This is critical to the

function of the device. If the EFOY Pro is operated continuously at temperatures above the

acceptable operating range (45 oC), the service fluid will be expelled faster than it can be

regenerated and cause a failure. For this reason, it is critical that the thermostat and fan

provided with the Fuel Cell Power Package are maintained in working order and set at an

appropriate temperature.

• Service fluid can be added by removing the exhaust line as pictured below.


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Section 6 Error Messages

6.1 Error Classifications Ranges

• 10 Internal hardware or firmware issue - Contact Ensol Systems.

• 20 Fuel - Change the cartridge and reset.

• 30 Service Fluid - Add service fluid and reset. Check thermostat and fan function.

• 40 Environmental Issue – Temperature too high or too low to maintain function.

• 50 Battery - Battery voltage too high or low. Check connections. Check solar charge controller.

• 70 Reservoir - Internal fuel problem. Check fuel connections and reset.

• 80 System - Internal voltage or system error. Reset.

6.2 Error Types

• A = Automatic reset (after error cause is remedied)

• M = Manual user intervention required

• F = Anti-freeze protection is possible from this error, if the error cause currently no longer exists

• P = Permanent error (not resettable)

• R = Reset required to restart system

• W = Warning

6.3 Most Common Error Messages

• 12, 13, 14 - Failure due to blocking of exhaust or circulation pump defect.

• 32, 31, 30, 41 - Failure due to high surrounding temperature. Check installation and ensure air

circulation is adequate.

• 52-54 - Check battery (voltage too low) and/or battery connection problem

• 72, 76 - Failure in Methanol dosing or internal sensors. Possible issues in Methanol cartridge

because of fuel line.


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Display

message

Error code error type Error description Remedial measure Potential error causes Notes

1 P System configuration

incomplete

Repair by SFC required Firmware update failed

10 P

15 P

13 A (1x / 30s)

R

F

Stack power output too low

14 A (1x / 30s)

R

F

Fluid level sensor defect

17 R

F

Abnormal power difference

between stack and output

11 A (1x /30s)

R

F

18 A (3x / 300s)

R

F

20 M

R

F

22 M

R

F

30 M

R

F

- Operation at high ambient

temperatures or insuff icient cooling

air

31 M

R

F

- Fluid level measurement defect

32 A

F

Service fluid level below 40%

41 A

F

Temparature to high (internal

sensor)

Interruption:

Please defrost

device slow ly

40 A

M

Temperature too low

(stack temperature sensor < 3 °C)

Defrost unit

(ca. 24 h at room temperature)

- Anti-freeze protection did not w ork

(due to an error)

50 A

F

T

Battery voltage too low

(sense line)

Battery voltage < 10,5 / 21 V ->

charge w ith battery charger

51 A Battery voltage too high

(sense line)

Battery voltage > 16,5 / 33 V ->

check external battery charger and

disconnect if necessary

52 A Batttery voltage too low

(power line)

53 A Battery voltage too high

(power line)

54 A Battery voltage measurement

defect

If the error persists a repair is

required

Circuit Board defect

70 R Error fuel reservoir sensors

73 R Internal fuel sensor defect

75 R Reservoir error (emptying time

too long)

80 R Internal voltage reference out of

tolerance

83 R DC/DC-Transformer defect

84 R

ASelf test equipment

76 PSerious reservoir error Permanent error - repair required

- Error 70 or error 72

reoccurred 3 times

Test: disconnect exhaust

hose and press "Reset", if

fuel cell is now running the

exhaust hose is blocked

Stack voltage too low

(error 11: during operation,

error 18: during start-up)

Solve potential error cause,

then press RESET (max. 3 attempts)

Exhaust hose blocked,

not suff icient fresh air

Please check

exhaust hose

Error causes if fuel cartridge not

empty:

- Bad connection of fuel cartridge

connector (air leak)

- Dirty fuel cartridge connector

Check connection to battery:

- Check battery cables

- Check battery fuses

Solve error cause

(check battery and connections)

Please change

fuel cartridge

Empty fuel cartridge detected

(internal fuel sensor)

Change fuel cartridge

(solve error cause)

then press RESET

Please ref ill

service f luid

Low service fluid level

(error 30: <20%, error 31: <5%)

-Ambient temperature to high (avoid

direct sunlight)

- Poor air ventilation in installation

space

Interruption:

Surroundings too

w armWait

(until temperature has dropped)

Serious system error

Please contact

service

Add service fluid

(solve potential error causes)

then press RESET

Repair by SFC required

Please check

battery voltage

Press RESET (max. 3 attempts),

repair required if error reoccurs

Stack damaged

Please contact

service

Please contact

service



Hardware defect


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Please check fuel

cartridge

connector

72 A

M

F

R

Reservoir error (refilling time

too long)

Solve potential error cause,

then press RESET (max. 3 attempts)

- Firmware problem (FW <9.11)

- Bad connection of fuel cartridge

connector (pumps air)

- Dirty fuel cartridge connector

Firmw are update

recommended (f ixed w ith

FW 9.11 or higher)

Please install

Filter XT

38 W Filter EFOY XT is removed install Filter only EFOY 2200 XT

Please contact

service

85 R Filter-Circuit-Board EFOY XT not

detected



only EFOY 2200 XT

no display

information

137 A Filter change confirmed no action required only EFOY 2200 XT

Please change

Filter XT

139 M Filter change is displayed change Filter EFOY XT only EFOY 2200 XT

no display

information

90 A Antifreezemode successfully no action required

Update: DO NOT

UNPLUG

BATTERY

99 A Firmware update is performed not interrupt firmware update

no display

information

140 AAntifreezemode not possible fix other error

another error is blocking the

antifreezemode

no display

information

172 AError 72 was once ignored

no action required

no display

information

184 A Self test equipment

successfully

no action required

Firmw are corrupt

update required

w ithout Atransfer defective firmware repeate firmware-update

- Remote control is connected to

w rong port (Data Interface)

- Batter voltage < 8,5 V

- No communication (defect)

No connect or

Check battery

w ithout Remote control has no

connection to fuel cell

Check connection, load battery if

necessary

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