Hybrid Light Tower Operating Manual

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1 M1014 REV. 0 Hybrid Light Tower Operating Manual Unit Panorama Drive Surrey, BC Canada V3S 1B7 Tel: ax:

2 orward Thank you for purchasing Ensol System s Hybrid Light Tower. 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 Panorama Drive Surrey, BC, Canada, V3S 1B7 Tel: ax: admin@ensolsystems.com M1014 REV. 0 2

3 Table of Contents Contents Section 1 WARNING NOTIICATIONS... 4 Section 2 Quick Startup Procedure... 5 Section 3 General Information Product Introduction Product Specifications... 6 Section 4 - System Setup/Startup Parking & Leveling the Trailer Raising the Mast Activating the System Methanol uel Cell... 9 Section5 Power System Operation Power System Introduction Solar System Operation uel Cell Operation UN Certified Methanol uel Cartridges Operational States Default Parameters of cutoff threshold Startup and Shutdown Phases Anti reeze Protection Mode Operation at the Device Service luid Section 6 Error Messages Error Classifications Ranges Error Types Most Common Error Messages M1014 REV. 0 3

4 Section 1 WARNING NOTIICATIONS ATTENTION: PLEASE OLLOW THESE WARNING NOTES. AILURE 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 UEL CELL ROM BATTERIES OR UEL WHEN LOCATED IN TEMPERATURES LOWER THAN 5 C. AILURE TO COMPLY WILL REEZE THE UEL CELL AND MAY VOID WARRANTY. 6. REMOVE LIGHTS ROM MAST AND STORE IN THE ENCLOSURE DOORS WHEN TRANSPORTING THE TRAILER. M1014 REV. 0 4

5 Section 2 Quick Startup Procedure This is a quick startup guide. or 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. M1014 REV. 0 5

6 Section 3 General Information 3.1 Product Introduction The Ensol Systems Hybrid Light Tower offers a clean quiet solution to portable lighting, with virtually no emissions. Powered by a hybrid system of photovoltaic cells and a DMC (Direct Methanol uel 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 Maximum Height of Mast Width with Side Outriggers Extended Weight Axle Hitch Jacks Tires Lighting Enclosure 4.32 x 1.98 x 1.83 m (170 x 78 x 72 in) 9 m (30 ft) 3.84 m (151 in) 950 kg (2100 lbs) 3500lb (1588kg) leaf spring axle Combo - 2" ball hitch & 2.5" pintle ring our, 2000 lb adjustable leveling jacks ST205/75R15 6 ply (15 in) DOT approved tail, side, brake & signal lights 14 gauge steel, polyester powder paint, SST hardware POWER & LIGHTING: METHANOL UEL CELL (QTY 2): Model EOY 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 M1014 REV. 0 6

7 BATTERIES (QTY 4): Model Type Nominal Voltage Capacity Powersonic PSG AGM 12 VDC 100 Ahr OPERATIONAL ESTIMATIONS: Max/Min Days of Operation 1,2 Annual uel Consumption 1,2 29 days / 158 days 711 Litres Annual uel Cost 1,2 $5,590 Annual Operating Hours Per 1,2 1 Estimations based on solar insolation and daylight hour values for ort Mcmurray, AB, Canada. 2 Values 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. ace 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. M1014 REV. 0 7

8 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 TOWERS 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. irst 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. ollow 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 (igure 1) and the power switches. irst 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. M1014 REV. 0 8

9 igure 1 uel 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 uel Cell The EOY Pro uel Cells will already be mounted, but all their accessories still may need to be connected. Connect all accessories in the following order: irst, 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 EOY Pro fuel cell s exhaust port. This is a small tube stub protruding just next to the fuel line. rom there bring it down into the empty M28 cartridge, used for water collection. M1014 REV. 0 9

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.

10 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 Tower 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 igure 2. igure 2 Hybrid System M1014 REV. 0 10

11 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 uel Cell Operation The SC EOY Pro fuel cell uses a catalytic process to directly convert methanol into electricity (see igure 3). The byproduct of this reaction is water, small amounts of CO 2 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. igure 3 M1014 REV. 0 11

12 Since the EOY Pro fuel cell is a smart fuel cell, charging and monitoring to the batteries is handled automatically (example in igure 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. igure 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. or a full description of the EOY Pro fuel cell s operation, please see the manual provided by SC s document _UM_EOY_Pro_GB_v UN Certified Methanol uel Cartridges The EOY 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 EOY Pro fuel cell. DO NOT THROW AWAY THE CARTRIDGE ADAPTER! M1014 REV. 0 12

13 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 UEL THE EOY PRO! Impure/contaminated methanol will severely degrade the performance and life of the EOY and will VOID WARRANTY. M1014 REV. 0 13

14 5.5 Operational States Note that a minimal battery voltage of 9.0V or 18.5 V is required for the EOY Pro to start. M1014 REV. 0 14

15 5.6 Default Parameters of cutoff threshold New charging strategy (firmware 9.20 since mid of August 2010): Switch on voltage: 12.3 V ( V) Switch off voltage: 14.2 V ( ) Switch off current: 2 A / 4 EOY Pro 2200 ( A) Switch off time: 3 hours (0-5 hours) This ensures full battery charging and maximizes battery life M1014 REV. 0 15

16 5.7 Startup and Shutdown Phases M1014 REV. 0 16

17 5.8 Anti reeze Protection Mode Note that the Hybrid Light Tower is heavily insulated to ensure that the system works in cold temperatures. THE ANTI-REEZE PROTECTION MODE WILL NOT WORK WITHOUT UEL! 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-reeze Mode will keep the EOY Pro warm while the temperature is below 5 o C (This will work even when the unit is O ). Anti-reeze Mode requires the connection to a faultless, adequately charged battery and fuel cartridge. uel consumption will be dependent upon external temperature differential. Weather, insufficient insulation, ambient temperature and operating mode can have an impact on fuel consumption. The EOY Pro does not give the produced energy to a fully charged battery in Anti-reeze 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-reeze Mode has not been activated) is 5 o C. M1014 REV. 0 17

18 5.9 Operation at the Device Remote Control: M1014 REV. 0 18

5.10 Service luid If service fluid is low the yellow light will turn on at the EOY Pro and the message Please refill service fluid will appear at the control panel display.

19 5.10 Service luid If service fluid is low the yellow light will turn on at the EOY 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 EOY Pro is operated continuously at temperatures above the acceptable operating range (45 o C), the service fluid will be expelled faster than it can be regenerated and cause a failure. or this reason, it is critical that the thermostat and fan provided with the uel 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. M1014 REV. 0 19

20 Section 6 Error Messages 6.1 Error Classifications Ranges 10 Internal hardware or firmware issue - Contact Ensol Systems. 20 uel - Change the cartridge and reset. 30 Service luid - 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 = 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 - ailure due to blocking of exhaust or circulation pump defect. 32, 31, 30, 41 - ailure due to high surrounding temperature. Check installation and ensure air circulation is adequate Check battery (voltage too low) and/or battery connection problem 72, 76 - ailure in Methanol dosing or internal sensors. Possible issues in Methanol cartridge because of fuel line. M1014 REV. 0 20

21 Display message Error code error type Error description Remedial measure Potential error causes Notes Please contact service 1 P System configuration incomplete 10 P 15 P Serious system error Repair by SC required Repair by SC required irmware update failed Stack damaged Please contact service 13 A (1x / 30s) R 14 A (1x / 30s) R 17 R Stack power output too low luid level sensor defect Abnormal power difference between stack and output Press RESET (max. 3 attempts), repair required if error reoccurs Hardware defect Please check exhaust hose 11 A (1x /30s) R 18 A (3x / 300s) R 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 sufficient fresh air Test: disconnect exhaust hose and press "Reset", if fuel cell is now running the exhaust hose is blocked Please change fuel cartridge 20 M R 22 M R Empty fuel cartridge detected (internal fuel sensor) Change fuel cartridge (solve error cause) then press RESET Error causes if fuel cartridge not empty: - Bad connection of fuel cartridge connector (air leak) - Dirty fuel cartridge connector Please refill service fluid 30 M R 31 M R Low service fluid level (error 30: <20%, error 31: <5%) Add service fluid (solve potential error causes) then press RESET - Operation at high ambient temperatures or insufficient cooling air - luid level measurement defect Interruption: Surroundings too w arm 32 A 41 A Service fluid level below 40% Temparature to high (internal sensor) Wait (until temperature has dropped) -Ambient temperature to high (avoid direct sunlight) - Poor air ventilation in installation space 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) Please check battery voltage 50 A T Battery voltage too low (sense line) 51 A Battery voltage too high (sense line) 52 A Batttery voltage too low (power line) 53 A Battery voltage too high (power line) Solve error cause (check battery and connections) Battery voltage < 10,5 / 21 V -> charge w ith battery charger Battery voltage > 16,5 / 33 V -> check external battery charger and disconnect if necessary Check connection to battery: - Check battery cables - Check battery fuses Please contact service 54 A Battery voltage measurement defect 70 R Error fuel reservoir sensors If the error persists a repair is required 73 R Internal fuel sensor defect 75 R Reservoir error (emptying time too long) Press RESET (max. 3 attempts), 80 R Internal voltage reference out of repair required if error reoccurs tolerance 83 R DC/DC-Transformer defect 84 R A 76 P Self test equipment Serious reservoir error Permanent error - repair required Circuit Board defect - Error 70 or error 72 reoccurred 3 times M1014 REV. 0 21

22 Please check fuel cartridge connector 72 A M R Reservoir error (refilling time too long) Solve potential error cause, then press RESET (max. 3 attempts) - irmware problem (W <9.11) - Bad connection of fuel cartridge connector (pumps air) - Dirty fuel cartridge connector irmw are update recommended (fixed w ith W 9.11 or higher) Please install ilter XT Please contact service no display information Please change ilter XT 38 W ilter EOY XT is removed install ilter only EOY 2200 XT 85 R ilter-circuit-board EOY XT not detected Press RESET (max. 3 attempts), repair required if error reoccurs only EOY 2200 XT 137 A ilter change confirmed no action required only EOY 2200 XT 139 M ilter change is displayed change ilter EOY XT only EOY 2200 XT no display information 90 A Antifreezemode successfully no action required Update: DO NOT UNPLUG BATTERY 99 A irmware update is performed not interrupt firmware update no display information 140 A Antifreezemode not possible fix other error another error is blocking the antifreezemode no display information 172 A Error 72 was once ignored no action required no display information 184 A Self test equipment successfully no action required irmw are corrupt update required w ithout A transfer defective firmware repeate firmware-update No connect or Check battery w ithout Remote control has no connection to fuel cell Check connection, load battery if necessary - Remote control is connected to w rong port (Data Interface) - Batter voltage < 8,5 V - No communication (defect) M1014 REV. 0 22

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