How Can Safety Design and On-Site Troubleshooting Be Achieved for Stationary Water-Cooled PEM Hydrogen-Fueled Power Generation Systems?

Fault Description

Possible Causes

Quick Fix

 High Anode Pressure Fault

 1. Malfunction of the external hydrogen pressure-reducing valve or failure of pressure stabilization;

 2. The hydrogen inlet solenoid valve does not close properly;
 3. Abnormal backpressure valve adjustment causing pressure buildup upstream;

 4. Hydrogen supply failed to adjust promptly due to sudden changes in load

 1. If the external hydrogen source is equipped with a pressure-regulating valve or pressure-reducing valve, re-calibrate or replace the hydrogen pressure-regulating valve or pressure-reducing valve;

 2. Check the sealing performance of the hydrogen solenoid valve; replace if defective;

 3. Fine-tune the backpressure valve opening to stabilize the pipeline pressure;

 4. Increase or decrease the load smoothly to match the hydrogen supply response

 Low Hydrogen Source Pressure Fault

 1. Insufficient pressure from the upstream hydrogen source;

 2. Leaks in the hydrogen piping or loose fittings;

 3. The pressure-reducing valve is stuck in the open position, causing restricted gas flow;

 4. Abnormal backpressure valve adjustment preventing hydrogen from flowing smoothly into the stack.

 1. Check the output pressure of the hydrogen cylinder or hydrogen supply equipment;

 2. Check for leaks and tighten pipe connections;

 3. Disassemble and clean the pressure-reducing valve spool, or replace the valve body;

 4. Check whether the backpressure valve is functioning properly.

High Hydrogen Concentration Malfunction

 1. Incomplete hydrogen purge and venting;

 2. The hydrogen concentration sensor has drifted and has not been calibrated;

 3. Gas leakage within the fuel cell or seal failure;

 4. Exhaust line blockage causing exhaust gas backflow

 1. Increase the purge frequency and duration;

 2. Recalibrate the hydrogen concentration sensor;

 3. Shut down the system to inspect the stack gaskets and end plate seals;

 4. Clear the hydrogen exhaust line to ensure unobstructed exhaust flow

 Air Compressor Malfunction

 1. Abnormal power supply to the air compressor, communication failure, or protection trip

 2. Air compressor overheating, insufficient coolant, water pump malfunction, or poor heat dissipation.

 3. Insufficient air flow due to a clogged air filter, air leaks in the piping, or abnormal rotational speed.

 1. Check whether the air compressor’s power supply is normal and verify that CAN communication is functioning properly.

 2. Check the operating status of the cooling system and radiator.

 3. Clean the filter element and check the air lines and speed feedback.

 Water pump flow rate is too low

 1. Water-cooling circulation pump failure or insufficient speed;

 2. Coolant lines are clogged or kinked, causing flow restriction;

 3. Significant air bubbles or air locks in the water circuit;

 4. Flow sensor is damaged / the throttle valve in the piping is partially closed

 1. Check the water pump’s power supply and drive; replace the water pump if necessary;

 2. Inspect the piping, clear blockages, and restore the pipe’s full cross-sectional area;

3. Open the bleed valve to force air out, then top off the coolant;

 4. Open the water circuit control valve and calibrate or replace the flow sensor

 Low Total Voltage Fault

 1. Insufficient hydrogen supply or low pressure

 2. Voltage drop due to excessive battery load

 3. Abnormal cell consistency or aging.

 4. High-power startup of the entire unit causes the bus voltage to drop

 1. Check whether the hydrogen supply pressure, pressure-reducing valve, and hydrogen piping are functioning normally and installed correctly.

 2. Reduce the system load and resume operation once the voltage has recovered.

 3. Inspect the battery and check for any abnormalities in its status.

 Low Voltage in Lowest Channel

 1. Insufficient system hydrogen supply

 2. Insufficient air supply

 3. Loose or faulty CVM sampling line

 4. CVM module communication or sampling failure

 5. CVM CAN bus communication line disconnection or abnormal terminating resistor;

 6. Damaged membrane electrode

 1. Check whether the pressure in the hydrogen and air lines is normal.

 2. Troubleshoot the CVM detection circuit.

 3. Check whether the CVM module is receiving power normally.

 4. Power off and restart the CVM module; if the issue persists, replace it;