User Manual UM1 1600 | 1200 | 900 | 600 Automatic Charge Control GB 2 1. Introduction 1. Introduction 1.1 Foreword Thank you for purchasing an EFOY product. We hope that you will enjoy your new unit. Please read these instructions first before using. Should you have any questions about installation or operation, please consult the EFOY hotline. SFC Smart Fuel Cell AG Eugen-Sänger-Ring 4 D-85649 Brunnthal-Nord Hotline: +49 89 673 5920 Freecall: 00800 732 762 78* Fax: +49 89 673 592 369 [email protected] www.efoy.com *The toll-free number is available in the following countries: Germany, Belgium, Denmark, France, Great Britain, Italy, the Netherlands, Norway, Austria, Sweden, Switzerland and Spain. 3 1. Introduction 1.2 Safety Information Read the instructions before operating and keep them nearby. Be sure to follow all directions in the manual. Do not open unit or fuel cartridges. Do not use force to open cartridges and do not refill them. Any modifications to the unit may affect safe operation, will lead to a loss of license and will void the warranty Use only original EFOY equipment. Do not store unit and fuel cartridges at temperatures above 45° C. Do not operate at temperatures above 40° C. Keep away from heat and direct sunlight. Store the unit where there is no danger of freezing, or use the automatic antifreeze feature. Do not smoke when handling the unit or the fuel cartridges. Keep away from heat and open flame. There is a danger of fire if methanol leaks out following an accident, or if the unit or the fuel cartridge has been damaged. Keep away from open fire and make sure area is well ventilated. Small amounts of methanol which may leak out will evaporate without leaving any residue. Keep unit and fuel cartridges (including empty or partially filled cartridges) out of children’s reach. Operate the unit only in accordance with instructions and keep operating area well ventilated. Do not block exhaust. Avoid inhaling exhaust fumes directly or for prolonged periods of time. 4 1. Introduction There is no risk of coming into contact with methanol provided that you handle the unit and fuel cartridges in accordance with instructions. We are required by law to print the following notice. Methanol is toxic if inhaled, ingested or if it comes into contact with skin. Irreparable damage may occur if inhaled, ingested or if it comes into contact with skin. In the event of an accident or if nausea occurs, consult a physician immediately. Be sure to bring the fuel cartridge label or these instructions to the consultation. (A caution concerning methanol can be found in the appendix.) System exhaust may contain harmful components. Avoid inhaling exhaust directly or for prolonged periods of time. Use the exhaust hose to conduct exhaust gases to the exterior. Improper use or improper connection to other electrical devices may result in damage. In addition to these safety instructions, please observe the passages in bold type. Otherwise, you may endanger yourself and others. 5 1. Introduction 1.3 Normal Operation The EFOY 600, EFOY 900, EFOY 1200 and EFOY 1600 are automatic charging devices for 12V lead batteries. The unit may be used only to charge lead batteries that conform to the specifications in Chapter 3.4, S. 12). The specifications allow for solid-state operation (see Chapter 3.4) on boats and on motor vehicles. Operate only with original-equipment EFOY fuel cartridges. The unit is not intended for emergency medical power generation, or for powering life-sustaining or agricultural devices. Do not operate unit if housing is damaged. 1.4 Declaration of Conformity SFC Smart Fuel Cell AG, Eugen-Saenger-Ring 4, 85649 Brunnthal-Nord declares that the EFOY 600, EFOY 900, EFOY 1200 and the EFOY 1600 conform to the European Community’s 89/336/EWG guidelines for electromagnetic compatibility. The following norms apply: DIN EN 61000-6-1, DIN EN 61000-6-3 6 1. Introduction 1.5 E 24 Seals of Approval These units have been tested in accordance with ECE Regulation No. 10 for electro-magnetic compatibility. Operation in motor vehicles is permitted. Approval number: E24 10R-020234 These units have undergone voluntary testing by TÜV SÜD for conformity with the basic requirements of IEC 62282-5 and have been awarded the seal of approval for product safety. 1.6 Warranty 1. Warranty SFC provides a) a 36-month warranty for up to 3,000 hours of operation. The warranty covers defects caused by materials or by the manufacturing process, provided that the manufacturer has a written registration of the unit on record. The unit must be registered online or by sending in the warranty card. The unit must be registered no later than 4 weeks after date of purchase. Registration is subject to the purchaser agreeing to have his data recorded by the manufacturer. b) a 24-month warranty for up to 3,000 hours of operation. The warranty covers defects caused by materials or by the manufacturing process should there be no registration of the unit on record as described in warranty 1a. The warranty does not extend to cover improper use of the unit or operation that is not in accordance with the user manual, in particular: If fuel cartridges other than original EFOY fuel cartridges are used, Inappropriate handling, Water damage, Improper transportation, If the unit has been opened. 7 1. Introduction 2. Extent of the warranty The warranty covers defects (see 1. Warranty) from the time of sale. The manufacturer shall remedy such defects by either repair or replacement (updated model where applicable) as he deems appropriate. Should the manufacturer provide a warranty, the warranty period with regard to repair or replacement parts shall not recommence from the time of service. Instead, the warranty from time of sale will remain in force. Any other claims, in particular claims for damages on the part of the purchaser or a third party, are invalid. The provisions of the product liability law remain in effect as well as any claims against the manufacturer pertaining to warrantees remain in force as provide by law. The warranty does not extend to any extra costs associated with mounting or dismounting the unit such as disassembling furniture or parts of a motor vehicle. 3. In Case of Claim Always notify the EFOY service center in writing in case of malfunction. Please describe the defect in detail. Please also indicate serial number and include the original invoice. The purchaser must bring or send the unit to the manufacturer at his own risk so that the manufacturer can determine whether the defect is covered by the warranty. The unit must be sent to the factory as freight. If the defect is covered by the warranty, the factory shall assume the transportation costs. Should the defect not be covered by warranty, the manufacturer shall notify the customer, informing the customer of what repair costs the manufacturer shall not assume. The customer shall bear the cost of transportation in this case. 8 1. Introduction The manufacturer’s address is: SFC Smart Fuel Cell AG Eugen-Saenger-Ring 4 D-85649 Brunnthal Tel.: +49 89 / 673 59 20 Free Call: 00800 / 73 27 62 78** Fax.: +49 89 / 673 592 369 [email protected] www.efoy.com Service EFOY customer service is available for technical inquiries concerning EFOY fuel cells during normal business hours at the following numbers: Toll-free number: 00800/73 27 62 78* If calling from outside the countries listed below, please dial +49 89 / 673 5920 *The toll-free number is available in the following countries: Germany, Austria, Belgium, Denmark, France, Great Britain, Italy, the Netherlands, Norway, Spain, Sweden and Switzerland. 9 1. Introduction 1.7 Packaging Disposal Packaging protects your unit during shipping. All materials used are environmentally compatible and recyclable. We recommend saving the packaging for eventual winter storage. Should you nevertheless wish to dispose of the packaging, please do so properly. Your dealer or your local recycling center can provide information about proper disposal. Danger of Suffocation! Keep packaging away from children. Plastic wrapping and cartons may cause suffocation. Fuel Cartridges Old Units Sort empty fuel cartridges with plastics. Dispose of partly filled fuel cartridges in the same manner as solvents or paint. Old units are still valuable! Proper disposal can yield valuable raw materials while protecting the environment. The EFOY hotline: Tel.: +49 89 673 5920 or 00800 732 762 78* can advise you about returning old units. 10 2. Table of Contents 2. Table of Contents 1. Introduction 1.1 Foreword 1.2 Safety Information 1.3 Normal Operation 1.4 Declaration of Conformity 1.5 Seals of Approval 1.6 Warranty 1.7 Disposal 3 3 4 6 6 7 7 10 2. Table of Contents 11 3. Configuration 3.1 Standard Equipment 3.2 Overview 3.3 Remote Control 3.4 Specifications 13 13 14 14 15 4. Installation 4.1 Tools and Materials 4.2 Space Requirements 4.3 Securing the unit 4.4 Off-heat duct 4.5 Installing the fuel-cartridge holder 4.6 Electrical Connections 4.7 Connecting the Remote Control 17 17 18 20 21 23 24 30 5. Operation 5.1 Connecting the Fuel Cartridge 5.2 Automatic Operation 5.3 Switching on the Fuel Cell 5.4 Display Information 5.5 Select Language 5.6 Switching Off the Fuel Cell 5.7 Automatic Antifreeze Feature 5.8 Storage 32 32 34 35 35 37 37 38 39 6. Maintenance 6.1 Service 6.2 Cleaning 41 41 41 11 2. Table of Contents 7. Troubleshooting 7.1 Safety 7.2 Problems and Solutions 7.3 Problems without Error Messages 7.4 Changing the Fuse 7.5 Replacing Service Fluid 42 42 43 46 47 48 8. Appendix 8.1 Accessories and Spare Parts 8.2 Output characteristic 8.3 Material Safety Data Sheet Methanol 49 49 50 52 12 3. Configuration 3. Configuration 3.1 Unit Standard Equipment The following is standard equipment: Unit Remote control with data line RC1 Fuel-cartridge holder with belt FH 1 Mounting plate with belt MP 1 Exhaust hose (1.5 m) EH 1 Charge line Service-Kit UM1 user manual Remote control with data line RC1 Fuel-cartridge holder with belt FH1 Mounting plate with belt MP1 Eexhaust hose EH1 Connecting line to fuel-cell 1m Off-heat duct OD1 Battery fuse power 7.5A Battery fuse sense 2A Service kit 13 3. Configuration 3.2 Overview 1 2 3 4 5 6 7 8 3.3 auto reset ! Charge line connection Remote-control connection RC 1 Data interface G-fuse 250V 8A M, 5 x 20 mm Fuel-cartridge connection Connection for EH 1 exhaust hose and nozzle for service fluid Cooling inlet (reverse) Warm-air outlet and connection for off-heat duct Remote Control 1 2 3 4 5 6 7 Display Information button and language-selection button >> On/Off button Button for automatic operation auto Yellow warning light “Please change fuel cartridge“ Red error warning light Reset button reset 14 3. Configuration 3.4 Specifications Performance Product EFOY 600 EFOY 900 EFOY 1200 EFOY 1600 Rating 25 W 38 W 50 W 65 W Charge capacity 600 Wh/Day (50 Ah/Day) 900 Wh/Day (75 Ah/Day) 1200 Wh/Day (100 Ah/Day) 1600 Wh/Day (130 Ah/Day) Nominal voltage 12 V 12 V 12 V 12 V Charging current @ 12 V 2.1 A 3,1 A 4.2 A 5.4 A Turn on threshold* Ubatt < 12.3 V Ubatt < 12.3 V Ubatt < 12.3 V Ubatt < 12.3 V Cut off threshold* Ubatt >14.2 V and Iout < 2.0 A Ubatt >14.2 V and Iout < 2.0 A Ubatt >14.2 V and Iout < 2.0 A Ubatt >14.2 V and Iout < 2.0 A Required starting voltage > 10.8 V > 10.8 V > 10.8 V > 10.8 V Quiescent current requirement 15 mA 15 mA 15 mA 15 mA Methanol requirement 1.1 l/kWh 1.1 l/kWh 1.1 l/kWh 1.1 l/kWh Compatible batteries 12 V rechargeable (lead-acid or lead-gel) batteries 10 to 100 Ah 15 to 150 Ah 20 to 200 Ah 25 to 250 Ah Sound pressure level at 7 m 23 dB(A) 23 dB(A) 23 dB(A) 23 dB(A) Weight 6,3 kg 7,1 kg 7,1 kg 7,3 kg Dimensions (L x W x H) 43,5 x 20,0 x 27,6 cm General Specifications * factory setting 15 3. Configuration Environmental conditions Space requirement (L x W x H) 51 x 35 x 30 cm minimum Inclination along the direct axis continual: 35° temporary (<10 min): 45° Inclination along the quadrature axis continual: 20° Operating temperature -20 to +40 °C Start temperature +5 to +40 °C Storage temperature +1 to +45 °C Instrumentation Operation via remote control with four buttons and multilingual display Electrical interface MNL 4-prong plug Type Tyco Electronics AMP Universal Mate-N-Lok (Mfr. No. 350779) Fuse G fuse 250V 8.0A M, 5 x 20 mm Fuel Cartridge M5 M10 Volume 5 liter 10 liter Weight 4.3 kg 8.4 kg Dimensions (L x W x H) 19.0 x 14.5 x 28.3 cm 23.0 x 19.3 x 31.8 cm 16 4. Installation 4. Installation Securely fasten unit and fuel cartridges when using on board motor vehicles. Do not operate unit if there is danger of explosion. Unit is not watertight. Make sure that no water can enter. Keep unit and fuel cartridges away from children, temperatures in excess of 45° C and direct sunlight. 4.1 Tools and Materials You will need the following tools and sealants to install the fuel cell in an RV: electric drill jigsaw screwdriver hexagonal (Allen) wrench sealant such as Sikaflex Use the following screws, depending on the mounting surface (screws are not included): 8 screws to attach the mounting plate 4 screws to attach the remote control 4 screws to attach the fuel-cartridge holder cable clamps and fixing screws, if needed 17 4. Installation 4.2 Space Requirements Installation should be carried out by trained personnel only. Wear proper work clothes. Avoid flowing garments and wear a hair net if you have long hair. Clothing and hair can get caught in moving or rotating parts such as in a drill. Be sure to leave enough space behind the installation area when drilling or cutting out openings. Also be sure to follow the tool manufacturer’s safety instructions. Solvents used in sealants may emit fumes. Make sure that there is sufficient ventilation and follow the instructions for the sealing compound. Make sure when choosing a location, that the temperature ranges between –20° C and +40° C. This unit generates heat, thus requiring ventilation. Please take this into account when considering possible locations. Provide for a vent opening measuring at least 10 cm across when installing. Use the off-heat duct (included) to remove warm air. Zuluft cooling air min. 10 cm Install only in upright position. Use the mounting plate (included). 18 4. Installation Make sure that the device does not exceed the maximum inclination. Inclination along the direct axis: continual: 35° temporary (<10min): 45° Inclination along the quadrature axis: continual: 20° All electrical connections, the fill opening for service fluid and the fuel cartridge should be easily accessible. max. 30 cm Make sure that the fuel cartridge is located within reach of the connecting hose (30 cm) and that the hose is neither kinked nor crushed. The fuel-cartridge hose and the exhaust hose may not be damaged. Do not substitute another hose for either of the two. Use only original-equipment EFOY hoses. 19 4. Installation 4.3 Locations 2 3 1 Ideas for installation: 4.4 1 false floor or side compartment 2 seat bench 3 rear storage area Securing the unit Select a suitable location as described in Chapter 4.2, paying attention to the dimensions in Chapter 3.4. 1. Run the belt in the groove under the mounting plate. 2. Secure the mounting plate tightly to the desired location. Use eight proper screws and dowels, if necessary, so that the mounting plate cannot shake loose in case of an accident. 3. Place the unit onto the mounting plate. 20 4. Installation 4. Strap the unit tightly to the mounting plate. 4.5 Off-heat duct The off-heat duct (included) extracts warm air so that the unit can also be operated in close quarters. Use the bow to conduct warm air to the side. cooling air Zuluft If you do not need the off-heat bow, you can disconnect it from the off-heat flange and connect the off-heat tube directly to the flange. exhaust warmKühlluft air Abluft erwärmte Make sure that the off-heat tube is not kinked; use a second bow if needed. warm air cooling ø min. Zuluft 10 cm air erwärmte Kühlluft Abluft exhau Sink the screws for the off-heat flange into the holes provided. 21 4. Installation Then pass the off-heat tube to the exterior. You will need an opening with a 100 mm diameter. Be careful of electrical lines when drilling. The RV manufacturer or your dealer can provide information as to the location of lines. 10 cm Pass the off-heat tube through the opening; any excess may be shortened. It may be necessary to use an external face plate to protect the outlet. Use a suitable sealant to prevent moisture from penetrating into the body or into the interior. 4.6 Connecting the Exhaust Hose Exhaust gasses contain moisture and may exceed 60° C, causing scalding. Exhaust byproducts may contain injurious substances. Avoid inhaling exhaust directly or for long periods of time. The exhaust hose may not be longer than 50 cm in order to prevent freezing in winter. The hose may be up to 150 cm long for summer operation and during transitional seasons. At no time may siphoning occur in the hose. Make sure that the hose is neither clogged nor blocked. Routing the exhaust hose Up Down 22 Avoid siphoning 4. Installation Remove the cap from the exhaust port. Retain the cap for winter storage or for possible returns. Attach the exhaust hose (included) to the exhaust port. Route the hose to the exterior and use a suitable sealant to seal the opening. The hose may be shortened as needed. The opening must be10 mm in diameter. 1 cm Make sure the exhaust hose has no kinks or blockage and that exhaust can escape freely. 4.7 Installing the fuel-cartridge holder Keep fuel cartridge and all reserve cartridges away from children. Keep cartridges away from heat and out of direct sunshine. Secure fuel cartridge and all reserve cartridges so that they can not shift. Make sure that the fuel-cartridge connecting hose is neither crushed nor kinked. warm air Do not place fuel cartridges or reserve cartridges in front of the air intake or outlet! Place fuel cartridges next to or in front of the unit as illustrated. Do not place objects such as reserve fuel cartridges in front of the air intake or outlet. electrical connection 23 4. Installation Install unit and fuel cartridge at the same level. Secure the fuel-cartridge holder with four suitable screws and dowels, if necessary, so that it will not shake loose in the case of an accident. 4.8 Electrical Connections All work should be carried out by qualified technicians in accordance with technical regulations. Improper connections or the use of wrong gauge wires could result in fire. All wires must be properly insulated and have adequate voltage rating. All connections must be tight. The use of uninsulated wires and contacts is not permitted. Use the wire harness (included) to connect the unit. The circuit connecting the battery must contain a fuse. Alternatively, use the fuse (available as optional equipment) to connect the battery. Check the polarity (see illustration) before connecting the unit. Both sensor and power lines must always be connected. Always use separate lines for charging (power) and for voltage metering (sensor) to the battery. Otherwise, the flow of current will cause false readings. 24 4. Installation The charging lines consists of four leads that must be connected to the battery as follows: Power lead: This lead carries current from the fuel cell to the battery. Power lead Sensor lead Sensor lead: This lead measures battery voltage. To minimize current loss in the leads, the following cross section is recommended, should the battery charging cable be insufficient: Length [m] min. cross section <5m 5 – 10 m 10 – 15 m 2.5 mm² 4 mm² 6 mm² Option: Extension sense line 8 m (Art. No. 151 906 005) Extension Power line 8 m (Art. No. 151 906 006) Two kinds of electrical connection are possible: via the central electrical box (Chapter 4.8.1) directly to the battery (Chapter 4.8.2) 25 4. Installation 4.8.1 Connection via the Central Electrical Box (EBL) TV entertainment refrigerators heating light Power lead EBL Sense lead 26 4. Installation red brown Fuse 2A 4 1 5 3 2 or 6 7 1. unit 2. connecting line to fuel cell 3. extension sense line (optional) 4. battery fuse 2 A 5. battery 6. extension power line with 2- or 3- pole plug (optional) 7. Central electrical box (EBL) 27 4. Installation 4.8.2 Connection directly to the battery TV entertainment light heating refrigerators power lead sense lead 28 4. Installation red brown Fuse 2A 1 4 5 3 2 6 Fuse 7.5A 7 1. unit 2. connecting line to fuel cell 3. extension sense line (optional) 4. battery fuse sense 2 A 5. battery 6. extension power line with 3-pole plug (optional) 7. battery fuse power 7.5 A 29 4. Installation 4.9 Connecting the Remote Control The remote control (1) displays the current status and is used to control the device. Mount the panel where it is easily accessible such as in the cockpit. 1 If installing the panel flush with the surface of the unit, make sure that there is a sufficient opening for the electronic components behind the opening. 2 3 Use templates for drilling and sawing when flush or surface mounting (2). Use a drill to start the opening and then cut out the rest of the opening with a keyhole or compass saw. 4 The secure the control panel (1) with four suitable screws (4) and place the frame (3) over the control panel. Flush mounting: 1 remote control 2 opening 3 frame 4 screws 1 Surface mounting (optional) 2 Secure the surface mount with two screws. Connect the remote control with the DL 1 data line (included). 3 4 Then secure the control panel (1) with four suitable screws (4) and place the frame (3) over the control panel. Surface mounting: 1 remote control 2 surface mount 3 frame 4 screws 30 4. Installation Connect the remote control with the DL data line (included). If the DL 1 data line is not long enough, you can replace it with a commercially available network line that is longer or shorter (Category 5 patch cable). Then insert the plug into the left socket on the unit marked “Remote Control“. 31 5. Operation 5. Operation 5.1 Connecting the Fuel Cartridge For safety’s sake, use only original EFOY fuel cartridges. Do not smoke while changing the cartridge and avoid open flames! Do not expose fuel cartridges to temperatures above 45°C. Do not place the fuel cartridge in front of the air intake or outlet. Original-equipment EFOY fuel cartridges contain EFOYapproved methanol. Even slight impurities in commercially available methanol may cause permanent damage to the unit and may void the warranty. Note: When the cartridge is empty, “Please change fuel cartridge“ will appear on the remote control and the yellow light will blink. The cartridge may be changed while the system is running. Unscrew the empty fuel cartridge and remove. Close each cartridge tightly with the cap after use. EFOY fuel cartridges are intended for one-way use only. They may not be refilled. Sort empty fuel cartridges with plastics. Dispose of partly filled fuel cartridges in the same manner as solvents or paint. 32 5. Operation 1 Place a new sealed original-equipment EFOY fuel cartridge into the fuel-cartridge holder (1). Fasten the belt on the fuel-cartridge holder (2). Do not attach fuel cartridges without a fuel-cartridge holder. Only remove the childproof cap when the new fuel cartridge has been placed into the fuel-cartridge holder (3). Screw the connector onto the new fuel cartridge. 2 Press reset on the control panel to extinguish the yellow warning light and the maintenance message. 3 33 5. Operation 5.2 Automatic Operation Before connecting to the electrical system, make sure the unit has been positioned properly and that the electrical system is protected by fuses (as described in Chapter 3.4) Do not operate at temperatures above 40° C or below - 20° C. If device has been exposed to temperatures under 0° C without being connected to a battery or with insufficiently filled fuel cartridge (antifreeze), it must stand at room temperature for 24 hours before operating. Make sure that a full fuel cartridge has been connected. Automatic operation will begin the moment that you connect the unit to a battery. The unit will monitor battery voltage by itself. Charging mode The unit charges the battery as needed or assists the battery in providing output. The second line of the display will indicate “charging mode“ as long as the unit is providing voltage to the electrical system. Automatic The device goes through a cold start phase of about 20 minutes before reaching its full rated output. Automatic Start phase Automatic Standby Automatic Please change fuel cartridge If the battery is sufficiently charged and the unit is not providing input, the unit will remain in the standby mode. Should the device detect a malfunction such as an empty fuel cartridge, it will shut down and advise you how to correct the situation. (“Please change fuel cartridge“.) Resume automatic operation using the reset button after the error has been corrected. (See also Chapter 7 Troubleshooting). 34 5. Operation 5.3 Switching on the Fuel Cell If desired, you can switch on the unit manually regardless of the battery voltage. The unit will then be in the “charging mode“. This function is only possible when the battery voltage is below 13.2V Press on the control panel once if the unit has been switched off, and twice if it is operating in automatic mode. The unit will start up regardless of the battery voltage and will continue charging until it reaches the cutoff point (Ubatt >14,2 V und Iout < 2,0 A). On Charging mode The device will then switch to automatic mode by itself and will only charge if the battery or the demand for power requires it. 5.4 Display Information The second line of the display provides information about normal operation, errors or malfunctions (see Chapter 7). The first line indicates the operating mode selected, such as “Automatic“. Press >> to obtain the following information. Automatic Battery voltage Voltage 13.6 V Automatic 4.6 A Charging current Please note that the device interrupts power generation briefly several times an hour during normal operation and a charging power of 0.0 A is displayed then. 35 5. Operation Automatic Firmware version Firmware 1200 4.12L Automatic Total operating hours Operating hours 500 h Automatic Maintenance messages (see also Chapter 7) Please change fuel cartridge Automatic Charging mode If you have connected the optional cartridge sensor to your unit, a fuel cartridge will appear in the display as soon as a predetermined amount is reached. Always keep a reserve fuel cartridge at the ready. The cartridge need only be changed when the message “Please change cartridge“ appears in the display. The standard display will be restored after about 30 seconds. Alternatively, you can return to the standard display by pressing >> again. By pressing >> for approximately 2 seconds, you will obtain the language menu (see Chapter 5.5). 36 5. Operation 5.5 Select Language Press >> on the control panel for 2 seconds. The control panel will display the language currently selected. The following languages are available: German (factory setting) English French Italian Dutch Spanish Deutsch Continue pressing >> until the desired language appears. Then hold >> 2 more seconds in order to set your language choice. 5.6 Switching Off the Fuel Cell Press device. on the remote control to switch off the The unit will gradually shut down, performing various function checks as it does so: Off Shutting down To protect components, the unit must run at least 30 minutes before shutting down. If the unit is shut off beforehand, it will continue running until 30 minutes have elapsed. The message “Shutting down” will appear in the display. Leave the fuel cartridge and the battery connected during this time. Please note that the fuel cell will only start up if it is connected to an intact battery. The fuel cell will not switch on if the battery is damaged. 37 5. Operation 5.7 Off Antifreeze mode Automatic Antifreeze Feature This unit features an intelligent antifreeze feature. The unit can keep itself warm at temperatures below 3° C as long as it is connected to a working battery and it is supplied with methanol. If the unit is in antifreeze mode, the message “Antifreeze mode” will appear on the second line. The first line will indicate the current operating mode, for example “Off”. The antifreeze function works only as long as a fuel cartridge and a sufficiently intact battery are connected. The unit will not be able to start if the battery voltage falls below 10.5 volts. Please note that the unit will not recharge the battery if the voltage drops below 10.5 volts. Please observe the following maintenance tips for storage and winter operation: 1 To cut energy costs, we recommend dismounting the unit and storing it away from cold if it is to be inactive for longer periods of time. Dismounting is easy; it requires just a few steps, no tools and no particular technical finesse. Store the unit in the original carton. 2 If, despite precautions, the unit does freeze, let it thaw in a warm place for approximately 24 hours before operating. Please note that the unit’s performance may diminish if it freezes repeatedly. Running in straight antifreeze mode, the unit will consume approximately 10 liters of methanol in the course of a five-month Central European winter. 38 5. Operation 5.8 Storage Press unit. Off Shutting down on the remote control to switch off the Wait until the unit has shut down and the display has disappeared (approx. 30 min.). Unplug the charging line and the data line for the remote control. Store the plugs and lines in a cool, dry place. Do not smoke when handling unit and fuel cartridge. Keep away from open flame! Unscrew the fuel cartridge and close it with a cap. Keep all elements clean. Keep unit and fuel cartridges – even empty or partially empty cartridges – away from children. Remove the exhaust hose. Keep it clean and place a cap over the exhaust outlet. Remove the off-heat tube and the off-heat bow if necessary. Release the belt and lift the unit off the mounting plate. Store unit in a cool place; however, the temperature should exceed 1° C because the automatic antifreeze feature will only work if a fuel cartridge is attached along with a sufficiently charged battery. (See Chapter 5.7) If the unit has been exposed to temperatures below 0° C without being connected to a battery and sufficiently filled fuel cartridge (antifreeze), it will have to stand at room temperature for approximately 24 hours before operating. 39 5. Operation Use a proper box such as the original carton to ship the unit. Use padding to prevent shocks. Transport the unit in an upright position only. 40 6. Maintenance 6. Maintenance 6.1 Service Do not open unit! Unauthorized tampering may jeopardize safe operation and void any warranty. The unit does not contain any components that you can service or repair yourself. The unit is maintenance free under normal operating conditions. Contact SFC if you intend to use it for other than its intended purpose. SFC Smart Fuel Cell AG Eugen-Sänger-Ring 4 D-85649 Brunnthal-Nord Hotline: +49 89 673 5920 Freecall: 00800 732 762 78* [email protected] www.efoy.com *The toll-free number is available in the following countries: Germany, Belgium, Denmark, France, Great Britain, Italy, the Netherlands, Norway, Austria, Sweden, Switzerland and Spain. 6.2 Cleaning Switch off device before cleaning and unplug the battery charging cable. The device is not watertight. Make sure that moisture cannot get inside. Clean only with a soft cloth dampened with a mild detergent. Reconnect the battery charging cable after cleaning so that the antifreeze feature remains activated. (See Chapter 5.7). 41 7. Troubleshooting 7. Troubleshooting 7.1 Safety Do not open unit! It contains no components that you can repair yourself. Contact SFC Smart Fuel Cell AG if you are unable to correct a malfunction using these instructions. SFC Smart Fuel Cell AG Eugen-Sänger-Ring 4 D-85649 Brunnthal-Nord Hotline: +49 89 673 5920 Freecall: 00800 732 762 78* [email protected] www.efoy.com *The toll-free number is available in the following countries: Germany, Belgium, Denmark, France, Great Britain, Italy, the Netherlands, Norway, Austria, Sweden, Switzerland and Spain. 42 7. Troubleshooting 7.2 Problems and Solutions The control panel signals problems via a red and/or yellow light and a running message on the second line of the display. The messages will assist you in solving the problem quickly and easily. Press the reset button on the control panel AFTER the problem has been solved. Message Solution Check battery Battery voltage is too low. or If battery voltage is under 10.5 V, check connection between unit and battery (see Chapter 4.8). No connect Interruption: Surroundings too warm Ambient temperature is too high. Unit will start automatically as soon as temperature drops below 30° C. Interruption: Please defrost device slowly Unit has been exposed to temperatures below 0° C without being connected to a battery and sufficiently filled fuel cartridge (automatic antifreeze feature). Let stand at room temperature for approx. 24 hours. Error 10: Please contact service Call the hotline at. Error 11: Please check exhaust hose Check that the exhaust hose has been properly connected and arrange it so that condensation cannot form. Error 12: Please check exhaust hose Freecall: 00800 732 762 78* Hotline: +49 89 673 5920 [email protected] www.efoy.com Check for kinks. Clean hose if necessary and keep opening clear. Shorten exhaust hose if condensation forms. 43 7. Troubleshooting Message Solution Error 11: Please check exhaust hose Check that the exhaust hose has been properly connected and arrange it so that condensation cannot form. Error 12: Please check exhaust hose Check for kinks. Clean hose if necessary and keep opening clear. Shorten exhaust hose if condensation forms. Error 13: Please contact service Call the hotline at. Error 14: Please contact service Error 15: Please contact service Freecall: 00800 732 762 78* Hotline: +49 89 673 5920 [email protected] www.efoy.com Error 16: Please contact service Error 17: Please contact service Error 20: Please change fuel cartridge Insert a new fuel cartridge as described in Chapter 5.1. Error 21: Please change fuel cartridge Check cartridge hose for kinks. Check hose and connection for dirt. Position fuel cartridge on the same level as unit. Error 22: Please change fuel cartridge Check connection and screw cartridge on tightly. Check connection and screw cartridge on tightly. Error 23: Please change fuel cartridge Error 30: Please refill service fluid Error 31: Please refill service fluid Check that exhaust can escape and that ambient temperature is below 40° C. Then add service fluid (see Chapter 7.5). 44 7. Troubleshooting Message Solution Error 50: Please check battery voltage Battery voltage is too low. Check battery voltage. If under 10.5 V, use an external battery charger to recharge. Check the connection of the sense line. Error 51: Please check battery voltage Battery voltage is too high. Check whether the battery is the proper type. Check the connection of the sense line. Check other charging devices such as generators or regulators for defects. Error 52: Please check battery voltage Battery voltage is too low. Error 53: Please check battery voltage Battery voltage is too high. If battery voltage is under 10.5 V, check connection between unit and battery (see Chapter 4.8). Check whether the battery is the proper type. Check other charging devices such as generators or regulators for defects. Error 63: Automatic restart Unit is restarting automatically. Error 65: Automatic restart 45 7. Troubleshooting 7.3 Description Problems without Error Messages Cause Solution The device doesn’t respond and Remote control is not nothing is displayed on the remote connected or is control. incorrectly connected. Check the connection of the remote control (see chapter 4.9). No battery connected, wrong battery or undercharged. Check contacts, polarity and cables. Connect a charged battery to start device. Short-circuit fuse tripped. Check polarity of charge line. Turn off unit, check reason for short circuit/overload or wrong polarity and correct. Replace fuse (see Chapter 7.4). If problem recurs: Contact the hotline at: Freecall: 00800 732 762 78* Hotline: +49 89 673 5920 [email protected] www.efoy.com 46 7. Troubleshooting 7.4 Changing the Fuse Replace fuses only with fuses of the same type and rating. Never repair or override a fuse. Before changing fuse, locate the reason for the malfunction and have your dealer repair it. Switch off the unit before replacing the fuse. Unplug the charge line. Replace the fuse: G fuse 250V 8 A M, 5 x 20 mm Reconnect the charge line. Make sure that you have replacement fuses on hand. Replacement fuses are available in electronics stores or from your dealer. 47 7. Troubleshooting 7.5 Replacing Service Fluid If service fluid is low the red light will come on and the message ”Please refill service fluid“ will appear in the control panel display. There is no need to add service fluid prior to the initial start-up. Use EFOY brand service fluid only. Switch off the unit before refilling fluid. Unplug the charge line. Always keep the device’s service fluid nozzle clean. Use a clean pair of scissors to cut off the tip of the cap. The service fluid bottle is for one time use only. Remove the exhaust hose from the device’s service fluid nozzle. Insert the tip into nozzle and gently squeeze the entire contents into the nozzle. Never refill more than one bottle of Service Fluid at a time. Wipe off any spilled service fluid with a cloth. Replace the exhaust hose. Reconnect the charge line. Press the reset button. The display will clear and the device will return to its former operating mode. Order a spare bottle service fluid at your local dealer. 48 8. Appendix 8. Appendix 8.1 Accessories and Spare Parts Use only original equipment! Use of unauthorized parts compromise safety and void the warranty. Description Item number Fuel cartridge M5 (2) 150 905 006 Fuel cartridge M10 150 905 008 Fuel-cartridge holder with belt FH1 150 905 002 Remote control with data line RC1 151 077 003 Frame for remote control 151 077 007 Surface mount for remote control 151 077 006 Data line DL1 (5 m) 151 075 003 Mounting plate 151 908 002 Belt 151 908 003 Charge line CL1 151 906 009 Exhaust hose EH1 (1.5 m) 000 999 674 Off-heat duct OD1 151 903 001 Off-heat flange and Off-heat bow 151 903 005 Off-heat tube 151 904 001 External face plate 151 903 013 Screw for fastening off heat flange M4 x 10 (4 pieces) 000 992 629 User manual UM1 151 901 001 G-fuse 250 V 8 A m, 5 x 20 mm 151 906 001 (10 pieces) Service-Kit 151 909 002 For further information on accessories and spare parts, please ask you dealer. 49 8. Appendix 8.2 Output characteristic U-I and U-P characteristic as per CE test 50 8. Appendix 51 8. Appendix 8.3 Material Safety Data Sheet Methanol When working with methanol fuel cartridges, be sure to comply with the following safety data sheet. In case of accident or nausea, immediately seek medical assistance and present this safety data sheet. 52 DR Page 1/5 Safety Data Sheet according to 1907/2006/EC, Article 31 Printing date 15.11.2007 Revision: 15.11.2007 1 Identification of the substance/preparation and of the company/undertaking - Product details - Trade name: METHANOL - Application of the substance / the preparation Solvents - Manufacturer/Supplier: SFC Smart Fuel Cell AG Eugen-Saenger-Ring 4 85649 Brunnthal Tel.: +49 (0)89 673 592-0 Fax: +49 (0)89 673 592-169 - Further information obtainable from: Safety Department - Department issuing MSDS: [email protected] - Information in case of emergency: Giftnotruf München: +49 89/19 240 2 Hazards identification - Hazard description: T Toxic F Highly flammable - Information concerning to particular hazards to man and environment: R 11 Highly flammable. R 23/24/25 Toxic by inhalation, in contact with skin and if swallowed. R 39/23/24/25 Toxic: danger of very serious irreversible effects through inhalation, in contact with skin and if swallowed. 3 Composition/information on ingredients - Chemical characterization: - CAS No. Description 67-56-1 methanol - Identification number(s) - EINECS Number: 200-659-6 - EU Number: 603-001-00-X 4 First-aid measures - General information: Immediately remove any clothing soiled by the product. Remove breathing equipment only after contaminated clothing have been completely removed. In case of irregular breathing or respiratory arrest provide artificial respiration. - After inhalation: Supply fresh air or oxygen; call for doctor. In case of unconsciousness place patient stably in side position for transportation. - After skin contact: After contact with skin, wash immediately with plenty of soap and water. If skin irritation continues, consult a doctor. - After eye contact: In case of contact with eyes, rinse immediately with plenty of water and seek medical advice. - After swallowing: Fresh air. Induce vomiting. Make victim drink ethanol (e.g. 1 drinking glass of a 40% alcoholic beverage). Call in physician, mentioning methanol ingestion. EU (Contd. on page 2) DR Page 2/5 Safety Data Sheet according to 1907/2006/EC, Article 31 Printing date 15.11.2007 Revision: 15.11.2007 Trade name: METHANOL (Contd. of page 1) 5 Fire-fighting measures - Suitable extinguishing agents: CO2, powder or water spray. Fight larger fires with water spray or alcohol resistant foam. - Special hazards caused by the substance, its products of combustion or resulting gases: Can form explosive gas-air mixtures. Formation of toxic gases is possible during heating or in case of fire. - Protective equipment: Wear self-contained respiratory protective device. Do not inhale explosion gases or combustion gases. - Additional information Cool endangered receptacles with water spray. Dispose of fire debris and contaminated fire fighting water in accordance with official regulations. 6 Accidental release measures - Person-related safety precautions: Wear protective equipment. Keep unprotected persons away. Ensure adequate ventilation Keep away from ignition sources. - Measures for environmental protection: Prevent seepage into sewage system, workpits and cellars. Inform respective authorities in case of seepage into water course or sewage system. - Measures for cleaning/collecting: Ensure adequate ventilation. Absorb with liquid-binding material (sand, diatomite, acid binders, universal binders, sawdust). Dispose of the material collected according to regulations. - Additional information: Fumes can combine with air to form an explosive mixture. 7 Handling and storage - Handling: - Information for safe handling: Keep receptacles tightly sealed. Ensure good interior ventilation, especially at floor level. (Fumes are heavier than air). - Information about fire - and explosion protection: Keep ignition sources away - Do not smoke. Protect against electrostatic charges. - Storage: - Requirements to be met by storerooms and receptacles: Store in a cool location. Store only in the original receptacle. - Information about storage in one common storage facility: Store away from foodstuffs. - Further information about storage conditions: Keep receptacle tightly sealed. Store under lock and key and with access restricted to technical experts or their assistants only. Store under lock and key and out of the reach of children. Protect from heat and direct sunlight. 8 Exposure controls/personal protection - Additional information about design of technical facilities: No further data; see item 7. (Contd. on page 3) EU DR Page 3/5 Safety Data Sheet according to 1907/2006/EC, Article 31 Printing date 15.11.2007 Revision: 15.11.2007 Trade name: METHANOL (Contd. of page 2) - Ingredients with limit values that require monitoring at the workplace: 67-56-1 methanol AGW (Germany) 270 mg/m³, 200 ppm 4(II);DFG, EU, H, Y IOELV (European Union) 260 mg/m³, 200 ppm Skin WEL (Great Britain) Short-term value: 333 mg/m³, 250 ppm Long-term value: 266 mg/m³, 200 ppm Sk - Additional information: The lists valid during the making were used as basis. - Personal protective equipment: - General protective and hygienic measures: Keep away from foodstuffs, beverages and feed. Immediately remove all soiled and contaminated clothing Avoid contact with the eyes and skin. - Respiratory protection: Use suitable respiratory protective device in case of insufficient ventilation. - Protection of hands: Protective gloves (EN 374) The glove material has to be impermeable and resistant to the product/ the substance/ the preparation. Due to missing tests no recommendation to the glove material can be given for the product/ the preparation/ the chemical mixture. Selection of the glove material on consideration of the penetration times, rates of diffusion and the degradation - Material of gloves The selection of the suitable gloves does not only depend on the material, but also on further marks of quality and varies from manufacturer to manufacturer. - Penetration time of glove material The exact break trough time has to be found out by the manufacturer of the protective gloves and has to be observed. - Eye protection: Tightly sealed goggles - Body protection: Use protective suit. 9 Physical and chemical properties - General Information Form: Colour: Odour: Fluid Colourless Alcohol-like - Change in condition Melting point/Melting range: -98°C Boiling point/Boiling range: 64°C - Flash point: 11°C - Ignition temperature: 455°C - Danger of explosion: Product is not explosive. However, formation of explosive air/vapour mixtures are possible. - Explosion limits: Lower: Upper: 5,5 Vol % 44 Vol % - Vapour pressure at 20°C: 128 hPa - Density at 20°C: 0,79 g/cm³ (Contd. on page 4) EU DR Page 4/5 Safety Data Sheet according to 1907/2006/EC, Article 31 Printing date 15.11.2007 Revision: 15.11.2007 Trade name: METHANOL (Contd. of page 3) - Solubility in / Miscibility with Fully miscible. water: 10 Stability and reactivity - Thermal decomposition / conditions to be avoided: Protect from heat and direct sunlight. - Dangerous reactions Forms explosive gas mixture with air. - Dangerous decomposition products: No dangerous products of decomposition if used and stored according to specifications. 11 Toxicological information - Acute toxicity: - LD/LC50 values relevant for classification: 67-56-1 methanol Oral LD50 13000 mg/kg (rat) - Primary irritant effect: - on the skin: No irritant effect. - on the eye: No irritating effect. - Sensitization: No sensitizing effects known. 12 Ecological information - General notes: Water hazard class 1 (German Regulation) (Assessment by list): slightly hazardous for water Do not allow undiluted product or large quantities of it to reach ground water, water course or sewage system. 13 Disposal considerations - Product: - Recommendation Disposal must be made according to official regulations. - European waste catalogue 07 00 00 WASTES FROM ORGANIC CHEMICAL PROCESSES 07 01 00 wastes from the manufacture, formulation, supply and use (MFSU) of basic organic chemicals 07 01 04 other organic solvents, washing liquids and mother liquors - Uncleaned packaging: - Recommendation: Disposal must be made according to official regulations. - Recommended cleansing agents: Water, if necessary together with cleansing agents. 14 Transport information - Land transport ADR/RID (cross-border) 3 (FT1) Flammable liquids. - ADR/RID class: - Danger code (Kemler): 336 1230 - UN-Number: II - Packaging group: 3+6.1 - Hazard label (Contd. on page 5) EU DR Page 5/5 Safety Data Sheet according to 1907/2006/EC, Article 31 Printing date 15.11.2007 Revision: 15.11.2007 Trade name: METHANOL (Contd. of page 4) - Description of goods: 1230 METHANOL - Limited quantities (LQ) LQ0 2 - Transport category - Tunnel restriction code D1E - Maritime transport IMDG: 3 - IMDG Class: 1230 - UN Number: 3+6.1 - Label II - Packaging group: F-E,S-D - EMS Number: - Proper shipping name: METHANOL - Air transport ICAO-TI and IATA-DGR: 3 - ICAO/IATA Class: 1230 - UN/ID Number: 3+6.1 - Label II - Packaging group: - Proper shipping name: METHANOL 15 Regulatory information - Labelling according to EU guidelines: The product has been classified and marked in accordance with EU Directives / Ordinance on Hazardous Materials. - Code letter and hazard designation of product: T Toxic F Highly flammable - Risk phrases: 11 Highly flammable. 23/24/25 Toxic by inhalation, in contact with skin and if swallowed. 39/23/24/25 Toxic: danger of very serious irreversible effects through inhalation, in contact with skin and if swallowed. - Safety phrases: 1/2 Keep locked up and out of the reach of children. 7 Keep container tightly closed. 16 Keep away from sources of ignition - No smoking. 36/37 Wear suitable protective clothing and gloves. 45 In case of accident or if you feel unwell, seek medical advice immediately (show the label where possible). - National regulations: - Waterhazard class: Water hazard class 1 (Assessment by list): slightly hazardous for water. 16 Other information This information is based on our present knowledge. However, this shall not constitute a guarantee for any specific product features and shall not establish a legally valid contractual relationship. EU SFC Smart Fuel Cell AG Eugen-Sänger-Ring 4 D-85649 Brunnthal-Nord Hotline: +49 89 673 5920 Freecall: 00800 732 762 78* Fax: +49 89 673 592 369 [email protected] www.efoy.com UM1-GB 080122 User Manual. Copyright by SFC Smart Fuel Cell AG 2007. All rights reserved. Subject to change without notice. *The toll-free number is available in the following countries: Germany, Belgium, Denmark, France, Great Britain, Italy, the Netherlands, Norway, Austria, Sweden, Switzerland and Spain. efoy.com ©EFOY is a registrated trademark of SFC Smart Fuel Cell AG.
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