Intelligent Energy LW351 Lightweight Hydrogen Regulator User Manual

Intelligent Energy LW351 Lightweight Hydrogen Regulator

The Lightweight regulator is constructed using a Pressure Tech LW351 regulator with fuel-cell specific modifications, for more information on the LW351 please refer to the Pressure Tech service manual at bit.ly/3IgDeOx

The CE label shows that the product complies with the basic requirements of the applicable directives. For the declaration of conformity contact the manufacturer at servicing@intelligent-energy.com

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

Lightweight Hydrogen Regulator

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.

1. By hand, carefully thread the regulator assembly into the cylinder.
2. Tighten the regulator until it is mated flush to the neck of the cylinder.
3. Once the regulator is flush, apply a maximum torque of 58Nm (42.8ft.lb).
4. Always conduct a leak check on the completed assembly.
5. Prior to operation the cylinder will need to be purged to remove air impurities. Contact Intelligent Energy for further information.

Assembly and connection

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.

1. Verify that the connector O-rings are in place and free from damage or debris.
2. Align the hose connector path with the regulator pins.
3. 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 servicing@intelligent-energy.com for details.

Troubleshooting

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 Energy Product Support

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 servicing@intelligent-energy.com

© 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).

T +441509 271 271 E servicing@intelligent-energy.comIntelligent Energy Charnwood Building, Ashby Road, Loughborough, LE11 3GB, UK www.intelligent-energy.com

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References

• bit.ly/3IgDeOx
• Hydrogen Fuel Cell Manufacturer | Intelligent Energy Limited

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