EPA-600/9-76-020
August 1976
EPA VAN OPERATIONAL MANUAL
Industrial Environmental Research Laboratory
Office of .Research and Development
U.S. Environmental Protection Agency
Research Triangle Park, North Carolina 27711
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RESEARCH REPORTING SERIES
Research reports of the Office of Research and Development, U.S. Environmental
Protection Agency, have been grouped into five series. These five broad
categories were established to facilitate further development and application of
environmental technology. Elimination of traditional grouping was consciously
planned to foster technology transfer and a maximum interface in related fields.
The five series are:
1. Environmental Heajth Effects Research
2. Environmental Protection Technology
3. Ecological Research
4. Environmental Monitoring
5. Socioeconomic Environmental Studies
This report has been assigned to the ENVIRONMENTAL PROTECTION
TECHNOLOGY series. This series describes research performed to develop and
demonstrate instrumentation, equipment, and methodology to repair or prevent
environmental degradation from point and non-point sources of pollution. This
work provides the new or improved technology required for the control and
treatment of pollution sources to meet environmental quality standards.
EPA REVIEW NOTICE
This report has been reviewed by the U.S. Environmental
Protection Agency, and approved for publication. Approval
does not signify that the contents necessarily reflect the
views and policy of the Agency, nor does mention of trade
names or commercial products constitute endorsement or
recommendation for use.
This document is available to the public through the National Technical Informa-
tion Service. Springfield. Virginia 22161.
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EPA-600/9-76-020
August 1976
EPA VAN
OPERATIONAL
MANUAL
by
Niels E. Scholar
Engelhard Minerals and Chemical Corporation
2655 Route 22
Union. New Jersey 07083
Contract No. 68-02-1482
ROAPs No. 21ADE-034, 21BBZ-009, and
21BJV-030, -035, -036, and -037
Program Element No. 1AB013
EPA Project Officer: Walter B. Steen
Industrial Environmental Research Laboratory
Office of Energy, Minerals, and Industry
Research Triangle Park, NC 27711
Prepared for
U.S. ENVIRONMENTAL PROTECTION AGENCY
Office of Research and Development
Washington, DC 20460
-------
CONTENTS
Table of Contents ii
Table of Contents iii
Figures iv
Figures v
I. Introduction 1
II. General System Description 2
III. Transportation 17
A. Pre-Transport Preparation 18
B. Towing Instruct ions 18
C. Set-Up Instructions 19
1. Orientation 19
2. Leveling Jacks 19
3. Stabilizing Jacks 19
4. Hurricane Tie-Downs 19
5. Battery Installation 19
6. Shoreline 19
7. Solar Panel a)Erection b) Retraction 19
8 . Ammonia Supply 21
IV. Start-Up Operation Instructions 25
1. Ammonia Cracker 25
2. Fuel-Cells 27
ii
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3 . Environmental Heating/Cooling 31
4. Water Heater 33
5. Kitchen Range 33
6. Shutdown Procedure 37
V. Safety Instructions 39
VI. Troubleshooting Guide 41
VII. Maintenance Instructions 45
VIII. Drawings & Schematics
IX. Manufacturers Manuals (See Volume 2)
111
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LIST OF FIGURES
Page
Fig. 1 System Component Location 6
Fig. 2 Environmental Flow Schematic 7
Fig. 2A "1st" Circuit Solar Heat Storage 8
Fig. 2B "2nd" Circuit Direct Heating from 9
Solar Panel
Fig. 2C-1 "3rd" Circuit "Indirect"Heating 10
Heat Pump in Heating Mode
Fig. 2C-2 "3rd" Circuit, Indirect Heating 11
Heat Pump with Waste Heat
Fig. 2D "4th" Circuit, Direct Heating with 12
Auxiliary Catalytic Heater
Fig. 3 EPA-Van Modes & Control System 14
Fig. 4 Exterior Components 16
Fig. 5 Manual Control Panel 22
Fig. 6 Flow System 1, Ammonia Cracker 23
Fig. 7 Electrical Schematic, Sheet No. 3 24
Fig. 8 Flow System 2, Fuel Cells 28
Fig. 9 Electrical Schematic, Sheet 1 29
Fig. 10 Electrical Schematic, Sheet 2 32
Fig. 11 NHs/Product Gas Schematic 36
Fig. 12 Flow System 3, Aux. Heater 34
Fig. 13 Flow System 4, Water Heater 35
Range Burner
iv
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Page
Fig. 14 Sequence Start-Up Timetable 47
Fig. 15 Control Instrument Function & 48
Setpoints
Fig, 16 Electrical Schematic, Sheet 4 49
Fig. 17 Performance Test, Terminal 50
Connections
Fig. 18 Wattmeter & Output Curve 51
Fig. 19 Flowmeter Output Curve 52
Fig. 20 Delta T Transmitter Output Curve 53
Fig. 21 Metric Conversion Table 54
Fig. 22 Temperature Conversion Chart 55
Fig. 23 Performance Testing 43
Fig. 24 Operating Data Sheet NH3 Cracker 44
System
-------
SECTION I
INTRODUCTION
The EPA-Van is a research unit designed and constructed by
Engelhard Industries for the U. S. Environmental Protection
Agency (EPA). It is a part of EPA's research program to control
air pollution through the demonstration of an energy supply
system for the home which contains environmentally clean and
energy conserving components. The EPA-Van is designed to be
mobile for experimental testing in various parts of the United
States.
-------
SECTION II
GENERAL SYSTEM DESCRIPTION
The EPA-Van, a research unit designed and constructed by
Engelhard Industries for the U. S. Environmental Protection
Agency (EPA), is part of EPA's research program to control air
pollution. The pollution control technique is an energy supply
system for the home which contains environmentally clean and
energy-conserving components. The EPA-Van is designed to be
mobile for experimental testing in various parts of the United
States.
The EPA-Van's energy supply system includes fuel cells, a
solar energy collector, a heat pump, and catalytic appliances.
This essentially non-polluting equipment is integrated so as to
optimize the energy-conserving features which characterize each
of its components. The integrated system provides all the
energy needed by the EPA-Van for space heating, cooling and
ventilating; cooking; lighting; food refrigeration; water
heating; and for appliances.
EPA-Van Design
The design of the EPA-Van began in 1973. Engineers at
EPA's Industrial Environmental Research Laboratory, Research
Triangle Park, N.C. decided to combine three approaches for re-
ducing air pollution and conserving energy: (1) better home
construction, and (2) solar energy (both of which reduce fuel
consumption and thereby reduce pollution) and (3) low-polluting
devices such as fuel cells and catalytic applicances.
Better Home Construction
Better home construction includes heavily insulated walls,
floors, and ceiling; storm doors and double-pane windows; and
accurately-controlled ventilation (uncontrolled infiltration of
cold air and exfiltration of heated room air is a large waster
of energy). The walls consist of several bonded layers: a
polystyrene core (5 cm) is sandwiched between two sets of wall
studs (3.75 cm each); the studs are covered by an outer skin /
of aluminum and an inner sheet of wood paneling; and urethane
foam fills the cavities between the studs.
-------
Solar Energy
Solar energy is used in a manner unique to the EPA-Van:
the solar energy system is integrated with'an electrically driven
heat pump.
Solar Energy System (Fig. 1)
The solar energy system includes a collector mounted on the
roof and a thermal storage tank located under the kitchen floor.
(In an actual home, the tank could be installed in a basement or
utility room or buried nearby.) The collector itself is a
commercially available standard design: a solution of ethylene
glycol and water is heated as it circulates (at 10 liters/min)
in tubes mounted on a black panel and under a glass cover. The
heated solution is either used immediately for space heating, or
its heat.is transferred to the storage tank (1,400 liters of
water) for later use.
Heat Pump (Fig. 1)
The heat pump extracts heat from the solar energy system
through a glycol-solution/FreonR heat exchanger. Solar-heated
glycol solution from the storage tanks is used to vaporize
FreonR in the heat pump. Thus, solar energy becomes the heat
source for the heat pump. (In conventional units, the heat
source is usually the air outside the home.) The rest of the
heat pump is conventional; the vaporized Freon is compressed
and used to heat air (via FreonR condensation) which is delivered
to the living areas. (The heat pump is also used for cooling
the EPA-Van in the summer; it operates just like a conventional
air conditioner, extracting heat from the inside air and de-
livering it to the outside air. No solar energy is used.)
The addition of a heat pump to a solar energy system offers
several advantages. First, unlike other solar heating systems,
the EPA-Van's system can extract energy from the thermal storage
tanks even when the temperature of the stored water is below
room temperature (down to 50°F or lower). This characteristic
increases the effective energy storage capacity of the tanks and
permits longer periods of operation without sunlight. Second,
because the tank temperature can be lower, the EPA-Van's solar
collector will operate at lower temperatures (on the average)
than those in other solar heating systems. This is an advantage
because a solar collector is more efficient at low temperatures-
-it retains more of the incident energy. Consequently, the
EPA-Van can be heated with a smaller solar collector; but at the
expense of electrical energy to drive the heat pump.
-------
Low-Polluting Devices (Fig. 1)
Fuel Cells: The EPA-Van needs electricity to power the
glycol-solution pumps for the solar energy system, the FreonR
compressor, the air blower for the heat pump, and the lighting,
food refrigeration, and electrical appliances. Normally, elec-
tricity would be purchased from a local power company; but the
EPA-Van uses a different approach, one which will result in less
pollution and more efficient use of our energy resources.
A fuel cell produces electricity by electrochemically com-
bining oxygen from the air with hydrogen. The by-products of
this process are heat and water. The EPA-Van utilizes two
Engelhard Model 750 fuel cells connected in parallel. Each fuel
cell produces 800 watts nominal at 28 volts. Storage batteries
are electrically floated in parallel with the fuel cells to pro-
vide supplementary power during start-up and periods of peak
power demand.
The fuel cells employ a cell design developed by Engelhard
that utilizes a single air stream to perform the three functions
of removing heat, removing moisture, and providing oxygen for
the fuel cell reaction. The basic cell contains two platinum-
catalyzed electrodes separated by a polymer matrix containing
the phosphoric acid electrolyte.
The hydrogen fuel for the fuel cells is produced in the
EPA-Van from anhydrous ammonia which is catalytically dissociated
into a fuel gas consisting of 75 percent H2 and 25 percent N2.
Traces of undissociated ammonia are scrubbed from the fuel gas
(via silica gel treated with sulfuric acid) before it enters the
fuel cells. The ammonia dissociator is heated by a burner that
consumes the bleed gas from the fuel cell.
The EPA-Van's fuel-cell system offers many advantages in
the form of low maintenance, simple operation and being virtually
pollution free. The use of the immobilized electrolyte and air
cooling permits a system which is simple (no bulk liquids) and
reliable (only one moving part, the air blower). More import-
antly, fuel cells appear to be nearly pollution-free they
produce only electricity, water, and hot air. (The effluents
from the hydrogen generator's burner and scrubber are potential
sources of pollution, though believed to be minor. These
effluents will be analyzed thoroughly during the testing program)
In addition, the hot air (r*^200°F) is not always discarded but
is used in winter for space heating. Thus, the heat from the
fuel cells supplements that provided by the solar/heat pump
system. During severely cold and cloudy periods, when the
energy demand for heating could exhaust the capacity of the fuel
cells and the solar/heat pump system, an auxiliary heater is used
to supplement the solar energy system.
-------
Catalytic Appliances (Fig. 1)
The auxiliary heater and the cooking range, are further
examples of the EPA-Van's special design. 'These two appliances
burn a gaseous fuel catalytically. The operation of the cooking
range is described below.
The range looks like a modern smooth-top unit, but under-
neath is a catalytic burner. Inside the burner, hydrogen fuel
(from the ammonia dissociator) and air are passed over a plati-
num-catalyzed surface. There the hydrogen burns readily without
a flame, thereby releasing heat and producing water vapor. The
heat is transmitted by radiation from the catalyst surface to
the underside of the range top. The top, made of ceramic/glass
material called CER-VITR, conducts the heat to the cooking
utensil. The combustion gases do not enter the kitchen, as they
do with most gas ranges, but are vented to the outside.
The catalytic burner does not need a pilot light for
ignition. Ignition occurs spontaneously at room temperature as
soon as the hydrogen reaches the catalyst. Thus the elimination
of pilot lights could significantly reduce energy consumption and
its associated pollution.
Flameless, catalytic combustion offers other environmental
benefits as well. Whereas normal gas ranges reach combustion
temperatures of 3,000°F or more, the catalytic range operates at
only 1,600°F. This means that the formation of nitric oxide,
which occurs at temperatures above 2,800°F, is virtually elimin-
ated. The catalytic combustion of hydrogen appears to be nearly
pollution-free; water is the combustion product. Even if un-
burned hydrogen were to appear in the exhaust gases, no environ-
mental damage would result, since hydrogen is not considered to
be a pollutant. However, hydrogen's safety hazard's do require
very careful consideration.
The other catalytic appliance, the auxiliary heater, uses
the same type of catalytic burner as the range, although the
burner shape and operating temperature is somewhat different.
Water Heater
Initially designed and successfully tested in the laboratory
with a catalytic heating unit, the water heater was converted to
flame heating using the 75 percent H2, 25 percent N2 as fuel.
The standard gas controls for the burner was successfully in-
tegrated into the EPA-Van control system.
The flame temperature was found to be 2100°F, well below
the formation temperature of nitric oxides.
-------
12
13
14
15
16
17
Fuel cells
Solar collector
Thermal storage tank
Heat pump
Cooking range
Water heater
Auxiliary heater
Ammonia tanks
Ammonia dissociator
Scrubber
Fuel/cell/heat recovery
unit
Pumps for glycol circuits
HVAC duct to living, areas
Battery box r-
Solar panel/erector control
Cover/fuel cell air inlet
Fuel cell/control panel
SYSTEM COMPONENT LOCATION
FIGURE 1
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9
-------
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10
-------
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Fig. 202
11
-------
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Direct Heating with Auxiliary
Catalytic Heater
Fig. 2D
12
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The- Integration of Components
As previously described, the EPA-Van is composed of a solar
collector and storage tank, a heat pump, two fuel cells, a water
heater, and two catalytic appliances. These components do not
function independently, however, but are integrated into one
system, which satisfies all domestic needs. The system provides
for space heating, cooling, and ventilating; cooking; water
heading; and electricity for lighting, food refrigeration, and
all other needs.
The methods by which the EPA-Van components are linked to-
gether and controlled are discussed in the following sections.
Four Glycol-Solution Circuits (Fig. 2,2A,2B,2C-1,2C-2,2D)
Four glycol-solution circuits serve as the key linkages
between the EPA-Van components. Each circuit is a closed loop
which transfers energy between two components. The first circuit
transfers solar energy from the solar collector to the thermal
storage tank. The second circuit transfers solar energy from
the collector to a glycol-air heat exchanger for "direct" space
heating. (Return air from the living areas is heated in this
exchanger and then recirculated.) The third circuit transfers
energy from the storage tanks to the heat pump for "indirect"
heating. The fourth circuit transfers energy from the auxiliary
heater to the glycol/air exchanger for "direct" space heating.
Pumps and control valves allow two circuits, the first and
fourth, to be operated simultaneously.
Eight HVAC Functions (Fig. 3)
The four glycol circuits allow for great flexibility in
operating the EPA-Van's system for heating, ventilating, and air
conditioning (the HVAC system). Eight separate HVAC functions
are possible, as summarized below:
Operation
Heating
Cooling
Neutral
Code
1
3
4
5
7
6w
6a
2
Function
Fuel-Cell Waste Heat
Auxiliary Heater
Stored Heat from Thermal
Storage Tank
Heat Pump
Direct Solar Heat
Heat Pump Rejecting Heat to
Thermal Storage Tank
Heat Pump Rejecting Heat to
Outside Air
Solar Energy Storage
13
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LEGEND:
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X VALVE CLOSED
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H HEATING
C COOLING
A AIR
W WATER
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WH-t- SH5T
WH + CAtBURNIR
V/H + CB + SHST
WH+ TANK HtAT
WHtSOLAR HIAT
WH + HIAT PUWP/H
HP/COOL (WATER)
HP/COOL (AIR)
HP/CCAIFO+SHST
SOLENOIDS
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DESCRIPTION
LIST OF MATERIAL
UNLCSI OTHERWI» IPKCirilO: ALL
DIMENSION! ARC IN INCHES, LIMITS ON:
FRACTIONS * DECIMALS * ANGLES *
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-------
HVAC Controller (Fig. 3)
The HVAC control system, automatically selects the proper
HVAC functions. Like the thermostat in a 'conventional home, the
controller senses room temperature and thereby determines the
HVAC requirements of the EPA-Van. It also selects the most fuel
conservative function (or combination of functions) to satisfy
the HVAC requirements.
Four temperature inputs allow the HVAC control system to
select the proper function(s): room temperature, storage tank
temperature, solar collector outlet temperature, and solar
collector inlet/outlet differential temperature (dynamic). Using
these inputs, and the logic matrix, the controller calls for
heating, cooling, or neutral functions.
Heating: When the room temperature falls below 70°F, the
HVAC control system calls for heating. The fuel-cell waste heat,
which is always the most fuel-conservative function, is used
first. If this waste heat is inadequate to maintain the room
above 69°F, it is supplemented by one of the other four heating
functions, depending upon solar conditions and the storage tank
temperature.
If the sunlight is intense (i.e., the glycol-solution exits
the solar collector above 100°F), direct solar heating is used.
If there is no sun, but the storage tank is hot ( + 100°F),
stored heat is used. If the tank is warm (50-100°F), the heat
pump function is used. If the tank is cold ( +50°F) and there
is insufficient sunlight, the auxiliary heater is called for.
Cooling: When the room temperature rises above 78°F, the
HVAC control system calls upon the heat pump for cooling. The
heat pump rejects its heat either to the outside air or to the
thermal storage tank, depending upon the tank temperature.
Neutral: At room temperatures between 70 and 78°F, neither
heating nor cooling is required. But if there is adequate sun-
light, solar energy is stored in the thermal storage tank for
later use. To be adequate, the amount of solar energy collected
must exceed the "pumping energy" consumed in transferring the
solar energy into and out of storage. Engelhard has calculated
that an inlet/outlet differential temperature of 3°F is adequate.
Solar energy is also stored concurrently with certain
heating and cooling functions. This concurrent capability is
particularly valuable during certain periods in the fall and
spring; the solar energy which is stored during the warm days,
when the heat pump is cooling the home, is used to heat the home
during the cool nights. Moreover, since the heat pump rejects
its heat to the thermal storage tanks during the day, this
rejected heat is also available for heating at night.
15
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I tern 1
2
3
4
5
6
7
8
9
10
Roof Support (Total
Tie-Down Hook(Total
6)
6)
2)
1)
2)
4)
Awning (Total
Battery Box (Total
Chucks (Total
Hydraulic (Total
Jacks
Mechanical (Total 4)
Jacks
Hurricane (Total 4)
Tie-Down
Filling (Total 1)
Connection Thermal Tanks
Drain Valve (Total 1)
Thermal Tanks
Location of shipping tie-down straps
EXTERIOR COMPONENT LOCATIONS
FIG. 4
16
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SECTION III
TRANSPORTATION INSTRUCTIONS
For basic trailer information and maintenance refer to
trailer manual.
A. Check List Prior to Transportation (Fig. 4)
1. Remove all roof supports, devices, and awnings
pack properly into compartments provided on the
roof of the trailer.
2. Retract solar panel all the way in and fasten
solar panel cover to bottom frame securely
using the appropriate straps.
3. Install three (3) shipping retainers on front
and three (3) on back of solar panel.
4. Close all ammonia valves tightly and remove
ammonia tanks from trailer.
5. Place the batteries (4 banks) in living room
compartment under front table.
6. Empty H20 tanks by opening appropriate valves
located underneath the trailer.
7. Secure all loose accessories and hardware.
B. Recommendations for Towing
1. Trailer dimensions: ,
Length: 41 ft. 3 inches
Width : 8 ft. 0 inches
Height: 13 ft. 4 inches
2. Trailer Shipping Weight:
Gross Vehicle Weight: 21,500 Ibs.
Hitch Weight: 2,440 Ibs.
17
-------
3. Towing Vehicle:
Minimum weight: 24,000 Ibs.
Ball Diameter : 2-5/16 inches
4. Safety Chain Arrangement:
A heavy safety chain must be used between the
frame of the towing vehicle and the hitch frame on
the trailer.
5. Coupler Safety Lock:
Use the coupler safety lock to prevent accidental
release of the spring loaded latch.
6. Escort Vehicles:
It is recommended to use both a front and a
rear vehicle during transport of the trailer. Both
vehicles should carry flags or lights for warning.
7. Maximum Speed:
The towing speed should never exceed 40 miles
per hour. Adjust the speed to road, wind, and traffic
conditions.
8. Wind Speed:
Do not tow the trailer when the wind velocity
exceeds 20 miles per hour.
9. Tunnels:
Tunnels should be avoided at all cost. Use
detours around the tunnel to avoid being jammed
against the roof of the tunnel.
10. Parking During Transport:
If short term parking is required make sure
to park on a level area, where the trailer is
protected against wind gusts. Place the 2 chucks
provided between the wheels. If overnight parking
is needed use both the 4 hydraulic and the 4
mechanical jacks in addition to the chucks to
secure the trailer.
18
-------
C. Set-Up of Trailer at Location (Fig. 4)
1. Orientation of the trailer should be such that the
solar panel has a due South exposure.
2. Leveling Jacks: The trailer should be leveled using
the 4 hydraulic jacks and the tongue jack.
Shoring lumber and/or timber may be needed to extend
the use of the hydraulic jacks working length.
3. Stabilizing: Use the four mechanical corner jacks
for stabilizing the trailer after the leveling has
been completed.
4. Hurricane Tie-Downs^ Connect the 4 steel cables
between the eye-rings in the solar panel base frame
and 4 solid anchors, secure firmly.
5. Return the batteries to the box on the rear bumper,
and make the connections in proper sequence, as marked
within the box.
NOTE: MAKE CONNECTIONS BOTH FOR 24 VOLTS AND 12 VOLTS SERVICE.
OBSERVE POLARITY AND MAKE SURE THE WIRES ARE FASTENED
SECURELY.
6. Shoreline: 110V, 60 Hz, 1 Ph., 30 amperes. Connect
the ^shoreline to an outside power source, with a
fusible disconnect switch.
The shoreline provides the following power:
1) For start-up 110V A.C. required and 2) all 24V-DC
power normally provided by the fuel cells.
7A. Erection of Solar Panel: (Figs. 1 and 4)
NOTICE: FILL THE 2 TANKS WITH WATER (350 GAL.) BEFORE
ATTEMPTING ANY SOLAR PANEL OPERATION.
THE RECIRCULATING SYSTEM IS ALREADY PRECHARGED WITH
WATER/GLYCOL MIXTURE.
a) The erection operation takes 2 men to perform.
Remove the 3 shipping tie-down straps from
the curbside and the 3 clamps on each end, and
loosen the 2 hand lines.
b) Inspect the top front and back for obstructions.
19
-------
c) Have 1 man take hold of the handlines, to
prevent wind gusts from catching the top
cover. Use only enough force on the line
to keep control of the panel. •
d) Power the erector control panel. Shoreline
rectified or battery power can be used
individually.
e) Pressing and retaining pressure on the "UP"
pushbutton will erect the panel.
WARNING: THE OPERATOR SHOULD BE ALERT FOR ANY UNUSUAL
BEHAVIOUR OR NOISES DURING THE ERECTION. HE MUST
INVESTIGATE AND CORRECT ANY PROBLEMS, OR THE SOLAR
PANEL MAY BE DESTROYED.
f) Press the "UP" button until no further upward
motion is detected. A limit switch is provided
to cut-off motor power once optimum solar panel
position is attained (60° from horizontal).
NOTICE: IF IT IS REQUIRED TO ERECT OR RETRACT THE SOLAR
PANELS DURING SEVERE WIND CONDITIONS, MAN BOTH END CABLES
AS WELL AS THE HANDLINE.
g) Push circuit breaker to the "OFF" position.
h) Go up to Van roof and install the roof support
between the roof frame and the solar panel.
i) Secure tie-down hooks to cover frame and
tighten securely. Large blue arrows show
these locations.
j) Install the triangular awning cover on each
end of the roof.
NOTICE: BY OBERVING THE MAIN DC AMMETER, IT WILL BE FOUND
THAT THE CURRENT DRAWN BY THE ERECTOR MOTOR RUNS AT 11
TO 12 AMPS, EXCEPT FOR A SHORT PERIOD OF UP TO 52 AMPS.
THE 52 AMP LOAD CORRESPONDS TO THE INITIAL PANEL LIFT
OFF FROM THE CAM FOLLOWERS.
7B. Retraction of Solar Panel:
NOTICE: THE SAME PRECAUTIONS FOR ERECTION MUST BE
OBSERVED DURING THE RETRACTION OF THE SOLAR PANEL.
1. Remove triangular awnings for both ends of the roof.
20
-------
2. , Remove the tie-down hooks and the six support rods and
place them in the provided compartment on the roof.
3. Push circuit breaker to the "ON" position.
4. Press "DOWN" button until the solar collector is
in the down position, the motor power will cut off
automatically, as a separate limit switch is provided
for the downward motion.
5. Secure roof cover to bottom frame with tie-down straps.
6. Push circuit breaker to the "OFF" position.
8. Ammonia Supply:
The ammonia supply to the system can be in the form of a
large supply tank or in the form of 150 Ib. cylinders.
WARNING
UNDER NO CIRCUMSTANCES MUST THE CYLINDERS BE STORED WITHIN
THE EPA-VAN.
IN CASE OF A FIRE IT WILL BE IMPOSSIBLE TO SAFELY REMOVE
THE CYLINDERS FROM THE UTILITY ROOM. THE CYLINDERS WILL
DEVELOP DANGEROUSLY HIGH PRESSURES WHEN EXPOSED TO
TEMPERATURES ABOVE 120°F.
The proper orientation of the EPA-Van and the location of
the ammonia door allow for keeping the cylinders in the shade
during daylight hours.
The cylinders must be securely chained to prevent accidental
upsets.
The cylinders can remain upright during operation.
Ammonia Quality:
NOTE: ONLY HIGH PURITY GRADE AMMONIA SHOULD BE USED, I.E.
METALLURGICAL GRADE TO PROVIDE LONG CATALYST LIFE IN THE
AMMONIA CRACKER.
21
-------
CB-\ CQ-1 CQ
-9 ca-sr
CIRCUVT cwnRFi IMF SHORELVNE CONTROL CRACKER
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1
22
-------
to
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-COHME.CTION TOR \HE.RT
OUT&iDt
SKA-18407
Flow System 1
Ammonia Crnrkor
P.OOF
VEHT
ROOP
VINT
-------
SHUT S •• 4
-------
SECTION IV
START-UP INSTRUCTIONS
1. Start-Up Ammonia Cracker (Fig. 6)
A) Close all hand valves shown on Fig. 6. Except HV-8 and HV-9.
These two valves are preset for gas burner control.
B) Hook-up and secure yokes on NHo cylinder. Use a new
rubber washer for each NH3 cylinder. Check for leaks.
C) Electric Preheat: (Fig. 5 and 7)
-1. Provide external power to the shoreline.
-2. Close CB-1 circuit breaker "SHORELINE".
-3. Close CB-9 circuit breaker "CONTROL PANEL".
-4. Close CB-2 circuit breaker "SHORELINE RECTIFIED".
-5. Switch SW-1 "CONTROL PANEL" to "ON" position.
"CONTROL PANEL" light will be lit. P-4 "SOLAR
PANEL ABSOLUTE TEMP", P-6 "SOLAR PANEL TANK
DELTA T", and P-7 "SOLAR PANEL DELTA T,
instruments will be.powered.
-6. Press SW-3 "CRACKER" green pushbutton in.
Indicator lights on P-l "CRACKER TEMP" and
P-2 "CRACKER TEMP PROTECTOR" instruments will
show power "ON".
Initially, "LOW TEMP" (RED) light will light,
and the blower will start. Make sure the
cracker blower control is set at "LOW" position.
-7. Check settings on P-l and P-2.
P-l: (Yellow setpoint) should be set at 810°F.
(Red setpoint) should be set at 1350°F.
P-2: (Red setpoint) should be set at 1700°F.
25
-------
(Yellow setpoint) should be set at 1850QF.
-8. Press SW-10 "START-UP" black pushbutton in.
Press cracker heater breaker "ON" . This will
initiate electric preheat of the cracker.
-9. Switch SW-15 "BURNER CONTROL" to HI/LO position.
D) Preheat: Using Partially Cracked Ammonia:
When the temperature on P-l reads 800°F sufficient H2 can
be generated to start using the Gas Burner in the
generator .
1. Open one NHs cylinder valves using appropriate wrenches,
2. Open HV-2, or HV-5 depending on which cylinder is to be
used.
(Use one NH3 cylinder at any given time, the other
cylinder is used for changeover.)
NOTE: HV-1 IS OPENED FOR OUTSIDE TANK CONNECTION. WHEN
OUTSIDE TANK CONNECTION IS USED, CLOSE HV-2 AND HV-5.
APPROPRIATE CHECK VALVES (CV) WHICH INSURE AGAINST
LIQUID AMMONIA BACKFLOW ARE PROVIDED FORWARD OF HV-1,
HV-2, AND HV-5; HOWEVER CLOSING OF UNUSED INLET VALVES
ARE RECOMMENDED.
3. Open valve HV-7B fully to allow flow to the burner
section of the ammonia cracker.
4. Turn blower speed control to "80%" setting.
5. Press "AMMONIA FLOW" on button and hold depressed until
Pl-4 reads 3 psig.
6. Flow should now be indicated on the F-6 flowmeter at
the "8" mark. If not, adjust HV-8 to obtain this
reading .
7. Switch "BURNER CONTROL" SW-15, Fig. 7 to "LO" position
to check the flow in "LOW FIRING". F-6 should read
about 1/2 to 1 mark on the flowmeter. Return "BURNER
CONTROL" to "HI/LO".
8. The heating of the generator is now done both by the
electrical heater and the gas-fired burner. The
temperature rise will now proceed at a more accelerated
rate.
26
-------
When P-l red setpoint (1350°F) is attained; "PREHEAT
TEMP OK" (green) light should go on. This means that
cracker heating is being accomplished solely by
generated hydrogen and that electrical preheating has
turned off automatically.
The heating will now continue until the P-2 setpoint
of 1700°F is satisfied. At 1700°F the control will
turn the gas flow for the burner to "LOW" as registered
on flowmeter F-6 approximately at "1/2". Once the
temperature on P-2 is 1700°F the generator is ready
to deliver a product gas suitable for use in the fuel
cells, water heater, auxiliary catalytic heater, and
in the kitchen range.
Do not admit the product gas unless the proper procedure
for starting each individual component has been followed,
NOTICE: THE FUEL GAS TO THE FUEL CELLS MUST ALWAYS PASS
THRU THE SCRUBBER TO REMOVE THE RESIDUAL AMMONIA. THE
FUEL GAS TO THE WATER HEATER, THE AUXILIARY CATALYTIC
HEATER, AND THE KITCHEN RANGE, DOES NOT PASS THRU THE
SCRUBBER IN ORDER TO EXTEND THE LIFE OF THE SCRUBBER
MATERIAL.
THE SMALL AMOUNT OF FREE AMMONIA IN THE UNSCRUBBED
PRODUCT GAS WILL COMPLETELY DISSOCIATE IN THE WATER
HEATER, CATALYTIC AUXILIARY HEATER, AND THE KITCHEN
RANGE.
Start-Up Fuel Cells: (Figs. 1,5,8,9)
1. Start preheat when gas firing begins on the cracker -
2. Press the green "HEATER" button on the fuel cell control
panel, located on the rear wall in the utility room.
After about 30 minutes the green light "FUEL ON" will
light.
3. Allow a minimum of 45 minutes of preheat time prior to
admitting product gas to the fuel cells.
4. Press "HEATER OFF" button after 1 hour of preheat time.
CAUTION: Do not operate preheat for more than 1 hour.
Placing the Fuel Cells in Power Operation:
1. a) Remove the fuel cell air-intake cover on
the road side wall.
27
-------
Flow System 2.
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28
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b) Using SLV-1 and SLV-2 direct the waste heat flow
for winter use below HE-2 or above HE-2 for summer
use.
c) Shutdown the use of shoreline by placing "SHORELINE",
CB-1, circuit breaker in "OFF" position.
2. Close MS-2 "FUEL CELL ISOLATION".
3. Shut off all lights and motors in the Van.
4. Close the battery circuit breaker CB-10, located on the
side of the battery charger.
5. Set P-3, "FUEL CELL CONTROL" to 1700°F.
6. Set P-2, "CRACKER CONTROL" to 1500°F.
7. Restart ammonia cracker by pressing:
a) SW-3 cracker "ON".
b) SW-8 ammonia flow "ON".
NOTE: HOLD SW-8 IN UNTIL Pl-4 READ 3 PSIG.
8. Open HV-10 fully and press "FUEL ON" button on the fuel
cell control panel (rear wall).
NOTE: THE FUEL CELLS ARE NOW OPERATING "OPEN CIRCUITED"
WITH A MINIMUM FUEL FLOW GOING THROUGH THE CELLS. MAINTAIN
THIS CONDITION FOR 4 MINUTES TO STABILIZE THE FUEL CELL
TEMPERATURE.
CHECK THE TEMPERATURE ON THE CRACKER CONTROL INSTRUMENT
TO MAKE SURE THAT EXCESS TEMPERATURE CONDITION IS NOT
REACHED.
AT THIS POINT THE EPA-VAN IS POWERED USING THE BATTERIES
ONLY TO SUPPLY BOTH THE 24 VOLTS DC AND THE 115 VOLTS
AC VIA THE INVERTER.
9. Place MS-2 "FUEL CELL ISOLATION" in "OFF" position.
This places the fuel cells in parallel with the
batteries. Observe the main D-C voltmeter,24 volt
should be maintained.
10. Gradually increase the electrical load on the system
as follows:
a) kitchen lights : 93 watts
30
-------
b) Living room lights : 186 watts
c) Room air blower : 186 watts
d) Pump A : 186 watts
e) Pump B : 186 watts
f) Heat pump motor : 186 watts
After each new load is added, observe the main D,C. volt-
meter. The voltmeter reading should not fall below 24 volts, or
the system will shutdown due to low voltage droput of the D-C
relays. As the fuel cells recover, the DC-voltage will stabilize
and the next load can be added.
Once the two fuel cell ammeters indicate outputs of 24 to
28 amps and the main voltmeter maintains a steady 24 volts
reading, the entire trailer system can be placed in automatic
mode operation.
3. Environmental Heating/Cooling (Fig. 2, 10)
A. Set the room thermostat in living room at 68°F for
the heating setpoint.
B. Set the room thermostat for cooling at 78°F,
C. Set tank temperature switch No. 1 for 50°F.
D. Set tank temperature switch No. 2 for 100°F.
NOTE: BOTH TS NO. 1 AND TS NO. 2 ARE LOCATED IN THE LOWER LEFT-
HAND SIDE OF THE PROJECTOR COUNTER CABINET, ONCE THE SETTINGS
ARE CORRECT NO FURTHER ATTENTION WILL BE NEEDED.
E. Close the circuit breakers on the motor control panel:
1) Room air blower CB-7
2) Pumps A & B i CB-8
3) Heat Pump Compressor CB-4
4) Condenser Fan CB-3
F. Adjust the makeup air louver to provide the required
makeup air-
G. Waste heat control is done by using SLV-1 and SLV-2
for the fuel cells. SLV-3 and SLV-4 controls the
31
-------
-------
waste heat flow from the ammonia cracker. The use of
waste heat is depending on summer or winter operation.
In periods where no heating of the Van is required the
waste heat from both the fuel cells and the ammonia
cracker should be vented to the outside without passing
across heat exchanger HE-2.
Auxiliary Catalytic Heater (Fig. 2, 12)
1. Open HV-11. The heater will automatically cut in and
out to satisfy the environmental heating control demand.
4. Water Heater (Note: Flame Type Combustion) (Fig. 13)
A) Fill the water system as described in the trailer manual,
See appendix.
B) The water heater burner system is lighted as per the
instructions attached to the cover plate.
C) The gas supply to the burner system is activated as
follows:
1. Close "WATER HEATER" switch on the main
control panel (SW-6).
2. Open the hand valves HV-12 and HV-13.
3. Check that the pressure on Pl-9 does
indicate 0.5 psig for actual operation.
4. Follow the burner lighting instructions (B).
NOTICE: ONCE THE PILOT HAS BEEN LIGHTED IT REMAINS "ON" AS
LONG AS THE PRODUCT GAS IS AVAILABLE. THE MAIN BURNER WILL
ONLY OPERATE DURING MODES 1, 2, 3, 6, AND 7 WHEN THE THERMOSTAT
CALLS FOR OPERATION.
5. Kitchen Range (Fig. 13)
A) Remove the transport cover plate from the air-grill
on the road side.
B) Install the storm cover using the cover plate from
"A" as the outer cover.
C) The gas supply to the range is opened by:
1. Open HV-12 and HV-14.
2. Close SW-7 "KITCHEN RANGE" on main panel.
33
-------
SKA-18409 Flow System 3
Aux Heater
VtMT
1 Th
Hli-^
3" DUCT
P^OOUCT
75V.
IS V0
FLUE GAS
(CRACKER)
ROOF
V6NT
£
-------
SKA-18410 Flow System 4
Water Heater &
Kitchen Range
CO
en
P\UOT
I
H^"-J
• .* ' •
BURNER,
sv
r
K\TCHEN i
no v
PR-Ci
HV-13
FLOWMETER.
I PRi'5
HV-12.
P^OOOCT -
"75 Vo VAv
IS V. Hx
H-
oq
CO
H
-------
NNECTION TOR IHEB.T
OUTftlOt
-------
3. The pressure gage "Pl-10" should read 0.5 psig.
4. Open "RBV" valve fully. This v.alve is located
on the front side of the kitchen counter just
below the range.
The range plate will start heating up in 10 to
15 seconds.
6.0 System Shutdown Procedure
The normal shutdown sequence of the system is as follows:
1. All motor circuit breakers in motor control panel.
2. Product gas supply to appliances.
3. Fuel cell operation shutdown.
4. Transfer to shoreline operation.,
5. Ammonia cracker shutdown.
6. Charging of batteries.
6.1 Motor Control Panel (Fig. 7)
Place the following circuit breakers in "OFF".
1. Heat pump compressor.
2. Condenser fan.
3. £ump.
4. Living room blower.
6.2 Product Gas Supply (Fig. 5, 11, 12, 13)
Switch and valve shutdown sequence:
Number Number
Appliance Hand Valve Selector Switch
Water Heater HV-12 HV-13 SW-6
Kitchen Range HV-12 HV-13 SW-7
Aux Catalytic Heater HV-11 None
6.3 Fuel Cell Operation Shutdown (F.ig. 5, 1, 8)
a) Open "FUEL CELL ISOLATION" switch. "MS-2".
37
-------
% b) Press "FUEL OFF" button.
c) Close HV-10 manual valve.
NOTICE: THE SYSTEM IS NOW OPERATING ON THE BATTERY BANK ONLY,
THUS THIS CONDITION SHOULD BE OF AS SHORT DURATION AS POSSIBLE
IN ORDER TO AVOID DRAINING THE BATTERY BANK.
6.4 Transfer to Shoreline Operation (Fig. 5, 7, 9)
a) Open battery circuit breaker (located on the
side of the battery charger).
b) Close "SHORELINE" circuit breaker "CB-1".
c) Close "SHORELINE RECTIFIER".
d) Restart "CRACKER BLOWER" by pressing "ON" button.
e) Raise blower speed to maximum,
6.5 Ammonia Cracker Fuel Supply
a) Press "AMMONIA FLOW" off button.
b) Close hand valves HV-1, HV-2, HV-5.
c) Close ammonia cylinder valve.
d) Close hand valve HV-7A, 7B, 7C.
e) Leave "CRACKER AIR BLOWER" running for cooling
of the cracker. When P-l indicates a temperature
of 400°F, it is safe to shut the power off to
the ammonia cracker by pressing SW-2, the
"CRACKER AIR BLOWER" off button.
Return the blower speed setting to "LOW".
6.6 Start Battery Charge (Fig. 9)
a) Close the switch SW-11 located next to the
battery circuit breaker on the side of the
battery charger.
b) Set the timer to the full timing. The
charging rate will register on the ammeter
on front of the battery charger -
38
-------
SECTION V
SAFETY PRECAUTIONS
1. Before the system is made operational, make sure the
hydrogen detectors located in living room, kitchen,
utility room are on. The instrument console is
located on the top shelf in the kitchen above the
mode panel.
2. Make sure the NHg supply is adequate, have extra
supply available and hooked up for easy changeover
and replacement.
3. Ammonia odor is easily detectable by the human
nose and if ammonia leakage is detected, trace and
pinpoint leak by using a sulfur candle, and eliminate
the leak(s).
4. When trailer/home is parked and operational, make sure
that trailer is anchored and fastened down on all
four corners using the guy wires provided.
5. When strong winds above 50 MPH are expected, the solar
panel has to be retracted and the solar panel cover
tied down securely. (See III 7BF 16 4 & 7)
6. Alarm System - An alarm condition exists and an audio
alarm (horn) will sound whenever any of the following
conditions prevail.
a) Hydrogen present in the room air (i.e., at 1%
H2 in air).
1. Red light on the left instrument
means hydrogen in the utility room.
2. Red light on the center instrument
means hydrogen in the kitchen.
3. Red light on the right instrument
means hydrogen in the living room.
Existence of this alarm condition shuts off
39
-------
feed to the cracker. Audio alarm can be silenced by
pressing the alarm SILENCE BUTTON on the instrument
console. (Fig. 9)
However, corrective measures must be taken to eliminate
the hydrogen leak before pressing the reset button.
b) Low Fuel Condition as evidenced by flashing
light by the NH^ supply timer on the mode
panel. When this condition occurs, silence
the horn by pressing the horn silence button
on top of the mode panel,
NOTE: THIS ALARM CONDITION IS PRESET AT 20 PSI ON THE NHo SUPPLY
SYSTEM.
THE SYSTEM WILL SHUTDOWN WHEN THE FUEL PRESSURE DROPS TO
10 PSI. AT 10 PSI, SYSTEM OPERATION IS AUTOMATICALLY TERMINATED.
PROVIDE A NEW CYLINDER BEFORE THIS HAPPENS.
c) Excess temperature or thermocouple break as
evidenced by RED light on control panel.
When this condition exists, NHg supply shuts
down automatically.
If a full upscale indication is consistent on P-l/P-2
an open circuit must be corrected, or a broken thermo-
couple be replaced in the ammonia cracker control system.
40
-------
SECTION VI
TROUBLESHOOTING GUIDE
Ammonia Cracker (Fig. 5, 6, 7)
1) Excess temperature condition - refer to Section IV
No. D-7 (page 26 ).
2) Temperature dropping towards lower setpoint on
Temperature Protector, P-2 dialatrol.
a) Check SW-10, make sure switch position is
on "HI/LO".
b) Check fuel supply gages, PI-2, Pl-1.
Pl-1 should be minimum of 20 psi,
Pl-2 should be set at 13 psig.
c) If alarm condition has just occurred, press
(green) NHo supply pushbutton in to reset
switch. (Fig. 5)
3) Fresh Ammonia Supply - low pressure in system.
a) Refer to Fig. 6, RV-1 or RV-2 (Relief Valves)
may be opened. Valve O-rings may have opened.
Valve O-rings may have to be replaced.
b) Check NH3 supply for closed valves.
4) Alarm Conditions - Refer to Section VI, 1, 2, 3.
Kitchen Range Section
1) Chattering of switch, amber light blinking on and off
check pressure gauge Pl-10 under countertop, set at
.5 psig.
2) Pilot light stays on, no heat being generated - this
indicates that initial combustion condition was
achieved, but time delay relay contact dropped out
before the thermoswitch was satisfied. The 24V
solenoid coil is closed so there is no danger of
41
-------
hydrogen leak but gas is trapped in the line thereby
keeping the pressure switch contact closed and the
pilot light on. This situation may occur when room
temperature in the trailer is allowed to drop to 40°F
during winter. Close the valve RBV Pig. 13, wait 30
seconds and reopen the valve.
42
-------
PERFORMANCE TESTING
DATE:
W.O. 10003 // EFA VAN
WEATHER CONDITION
Sun Rain Wind Temp/Hum.
Time
.
"d
J-J-
TO
CO
f,1
Indicating
KorJe
'
Teniperatures °P
Outside
,
Livinp
Room
Solar
Panel
ABS
AT
Nv/°F
Tanks
AB2
AT
Mv/°:-'
Air Duct Registers
Kitchen
Return
Air
1
Living Room
t.
3
H
NH Cracker
Temp
Inlet
Press
Outlet
Tress
Pumps
A
Pres
Total
Gal
S
Fres
Total
Gal
REMARKS
1
•
CO
-------
OPrRATIHC PftTft
W/0 A0003 EPA VAN MH3 - CRACKER SYSTEM^
DATE.
LOCATION.
TIME
.
AtANVOVUN GRKC.KGR
COHTR01
TEtW
°F
-
NH3 SUPPLY
Pl-l
P=>\G<
PI-2
PS1G,
PI-?«
PSI6,
P-l
V. D.C.
PRODUCT GAS
EURtlER/ SCRlifiaEH
PI -A
PC3\G,
PI-5
P^IC,
P\-&
P<=,VG,
NH?
PPM
FUEL CELLS
PI- 7
PSIG
F-2
V.D.C.
AUX.
HEATER
P\-S
P«s\
F-^
V/CFH
HW
?\-9
P^>\
•
F-4
V/CFN
RANGE
P>-1D
?•:.>
V/CFH
TOTAL
FLOW
PRODUCT
Ss. _
|.WV «J_^
**** -
. -^
CS1
•
KM
•H
P^
-------
SECTION VII
MAINTENANCE INSTRUCTIONS
1. Calibrate Hg Detectors as recommended in the equipment
manual. Calibrate weekly until experience warrants
longer periods. DO NOT EXCEED 6 MONTHS BETWEEN
CALIBRATIONS.
2. Check for free ammonia in the product gas. Use the
two test ports located on the top of the ammonia
scrubber.
The test port originating in the outlet elbow takes
the sample halfway down the scrubber material.
The test port in the outlet tube provides a sample
of the final scrubbed gas.
The halfway sample should be used to guide and judge
the operation time still available before new scrubber
material will be needed. Contact Engelhard Industries
for proper material replacement.
There should be no free ammonia in the gas going to
the fuel cells.
3. Data Logging
Figures 23 and 24.
The use of these data sheets provides an easy way of
understanding the system operation and component location,
The data sheets also provides a ready means of pin-
pointing potential problems.
Any unusual pressure drops will reveal the location
of problem.
4. Refrigeration Service
Have a competent refrigeration serviceman check
periodically the system for proper operational
45
-------
pressures. (Fig. 2)
5. Fuel Cells
The air inlet cover and SLV's No. 1 and No. 2
must always be closed during down time to prevent
moisture from entering the fuel cells when they
are cold.
Remove and clean the air filter regularly.
6. Recommended Test Equipment
1) Volt-Ohm Milliammeter
Simpson Model 260
2) Temperature Measuring Instrument
Thermoelectric "Minimite"
Range: 0-2000°F Type K & Type J
3) Free Ammonia Tester
Bendix/Gastel Model 400
Test Tubes for: 2-30 ppm
50-500 ppm
1-18%
4) Calibration Gas for H2 Detector
0.8% H2 in air.
46
-------
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DIRL^ROL
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DIMENSION
FR»CTION«
SE^m&/CDH-V ROLLED
CON\PONEMT
NH^ CRACKER
HHj CRhCKEK
NHaCRPiCKER./FUtLCCLL'b
SOLKR PNUEL
A \\S/ WNTER.
A T
SOL(\R.PNHEL.
A T
TI^NK. TENvV.
TNNVv TEtAV.
= NVlRr'NW,EHTNL
H E RT m&y/C 0 0 H NG»
• ARE IN INCHES. LIMITS ON:
± DECIMALS t ANCLES ±
Jr^fiTSvT^
,-. . :.';.:-,•::,"...;,„.
FUNCTION po ,Y,TE^
EL - PREWtNT _i^i=i^_=^-j: — =^_
OPERfvTINt TEVNVERN^URE 1
GN^ FLOW 10 FUEL CELL1^ [tXCtSS WtG,OES10 C,XS CjU^UE^T]^5
NOUCE FOR FUEL CELL OPERNT\ON
RESET P-Z TO \500°F
lAnnn *^ci FrT\nv»i
*E>"\KRT SOLFW Ht(\^\\HG^
"0^? ^J,^M WORIV&£ 0
fO! AT CiELO^ "i"?
CONTROLS AUX HMKLXT VC SVl¥,NtK -H
B6.LOVJ 50°F ^O^DE 5] ^
AOOVE 50°F NS ODE. SELECT VOV4
TRANSFERS TO T'b-Z
CONTROLS N\OQE.S Co, a, 9 ,\0,\\
ENVIRONMENTAL COHTROL
COOHN& MODES ?) 10, A '
VA»4
Blv-ii&MU ... — 4Gl>0^>
aS? CONTROHHSTRUNvtUTS g i o-a-i a j
-r,= FUNtTlOMS^SETFOmiS " | j
00
-------
ISOUKTION
SWITCH
., ,_ H(JV A_!__
[ TMR.I
s*&-
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11
VkJMT
U
V1AUT 4 OV 4
-------
AC DC
TERMINALS DESCRIPTION TERMINALS DESCRIPTION FI
1 Mode 1 27 & 28 NH, Flowmeter 0-
2 Mode 2 29 s 30 Kitchen Flowmeter, H2 0-
3 Mode 3 31 4 32 Water Heater Flowmeter H2 0-
4 Mode 4 33 & 34 Fuel Cell Flowmeter H2 0-
5 Mode 5 35 & 36 Catalytic Burner Flowmeter H2 0-
6 Mode 6 37 & 38? fifjT uieo
7 Mode 7 39 i 40j
8 Mode 8 45 & 46 ^j.j {Puel Cell to Battery) 0-
9 Mode 9 47 6 48 ^.j (Fuel Cell output) 0-
10 Mode 10 49 & 50 WM-3 (Input to Inverter) 0-
11 Mode 11 51 s 52 WM-4 (Input to Compressor) 0-
12 Neutral 53 & 54 WM-5 (A.C. Power Usage) 0-
19 ' Vacant 55 & 56 TMR-1 (Tank H2O In Out T) \
20 Alarm Hot 57 & 58 TMR-2 (Solar Panel H2O) J °"
21 Alarm Neutral 59 & 60 TMR-3 (Input Heat Exchanger) X
22 Vacant
23 Hot 110 volts 61 & 62 TMR-4 Auxilliary Catalytic Heater
24 Neutral 110 volts 63 & 64 TMR-5 Output, Heat Exchangers
25 Speaker t 65 & 66 TMR-i" Froon, Compressor
26 Speaker - 67 8, 68 TMR-7 Freon, Condenser
69 (, 70 TMP-R Freon to H,0,Hpat Exchanger
71 & 72 TMR-9 Ft eon to Air, Heat Exchanger,
TERMINALS NOT POWERED
lB*i B "ffg^rSge
,OWRATK/0-b VDC
•60 5I/M
50 "
20 "
100 '
50 "
700 Halts"}
2800 " / /0-250 raV
1400 " 1 '
1400 i->
2500 "/0-5 volt
180°F/0-5 volt
-HE-2
0-125°F/0-5 volts
-HE-1
swut=u - :/i/7< ^¥
t>
H
•
bJD
•H
fe
13,14,15 HO. C, N.C.
Pump A (I12O FlowimtQr)
16,17,IS NO, C, N. C.
Pump n W2n Flovraetor)
41 & 42 Compressor Pressure (inlet)
43 s 44 Compressor Pressure (Outlet)
DESCRIPTION
LIST OF MATERIAL
UNUI88 OTHERWISE SPECIFIED: ALL
DIMENSION! ARE IN INCHES, LIMITS ON:
FRACTIONS ± DECIMALS t ANOLES 1
400Q3
INDUSTRIES
^ DIVISION or CHCCIHARD MINERAL! t CHEMICALS COLORATION
TERMINAL CONNECTIONS
PERFORMANCE TEST FOR
RPAVAN
B- 18296 -
-------
-------
0-60 SL/M
0-50 "
0-20 "
0-100 "
0-50 "
NH, Flowmeter •'
Kitchen Flowmeter,
Water Heater Flowmeter Hj
Catalytic Burner Flowmeter
PGRFORIW^MCE TEST
EPA VAN A0003.
B-18311
-------
-------
METRIC CONVERSION TABLE
Length:
Volume:
Mass:
Pressure:
Velocity:
Flowrate:
Temperature:
To Convert to
Feet Meters
Inches Meters
Miles Kilometers
Gallons Liters
Cubic Ft. Liters
Pounds Kilograms
Pounds/in2 Kilo Pascal
Miles/hr Km/hr
Cubic Ft/hr Liters/Min,
Celsius-°C °C -
Kelvin °K °K =
Fahrenheit °F °F =
Multiply by
0.3048
2.54 x 10-2
1.6093
3.785
28.32
0.45359
6.8948
1.6093
0.472
5/9 (°F-32)
°C + 273.15
9/5 (°C) + 32
Figure 21
54
-------
MELTING POINTS
OF THE PLATINUM GROUP METALS
Degrees F=(*C x 9/5) + 32
De8r«e*C=(°F-32)x5/9
DECREES FAHRENHEIT
_«SOO O
6300
200
6200
300
eioo
TEMPERATURE
CONVERSION
CHART
3560
2826
3216
ENGELHARD INDUSTRIES DIVISION
rORM EM-6412-1
Fig. 22
55
-------
TECHNICAL REPORT DATA
(Please read Instructions on the reverse before completing/
1. REPORT NO.
EPA-600/9-76-020
3. RECIPIENT'S ACCESSION NO.
4. TITLE AND SUBTITLE
EPA VAN OPE RATIONAL MANUAL
5. REPORT DATE
August 1976
6. PERFORMING ORGANIZATION CODE
7. AUTHOR(S)
&iels E. Scholar
8. PERFORMING ORGANIZATION REPORT NO.
9. PERFORMING ORdANIZATION NAME AND ADDRESS
Engelhard Minerals and Chemical Corp.
2655 Route 22
Union, New Jersey 07083
10. PROGRAM ELEMENT NO.
1AB013; ROAP (see 15, below)
11. CONTRACT/GRANT NO.
68-02-1482
12. SPONSORING AGENCY NAME AND ADDRESS
EPA, Office of Research and Development
Industrial Environmental Research Laboratory
Research Triangle Park, NC 27711
13. TYPE OF REPORT AND PERIOD COVERED
Operating manual: 10/74-6/76
14. SPONSORING AGENCY CODE
EPA-ORD
is. SUPPLEMENTARY NOTES Project officer for this report is W. B. Steen, Mail Drop 61,
Ext 2825. Work under six tasks of three ROAPs supports this manual: 21ADE-034;
21P.K7.-009- and 21R.TV-3Q. -35. -36. and -37
16. ABSTRACT
The manual generally describes the EPA Van, and discusses both its energy control
system and Van operation. The manual includes instructions for the Van's transpor-
tation, setup, safety, troubleshooting, and maintenance. The Van is a mobile
research unit, designed for testing in various parts of the United States. Its unique
energy supply system includes fuel cells, a solar energy collector, a heat pump,
and catalytic appliances. An energy control system optimizes the energy consumed
by the integrated system.
KEY WORDS AND DOCUMENT ANALYSIS
DESCRIPTORS
Air Pollution
Energy Conversion
Heat Sources
Laboratories
Mobile Equipment
Energy Storage
Tests
Fuel Cells
Solar Energy
Solar Energy Con-
centrators
Heat Pumps
b.lDENTIFIERS/OPEN ENDED TERMS C. COSATI Field/Group
Air Pollution Control
Stationary Sources
EPA Van
Energy Consumption
Catalytic Appliances
Operating Instructions
13B
10B
14B
15E
IOC
13A
3. DISTRIBUTION STATEMENT
Unlimited
19. SECURITY CLASS (This Report)
Unclassified
21. NO. OF PAGES
56
2O. SECURITY CLASS (This page)
Unclassified
22. PRICE
EPA Form 2220-1 (9-73)
56
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