Fuel cell Test System PowerStation™

Precision Equipment Used for the USFCC Standardizing Testing

What is the Power Station™?
The Power Station™ is an integrated family of laboratory modules that provide data acquisition, operational control, gas management, humidification, and temperature controls. In each system there is a:

1) Power Station System Controller (and Load),
2) One or more gas management units,
3) Additional optional components,
4) Integrated Power Station Software.

The "First Family" of Fuel Cell Test Stations

• Fully Integrated Systems and WindowsTM- based Software
• Designed Explicitly for Fuel Cell Testing
• User Friendly Software Provides Flexibility of Operation in a Safe Environment
• Supports PEM, Alkaline, Phosphoric Acid, and DMFCKey

How the Power Station™ Meets These Needs

• Modular Construction - Fixed Designs for Safety and Reliability - Meets CE Marking Requirements
• Fully Integrated Software and System Control
• Components Selected for Quality, Safety and Cost
• System Designs Responsive to Customer Needs
• Cleanliness in Materials and Design - Stainless Steel Internal Components
• Automated Data Acquisition and System Control
• Unattended Safe Operation
• Flexible Operation In Manual Modes
  

What Test Stations Need to Be
Fuel Cell performance depends on key operational variables that ultimately define the viability for specific applications. Defining
this performance and its repeatability is critical to the ongoing advancement of this exciting technology.

The Fuel Cell Test Station is the R&D tool for reliable and efficient quantification of performance. Providing control and data acquisition during fuel cell operation, it enables complete performance characterization and validation.

Compatible Modules and Accessories
CompuCell - 2 humidified and controlled gas lines
PS-R (Reformer) 6 Independently Controlled Gas Lines for Simulated Reformer Gas supply
PS-DR - (Dual Range) 2 gas lines with 4 MFCs for high dynamic range
DMFC - Methanol reservoir and fuel pump. Computer Controlled for precision, variable condition, and unattended testing.
PS-Ultima - 8 humidified and controlled gas lines
GTL - Heated Gas Transfer Lines. Temperature controlled by the Power Station , guaranteeing gas conditions to the cell.
Moisture Traps - Capture of downstream condensed water.

Controller	Gas Management	Accessories	Application
Power Station™ System Controller and Software	CompuCell™	DMFC, GTL, & Water Traps	Testing of Catalysts, MEAs, Single Cells, Stacks, and Direct Methanol Fuel Cells
	PS-R (Reformer)	GTL	Simulated Reformer Performance of Catalysts, MEAs, Single Cells and Stacks
	PS-DR (Dual Range)	GTL	Wide dynamic Range Testing of Single Cells and Stacks

Added Interests
Testing of many cells accurately and efficiently
The ability to address several fuel cell technologies

What is the PS-Ultima ™?
The PS-Ultima™ is a special variation of the Power Station™ that provides the ability to test up to five fuel cells si-multaneously while under independent gas management, humidification, and temperature controls. Its main mod-ules are: 1) PS-Ultima™ System Controller (and Load), 2) CompuCell™ gas management unit, 3) Ultima gas man-agement unit, 4) Additional optional components, 5) Integrated PS-Ultima™ Software .

Features Common to All Gas Management Modules (CompuCell, R, and DR)
50 psig operation (ca. 4,5bar) Manual backpressure regulators NEMA rated solenoid valves Normally closed on reactant lines (for safety) Normally open on purge lines (for safety) Reactant lines separated by leak-free solenoid valves Strategically located check valves prevent back-flow of reactant gases Precision, all stainless steel mass flow controllers (same as those used in the semiconductor industry)	Under programmed control of the PowerStation™ Gas flow accuracy +/-1% of full scale Gas flow precision +/- 0,2% of full scale Gas flow resolution 0,1% of full scale Seamless #316 stainless steel tubing throughout Factory leak-checked
"State of the Art" Humidification Control
Proprietary design Dual reservoir construction Complete saturation at 75°C and 2 liters/min. No erratic flow or water slugs in gas supply to cell. Front panel sight tubes indicate water level Easy refill of water reservoirs	Contact thermostats provide high tem-perature automatic cutoff for safety (automatically reset) Controlled by PID temperature control algorithm (parameters set in PowerStation™ Software) All stainless steel construction
System Control Features
Independent Control of Each Mass Flow Controller Pressure switches sense gas supply pressure - defines safe operation for reactant and purge gas supplies Pressure transducers sense back pressure - senses gas leak for safety shutdown PID Temperature control software provides precision temperature control of humidifiers and fuel cells
Integrated Software for Safety and Flexibilty
WindowsTM- based Software Integral to the Power Station™ Not based on general purpose lab test software Not adapted from battery test Not modified from a 3rd party product Safety Designed In - for Unattended Operation Quick and Easy Test Configuration Real-Time Graphic Data Output User Friendly Graphic User Interface
Electronic Load
Power: 800 Watts (8”W x 5.25”H 22”D, ca. 40kg) 2000 Watts (19”W x 5.25”H 22”D) 4000 Watts (19”W x 8”H 22”D) Selectable Voltage: 0-10, 0-20, and 0-50 Volts Selectable Current: 0-2, 0-20, and 0-150 Amps	Constant Current and Voltage Mode: Accuracy: ± 0,25% FS for med/high ranges ± 0,50% FS for low range Resolution: 1/4000 of full scale Constant Power Mode: Accuracy: ± 3% FS for all ranges Resolution: 0,25% of full scale

Detailed Specifications

Power Station Electronic Load

• Power:
  800 Watts (8”W x 5.25”H 22”D, ca. 40kg)
  2000 Watts (19”W x 5.25”H 22”D
  4000 Watts (19”W x 8”H 22”D
• Selectable Voltage: 0-10, 0-20, and 0-50 Volts
• Selectable Current: 0-2, 0-20, and 0-150 Amps
• Constant Current and Voltage Mode:
  Accuracy: ± 0,25% FS for med/high ranges
  ± 0,50% FS for low range
  Resolution: 1/4000 of full scale
• Constant Power Mode:
  Accuracy: ± 3% FS for all ranges
  Resolution: 0,25% of full scale
• Digital Front Panel Display
• Expandable to Second Load in Parallel
• Digital Interface via IEEE-488
• Manual or Computer Controlled Operation
• Convenient Front Panel Connection (800W Load)
• Current and Voltage Performance*
  800W Current - Up To 50A at 0.1V
  Up To 150A at 0.4V
  Voltage 0 to 50V
  2000W Current - Up To 150A at 0,1V
  Up To 500A at 0,4V
  Voltage 0 to 50V
  4000W Current - Up To 250A at 0,1V
  Up To 1000A at 0,4V
  Voltage 0 to 50V
  *Higher Voltage Options Available
  

Connection Cables Provided

All Back-panel Connecting Cables to Supporting
Modules are Provided -

Load Cables to Fuel Cell - 8 gauge high flexibility,
ring terminal connectors both ends 2

Cell Voltage Sensing Leads - test lead wires with
banana plug connectors 2

Heater Cables - 2 wire AC heater cables and
connectors

PS Station ™ - Interface

Supports up to 6 Mass Flow Controllers Provides PID Temperature Control to 2 Humidifiers Monitors Backpressure of Anode and Cathode Watchdog Timers Monitors Computer Activity High Reliability Solid State Components Throughout

Power Station™ - Computer

Key Features	Specifications
Power Stationä Software Installed Free Upgrades and Support Provides Digital and Analog Control and Data Acqui-sition from All Integrated Peripherals Visual Display of Real Time Data and System Status Network Compatible via Ethernet	Pentium™ class computer 4 Digital Interface Cards Factory Installed 4 Customized Cables to Interface Module Ethernet Network Interface Supported 15” Monitor CD-RW 40 GB Hard Drive 3 1/2” Floppy Drive Mouse Mouse Pad Windows XP Pro™ Operating System Microsoft Office™ (Includes Excel™, Word™, PowerPoint™ 110 or 220 V operation)

Power Station™ Control Software
Power Station™ Control Software
Power Station™ is operated by using our proprietary Windows™-based software. The fuel cell system is controlled by specifying the number of cells to test, cell sizes, operating conditions, and type of performance tests. A graphical user interface allows the operator to quickly scan the operating state of all fuel cells together or individually for detailed performance. Polarization performance is displayed in different graphical representations as well as written to data files for posttest analysis. Multi-sequence electrochemical tests may be programmed to simulate electrical load conditions ranging from constant voltage, current, or power to cyclic studies and dynamic loads.

Integrated Software for Safety and Flexibility	Key Software Features
Integral to the Power Stationä Not based on general purpose lab test software Not adapted from battery test Not modified from a 3rd party product Safety Designed In - for Unattended Operation Simple - for the Novice User Flexible - for Professional Fuel Cell R&D Needs	Quick and Easy Test Configuration Real-Time Graphic Data Output User Friendly Graphic User Interface Continuous Data Logging Two Stage Software Structure Reduces-Dangerous User Input Errors

Real Time Graphic Data Presentation
Current vs. Time
Voltage vs. Time
Voltage vs Current Density
Power vs Current Density

Digital Data Readout
All critical parameters in
a single view

Cell Configuration

• Define fuel cell characteristics based on real properties,
  such as active area and number of cells
• Define gas flow conditions in convenient measures such
  as stoichiometric ratio and ml/min.
• Select gas lines to be used.
• Preset purge conditions for end of test
• Enable Temperature Controls for cell heaters, gas line
  heaters and humidifiers.
• Enable temperature and pressure safety controls

Load Profiles

• Conveniently define complex load/time sequences tests
• Gas flows adjust to match load variations
• Select constant or linearly varying parameters
• Combine sequential tests for complex variable load conditions
• Repeat tests on a scheduled basis
  

System Configuration
Allows long term compatibility with
multiple ElectroChem Modules

Compucell - 2 humidified reactants
PS-R - Reformate Simulation (6 reactant gases)
PS-DR - (Dual Range) - for added gas flow precision
HSS - humidification for R or DR modules
PS-DMFC - Precision methanol supply
GTL - Heated gas supply lines

Setup - Flow Control
User define gas correction factor allows users to select new gas mixtures.

Setup - Temperature
Select thermocouples to use Use measurements for logging, and/or control.
Select PID controller algorithm characteristics to match heater
requirements.

Setup - Pressure
Backpressure transducers monitoring active pressure to sense leaks and
activate safety shutdown. User selects shutdown criterion.




Setup - Load
Expand electronic load capacity by adding an optional secondary load.

Fixed, Load Following, and Combination Gas Flow Control Options

a) Fixed Flow
b) Stoichiometric Load Following
c) Fixed minimum plus load Following


Very Wide Flexibility in Load Control Sequences


•Stepped, Ramped, Constant Load Control
• Simulates Real-World Power Applications

The Power Station™ Software package is included with Microsoft Windows XP™, and Microsoft Office™ which includes Excel™, Word™ and PowerPoint™.
Upgrades and online technical support for the Power Station™ Software package are free.

Meets Requirements for CE Marking.

Power Station™ Software is an integral part of the Power Station™ product line. It is not sold or distributed separately from the Power Station™.
Demonstration software versions are available to interested customers.