F U E L C E L L S U P E R V I S O R H 2

Transcription

1 MES DEA SA Via Laveggio 15 CH 6855 Stabio Switzerland I N S T A L L A T I O N O P E R A T I O N Revision : 2.04 Date : 14 th of January 2009 F U E L C E L L S U P E R V I S O R H 2 CONTENTS INSTALLATION & OPERATION MANUAL 1. Installation of the software and set-up of the connection 2. Start 3. System survey 4. Measurement 5. Monitor scope 6. Polarization scope 7. Data Visualization 8. Black Box Trip Event 9. Black Box Measurement Recording 10. Status 11. CAN Bus Tel / Fax / info@mes-dea.ch MES-DEA S.A. is reserving all copyright concerning the Fuel Cell Supervisor H2. For further information please contact MES-DEA

2 1 INSTALLATION OF THE SOFTWARE AND SET UP OF THE CONNECTION 1.1 SYSTEM REQUIREMENT PC or laptop, Pentium II 400Mhz, 64 MB RAM ( minimum configuration for best performances) Operation system MS Windows 95 / 98 / NT4 / 2000 / XP / Vista ( 2000 recommended ) 30 Mbyte free on local hard disk Recommended screen resolution 1024x768 px 1.2 GUIDE TO THE INSTALLATION OF THE SOFTWARE To install the program Fuel Cell Supervisor H2 you have to carry out the following steps: 1. Move the content of the supplied floppy disks to a folder of your PC. Installation of the software and set up of the connection - Pag. 1-2

3 2. Double click on the set-up icon. 3. Start the set-up program by clicking OK. Installation of the software and set up of the connection - Pag. 1-3

4 4. Choose the directory where you want to install the program, and press the install button in order to start the installation. 5. Choose the program group, where you want to add the Fuel Cell Supervisor H2. Installation of the software and set up of the connection - Pag. 1-4

5 6. To complete the installation press OK, when the following message appears. 1.3 TROUBLE SHOOTING 1. If during the installation the following window appears You have to press the no to All button Installation of the software and set up of the connection - Pag. 1-5

6 1.4 SET-UP OF THE COMMUNICATION BETWEEN THE ECU AND A PC To connect the ECU of the Fuel Cell System to a PC, it is recommended to use the supplied (ninepole) communication cable. The connector labelled ECU has to be connected to the appropriate nine pole connector of the ECU, the connector labelled PC to a COM-port of the PC. ECU shield PC If the user has to replace the supplied communication cable, the connection has to be made according to the following scheme: Type of connector: Type of connection: Pins connected: Shield: RS 232 (nine-pole) Pin to pin Pin number: 1: VDD 2: Tx 3: Rx1 4: Rx2 5: Gnd Must be connected on the PC side and unconnected on the ECU side! The communication channel is not isolated from the Fuel Cell System and the ground pin (pin number 5) is connected directly to the negative terminal of the Fuel Cell Stack. For this reason to avoid the possibility of creating ground loops, the use of an opto-isolator bridge is recommended. Installation of the software and set up of the connection - Pag. 1-6

7 2 WINDOW : START 2.1 NORMAL OPERATION Double click on the icon shown below to start the program: Start window: Button to change the setting of the COMport Button to enter in offline mode (without communication to an ECU) Button to establish the communication link to the ECU Button to abandon the program Window: Start - Pag. 2-1

8 Window for setting the COM-port: Button used to chose the port number Button used to check if the COM-port selected is available Window used to select the port speed Button used to confirm the chose in this window is possible: Check which is the actual COM-port selected Execute a fast selection of the preferred COM-port Select the communication speed Using the Test button, check if the COM-port selected is available and if an active FC control is connected to this port The related message windows could be: Window: Start - Pag. 2-2

9 After pushing the button Link the Start window changes according to the picture shown below: Link Bar that indicates the work in progress Window: Start - Pag. 2-3

10 When the communication link is established successfully the following message appears: By pushing the button OK you can enter the Fuel Cell Supervisor H2 PC interface. Window: Start - Pag. 2-4

11 2.2 ERROR OCCURRED If there occurs an error concerning the communication link, one of the following error messages will appear: 1) This can happen if: the control is off the communication cable is not connect the COM Port is already used In this case you have the possibility to: press Ok and retry to establish the link press Ok two times and open the PC interface in order to display previously recorded data Window: Start - Pag. 2-5

12 2) This can happen if: there is an error in the communication the control is turned off the communication cable is not connected steadily In this case you have to press OK in order to restart the program. Window: Start - Pag. 2-6

13 3) This can happen if: there is an error in the communication the control is turned off the communication cable is not connected steadily In this case you have to press OK in order to restart the program. Window: Start - Pag. 2-7

14 3 WINDOW : SYSTEM SURVEY 3.1 IN THIS WINDOW the operator can: view the general state of each part of the system check the state of the system check the elapsed total operation time of the fuel cell system monitor the control flags of the ECU software monitor the state of the alarm level of the ECU software Window : System Survey- Pag. 3-1

15 3.2 HOW TO ENTER THIS WINDOW: To access this window the operator has to click on: Synoptic in the menu bar of the Fuel Cell Supervisor H2 program: 3.3 PRINCIPAL WINDOW: Menu bar Status bar System survey area Window : System Survey- Pag. 3-2

16 3.4 STATUS BAR: State of the system Status the link of Flag monitor Visualization of the actual alarm level STATE OF THE SYSTEM In this box the operator can read the actual operational status of the Fuel Cell System control and the already elapsed total operation time of the fuel cell system: Operational status of the system control Elapsed total operation time of the fuel cell system The picture above shows the system in HIDLE state (the control is active, but the fuel cell system is stopped). Other possible state are: the control is active and the fuel cell system is executing the starting phase the control is active and the fuel cell system is in RUN phase Window : System Survey- Pag. 3-3

17 the control is active and the fuel cell is executing the stopping phase the control is active and the fuel cell system has been stopped, because a security shut off condition has occurred FLAG MONITOR In this area the actual values of the ECU control flags are displayed: The operator can choose the flag family that is displayed. To do this, you have to double click on the name of the actually displayed flag family (e.g. Enable_w). Then a list of the available flag families appears and the operator can choose a different flag family to be displayed. Window : System Survey- Pag. 3-4

18 3.4.3 VISUALIZATION OF THE ACTUAL ALARM LEVEL In this box the operator can read the actual alarm level of the Fuel Cell System control. Neither the conditions for an alarm nor the security shut off (TRIP) conditions are fulfilled. Conditions for a level 1 alarm are fulfilled. No TRIP condition. Conditions for a level 2 alarm are fulfilled. No TRIP condition. The condition for a security shut off (TRIP) is fulfilled and the system will shut off automatically, if this condition remains unchanged for a certain security time STATUS OF THE COMMUNICATION LINK Here the status of the communication link can be seen: Link OK: the communication is active and working normally Link??: the communication is active but not working normally Link lost: the communication is active, but is interrupted by a fault. In this case the operator can click on the H 2 icon with the mouse to try to re-establish the communication link Window : System Survey- Pag. 3-5

19 The operator can check the quality of the communication by moving the mouse cursor over the icon. A label appears showing the value of the parameter TimeOutCounter. If the value is near to 0 % the communication is working normally, when it reaches 100 % the communication is stopped, as there is no response from the ECU. 3.5 SYSTEM SURVEY AREA In this area the operator can check the general state of operation of the Fuel Cell System; it changes its configuration according to the size of the connected fuel cell system. The configuration for the single fuel cell stack systems is shown here: Condition of the stack Power Recover command System Start/Stop command Condition of the starting power source Small Monitor Scope Condition of the valves Condition of the blowers Condition of load switch, short circuit switch and load voltage indicator Window : System Survey- Pag. 3-6

20 3.5.1 CONDITION OF THE STACK In this area the operator can examine the operational parameters of the stack: Identification of the fuel cell system Electrical measurements on the stack: Current Voltage Power This picture represents the configuration of the system: number of stacks and their connection. Internal temperatures of the stack: Temp.1 represents the stack temperature near the reaction air outlet, Temp. 2 the stack temperature near the hydrogen inlet and Temp. 3 the stack temperature in the middle of the near reaction air inlet channel Window : System Survey- Pag. 3-7

21 3.5.2 CONDITION OF THE VALVES The Fuel Cell System comprises two sets of valves: Hydrogen main valves: permit the flow of hydrogen into the stack Hydrogen main valve closed: supply of hydrogen interrupted Hydrogen main valve open: supply of hydrogen permitted Hydrogen purging valves: They open to release some of the hydrogen inside the stack, in order to eliminate water from the anode of the fuel cells and to purge out accumulated impurities of the supplied hydrogen Hydrogen purging valve closed: no purging of hydrogen Hydrogen purging valve open: purging of hydrogen Window : System Survey- Pag. 3-8

22 3.5.3 CONDITION OF THE BLOWERS The Fuel Cell System comprises two different kinds of air blowers: The cooling blowers are used to regulate the operating temperature of the stacks. Cooling Blower Off: cooling blowers do not work Cooling Blower Min: they work at a constant speed without regulation Cooling Blower On: they work with regulation (normal operation) The reaction air blowers that are used to supply the fuel cell stacks with the right flow of air for the electrochemical reaction. Reaction Air Blower Off: reaction air blowers do not work Reaction Air Blower Min: they work at a constant speed without regulation Reaction Air Blower On: they work with regulation (normal operation) Window : System Survey- Pag. 3-9

23 3.5.4 CONDITION OF LOAD SWITCH AND SHORT CIRCUIT SWITCH The Fuel Cell System comprises two different kinds of electronical switches: The load switch is used to connect and disconnect the load to and from the stack Load Switch open: load disconnected Load Switch closed: load connected The short circuit switch is used to short circuit the fuel cell stacks periodically for a very short time. Short Circuit Switch open Short Circuit Switch closed Note, that the short circuit of the stack is of a very short duration and therefore it is possible that not every short circuit is visualized by this indicator. Nevertheless the short circuit is carried out by the ECU regularly, if the short circuit function is enabled. Window : System Survey- Pag. 3-10

24 3.5.5 CONDITION OF THE STARTING POWER SOURCE To supply the ECU with the necessary power to start the Fuel Cell System and to maintain it on during the short circuit cycle of the stacks, it has to be connected with an external DC voltage source (power supply, storage battery, etc.). The voltage of this starting power source is monitored by the control and can also be the cause for a security shut off, if it is low. In the system survey area its state is visualized by the following symbol: Voltage level of the starting power source is sufficient Voltage level of the starting power source is low Voltage level of the starting power source is too low to restart the system Window : System Survey- Pag. 3-11

25 3.5.6 SYSTEM START/STOP COMMAND The operator also has the possibility to start or stop the system by a software command that is represented by the symbol shown below. To send the start command the operator has to click on the button shown to the left, which changes its appearance to the one shown on the right. The latter can be used to stop the system, if it was started with a software command. After clicking on this buttons a window appears and the operator has to confirm his choice. Furthermore the operator can check the state of this software Start/Stop by the SoftW_SS flag, that is placed in the Command_Word group: This Start/Stop command has the same priority than the mechanical Start/Stop switch, i.e. if one of these is active the changing of the state of the other one has no effect. Window : System Survey- Pag. 3-12

26 3.5.7 POWER RECOVERY COMMAND The operator also has the possibility to start a particular procedure which is able to recover the system power loss due to the dehydration of the membrane. To send the start command the operator has to click on the button shown below and subsequently choose the right option ( see MES-DEA maintenance manual for details ) The wrong use of these procedures could create a permanent damage to the fuel cell components therefore the operator has to follow scrupulously the instruction reported in the MES-DEA maintenance manual. Window : System Survey- Pag. 3-13

27 3.5.8 SMALL MONITOR SCOPE In this window there is also the possibility to use a small scope to visualize either the stack voltage, the stack current or the gross power generated by the stack (including the power that is consumed by the auxiliaries, i.e. blowers, valves etc.). The desired variable (voltage, current or power) is displayed in a rectangular diagram, where the vertical axis represents its value and the horizontal axis the time. To toggle the visualized variable it is enough to move the cursor over the title and double-click. Is also possible to change the range of the vertical axis by writing a new full scale value into the topmost box beside the vertical axis and subsequently confirming the new choice. To clear the trace from the monitor you have to move the cursor over the scope and double-click. Window : System Survey- Pag. 3-14

28 4 WINDOW : MEASUREMENT 4.1 IN THIS WINDOW the operator can: view the measurement system of the control check the state of the system check the elapsed total operation time of the fuel cell system monitor the control flags of the ECU software monitor the state of the alarm level of the ECU software examine the values acquired by each measurement channel create a data record file Window : Measurement- Pag. 4-1

29 4.2 HOW TO ENTER THIS WINDOW: To access this window the operator has to click on: Measurement in the menu bar of the Fuel Cell Supervisor H2 program: 4.3 PRINCIPAL WINDOW Menu bar Status bar Measurement area Recording bar Window : Measurement- Pag. 4-2

30 4.4 STATUS BAR For information concerning the status bar refer to the appropriate section in the chapter: System survey. 4.5 MEASUREMENT AREA In this area the operator can observe the values of the measured variables. Its format depends on the number of the measurement channels, and can for example look like this: Measurement channel area Window : Measurement- Pag. 4-3

31 For a high number of channels there are different pages of visualization: Measurement page For each measurement channel there is the following area: Measurement channel Check box to enable/disable the updating of the values Displayed variable measurement Direct value of the variable Filtered value of the variable Offset used by the software to calibrate the measurement Gain used by the software to calibrate the measurement Time constant of the filter applied to the measurement Graphical visualization of the value of the measured variable Window : Measurement- Pag. 4-4

32 The graphical visualization of the measurement value consists in: Vertical bar representing the filtered value of the variable Full scale value of the graphical representation Vertical bar representing the direct value of the variable Axis of the graphical representation 4.6 DATA RECORDING In this window the operator can create a data record file that contains the values of the measurement variables as ASCII strings. The variables recorded are all the measurements of the control. The operator can select: 1. the length of the recording (number of recorded samples or unlimited recording) 2. the sample time A data record file created by the FCSH2 is a text (ASCII) file, which can be read by commercial software like MS Excel. The state of the data recording can be monitored by the Data Recording Status bar. This bar can show three different states of the recording: Recording function off Recording function active Window : Measurement- Pag. 4-5

33 Recording function waiting to resume its activity (This condition normally occurs only when the communication link is lost ) To start the data recording the operator has to click on: File Recording Data Measurement Data Start Recording in the menu bar of the Fuel Cell Supervisor H2 program: Before the start of the recording a window appears in which the name of the file and the folder to which it will be saved can be chosen: Window : Measurement- Pag. 4-6

34 After this the set-up of the recording can be adjusted: Start recording button Escape recording function button Management of the sampling Path of data record file Button to change the path of the data record file MANAGEMENT OF THE SAMPLING Enable/disable unlimited recording Number of samples Scroll to change the number of samples Scroll to change the sample time Sample time Window : Measurement- Pag. 4-7

35 The length of the record, i.e. the number of samples recorded, can be unlimited and in this case the operator has to check the Unlimited Recording check box like shown below: The data recording then has to be stopped by selecting in the menu bar: File Recording Data Measurement Data Stop Recording If the operator wants to create a limited record, he can set the number of samples (from 2 to 10000) by writing the desired number into the text-box or by using the scroll-bar. In this case the data recording is stopped automatically after the pre-selected number of samples has been recorded. The sample time (time between two samples) can be chosen by the operator in the range from 0.5 to 60.0 seconds by writing the desired value into the text-box or by using the scroll-bar. After all the settings have been made the Start button has to be pressed in order to begin the recording. Window : Measurement- Pag. 4-8

36 5 WINDOW: MONITOR SCOPE 5.1 IN THIS WINDOW the operator can: display the trace of nine different variables, to be chosen from the range of all variables, on a scope-like monitor (for the activated traces there exists also a numerical display of the updated values of these variables) enable and disable each of these traces change the look of each traces check the values of two parameters, to be chosen from the range of all parameters, use two measurement cursors choose the scale of the display or use the auto-scale function stop/start the updating of the traces invert the traces refresh the monitor change the appearance of the monitor grid create a data record file Window : Monitor Scope - Pag. 5-1

37 5.2 HOW TO ENTER THIS WINDOW: To access this window the operator has to click on: Scope Monitor in the menu bar of the Fuel Cell Supervisor H2 program: 5.3 PRINCIPAL WINDOW Menu bar Set-up bar Monitor Window Window : Monitor Scope - Pag. 5-2

38 5.4 SET-UP BAR Management of the visualized variables Monitor of parameter values Status the link of Management of the cursors Management of the scale MANAGEMENT OF THE VISUALIZED VARIABLES Trace 4,5,6 Trace 1,2,3 Button to enable/disable a trace Trace 7,8,9 Button to change the trace characteristics To select a variable to be displayed from the range of available variables, you have to move the cursor over the name of a currently displayed variable and double-click. A list of the available variables occurs and you can select the variable to be displayed by this trace by clicking on it. List of variables The operator can stop the updating of each trace by clicking on the on/off button. Window : Monitor Scope - Pag. 5-3

39 Trace actually disabled the operator can recognize easily which trace value isn t updated by the colour Trace actually disabled Note, the less variables are active, the higher is the frequency of the updating of their value. If the operator push the bottom marked with a S he can change the look of each trace using the following window: Name of variable Change the colour Apply a gain and an off-set Change the size Window : Monitor Scope - Pag. 5-4

40 in particular the operator can modify: the value of the trace applying an off-set and a gain: Value of the gain Scroll to change the value of the gain Value of the off set Scroll to change the value of the off set the ranges of this two parameters are Min Value Max Value Gain Off Set the operator can understands that same of the trace value are distorted by this two parameter (and only in this case) by the set up button where appears an asterisk and also by a change in the value box aspect: N.B. in any case in the recording file are saved the original values off the variable the colour of the trace: Button to open the colour window set up Actual colour of the trace Window : Monitor Scope - Pag. 5-5

41 To change the colour of the trace you have to move the cursor over the provided button and click. A special window appears and you can select your preferred colour: the size of the trace using the check box list: to each of this box corresponds one of the following trace size: Window : Monitor Scope - Pag. 5-6

42 5.4.2 MONITOR OF PARAMETER VALUES Parameter 1 Value of Parameter 1 Parameter 2 Value of Parameter 2 Parameter 3 Value of Parameter 3 The name and numerical value of three parameters can be shown simultaneously in this area of the Monitor Scope window. To select a parameter to be shown from the range of available parameters, you have to move the cursor over the name of a currently visible parameter and double-click. A list of the available parameters occurs and you can select a different parameter by clicking on it MANAGEMENT OF THE CURSORS To activate/deactivate the bar cursor function you have to check or uncheck the Cursor Enable check box. Cursor Enable check box Scroll to move the horizontal bar Scroll to move the vertical bar Position of the horizontal bar Position of the vertical bar Window : Monitor Scope - Pag. 5-7

43 Vertical Bar Horizontal Bar To move the cursor the operator can use: -the scroll bar in the cursor management section of the Set-up bar -the mouse: To move the bar you can: point the mouse cursor on the bar cursor that you want move push the left button of the mouse drag the bar cursor to the desired position while holding the left mouse button release the left mouse button Window : Monitor Scope - Pag. 5-8

44 5.4.4 MANAGEMENT OF THE SCALE In this section of the Set-up bar the operator can change the scale of the display. The vertical range of the display can be set manually by entering numerical values in the Ymin and Ymax text-boxes or automatically by enabling the auto-scale function. Enable/disable auto-scale check box Maximum value of the vertical range Minimum value of the vertical range Time displayed on one screen in seconds Button to Update the scale of the display The values written into the text-boxes are not immediately valid, which is shown by their blue color. To change the scale of the display according to the newly entered values, you have to click on the button Update, which will also change the color of the changed values to black. You are able to change the values in the range shown below: Min Value Max Value Xmax 1 s 1000 s Ymax Ymin Window : Monitor Scope - Pag. 5-9

45 5.4.5 STATUS OF THE COMMUNICATION LINK Here the status of the communication link can be seen: Link OK: the communication is active and working normally Link??: the communication is active but not working normally Link lost: the communication is active, but is interrupted by a fault. In this case the operator can click on the H 2 icon with the mouse to try to re-establish the communication link The operator can check the quality of the communication by moving the mouse cursor over the box. A label appears showing the value of the parameter TimeOutCounter. If the value is near to 0 % the communication is working normally, when it reaches 100 % the communication is stopped, as there is no response from the ECU. Window : Monitor Scope - Pag. 5-10

46 5.5 MONITOR Max vertical value Values of the traces Monitor Grid Min vertical value Max horizontal value Management of the updating of the traces Data Recording Status Window : Monitor Scope - Pag. 5-11

47 5.5.1 MANAGEMENT OF THE UPDATING OF THE TRACES Invert Trace button Start/Stop updating the traces Refresh button Monitor Using this buttons the operator can: change the orientation of the vertical axis (exchange the Ymin and Ymax values) stop and restart the updating of all the traces on the monitor simultaneously clear the monitor CHANGE MONITOR GRID The operator can change the appearance of the monitor grid according to the sequence shown below by double-clicking on the monitor display area: Window : Monitor Scope - Pag. 5-12

48 5.6 DATA RECORDING In this window the operator can create a data record file that contains the values of nine variables as ASCII strings. The variables recorded are the same that are chosen to be displayed on the monitor. The operator can select: 3. the length of the recording (number of recorded samples or unlimited recording) 4. the sample time A data record file created by the FCSH2 is a text (ASCII) file, which can be reloaded and displayed by the FCSH2 or read by commercial software like MS Excel. The state of the data recoding can be monitored by the Data Recording Status bar. This bar can show three different states of the recording: Recording function off Recording function active Recording function waiting to resume its activity (This condition normally occurs only when the communication link is lost ) Window : Monitor Scope - Pag. 5-13

49 To start the data recording the operator has to click on: File Recording Data Monitor Data Start Recording in the menu bar of the Fuel Cell Supervisor H2 program: Before the start of the recording a window appears in which the name of the file and the folder to which it will be saved can be chosen: Window : Monitor Scope - Pag. 5-14

50 After this set-up of the recording can be adjusted: Start recording button Escape recording function button Management of the sampling Path of data record file Fields to insert comments in the record file Button to change the path of the data record file Window : Monitor Scope - Pag. 5-15

51 5.6.1 MANAGEMENT OF THE SAMPLING Enable/disable unlimited recording Number of samples Scroll to change the number of samples Scroll to change the sample time Sample time The length of the record, i.e. the number of samples recorded, can be unlimited and in this case the operator has to check the Unlimited Recording check box like shown below: The data recording then has to be stopped by selecting in the menu bar: File Recording Data Monitor Data Stop Recording Window : Monitor Scope - Pag. 5-16

52 If the operator wants to create a limited record, he can set the number of samples (from 2 to 10000) by writing the desired number into the text-box or by using the scroll-bar. In this case the data recording is stopped automatically after the pre-selected number of samples has been recorded. The sample time (time between two samples) can be chosen by the operator in the range from 0.5 to 60.0 seconds by writing the desired value into the text-box or by using the scroll-bar. After all the settings have been made the Start button has to be pressed in order to begin the recording. If the operator wants to include in the record file a list of all the available parameters with their values, he must select in the menu bar: File Recording Data Monitor Data Add Parameter Values 5.7 SCOPE CONFIGURATION In this window the operator can create a record file that contains all the scope settings ( variable monitored, parameter monitored, cursors, etc.). Using this tool the operator can easily set the scope configuration at the beginning of its work. To save the scope configuration file the operator has to click on: File Recording Data Monitor Data Scope Configuration Save Configuration in the menu bar of the Fuel Cell Supervisor H2 program: Window : Monitor Scope - Pag. 5-17

53 A dialog window appears to choose the name ( *.scf ) of the file and the place where it will be saved: To load the scope configuration file the operator has to click on: File Recording Data Monitor Data Scope Configuration Save Configuration Window : Monitor Scope - Pag. 5-18

54 6 WINDOW : POLARIZATION SCOPE 6.1 IN THIS WINDOW the operator can: monitor the position of the fuel cell working point respect to a previously saved reference polarization curve choose among two different types of polarization curve: Voltage Current Power - Current upload a different reference polarization curve choose the voltage and current variables available use two cursors latch the cursor onto the working point choose the scale of the display or use the auto-scale function stop/start the updating of the trace visualize only the working point or also its tail use an auto-refresh of the monitor to clear the working point tail change the appearance of the monitor grid Window : Polarization Scope - Pag. 6-1

55 6.2 HOW TO ENTER THIS WINDOW: To access this window the operator has to click on: Scope Polarization in the menu bar of the Fuel Cell Supervisor H2 program: 6.3 PRINCIPAL WINDOW Menu bar Set-up bar Polarization Curve Window Window : Polarization Scope - Pag. 6-2

56 6.4 SET UP BAR Management of the visualized variables Management of the polarization curve Status the link of Monitor of parameter values Management of the cursors Management of the scale MANAGEMENT OF THE VISUALIZED VARIABLES Button to enable/disable working point tail Voltage trace Current trace You can choose, if you want to use the unfiltered or the filtered variables to be displayed. To from one to the other, you have to move the cursor over the name of a currently displayed variable and doubleclick. A list of the available variables occurs and you can select the variable to be displayed by this trace by clicking on it. List of variables Note, that the power displayed in the power current mode is calculated as the product of the variables chosen in this section. Window : Polarization Scope - Pag. 6-3

57 6.4.2 MONITOR OF PARAMETER VALUES Parameter 1 Value of Parameter 1 Parameter 2 Value of Parameter 2 The name and numerical value of two parameters can be shown simultaneously in this area of the Polarization Scope window. To select a parameter to be shown from the range of available parameters, you have to move the cursor over the name of a currently visible parameter and double-click. A list of the available parameters occurs and you can select a different parameter by clicking on it MANAGEMENT OF THE POLARIZATION CURVE At every start of the FCSH2 program a default polarization curve is loaded and displayed as a reference in the Polarization Curve window. This can be used to compare the position of the actual working point of the system (actual values of voltage(current) or power(current) ) with a reference polarization curve. Attention! It has to be clear, that this default curve, or in general a polarization curve loaded by the user, can only be a rough reference for a comparison between the actual stack performance and a previously achieved performance, represented by the loaded polarization curve. Button to change the type of polarization curve: voltage - current power - current Button to upload a reference curve from a file Button to reload the default reference curve Window : Polarization Scope - Pag. 6-4

58 The operator can choose the type of polarization curve (voltage current or power current) using the button described above: To upload a user-defined reference polarization curve, the data for this curve must exist as an ASCII file with the following characteristics: the first line contains the number of data points, i.e. of following lines the following lines contain 3 values separated by a comma: 1. the current value (in ma, without decimal point) 2. the voltage value (of the single cell, in mv, without decimal point) 3. the power value (of the single cell, in mw, without decimal point) the official extension for this file is *.pcd (Polarization Curve Data), but this is not obligatory an example is shown below: , 946, , 910, , 869, , 829, , 790, , 750, , 710, , 671, , 632, , 592, , 552, , 513, , 473, , 433, , 417, Window : Polarization Scope - Pag. 6-5

59 6.4.4 MANAGEMENT OF THE CURSORS To activate/deactivate the bar cursor function you have to check or uncheck the Cursor Enable check box. Cursor Enable check Latch working check box onto point Scroll to move the horizontal bar Scroll to move the vertical bar Position of the horizontal bar Position of the vertical bar Vertical Bar Horizontal Bar Window : Polarization Scope - Pag. 6-6

60 To move the cursor the operator can use: -the scroll bar in the cursor management section of the Set-up bar -the mouse: To move the bar you can: point the mouse cursor on the bar cursor that you want move push the left button of the mouse drag the bar cursor to the desired position while holding the left mouse button release the left mouse button If the operator enables the latch onto working point function the scroll-bars are deactivated and the cursors permanently indicate the position of the actual working point MANAGEMENT OF THE SCALE In this section of the Set-up bar the operator can change the scale of the display. The range of the display can be set manually by entering numerical values into the text-boxes or automatically by enabling the auto-scale function. Enable/disable auto-scale check box Maximum value of the vertical axis Minimum value of the vertical axis Minimum value of the current axis Maximum value of the current axis Window : Polarization Scope - Pag. 6-7

61 The values written into the text-boxes are not immediately valid, which is shown by their blue color. To change the scale of the display according to the newly entered values, you have to click on the button Update, which will also change the color of the changed values to black. You are able to change the values in the range shown below: Min Value Max Value Xmax Ymax STATUS OF THE COMMUNICATION LINK Here the status of the communication link can be seen: Link OK: the communication is active and working normally Link??: the communication is active but not working normally Link lost: the communication is active, but is interrupted by a fault. In this case the operator can click on the H 2 icon with the mouse to try to re-establish the communication link The operator can check the quality of the communication by moving the mouse cursor over the box. A label appears showing the value of the parameter TimeOutCounter. If the value is near to 0 % the communication is working normally, when it reaches 100 % the communication is stopped, as there is no response from the ECU. Window : Polarization Scope - Pag. 6-8

62 6.4.7 POLARIZATION CURVE WINDOW Max vertical value Vertical value of the work point Monitor Grid Min vertical value Number of single cells Horizontal value of the work point Min horizontal value Management of the updating of the traces Max horizontal value FCSH2 calculates the voltage of a single fuel cell from the total stack voltage and the number of single cells. The operator has the possibility adjust this number manually by using the text-box shown below: Window : Polarization Scope - Pag. 6-9

63 6.4.8 MANAGEMENT OF THE UPDATING OF THE TRACES Start/Stop updating the traces Enable/disable the autorefresh of the working point tail Using this buttons the operator can: stop and restart the updating of the trace enable/disable the automatic clearing of the working point tail, which occurs in 60 second intervals CHANGE MONITOR GRID The operator can change the appearance of the monitor grid according to the sequence shown below by double-clicking on the monitor display area: Window : Polarization Scope - Pag. 6-10

64 7 WINDOW : DATA VISUALIZATION 7.1 IN THIS WINDOW the operator can: open data record files that have a limited number of samples and that were not interrupted choose which of the traces to visualize use two main cursors and two auxiliary cursor choose the scale of the display or use the auto-scale function read the value of a variable at the position of the cursor invert the traces use a zoom function change the appearance of the monitor grid Window : Data Visualization - Pag. 7-1

65 7.2 HOW TO ENTER THIS WINDOW: To access this window the operator has to click on: File Recording Data Monitor Data Upload Recording in the menu bar of the Fuel Cell Supervisor H2 program: Note, that this window is accessed automatically after starting FCSH2, if there is no communication with an ECU. Before the Data Visualization window is opened, the operator has the possibility to load a previously saved data record file by using the window shown below: Note, that this window is also accessible from the Data Visualization window by clicking File Recording Data Upload Recording Window : Data Visualization - Pag. 7-2

66 Menu bar in the menu bar of the Fuel Cell Supervisor H2 program for another time to load a different data record file. 7.3 PRINCIPAL WINDOW Set Up bar Visualization Window 7.4 SET UP BAR Management of the visualized variables Status the link of Management of the cursors Management of the scale Window : Data Visualization - Pag. 7-3

67 7.4.1 MANAGEMENT OF THE VISUALIZED VARIABLES If no data record file is opened this area appears like shown below: Button to enable/disable a trace Button to change the colour of the trace After a data record file has been opened for visualization the names of the variables chosen during the recording of the loaded file appear in the appropriate boxes, and it is indicated if this variables were active or not during the recording. (If the display of a variable is deactivated during the recording, no values are recorded for this variable, and therefore it is not possible to visualize a recorded trace.) List of variables Variable active during the recording Variable not active during the recording It is also possible to deactivate the visualization of a trace that was active during recording by clicking on the on/off button beside its name. Trace deactivated in the visualization window Window : Data Visualization - Pag. 7-4

68 7.4.2 MANAGEMENT OF THE CURSORS To activate/deactivate the bar cursor function you have to check or uncheck the Cursor Enable check box. Cursor Enable check Scroll to move the horizontal bar Position of the horizontal bar Horizontal auxiliary cursor enable Vertical auxiliary cursor enable Scroll to move the vertical bar Position of the vertical bar Window : Data Visualization - Pag. 7-5

69 Vertical Bar Horizontal Bar To move the cursor the operator can use: -the scroll bar in the cursor management section of the Set-up bar -the mouse: To move the bar you can: point the mouse cursor on the bar cursor that you want move push the left button of the mouse drag the bar cursor to the desired position while holding the left mouse button release the left mouse button To carry out measurements of the difference between to points of the recorded data two auxiliary bar cursors can be used. Scroll to move the horizontal aux. bar Scroll to move the vertical aux. bar Position of the horizontal aux. bar Position of the vertical aux. bar Window : Data Visualization - Pag. 7-6

70 Vertical bar Vertical aux. bar Horizontal aux. bar Horizontal bar MANAGEMENT OF THE SCALE In this section of the Set-up bar the operator can change the scale of the display. The vertical range of the display can be set manually by entering numerical values in the Ymin and Ymax text-boxes or automatically by enabling the auto-scale function. Enable/disable auto-scale check box Maximum value of the vertical range Minimum value of the vertical range Time displayed on one screen in seconds Button to Update the scale of the display Window : Data Visualization - Pag. 7-7

71 The values written into the text-boxes are not immediately valid, which is shown by their blue color. To change the scale of the display according to the newly entered values, you have to click on the button Update, which will also change the color of the changed values to black. You are able to change the values in the range shown below: Min Value Max Value Xmax Ymax Ymin STATUS OF THE COMMUNICATION LINK Normally the status of the communication link can be seen here. While using the Data Visualization window the communication is deactivated and the corresponding status icon is shown below: No link: the communication is not active Window : Data Visualization - Pag. 7-8

72 7.5 VISUALIZATION WINDOW Max vertical value Values of the traces Monitor Grid Min vertical value Min horizontal value Max horizontal value Button to invert the traces Name and path of data record file Management of the zoom system VALUES OF THE TRACE Enable/disable the visualization of the numerical values at the position of the vertical bar cursor Window : Data Visualization - Pag. 7-9

73 If the cursor function is enabled, the operator can decide to enable this function to visualize the numerical values of the traces at the actual position of the vertical bar cursor. Value of the first variable Value of the last variable When this function is activated, the vertical bar cursor can only be moved from the position of one recorded data point to the position of another RECORD FILE In this area the operator can have some information about the record file Path of the data record file Properties of the data record file Window : Data Visualization - Pag. 7-10

74 7.5.3 MANAGEMENT OF THE ZOOM SYSTEM When a record file is loaded and its length is bigger than 20 samples, the operator can use a zoom function: Zoom in button Value of the zoom Zoom out button Zoom navigator The characteristics of this function are: Zoom in button: to enlarge the trace in the horizontal (time) axis direction Zoom out button: to reduce the trace in the horizontal (time) axis direction Value of the zoom: magnification of the complete data range (range: x1 to x5) Zoom navigator: to change the display of data according to the position within the complete data range Window : Data Visualization - Pag. 7-11

75 7.5.4 CHANGE MONITOR GRID The operator can change the appearance of the monitor grid according to the sequence shown below by double-clicking on the monitor display area: Window : Data Visualization - Pag. 7-12

76 8 WINDOW : BLACK BOX TRIP EVENT 8.1 IN THIS WINDOW the operator can: view the old trip causes and when these trips occurred check the total numbers of trips that occurred check the total numbers of system starts that were carried out check the state of the system check the elapsed total operation time of the fuel cell system monitor the control flags of the ECU software monitor the state of the alarm level of the ECU software save the black box data in a file load the black box data from a file Window : Black Box Trip Event - Pag. 8-1

77 8.2 HOW TO ENTER THIS WINDOW: To access this window the operator has to click on: Black Box Trip Event in the menu bar of the Fuel Cell Supervisor H2 program: Note, that this window is accessible after starting FCSH2, also if there is no communication with an ECU. Menu bar 8.3 PRINCIPAL WINDOW Status bar Visualization Window Window : Black Box Trip Event - Pag. 8-2

78 8.4 STATUS BAR For information concerning the status bar refer to the appropriate section in chapter: System survey. 8.5 VISUALIZATION WINDOW Management of the black box data General information about the opened black box record Data visualization grid Window : Black Box Trip Event - Pag. 8-3

79 8.5.1 MANAGEMENT OF THE BLACK BOX DATA Load the black box from ECU Load the black box from a file Save the black box in a file Using this buttons the operator can: acquire and visualize the black box data that is stored in the ECU. When the operator pushes the button Up Load, FCSH2 starts to communicate with the ECU to acquire the stored black box data; during this acquisition the three buttons shown above are disabled. When this process is finished correctly the three buttons are reenabled and the acquired data is visualized in the grid immediately. There is the possibility that there is no trip event data stored in the ECU, and in this case the following message appears: If during the operation of reading the communication link fails, the operator can try to recover the communication by clicking on the provided icon. If also this operation fails the communication with the ECU must be reactivated from another window. acquire and visualize the black box data that is stored in a file *.bbx Window : Black Box Trip Event - Pag. 8-4

80 When the operator pushes the button Load, a dialog window appears to choose the file to open: save the currently visualized black box data in a file *.bbx When the operator pushes the button Save, a dialog window appears to choose the name of the file and the place where it will be saved: A black box file created by the FCSH2 is a text (ASCII) file, which can be reloaded and displayed by the FCSH2 or read by commercial software like MS Excel. Window : Black Box Trip Event - Pag. 8-5

81 8.5.2 DATA VISUALIZATION GRID In this area the operator can see the last trip events recorded by the ECU. for the systems 1.5 kw the max. number of trip events saved is 40 for the systems > 1.5 kw the max. number of trip events saved is 200 This internal function of the ECU works with a circular buffer, so when the max. number is reached the first trip event data is lost. Trip time Trip numbers Scroll bar to navigate in the black box Trip grid Trip reasons Window : Black Box Trip Event - Pag. 8-6

82 Trip numbers: sequence of numbers identifying the single entries of the circular buffer, each containing the saved data for one trip event Trip time: operation time hour of the fuel cell system when the trip event has occurred Scroll bar: if the number of events contained in the black box is higher than eight this scroll bar is enabled and can be used to navigate in the data entries, like shown in the example below: Trip grid: is a grid of cells where each of them has two coordinates: 1. vertical: sequential number of the stored trip event 2. horizontal: reason of the trip event and in the grid two possible values can appear: TRUE: if the linked reason was active when the trip event occurred FALSE: if the linked reason was not active when the trip event occurred Trip reasons: in this column you can find the name of the flag that caused the trip event Window : Black Box Trip Event - Pag. 8-7

83 8.5.3 GENERAL INFORMATION ABOUT THE OPENED BLACK BOX RECORD Size of the fuel cell system Number of trip events stored in the black box Number of starts executed during the total operation time of the fuel cell system Number of trip events that occurred during the total operation time of the fuel cell system Total operation time of the fuel cell system when the black box data was up-loaded Window : Black Box Trip Event - Pag. 8-8

84 9 WINDOW : BLACK BOX MEASUREMENT RECORDING 9.1 IN THIS WINDOW the operator can: manage (e.g. start and stop manually) a small & fast recoding of the system measurements (this recording is composed of a circular buffer of 51 samples for each measurement channel) upload these measurement values of the ECU and visualize this recording set the sample time of the recording check the state of the system check the elapsed total operation time of the fuel cell system monitor the control flags of the ECU software monitor the state of the alarm level of the ECU software save the black box data in a file load the black box data from a file Window : Black Box Measurement Recording - Pag. 9-1

85 9.2 HOW TO ENTER THIS WINDOW: To access this window the operator has to click on: Black Box Measurement Rec. in the menu bar of the Fuel Cell Supervisor H2 program: Note, that this window is accessible after starting FCSH2, also if there is no communication with an ECU. Menu bar 9.3 PRINCIPAL WINDOW Status bar Visualization Window Window : Black Box Measurement Recording - Pag. 9-2

86 9.4 STATUS BAR For information concerning the status bar refer to the appropriate section in the chapter: System survey. 9.5 VISUALIZATION WINDOW Management of the black box data Size of the fuel cell system on which the data was recorded Data area visualization Window : Black Box Measurement Recording - Pag. 9-3

87 9.5.1 MANAGEMENT OF THE BLACK BOX DATA Manual start & stop of the recording Set the sample time of the recording Scroll bar to navigate in the black box data Load the black box data from the ECU Load black box data from a file Save the black box data in a file Data time sample Using this buttons the operator can: start and stop the recording the recording starts automatically with the start of the system and stops either with the stop or with the trip of the system, but the operator can choose to activate or deactivate the recording by clicking on the Start/Stop button. When the operator decides to upload the data, the recording stops also automatically. The operator can check status of this recording by the control flag BB_MeasR contained in the Command_word: acquire and visualize the black box data that is stored in the ECU when the operator pushes this button, FCSH2 starts to communicate with the ECU to acquire the stored black box data; during this acquisition the four buttons are disabled and a progress bar appears. Window : Black Box Measurement Recording - Pag. 9-4

88 If this process is finished correctly the three buttons are reenabled and also the scroll bar is activated: change the sample time of the recording: when the operator pushes the button Setup Rec., a dialog window appears to choose the favourite sample time pushing the related check box acquire and visualise the black box data that is stored in a file *.bbx When the operator pushes the button Load, a dialog window appears to choose the file to open: Window : Black Box Measurement Recording - Pag. 9-5

89 save the currently visualized black box data in *.bbx file When the operator pushes the button Save, a dialog window appears to choose the name of the file and the place where it will be saved: A black box file created by the FCSH2 is a text (ASCII) file, which can be reloaded and displayed by the FCSH2 or read by commercial software like MS Excel. Window : Black Box Measurement Recording - Pag. 9-6

90 9.5.2 DATA VISUALIZATION AREA In this area the operator sees the measurements recorded by the ECU. The measurements shown below as examples are from a system DEA 0.5: and from a system DEA 6.0: Window : Black Box Measurement Recording - Pag. 9-7

91 For each measurement channel you can find an area containing the numeric values and a graphical visualization: Measurement numbers channel Displayed variable measurement Graphical visualization of the value of the measured variable Direct value of the variable Filtered value of the variable Vertical bar representing the filtered value of the variable Vertical bar representing the direct value of the variable Full scale value of the graphical representation Axis of the graphical representation Window : Black Box Measurement Recording - Pag. 9-8

92 10 WINDOW : STATUS 10.1 IN THIS WINDOW the operator can: check all the control and alarm flags existing in the control check the elapsed operation time of the fuel cell system monitor the state of the alarm level Window : Status - Pag. 10-1

93 10.2 HOW TO ENTER THIS WINDOW: To access this window the operator has to click on: Status in the menu bar of the Fuel Cell Supervisor H2 program: 10.3 PRINCIPAL WINDOW Menu bar Information bar Flag area Window : Status - Pag. 10-2

94 10.4 INFORMATION BAR Operation time of the system Status the link of Visualization of the actual alarm level OPERATION TIME OF THE SYSTEM: In this box the operator can read the already elapsed total operation time of the Fuel Cell System VISUALIZATION OF THE ACTUAL ALARM LEVEL In this box the operator can read the actual alarm level of the Fuel Cell System control. Neither the conditions for an alarm nor the security shut off (TRIP) conditions are fulfilled. Conditions for a level 1 alarm are fulfilled. No TRIP condition. Conditions for a level 2 alarm are fulfilled. No TRIP condition. Window : Status - Pag. 10-3

95 The condition for a security shut off (TRIP) is fulfilled and the system will shut off automatically, if this condition remains unchanged for a certain security time STATUS OF THE COMMUNICATION LINK Here the status of the communication link can be seen: Link OK: the communication is active and working normally Link??: the communication is active but not working normally Link lost: the communication is active, but is interrupted by a fault. In this case the operator can click on the H 2 icon with the mouse to try to re-establish the communication link The operator can check the quality of the communication by moving the mouse cursor over the box. A label appears showing the value of the parameter TimeOutCounter. If the value is near to 0 % the communication is working normally, when it reaches 100 % the communication is stopped, as there is no response from the ECU. Window : Status - Pag. 10-4

96 10.5 FLAG AREA In this area the operator can check the values of all flags used in the control. It is realized by a multipages format like this: Multi pages format The flag groups are divided in the different pages according to their purpose. Window : Status - Pag. 10-5

97 CONTROL FLAG This page shows the flags used in the management of the control: Status word: This group of flags shows the state of the system control. Auxiliary Status word: This group of flags is used to indicate the change of the state of the system control. Auxiliary Status word: This group of flags shows which control functions are enabled. Window : Status - Pag. 10-6

98 Command word: This group of flags shows the execution of certain range of control commands. a SECURITY FLAG This page shows the flags used to indicate alarm and security shut off (Trip) conditions: Alarm Level 1 word: This group of flags indicates, if the conditions for a level 1 alarm are fulfilled. Alarm Level 2 word: This group of flags indicates, if the conditions for a level 2 alarm are fulfilled. Window : Status - Pag. 10-7

99 Trip word: This group of flags indicates, if the conditions for a standard security shut off are fulfilled (i.e. security delay 3 seconds). Fast Trip word: This group of flags indicates, if the conditions for a fast security shut off are fulfilled (i.e. security delay 1 second) DIAGNOSTIC FLAG This group of flags shows the state of some digital input/output ports of the control: In/Out put word: This group of flags shows the state of some digital input/output ports of the control Window : Status - Pag. 10-8

100 and the state of command, if system components are used in manual mode Manual word: This group of flags shows the state of command, if system components are used in manual mode Window : Status - Pag. 10-9

101 11 WINDOW : CAN BUS 11.1 IN THIS WINDOW the operator can: check the CAN bus communication setup modify the CAN bus baud rate modify the CAN bus input/output messages check the state of the system check the elapsed total operation time of the fuel cell system monitor the control flags of the ECU software monitor the state of the alarm level of the ECU software 11.2 HOW TO ENTER THIS WINDOW: Window : CAN Bus - Pag. 11-1

102 To access this window the operator has to click on: CANBus. in the menu bar of the Fuel Cell Supervisor H2 program: 11.3 PRINCIPAL WINDOW Menu bar Status bar Visualization and Setup Window Window : CAN Bus - Pag. 11-2

103 11.4 STATUS BAR For information concerning the status bar refer to the appropriate section in the chapter: System survey VISUALIZATION AND SETUP WINDOW Current of the Communication flags Management the Baud Rate of Management of the exchange data Window : CAN Bus - Pag. 11-3

104 MANAGEMENT OF THE BAUD RATE Actual Baud Rate Baud Rate configuration parameters Fast buttons to choose a predefined baud rate Button to send the new baud rate chosen Using this buttons the operator can choose a different baud rate. Particularly the operator can choose among three predefined baud rate ( 500/250/125 kbit/s ) by the proper check buttons. If the operator needs a different baud rate for his application he can select the User options and set the suited parameter values ( in this case please before contact the MES-DEA FC laboratory ). Afterwards the operator has to send the new baud rate value to the ECU by the proper button. Window : CAN Bus - Pag. 11-4

105 The new set up will be not active until the operator reset the ECU ( power off -> power on ). The grey background indicates that a new baud rate was sent to the ECU but it s still not active MANAGEMENT OF THE EXCHANGE DATA Message length setup ID Output messages setup Input setup messages Button to send the new messages setup chosen Button to set the default messages setup Window : CAN Bus - Pag. 11-5