The new differential analog input module expands the u-remote remote I/O system with a solution for individual cell and group monitoring. Weidmüller has succeeded in fitting 15 differential analog inputs into the module within a width of just 11.5 mm, with an insulation resistance of up to 1500 VDC. The integrated switchable bridge simplifies the cascading of multiple modules without duplicate terminal assignments – thus creating the basis for efficient processes, early fault detection, and predictive maintenance.
Reliable monitoring of fuel cells and electrolyzers
The new u-remote module demonstrates its advantages particularly in the hydrogen industry. To fully exploit the potential of hydrogen production and its reconversion to electricity, operators need one thing above all: transparent and stable operating conditions for their systems. Continuous monitoring of individual cell voltages in electrolysis stacks and fuel cells is a crucial component in achieving this.
Electrolysis stacks and fuel cells consist of many individual cells connected in series. If just one of them experiences a decline in performance—for example, due to degradation or local overload—this affects the entire stack. Abnormal cell voltages are therefore considered a reliable early indicator of impending cell reversal, uneven aging, local hotspots, membrane or contact problems, as well as operating conditions with increased wear or efficiency loss.
The new u-remote module measures differentially between two channels at a time, thus precisely capturing the voltage of individual cells or cell groups. It does this by measuring the voltage difference between two consecutive channels, which are connected, for example, to the poles of a cell in a stack. Each module, with its 16 connections, can monitor up to 15 individual cell voltages. Thanks to enhanced insulation of up to 1500 VDC, even large stacks can be monitored without additional protective measures. In electrolysis stacks, the cell voltage is typically 1.7 V to 2.2 V per cell (in PEM electrolysis). Ideally, a single u-remote station can monitor up to 880 cells. This is made possible by the support of up to 64 active I/O modules per fieldbus coupler, reducing complexity and costs.
This allows operators to identify critical trends early and react accordingly via their control systems – even to the point of automated load reduction or an orderly shutdown of the affected stack.
Increase system reliability with measurement data
Continuous cell voltage monitoring helps operators detect unusual cell conditions early and makes maintenance more predictable and economical. Condition-based maintenance becomes possible instead of fixed maintenance intervals. The data collected by the u-remote module forms the basis for integrating a hydrogen plant into the Industrial IoT. This opens up opportunities for predictive maintenance, remote maintenance, and condition monitoring for operators. In the long term, this helps avoid unplanned downtime, extends the lifespan of the fuel stacks, and reduces efficiency losses.
Direct integration into Weidmüller’s u-mation hardware and software solution facilitates cloud and edge integration of the hydrogen plant. Measurement data from cell voltage monitoring can be visualized and analyzed in real time and used for predictive maintenance strategies. u-mation’s open architecture also enables seamless connectivity to various IoT platforms and industrial communication protocols. This promotes efficient process control, simplifies integration into existing automation environments, and lays the foundation for the digital transformation of hydrogen production.
Easy configuration
The u-remote remote I/O system offers exceptional flexibility thanks to its modular design. Electronic modules can be replaced or expanded without removing the entire station – ideal for retrofitting or expanding functionality. An integrated web server enables convenient parameterization, diagnostics, and the loading/saving of configurations. The cell voltage input can be configured according to the user’s specific needs. This flexibility allows for the monitoring of individual cells or defined cell groups. Many voltage ranges are possible, such as the low-voltage range of 0–3 V or 0–30 V. Alternatively, very large differences of -100–100 V can also be covered. Fieldbus couplers and gateways for common fieldbus and Industrial Ethernet protocols allow for use in heterogeneous systems. These include, for example, PROFINET, EtherCAT, Modbus TCP, and EtherNet/IP.
“` A u-remote I/O station can be expanded modularly and accommodate up to 64 different modules. This allows even complex measurement and control tasks to be implemented flexibly and individually – a crucial advantage, especially with growing or changing requirements in the field of hydrogen technology. This enables users to tailor the station precisely to their specific needs without compromising scalability or adaptability.
Furthermore, the system meets high safety and quality standards: The u-remote solution has all the necessary certifications, including CE, ATEX, IECEx, UL, and DNV. This makes u-remote flexible to use: in global markets, but also in environments with specific requirements, such as ATEX Zone 2. This significantly expands the technology’s application possibilities and provides additional investment security.
Designed for a growing hydrogen industry
Since standards, requirements, and operating strategies for the hydrogen industry are still evolving, operators particularly benefit from modular systems. The u-remote I/O system can be adapted to changing requirements – for example, through new electronic modules or additional diagnostic functions – thus supporting the rapid industrial ramp-up of the hydrogen economy.
With solutions like the u-remote remote I/O system, Weidmüller expands its existing stack monitoring capabilities to include a fuel cell monitoring solution. This provides comprehensive data acquisition solutions – from hydrogen production and power generation to energy storage in batteries. With its extensive solutions, Weidmüller supports operators and manufacturers of hydrogen plants throughout their entire lifecycle – from planning and commissioning to operation.