FCvelocity™-9SSL FUEL
CELL STACK,
PRODUCT SPECIFICATION
25/50/75/90/110 CELL CONFIGURATION
DOCUMENT NUMBER:
SPC5101532
REV 0M
Ballard Power Systems
9000 Glenlyon Parkway
Burnaby, BC V5J 5J8
Canada
Telephone 604.454.0900
Facsimile 604.412.4700
SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 2
FCvelocity™-9SSL Fuel Cell Stack
Product Specification
Ballard Power Systems Inc.
NOTE
There are inherent risks in the operation of the fuel cell stack which could result in bodily injury or loss or damage to
property. It is therefore expected that the customer take all necessary safety precautions in the operation of this
device. Those who install and operate the fuel cell stack must be technically qualified and experienced in the
handling of hydrogen and compressed gases. It is the responsibility of the customer to meet all local safety
requirements and to ensure safety during operation, maintenance and storage of the fuel cell stack. Ballard Power
Systems Inc. (Ballard) has limited its liability for damages incurred by the customer or its personnel in the
contractual documents pursuant to which the fuel cell stack is provided to the customer.
Although all efforts have been made to ensure the accuracy and completeness of the information contained in this
document, Ballard reserves the right to change the information at any time and assumes no liability for its accuracy.
The fuel cell stack may be integrated in a variety of stationary and motive applications, as reflected in the dual
product names. This manual is applicable to both the FCgen-9SSL product for stationary applications and the
FCvelocity™-9SSL product for motive applications. This document does not attempt to address all possible
integration options. The customer is responsible for determining the suitability of the various integration options for
the customer's particular needs, and for ensuring the safe operation, maintenance, and storage of the device and
any systems into which it is integrated. It is the responsibility of the customer to ensure that his or her design is free
from claims of patent infringement. Ballard cannot be responsible for any injury or damage caused by the use of its
products in ways, or as part of systems, not expressly approved by Ballard.
The information contained in this document is the intellectual property of Ballard and is Commercially Confidential.
No part of this document may be reproduced or transmitted in any form or by any means, electronic or mechanical,
for any purpose, without the express written permission of Ballard.
Commercial Confidential – Ballard Power Systems
SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 3
Model number: FCvelocity™-9SSL
Document number: SPC5101532
Revision: 0M
Date: 30 July, 2009
Copyright: © Ballard Power Systems Inc. (2008)
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 4
Change Record
Rev CO Date Created Approved
0A 10056 17 Nov 2005 R. Rempel N. Simon
0B 10127 16 Dec 2005 N. Simon R. Dunkley
0C 10493 Mar 03 2006 N. Simon R. Dunkley
0D 11053 5 June 2006 R. Dunkley N. Simon
0E 11707 2 Oct 2006 M. Turchyn N. Simon
0F 12748 27 March, 2007 S. Jung N. Simon
0G 13658 17 August, 2007 S. Jung J. Sturek
OH 14218 10 Dec 2007 R. Dunkley S. Jung
0J 14599 17 March 2008 W. Cellik S. Jung
0K 15514 12 August, 2008 N. Blackadar N. Simon
0L 16356 9 February 2009 N. Blackadar N. Simon
0M 17469 28 July 2009 D. Hawthorne S. Jung
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 5
Table of Contents
1 General 65
1.1 Applicability of Product Specification ................................................................................. 65
1.2 Related Documents............................................................................................................65
2 Fuel Cell Stack Description 65
2.1 Overview ............................................................................................................................ 65
2.2 Included Components ........................................................................................................76
2.3 Stack Configurations ..........................................................................................................76
2.4 Mass Properties (Fuel Cell Stack Drained, Wet)................................................................ 76
2.5 Circuit Volumes .................................................................................................................. 76
2.6 Geometric Properties .........................................................................................................87
2.7 Electrical Connections and Electrical System Interfaces ................................................... 87
2.7.1 Fuel Cell Stack Cell Pitch ...............................................................................................87
2.7.2 Fuel Cell Stack Isolation Resistance ..............................................................................87
2.8 Mechanical Connections ..................................................................................................109
2.8.1 Fluid Connections.........................................................................................................109
2.8.2 Fuel Cell Stack Mounting .............................................................................................109
2.8.3 Fuel Cell Stack Orientation...........................................................................................109
2.8.4 Fuel Cell Stack Cover.................................................................................................1110
3 Gas and Fluid Compatibility 1110
4 Standard Operation 1211
4.1 Operating Conditions .....................................................................................................1211
4.2 Fuel Cell Stack Performance ......................................................................................... 1312
4.3 Fuel Cell Stack Operating Limits ....................................................................................1413
5 Internal and External Leak Rates (Beginning of Life) 1413
6 Environmental Condition Limits 1514
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 6
1 General
1.1 Applicability of Product Specification
This document describes the specifications for the FCvelocity™-9SSL Fuel Cell Stack that
has been developed by Ballard Power Systems. The configurations covered by this Product
Specification are listed in Section 2.3. Unless noted otherwise, all specification values
stated are applicable at the beginning of operational lifetime. Some characteristics will
change over time as the fuel cell stack is operated.
1.2 Related Documents
Additional documents that complement this Product Specification are:
• MAN5100183 Product Manual and Integration Guide
• SAE Hydrogen Purity Specification: TIRJ2719
2 Fuel Cell Stack Description
2.1 Overview
The principal functionality of FCvelocity™-9SSL fuel cell stack is to provide stable electrical
power to a system over a wide range of operating and environmental conditions.
Additionally, it is intended that the fuel cell stack exhibit the following attributes over these
same ranges of conditions:
• Safe operation
• Robust operation (tolerance to input variation)
• Operation in specified environmental conditions
• Fast dynamic response (stability under fast transient loading)
• Reliable and durable
For areas of operation not mentioned in this document, it is recommended that the
customer discuss with Ballard the safest way to run the fuel cell stack to avoid causing
damage and to obtain the best performance and reliability.
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 7
2.2 Included Components
Major components of the FCvelocity™-9SSL Fuel Cell Stack are listed below:
• Fuel cell stack consisting of plates and MEAs (Membrane Electrode Assembly)
• Compression hardware
• Optional Components
• High voltage power connectors
• Fluid connector kit
• Mounting bracket kit
• CVM pick ups
2.3 Stack Configurations
Ballard Part Number Number of Cells
5109072, 5112371, 5114021 25
5109827, 5112438, 5114035 50
5109828, 5112448, 5114036 75
5110788, 5112451, 5114037 90
5109829, 5112456, 5114038 110
2.4 Mass Properties (Fuel Cell Stack Drained, Wet)
No. of Cells Mass (kg)
25 7.2
50 10
75 13
90 15
110 17
2.5 Circuit Volumes
No. of cells Coolant (l) Fuel (l) Air (l)
25 0.21 0.11 0.19
50 0.41 0.20 0.36
75 0.61 0.30 0.54
90 0.73 0.36 0.64
110 0.89 0.44 0.78
Note: fluid volumes are measured from the manifold interface.
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 8
2.6 Geometric Properties
Stack length can vary from the nominal given below, and tolerances increase as the
number of cells increase. Refer to the Interface Control Drawing for detailed
information.
Dimension (not including Unit 25 Cell 50 Cell 75 Cell 90 Cell 110 Cell
CVM mounting brackets)
Stack Length (Approx.) mm 106.5 166.8 227.1 263.3 311.5
Stack Width mm 760 760 760 760 760
Stack Height mm 60 60 60 60 60
2.7 Electrical Connections and Electrical System Interfaces
2.7.1 Fuel Cell Stack Cell Pitch
Plate to Plate 2.412 +/- .045 mm
2.7.2 Fuel Cell Stack Isolation Resistance
Fuel Cell Stack (filled with coolant IEC 62282-2 Fuel Cell Modules
but not operating)
Typical leakage paths from the fuel cell stack include the following:
• Leaks from the surface of the stack
• Leaks through the stack coolant system
• Leaks via the customer’s bus
The required amount of isolation for electrical safety will be specified by the applicable
design standard. Note that the specification for coolant conductivity given in Section 3 is
the maximum coolant conductivity at which the stack can be operated without damage
from internal corrosion. However, it is the integrator’s responsibility to calculate the
coolant conductivity required to comply with the applicable standards for voltage
isolation. These calculations may dictate a choice of coolant with lower conductivity
than stated in Section 3.
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 9
Ballard recommends a minimum shutdown threshold for isolation resistance between
the fuel cell stack (high voltage) and system ground of 1200 ohms per cell. The
minimum isolation resistance is calculated by:
Rmin = 1200 ς x Ncells (ς)
Note that the isolation resistance of the customer supplied Cell Voltage Monitoring
(CVM) system must be adequate to prevent grounding the fuel cell stack voltage.
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 10
2.8 Mechanical Connections
2.8.1 Fluid Connections
Ports are labelled on the stack end plate as “Fuel” for Fuel, “Ox” for the oxidant and “C”
for the Coolant. Refer to the Interface Control Drawing for port location and fluid fitting
details. The fuel cell stack can be operated in co-flow (all fluids in flowing in one
direction) or counter flow (fuel flowing in opposite direction to air and coolant). Coflow
is the preferred method of operation. The optimized operating conditions are dependent
on whether a counter or co-flow configuration is used.
2.8.2 Fuel Cell Stack Mounting
The FCvelocity™-9SSL fuel cell stack has 4 optional mounting brackets, two 1-hole
brackets on the anode side and two single hole brackets on the cathode side. Refer to
the Interface Control Drawings for mounting point location dimensions. In order to meet
the shock and vibration requirements stated in Section 6, the stack must be secured
using four M6 fasteners to a suitably rigid frame.
The maximum allowable vertical misalignment of any one mounting point relative to any
other is ±2 mm (static, as installed). The maximum allowable vertical movement of any
one mounting point relative to any other during operation is ±1 mm (dynamic). These
limits prevent damage to the fuel cell stack resulting from excessive twist.
Note - The fluid connectors and stack cover should NOT be used for mounting.
2.8.3 Fuel Cell Stack Orientation
The fuel cell stack orientations as shown below.
Logo Side Up Logo Side on side
Inlet
Outlet
Coflow or Counterflow Coflow Counterflow
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 11
2.8.4 Fuel Cell Stack Cover
The optional fuel cell stack cover is NOT a structural member and should not be used
for mounting. The cover does not provide immersion protection or any means of
containment in the event that hydrogen or coolant leak from the fuel cell stack.
3 Gas and Fluid Compatibility
Oxidant (Ambient Air)
Composition (pre- > 20.9% oxygen
humidification) < 50 ppm hydrocarbons (mole basis)
< 35 ppm carbon monoxide (mole basis)
< 1% carbon dioxide
< 1 ppm ozone
< 0.3 ppm sulfur compounds (mole basis)
< 1 ppm hydrogen sulfide (mole basis)
< 0.5% liquid water @ < 5 µS/cm
< 0.01% inorganics (including salt)
< 25 µm particulate size
Fuel
Composition (pre-
> 95% H2
humidification) H2 purity as per SAE specification: TIRJ2719
Exceptions to specification:
CO2 < 1 ppm
CO < 1 ppm
S < 10 ppb
Coolant
Composition 50 to 0% pure ethylene glycol (reagent grade)
50 to 100% de-ionized water
< 100 µm particulate size
Conductivity < 50 µS/cm
This limits the cell-to-cell current leakage. The
integrator may have isolation requirements that lead
to a choice of coolant with lower conductivity. Also
see Section 2.7.2, “Fuel Cell Stack Isolation
Resistance”
Humidification Water
Composition 99.99% de-ionized water
< 100 µm particulates
Conductivity < 5 µS/cm
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 12
4 Standard Operation
4.1 Operating Conditions
The recommended operating conditions (at the fuel cell stack interface) are given below.
Current (A)
Reactant Parameter
15 30 60 120 240 300
Fuel (Pure Hydrogen)
Inlet Stoichiometry Min. ~6.3* ~3.4* ~2.2* ~1.6* 1.6 1.6
Nominal Inlet Pressure kPa (abs) 115 116 131 157 200 220
Pressure Drop kPa 10.0* 10.0* 10.0* 10.0* 14.2 17.5
Nominal Inlet Temperature °C 61 61 61 61 61 60
Relative Humidity** % 95 ± 5 95 ± 5 95 ± 5 95 ± 5 95 ± 5 95 ± 5
Oxidant (Ambient Air)
Inlet Stoichiometry Min. ~5.1 * ~2.4* 1.8 1.8 1.8 1.8
Nominal Inlet Pressure kPa (abs) 108 110 117 135 180 200
Pressure Drop kPa 10.0* 10.0* 15.5 27.0 39.0 45.0
Nominal Inlet Temperature °C 61 61 61 61 61 60
Relative Humidity** % 95 ± 5 95 ± 5 95 ± 5 95 ± 5 95 ± 5 95 ± 5
Coolant
Nominal Inlet Pressure kPa (abs) ≤ Oxidant Inlet Pressure
Inlet Temperature Max. °C 61 61 61 61 61 60
Outlet Temperature Max. °C 62 64 67 68 69 70
Cross Pressure between Fluid Streams
Minimum Fuel over Oxidant kPa 7 8 10 13 20 20
Maximum Fuel over Oxidant
Coflow KPa 50 50 50 50 50 50
Counterflow kPa 65 65 65 65 65 65
Minimum Reactant over Coolant kPa 7 7 7 7 7 7
Maximum Coolant over Reactant
kPa 100 100 100 100 100 100
Transient.***
Notes :
* Operation at currents of 120A or less are dominated by minimum pressure drop requirements. Reactant flows are
determined by minimum pressure drop of 10.0 kPa on Fuel and Oxidant circuits.
** Anode inlet relative humidity is relative to:
• Coflow – coolant inlet temperature
• Counterflow – coolant outlet temperature
*** During normal steady state operation, reactant pressure should be above coolant pressure. For short transients and
during startup, coolant pressure can exceed reactant pressure.
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 13
4.2 Fuel Cell Stack Performance
Current (A)
Performance Parameter
0 15 30 60 120 240 300
25 Cell Stack Minimum 0.0 0.3 0.6 1.1 2.0 3.7 4.4
kW
Gross Power – BOL
50 Cell Stack Minimum kW 0.0 0.6 1.1 2.2 4.1 7.5 8.8
Gross Power – BOL
75 Cell Stack Minimum kW 0.0 0.9 1.7 3.3 6.2 11.2 13.2
Gross Power – BOL
90 Cell Stack Minimum kW 0.0
Gross Power – BOL 1.1 2.1 4.00 7.5 13.5 15.9
110 Cell Stack Minimum kW 0.0 1.3 2.5 4.9 9.2 16.5 19.4
Gross Power – BOL
Average Cell Voltage - BOL 0.952 0.811 0.769 0.740 0.693 0.627 0.588
V
Minimum
Individual Cell Voltage
Differential below Average 0.025 0.025 0.025 0.025 0.025 0.025 0.080
V
Cell Voltage - BOL
maximum
Individual Cell Voltage
µV/hr Determined by Operating Conditions and Load Profile
Decay
Lifetime hours Determined by Operating Conditions and Load Profile
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 14
4.3 Fuel Cell Stack Operating Limits
Parameter Limit
Pressure
Maximum Allowable Working Pressure 420 kPa (abs)
Minimum allowable steady state reactant cross 7 kPa to 20 kPa
pressure (fuel over oxidant) depending on load
Maximum allowable reactant cross pressure (steady 50 kPa Coflow
state) 65 kPa Counterflow
Maximum allowable cross pressure – anode to
100 kPa
coolant (steady state)
Temperature Maximum Allowable Coolant Outlet Temperature
80°C
(excursion for short periods only)
Maximum Allowable Coolant Temperature Differential
10°C
(steady state)
Maximum allowable reactant inlet temperature
80°C
(steady state)
Voltage and Minimum recommended operating cell voltage
Current 0.2 V
(steady state)
Maximum recommended cell voltage (with load
0.85 V
applied)
Maximum EOL individual cell variability from the
80 mV
average cell voltage
5 Internal and External Leak Rates (Beginning of Life)
Fuel to External < 1 cc/min air per cell @ 2 barg
Air to External < 1 cc/min air per cell @ 2 barg
Coolant to External < 2.66 cc/min air (total) @ 2 barg
Air to Fuel Internal < 0.5 cc/min air per cell @ 0.5 bar
Fuel to Air Internal < 0.5 cc/min air per cell @ 0.5 bar
Air to Coolant Internal < 0.2 cc/min air (total) @ 0.5 bar
Fuel to Coolant Internal < 0.2 cc/min air (total) @ 0.5 bar
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SPC5101532 Rev 0M FCvelocity™-9SSL - Fuel Cell Stack Product Specification 15
6 Environmental Condition Limits
Storage temperature 1 +2 °C to +40 °C
Start Up temperature > 2 °C
Fluid Inlet temperature (operating) +2 °C to +65 °C
External stack temperature (operating) 2 -25 °C to +75 °C
Pressure Atmospheric
Vibration 5g, meets USABC 3.
Shock 5g, meets sections of IEC
600068-2-27 Ea and IEC
600068-2-29 Eb 4.
1. Core Temperature is defined as the temperature inside the fuel cell stack, usually taken as the coolant
inlet temperature. The core temperature must remain at +2°C or above at all times, whether the fuel cell
stack is operating or non-operating.
2. External Temperature is defined as the temperature measured at any point on the surface of the fuel cell
stack cover.
3. USABC – US Advanced Battery Consortium, Electrochemical Storage System Abuse Test Procedure
Manual, USABC/SNL CRADA No. SC961447
([Link]
4. IEC – International Electrochemical Commission
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