IE-SOAR Lightweight Hydrogen Regulator User Manual
- June 3, 2024
- IE-SOAR
Table of Contents
IE-SOAR Lightweight Hydrogen Regulator
Safety warnings
- Only qualified technicians trained in high pressure flammable gases must carry out fitting of regulators and filling of cylinders, and do so in accordance with local laws and Health and Safety (H&S) regulations.
- The customer is responsible for ensuring all technicians and pilots are suitably trained, accredited and in compliance with local laws and H&S regulations.
- The customer is responsible for ensuring the safe operation of the Lightweight Hydrogen Regulator.
- Do not open or dismantle the Lightweight Hydrogen Regulator.
- Do not remove any external covers or cowlings.
- Pressurised hydrogen present. Highly flammable!
- Do not use the Lightweight Hydrogen Regulator if the unit is damaged.
- The Lightweight Hydrogen Regulator should be inspected for damage and leak checked prior to use.
When shipping or transporting your Unmanned Aerial Vehicle and Fuel Cell Power
Module (FCPM), the FCPM must always be disconnected from the hydrogen source.
When transporting pressurised gas check for relevant local regulations.
This user manual is intended as a general guidance only and does not purport
to address the specific situations that could potentially arise from the use of
the Lightweight Hydrogen Regulator with pressurised hydrogen systems and their
usage in connection with UAVs. The recipient is responsible for ensuring that
all personnel have read and understood this User Manual before being allowed
to handle, operate, install and store any equipment supplied by Intelligent
Energy.
The recipient must ensure that any personnel responsible for handling the
Lightweight Hydrogen Regulator with hydrogen cylinders and operating UAVs are
suitably trained and certified in compliance with any applicable local, state
and federal laws and regulations and good industry practice. The recipient is
responsible for complying with any relevant health and safety policies and
procedures that may apply to the operation of UAVs and use and storage of
hydrogen on any sites.
Intelligent Energy warrants to the recipient and it will repair and replace
any defective equipment resulting from the authorised use of the equipment
provided, in accordance with the warranty terms. Notwithstanding the above,
Intelligent Energy, to the fullest extent permitted by law, accepts no
liability (including liability in respect of any error or defects in the
Lightweight Hydrogen Regulator) for any damage caused as a result of
Recipient’s unauthorised use of the equipment provided. The recipient
acknowledges that the manner in which the equipment is stored, used or
operated is not under the control of Intelligent Energy Limited.
Intelligent Energy has made every effort to ensure that this User Manual is
accurate and disclaims liability for any inaccuracies or omissions that may
have occurred.
Lightweight Hydrogen Regulator
Product Overview
The Lightweight Hydrogen Regulator has been designed for use with the Intelligent Energy IE-SOAR FCPMs. It is intended to provide the necessary pressure regulation and safety features required to operate an IE-SOAR FCPM. The Regulator has been designed to meet relevant safety standards. It is designed to operate with compressed gaseous hydrogen.
Product specification
Hydrogen Regulator
- Mass 315g
- Maximum regulator (cylinder) pressure 300 or 350 Bar/4350 or 5075 PSI*
- Output pressure 0.9 Bar ± 0.1 Bar/13 PSI ± 1.5 PSI
- PRV set pressure 2 Bar/29 PSI
- Burst disc set pressure 427 or 491 Bar/6190 or 7120 PSI*
- Cylinder interface M18 × 1.5
- Configuration dependent on maximum cylinder operating pressure. 10kg
Main components
Assembly and connection
Assembly of regulator to cylinder
- Take the cylinder and regulator and inspect for physical damage or debris, reject if visible to the eye.
- Inspect the mating threads for damage or debris, reject if visible to the eye.
-
By hand, carefully thread the regulator assembly into the cylinder.
-
Tighten the regulator until it is mated flush to the neck of the cylinder.
-
Once the regulator is flush, apply a maximum torque of 58Nm (42.8ft.lb).
-
Always conduct a leak check on the completed assembly.
-
Prior to operation the cylinder will need to be purged to remove air impurities. Contact Intelligent Energy for further information.
Filling of cylinder
Only qualified technicians trained in high pressure and flammable gases can
carry out fitting of regulators and filling of cylinders, and do so in
accordance with local laws and Health and Safety (H&S) regulations.
A leak check must be conducted after filling the cylinder.
The female swagelok part number is SS-QF4-B-4PF. This part must be a
constituent of the equipment used to fill the HFLW regulator.
Consult local H&S / facilities management for guidance on storage of cylinders
and advisable safety equipment.
Hydrogen fuel
When installing and operating hydrogen systems, hydrogen general safety
guidance should be considered, for more detailed information see:
ISO/TR 15916 – Basic considerations for the safety of hydrogen systems
Hydrogen purity is an important consideration for fuel cell performance, it
should comply with the specification in the table below for best performance:
Fuel Characteristics : Fuel Requirements
- Hydrogen concentration > 99.90 %
- Nitrogen, Helium, Argon < 0.10%
- Oxygen < 50 ppm
- Carbon Dioxide < 2 ppm
- Carbon Monoxide < 0.2 ppm
- Ammonia < 0.1 ppm
- Sulphur containing compounds < 4 ppb
- Max particle concentration < 1 mg/kg
- Max particle diameter < 75 μm
For more details about hydrogen quality see the user manual for your FCPM or contact Intelligent Energy Product Support, see Section 6
Hydrogen connection
The Lightweight Hydrogen Regulator is designed to be connected to an
Intelligent Energy FCPM, please refer to the FCPM user manual for details of
how to make the hydrogen connection to that unit.
Ensure the hydrogen cylinder and FCPM are securely mounted before proceeding.
- Verify that the connector O-rings are in place and free from damage or debris.
- Align the hose connector path with the regulator pins.
- Push the hose connector and twist anti-clockwise. It will click when located.
Refuelling
There are multiple ways to fill cylinders and Intelligent Energy has application notes available for some fill options. Contact Intelligent Energy Product Support at [email protected] for details.
Troubleshooting
| Symptom | Reason(s) | Action |
|---|---|---|
| High H2 pressure fault | Gas pressure regulation fault | Contact Intelligent |
Energy Product Support
Low H2 pressure fault| No hydrogen supplied from cylinder
Cylinder is empty
**** Gas pressure regulation fault
| 1. Check cylinder pressure, refill if needed
2. Inspect the pressure transducer cable Replace if damaged If the steps
above do not resolve the issue, contact Intelligent Energy Product Support,
see Section 6
Loss of cylinder pressure| Leak between cylinder and regulator
Leak from the regulator
| 1. Place cylinder and regulator in a well- ventilated space, preferably
outdoors
2. Purge the gas from the cylinder by lifting the cap of the PRV, see
diagram in section 2.2
3. When the cylinder is empty. A person trained in the use of pressurised
gas should remove the regulator from the cylinder and inspect the sealing
o-ring. Replace if damaged
4. Reassemble and refill the cylinder
5. Check for leaks
If the steps above do not resolve the issue, contact Intelligent Energy
Product Support,
Contacting Intelligent
For all other issues and questions please contact your local Intelligent Energy representative or the Product Support team by email servicing @intelligent-energy.com
End of life treatment and disposal
When the Lightweight Hydrogen Regulator or cylinder reaches end of life please
contact Intelligent Energy for support with reconditioning or disposal at
[email protected]
© Intelligent Energy Limited 2022. All Rights Reserved.
The information contained herein is the intellectual property of Intelligent
Energy Ltd and it may not be copied or reproduced in any format.
The information contained in this publication is intended only as a guide and
is subject to change as a result of the constant evolution of Intelligent
Energy’s business and its technology. This publication and its contents do not
include all details which may be relevant to particular circumstances and
should not be regarded as being a complete source of Information. To the
fullest extent permitted by law, Intelligent Energy offers no warranty as to
the accuracy of the content of this publication, shall not be liable for the
content of this publication and no element of this publication shall form the
basis of any contractual relationship with a third party. Printed August 2019.
53527-IE-UM-201908
Published by: Intelligent Energy Ltd, Charnwood Building, Holywell Park, Ashby
Road, Loughborough LE11 3GB. Tel: +44 (0) 1509 271 271
Document No: 10010368
(Registered in England with company number: 03958217).