Patricia Loyselle

Glenn Research Center, Cleveland, Ohio

Kevin Prokopius

Analex Corporation, Cleveland, Ohio 

Characterization Testing of the Teledyne 

Passive Breadboard Fuel Cell Powerplant

NASA/TM—2011-216783

July 2011
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Patricia Loyselle

Glenn Research Center, Cleveland, Ohio

Kevin Prokopius

Analex Corporation, Cleveland, Ohio 

Characterization Testing of the Teledyne 

Passive Breadboard Fuel Cell Powerplant

NASA/TM—2011-216783

July 2011

National Aeronautics and

Space Administration

Glenn Research Center

Cleveland, Ohio 44135
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Level of Review: This material has been technically reviewed by technical management. 
NASA/TM—2011-216783 1

Characterization Testing of the Teledyne 

Passive Breadboard Fuel Cell Powerplant

Patricia Loyselle

National Aeronautics and Space Administration

Glenn Research Center

Cleveland, Ohio 44135

Kevin Prokopius

Analex Corporation

Cleveland, Ohio 44142

Summary

NASA’s Exploration Technology Development Program (ETDP) is tasked with the development of 

enabling and enhancing technologies for NASA’s exploration missions. As part of that initiative, the 

return to the Moon requires a reliable, efficient, and lightweight fuel cell powerplant system to provide 

power to the Altair Lunar Lander and for lunar surface systems. Fuel cell powerplants are made up of two 

basic parts; the fuel cell itself and the supporting ancillary subsystem. This subsystem is designed to 

deliver reactants to the fuel cell and remove product water and waste heat from the fuel cell. Typically, 

fuel cell powerplant ancillary subsystems rely upon pumps and active water separation techniques to 

accomplish these tasks for closed hydrogen/oxygen systems. In a typical system, these components are 

the largest contributors to the overall parasitic power load of the fuel cell powerplant.A potential step 

towards the development of an efficient lightweight power system is to maximize the use of “passive” or 

low-power ancillary components as a replacement to these high-power load components. 

Introduction

The Teledyne proton exchange membrane (PEM) fuel cell breadboard powerplant was designed to 

address alternatives to two subsystems within the powerplant: the gas and water separator and the reactant 

gas recirculation pumps. Both the recirculation pumps and the active water separation methods are the 

major contributors to the parasitic power load of a fuel cell powerplant (Ref. 1, internal report). As such, 

the development of alternative, low-power ancillary components for these tasks were chosen. The 

powerplant consists of a water-cooled, hydrogen/oxygen PEM fuel cell stack along with supporting 

ancillaries (Fig. 1) and a separate control and data acquisition system. Facility power is used to initially 

start the powerplant, that is, the opening of reactant valves and initiation of the coolant and heating loop. 

After the powerplant is operational, the ancillary components, except for the data acquisition and control, 

are powered by the powerplant itself. 

The breadboard powerplant uses a unique water separation mechanism to separate the product water 

from the oxygen reactant stream. In the past, for variable gravity water separation, a centrifugal method of 

separating the water from the reactant gas stream had been used. The method integrated within the 

breadboard powerplant has no moving parts but rather relies upon the separation of water from gas via a 

porous membrane. This membrane allows the passage of water but not the reactant gas. Within the 

breadboard, this passive water separator was used on the oxygen reactant stream. A backup, gravitydependent water separator was placed in series with the passive unit to collect any water not separated 

from the oxygen gas stream. This was done to prevent damage to the fuel cell stack in the instance that 

the passive system did not work sufficiently. A gravity-dependent water separator was used to separate 

any small quantities of water carried by the hydrogen reactant stream.
NASA/TM—2011-216783 2

The breadboard powerplant uses a low-power alternative to the stand recirculation pumps used in the 

past. The role of the active gas reactant recirculation pumps normally used for reactant recirculation, has 

been replaced by a combination of a fuel injector/ejector on the hydrogen side and a solenoid/ejector on 

the oxygen side (Ref. 2, internal report). The gas recirculation rate is a function of the pulse rate of the 

fuel injector/ejector or solenoid valve/ejector. The parasitic power required to operate the injector/ejector 

or solenoid valve/ejector is on the order of approximately 10 W as opposed to the 100 to 200 W used by 

gas recirculation pumps.

The fuel cell stack comprised 32 individual cells in a series configuration. The fuel cell stack was 

designed to provide 1.5 kW (nominal) and up to 1.8 kW peak. The passive water separator is located 

downstream of the fuel cell (Ref. 2, internal report).While the fuel cell product water is removed from the 

stack using a passive gravity independent water separator, a backup gravity-dependent water separator on 

the oxygen side is also installed (Ref. 2, internal report). On the hydrogen side, any water is removed from 

the gas stream via a gravity-dependent water separator. Waste heat is removed from the stack via an 

internal liquid cooling loop. The powerplant cooling system in turn rejects the heat to a facility cooling 

system external to the powerplant.

Test Summaries

The stability, performance, life, and response time of the Teledyne breadboard powerplant were 

evaluated using a series of tests. These performance tests were conducted to assess performance and 

stability over conditions anticipated to be encountered during operation under mission scenarios. A brief 

description of each test type follows below. Detailed information regarding operating parameters of each 

test is included in Appendix C.
NASA/TM—2011-216783 3

Calibration Series Test

The calibration series test was a reference test for the breadboard powerplant. The series comprised a 

polarization test and an abbreviated version of the performance load profile test. This test was performed 

at specified intervals during the evaluation of the breadboard powerplant at NASA Glenn Research 

Center. The calibration series test was used to quantify performance changes of the breadboard model as a 

function of damage resulting from shipment, testing, or age. Voltage transitions were recorded at a rate of 

200 kHz during the various transitions in current. 

Performance Load Profile Test

The performance load profile test was a benchmark test for the breadboard model powerplant. This 

load profile was developed to approximate a typical power load on the Space Shuttle orbiter. Voltage 

transitions were recorded at a rate of 200 kHz during some of the transitions in current.

Transient Load Profile Test

The utilization of passive components could negatively impact the ability of the powerplant system to 

follow rapid changes in power load demand. The transient load profile test was used to assess the 

performance and response of the passive ancillary components to multiple, rapid changes in power 

demand. 

Water Separator Evaluation

The gravity-independent, passive water separator was evaluated by applying a constant power load to 

the powerplant for 20 hr. During that time, the water collected by the oxygen gravity-independent, passive 

water separator, the oxygen gravity-dependent backup water separator and the hydrogen gravitydependent water separator was collected and measured. Several power levels were applied to the 

breadboard powerplant to evaluate the water separator.

Test Results and Discussion

Calibration Series Tests

During the course of the evaluation testing of the Teledyne breadboard powerplant, a power profile

calibration series was applied at regular intervals to the powerplant (Figs. 2 and 3). The aim of this test 

was to not only monitor current performance of the powerplant but also capture changes in the 

performance over time as a result of age, extended testing or any environmental effects. 

Figure 3 shows, even as the power load level drawn from the fuel cell changes from 0 to 1800 W, the 

ancillary component parasitic power remains relatively constant, varying between 130 and 150 W. Within 

the powerplant, only the injector/ejector recirculation system varies with fuel cell power. The parasitic 

power required by this combination is constant with only the duty cycle (how many on/off pulses per 

minute) varying as the rate at which the fuel injector/solenoid pulse changes.

In Figure 4, the results of the calibration testing carried out during the test regime are presented. 

There is some minor variation within the stack voltages. The variation observed can be a result of several 

factors, including coolant temperature, reactant temperature, and internal hydration content of the 

membranes. The stack voltage variation observed is minor and within reason given the day-to-day 

variation of environmental conditions.
NASA/TM—2011-216783 4

Figure 5 shows the first and last calibration series collected, approximately 3 months apart, are not 

significantly different. However, there are some minor variations in the stack voltage. In this instance, 

the performance of the last calibration series collected was actually slightly better than the initial 

performance observed. A number of factors could be responsible for the slight performance change. 

These include temperatures of the reactants or the fuel cell and the relative hydration level of the 

membranes within the fuel cell.
NASA/TM—2011-216783 5

In Figure 6, there is a similar performance variation seen between separate calibration series run on 

the same day. Minor variations in coolant temperature and variable internal water content of the 

membranes is likely responsible for the slight voltage variation observed.
NASA/TM—2011-216783 6

Performance Load Profile Test 

Performance load profiles are measures of the performance and stability of the fuel cell powerplant 

over an 8-hr period. Performance load profile results from approximately 1 month apart can be seen in 

Figure 7. During this month, the breadboard powerplant had been operated for 322 hr. (The powerplant 

was operated for a total of 850 hr while at the Glenn Research Center.) Only minor variations in the stack 

voltage and power are present. As was seen for the calibration series results, small changes in temperature 

can result in these minor performance changes. 

Transient Load Profile Test 

The transient load profile was intended to evaluate the performance of the breadboard powerplant to 

rapid changes in power demand. The change from active recirculation pumps that quickly recirculate 

unused reactants to injector/ejector or solenoid valve/ejector may limit the response of the powerplant to 

rapid load changes. The power profile combines several instances of longer times at different power 

levels to several rapid changes in power load over the course of a few minutes. The applied current load 

and resulting powerplant power output can be seen in Figure 8. The parasitic power remains essentially 

constant regardless of the power output of the breadboard powerplant. This reflects the largely passive 

design of this powerplant.

Figure 9 displays an expanded view of the profile. This portion includes several rapid power 

transitions. The fuel cell powerplant is able to follow the current demands applied to it. After each 

transition, the power level delivered rapidly follows the current draw and remains constant and stable 

until the next load step. However, it should be noted that all load steps were within the design power 

delivery range of the powerplant. If the load steps were above or below the design range, the performance 

stability would likely degrade. Beyond this range, the reactant delivery and recirculation may not be 

adequate to meet the power demand or provide enough circulation to move the water from within the 

stack to the water separator. 
NASA/TM—2011-216783 7
NASA/TM—2011-216783 8

Transient load profile tests were carried out at various times during the overall test regime. The 

results of these tests can be seen in Figure 10. There is some variation in stack voltage between the 

various test runs. As previously discussed, this variation can be caused by a number of factors, including 

the temperature of the fuel cell from run to run. In Figure 11, the coolant inlet temperature for the various 

transient load profile runs is plotted. The coolant inlet temperature also varies from run to run with the 

higher temperature runs corresponding to the slightly higher stack voltages. 
NASA/TM—2011-216783 9

Water Separator Evaluation Test

The Teledyne breadboard powerplant uses a unique water separation mechanism to separate the 

product water from the oxygen-reactant stream. In the past, for variable gravity water separation, a 

centrifugal method of separating the water from the reactant gas stream has been used. The method 

integrated within the breadboard powerplant has no moving parts but rather relies upon the separation of 

water from gas via a porous membrane. This membrane allows the passage of water but not the reactant 

gas. Within the breadboard, this passive water separator was used on the oxygen reactant stream. A 

backup gravity-dependent water separator was placed in series with the passive unit to collect any water 

not separated from the oxygen gas stream. This was to prevent damage to the fuel cell stack in the 

instance that the passive system did not work sufficiently. A gravity-dependent water separator was used 

to separate any small quantities of water carried by the hydrogen reactant stream.

To evaluate the performance of the passive water separator, the powerplant was run at several power 

levels (Fig. 12) for a set period of time of 20 hr. During that time, product water was collected from the 

passive water separator on the oxygen reactant loop and the gravity dependent water separators on the 

hydrogen and oxygen reactant loop. At the end of each time period, the water collected in each water 

separator was measured. The results of the water separator test can be seen in Figure 13.

Figure 13 shows the quantity of water collected by the gravity-independent passive water separator 

follows a linear relationship with increasing current. Small quanities of water were also collected within 

the gravity-dependent separators on both the hydrogen and oxygen lines. The quantity of water collected 

in those separators was less than 1 percent of the water collected by the gravity-independent separator. It 

is likely that the water collected by the backup gravity-dependent separator is due to condensation as the 

temperature of the gas stream is reduced. The gravity-independent separator removed the water produced 

by the fuel cell over the entire range of power levels applied to the breadboard fuel cell powerplant.
NASA/TM—2011-216783 10

Mission Profile Test

A 240-hr mission profile test profile was applied to the Teledyne breadboard powerplant. This test 

serves the purpose of an abbreviated life test of the powerplant. The profile is an approximation of the 

typical power load experienced by the Shuttle orbiter fuel cell powerplant. Figure 14 shows the test is 

primarily composed of a long-duration steady-state power load, with load variations in the beginning and 

end of the profile. Over extended periods of time, the stack voltage degrades slightly. This had been 

observed before in other powerplants evaluated (Ref. 3). It is likely this is due to a buildup of impurities 
NASA/TM—2011-216783 11

and/or excess water vapor within the powerplant. Unfortunately, the powerplant shut down 72 hr short of 

the planned 240-hr test. The powerplant was shut down automatically by the powerplant controller as a 

result of a pressure differential between the oxygen and hydrogen inlet lines exceeding 8 psi. This 

pressure differential was caused as a result of intermittent burping of the reactant systems to vent 

accumulated impurities combined with the timing of the recirculation system pulses. 

Conclusion

The Teledyne passive breadboard fuel cell powerplant has been evaluated with regard to its 

performance and stability. Repeated tests over time were conducted and evaluated. Minor variation in 

performance between test runs was noted, however, these variations could be attributed to temperature 

changes within the fuel cell, not degradation or instability. In general, the powerplant exhibited consistent 

and reproducible performance over time. The passive, gravity-independent water separator was evaluated 

during extended operation over a variety of power loads. Over the entire range of power levels applied, 

the passive water separator effectively separated the product water from the oxygen stream exiting the 

fuel cell maintaining stable performance over the entire 20-hr test period at each power level.

References

1. Teledyne Energy Systems, Inc.: PEM Fuel Cell Engineering Model Critical Design Review (CDR). 

December 7, 8, and 9, 2004 (internal report). 

2. TESI 1.5kW Option 5 Breadboard H2/O2 PEM Fuel Cell System User Manual & System 

Documentation Rev 04, December 2007 NASA contract no. NAS3-02093 (internal report).

3. Loyselle, P.L.; and Prokopius, K.P.: Proton Exchange Membrane Fuel Cell Engineering Model 

Powerplant. Test Report: Benchmark Tests in Three Spatial Orientations. NASA/TM—2011-216224, 

2011. 
NASA/TM—2011-216783 12

Appendix A.—Test Matrix

A.1 Test Schedule—2007 

• Verify reproducible performance over a 3-day period

– October 26, 2007

• Calibration series, transient test, calibration series, transient test

– October 29, 2007

• Calibration series, transient test

– October 30, 2007

• Calibration series, transient test

October 30, 2007

• Performance Load Profile Test

• Verify long-term behavior of powerplant/stack; verify reproducibility with respect to testing at 

Teledyne

– October 31, 2007, to November 9, 2007

– Mission Profile Test

• Evaluate any performance changes after 240-hr mission profile test

– November 26, 2007

– Calibration Series Test, Transient Test, Performance Load Profile Test

November 30, 2007, to December 12, 2007

• Water Separator (Teledyne Unit) Test

December 12, 2007

• Calibration Series Test, Transient Test

December 13, 2007, to December 18, 2007

• Mission Profile Test
NASA/TM—2011-216783 13

Appendix B.—Operating Procedure for Teledyne’s 

Upgraded Breadboard Computer

Updated: 3 January 2008

Date: ___________

1.0 Start up Procedure

______ Double click on the 20071116_NASA BB INTERFACE.vi icon on the desktop of the 

Teledyne Computer.

______ Select a data storage rate for the test profile to be run (Fig. B1, green circle). Selecting a 

storage rate of zero will collect data at a rate of about 7 samples/second.

______ Change the Delta V Shutdown Limit from 0.08 to 0.12 V.

______ Press the white arrow at the top left of the screen to start up the program.

______ Click “OK” to proceed with startup.

______ Click “OK” to keep default file name for data storage or modify the file name and then click 

“OK.” If “CANCEL” is clicked data will not be stored.

______ Click “OK” at Confirm Nitrogen Supply prompt to begin purging and leak testing.

______ Click “OK” at Confirm Reactant Supply prompt to open reactants. 

______ When the TEST STATUS display indicates “STARTUP COMPLETE: FUEL CELL 

SYSTEM FULLY OPERATIONAL,” the power plant is at open circuit and load currents can 

now be applied.

______ Begin test profile using the LabVIEW system.
NASA/TM—2011-216783 14

2.0 Normal Shutdown Procedure

______ Click the PRESS TO SHUTDOWN button located at the top of the Fuel Cell Interface Screen 

(Fig. B1, red circle). This will initiate a normal sequenced shutdown. Do not attempt to 

intercede or interrupt the shutdown since purging and cooling performed during shutdown is 

very important to maximize stack life.

3.0 Emergency Shutdown Procedure

______ Push in one of the red E-STOP buttons in the control room. This will immediately shut down 

the power plant.

______ Once the emergency circumstance has been resolved, close the Teledyne program, reopen it,

and restart it. Proceed with a normal startup until just after the nitrogen purging begins and 

then click the PRESS TO SHUTDOWN button (Fig. B1, red circle). This will cause the 

breadboard to go through a normal shutdown allowing any residual reactant gases to be 

consumed and to assure the stack voltage is brought down to a safe level.

4.0 Miscellaneous Notes

______ The graph in Figure B1 is set up to show the voltage of all 32 cells. This graph can be 

changed to digital display or sweep graph. It is displayed currently in histogram mode 

(Fig. B1, yellow circle).

______ Figure B1 is currently set to the fuel cell interface screen. The screen can be changed to show 

the power plant P&ID screen (Fig. B2) as well as the power plant status display screen 

(Fig. B3).

______ If the maximum cell voltage difference becomes greater than 0.1 V, the system will 

automatically shut down.
NASA/TM—2011-216783 15

______ If the minimum voltage at any individual cell is less than 0.75 V, the system will 

automatically shut down.

______ Do not apply peak loads in excess of 1.5 kW on a continuous basis. Peak loads between 1.5 

and 1.8 kW must not exceed 15 seconds in duration.
NASA/TM—2011-216783 16
NASA/TM—2011-216783 17

Appendix C.—Test Description Tables

Element 

no.

Increment 

time,

sec

Current,

A

Teledyne data 

recording 

interval,

sec

GRC 

data recording 

interval,

sec

High speed 

data recording 

rate,

kHz

Stack 

voltage,

V

Total time, 

sec

Current 

density,

mA/cm2

Comments

1a 115 0.0 1 1 115 0 Voltage transient 

1b 5 0.0 1 1 200 120 0 

2a 5 5.8 1 1 200 125 20 

2b 115 5.8 1 1 240 20 Between Elem. 1, 2 

3a 115 11.7 1 1 355 40 Voltage transient 

3b 5 11.7 1 1 200 360 40 

4a 5 17.5 1 1 200 365 60 

4b 115 17.5 1 1 480 60 Between Elem. 3, 4 

5 120 23.4 1 1 600 80 

6 120 29.2 1 1 720 100 

7 120 35.0 1 1 840 120 

8 120 40.9 1 1 960 140 

9 120 46.7 1 1 1080 160 

10 120 53.2 1 1 1200 182.2 

11 5 60.0 1 1 1205 205.4 

12 5 67.0 1 1 1210 229.4 

13 5 60.0 1 1 1215 205.4 

14 120 53.2 1 1 1335 182.2 

15 120 46.7 1 1 1455 160 

16 120 40.9 1 1 1575 140 

17 120 35.0 1 1 1695 120 

18 120 29.2 1 1 1815 100 

19 120 23.4 1 1 1935 80 

20 120 17.5 1 1 2055 60 

21 120 11.7 1 1 2175 40 

22 120 5.8 1 1 2295 20 

23 120 0.0 1 1 2415 0 

24 20 0.0 1 1 2435 0 

25 120 33.6 1 1 2555 115.2 

26 1200 29.0 1 1 3755 99.3 

27a 55 13.3 1 1 3810 45.6 Voltage transient 

27b 5 13.3 1 1 200 3815 45.6 

28a 5 46.0 1 1 200 3820 157.6 

28b 55 46.0 1 1 3875 157.6 Between Elem. 27, 28 

29 60 13.3 1 1 3935 45.6 

30 60 37.1 1 1 3995 127.2 

31 15 54.9 1 1 4010 188 

32 1200 37.1 1 1 5210 127.2 

33a 55 46.0 1 1 5265 157.6 Voltage transient 

33b 5 46.0 1 1 200 5270 157.6 

34a 5 13.3 1 1 200 5275 45.6 

34b 55 13.3 1 1 5330 45.6 Between Elem. 33, 34 

35a 25 0.0 1 1 5355 0 Voltage transient 

35b 5 0.0 1 1 200 5360 0 

36a 5 37.1 1 1 200 5365 127.2 

36b 55 37.1 1 1 5420 127.2 Between Elem. 35, 36 

37 40 13.3 1 1 5460 45.6 

38 60 37.1 1 1 5520 127.2 

39 15 54.9 1 1 5535 188 

40 60 37.1 1 1 5595 127.2 

41 40 26.9 1 1 5635 92

42 60 37.1 1 1 5695 127.2 

43 40 50.6 1 1 5735 173.4 

44 60 37.1 1 1 5795 127.2 

45 40 31.5 1 1 5835 108 
NASA/TM—2011-216783 18

Element 

no.

Increment 

time,

sec

Current,

A

Teledyne data 

recording 

interval,

sec

GRC 

data recording 

interval,

sec

High speed 

data recording 

rate,

kHz

Stack 

voltage,

V

Total time, 

sec

Current 

density,

mA/cm2

Comments

46 60 37.1 1 1 5895 127.2 

47 40 46.0 1 1 5935 157.6 

48 60 37.1 1 1 5995 127.2 

49 40 38.0 1 1 6035 130 

50 60 37.1 1 1 6095 127.2 

51 40 43.3 1 1 6135 148.4 

52a 145 37.1 1 1 6280 127.2 Voltage transient 

52b 5 37.1 1 1 200 6285 127.2 

53a 5 0.0 1 1 200 6290 0 

53b 55 0.0 1 1 6345 0 Between Elem. 52, 53 

C.1 Performance Load Profile

Element 

no.

Increment 

time,

sec

Current,

A

Teledyne data 

recording 

interval,

sec

GRC 

data recording 

interval,

sec

High speed 

data recording 

rate,

kHz

Stack

voltage,

V

Total time,

sec

Current 

density,

mA/cm2

Comments

1 60 0.0 1 1 60 0 

2 150 33.6 1 1 210 115.2 

3 3600 29.0 1 1 3810 99.3 

4a 3295 13.3 1 1 7105 45.6 Voltage transient 

4b 5 13.3 1 1 200 7110 45.6 

5a 5 46.0 1 1 200 7115 157.6 

5b 895 46.0 1 1 8010 157.6 Between Elem. 4, 5 

6 3600 13.3 1 1 11610 45.6 

7 960 37.1 1 1 12570 127.2 

8 15 54.9 1 1 12585 188 

9 6120 37.1 1 1 18705 127.2 

10a 895 46.0 1 1 19600 157.6 Voltage transient 

10b 5 46.0 1 1 200 19605 157.6 

11a 5 13.3 1 1 200 19610 45.6 

11b 1675 13.3 1 1 21285 45.6 Between Elem. 10, 11 

12a 55 0.0 1 1 21340 0 Voltage transient 

12b 5 0.0 1 1 200 21345 0 

13a 5 37.1 1 1 200 21350 127.2 

13b 855 37.1 1 1 22205 127.2 Between Elem. 12, 13 

14 40 13.3 1 1 22245 45.6 

15 885 37.1 1 1 23130 127.2 

16 15 54.9 1 1 23145 188 

17 860 37.1 1 1 24005 127.2 

18 40 26.9 1 1 24045 92 

19 860 37.1 1 1 24905 127.2 

20 40 50.6 1 1 24945 173.4 

21 860 37.1 1 1 25805 127.2 

22 40 31.5 1 1 25845 108 

23 860 37.1 1 1 26705 127.2 

24 40 46.0 1 1 26745 157.6 

25 860 37.1 1 1 27605 127.2 

26 40 38.0 1 1 27645 130 

27 860 37.1 1 1 28505 127.2 

28 40 43.3 1 1 28545 148.4 

29a 220 37.1 1 1 28765 127.2 Voltage transient 

29b 5 37.1 1 1 200 28770 127.2 

30a 5 0.0 1 1 200 28775 0 

30b 55 0.0 1 1 28830 0 Between Elem. 29, 30 
NASA/TM—2011-216783 19

C.2 Transient Tests

Element 

no.

Increment 

time,

sec

Current,

A

Teledyne data 

recording 

interval,

sec

GRC data 

recording 

interval,

sec

High 

speed data 

recording rate,

kHz

Stack 

voltage,

V

Total time,

sec

Current 

density,

mA/cm2

Comments

1a 55 0.0 1 1 55 0.0 

1b 5 0.0 1 1 200 60 0.0 Voltage transient

2a 5 54.0 1 1 200 65 184.9 Between Elem. 1b, 2a 

2b 50 54.0 1 1 115 184.9 

2c 5 54.0 1 1 200 120 184.9 Voltage transient

3a 5 0.0 1 1 200 125 0.0 Between Elem. 2c, 3a 

3b 50 0.0 1 1 175 0.0 

3c 5 0.0 1 1 200 180 0.0 Voltage transient

4a 5 37.1 1 1 200 185 127.1 Between Elem. 3c, 4a 

4b 50 37.1 1 1 235 127.1 

4c 5 37.1 1 1 200 240 127.1 Voltage transient

5a 5 0.0 1 1 200 245 0.0 Between Elem. 4c, 5a 

5b 50 0.0 1 1 295 0.0 

5c 5 0.0 1 1 200 300 0.0 Voltage transient

6a 5 17.5 1 1 200 305 59.9 Between Elem. 5c, 6a 

6b 50 17.5 1 1 355 59.9 

6c 5 17.5 1 1 200 360 59.9 Voltage transient

7a 5 0.0 1 1 200 365 0.0 Between Elem. 6c, 7a 

7b 55 0.0 1 1 420 0.0 Voltage transient

8 6 54.0 1 1 200 426 184.9 Between Elem. 7b, 8 

9 12 65.0 1 1 200 438 222.6 Voltage transient between Elem. 

8, 9 

10a 6 54.0 1 1 200 444 184.9 Voltage transient between Elem. 

9, 10a 

10b 120 54.0 1 1 564 184.9 

10c 5 54.0 1 1 569 184.9 Voltage transient

11 6 37.1 1 1 200 575 127.1 Between Elem. 10c, 11 

12 6 54.0 1 1 200 581 184.9 Voltage transient between Elem. 

11, 12 

13 6 17.5 1 1 200 587 59.9 Voltage transient between Elem. 

12, 13 

14 6 54.0 1 1 200 593 184.9 Voltage transient between Elem. 

13, 14 

15 6 17.5 1 1 200 599 59.9 Voltage transient between Elem. 

14, 15 

16 6 0.0 1 1 200 605 0.0 Voltage transient between Elem. 

15, 16 

17 6 17.5 1 1 200 611 59.9 Voltage transient between Elem. 

16, 17 

18 6 0.0 1 1 200 617 0.0 Voltage transient between Elem. 

17 18 

19 6 37.1 1 1 200 623 127.1 Voltage transient between Elem. 

18, 19 

20a 5 37.1 1 1 628 127.1 

20b 600 37.1 1 1 1228 127.1 Voltage transient 

20c 5 17.5 1 1 200 1233 59.9 Between Elem. 20b, 20c 

21 6 37.1 1 1 200 1239 127.1 Voltage transient between Elem. 

20c, 21 

22 6 17.5 1 1 200 1245 59.9 Voltage transient between Elem. 

21, 22 

23 6 37.1 1 1 200 1251 127.1 Voltage transient between Elem. 

22, 23 

24 6 17.5 1 1 200 1257 59.9 Voltage transient between Elem. 

23, 24 

25 300 54.0 1 1 200 1557 184.9 Voltage transient between Elem. 

24, 25 

26 6 17.5 1 1 200 1563 59.9 Voltage transient between Elem. 

25, 26 

27 6 54.0 1 1 200 1569 184.9 Voltage transient between Elem. 

26, 27 
NASA/TM—2011-216783 20

Element 

no.

Increment 

time,

sec

Current,

A

Teledyne data 

recording 

interval,

sec

GRC data 

recording 

interval,

sec

High 

speed data 

recording rate,

kHz

Stack 

voltage,

V

Total time,

sec

Current 

density,

mA/cm2

Comments

28 6 17.5 1 1 200 1575 59.9 Voltage transient between Elem. 

27, 28 

29 6 0.0 1 1 200 1581 0.0 Voltage transient between Elem. 

28, 29 

C.3 Mission Profile Test 

Element 

no.

Increment 

time

Current,

A

Teledyne data 

recording 

interval,

sec

GRC data 

recording 

interval,

sec

High speed 

data recording 

rate,

kHz

Stack 

voltage,

V

Total 

time

Current 

density,

mA/cm2

Comments

1a 55 min 20.0 300 300 55 min 68.5 Restart, transient from OCV to 

20 A

1b 5 min 20.0 300 5 1 hr 68.5 Restart 

2a 5 min 20.0 300 5 1 hr 

5 min 

68.5 Prelaunch

2b 5 hr 

50 min 

20.0 300 300 6 hr 

55 min 

68.5 Prelaunch

2c 5 min 20.0 300 5 7 hr 68.5 Prelaunch 

3a 5 min 31.5 300 5 7 hr 5 min 107.9 Launch 

3b 50 min 31.5 300 300 7 hr 

55 min 

107.9 Launch 

3c 5 min 31.5 300 5 8 hr 107.9 Launch 

4a 5 min 27.6 300 5 8 hr 

5 min 

94.5 Mission 

4b 177 hr 

50 min 

27.6 300 300 185 hr 

55 min 

94.5 Mission 

4c 5 min 27.6 300 5 186 hr 94.5 Mission 

5a 5 min 20.0 300 5 186 hr 

5 min 

68.5 Landing 

5b 23 hr 

50 min 

20.0 300 300 209 hr 

55 min 

68.5 Landing 

5c 5 min 20.0 300 5 210 hr 68.5 Landing 

6 0.5 hr 12.9 300 5 210.5 hr 44.2 Calibration 1 

7 0.5 hr 53.2 300 5 211 hr 182.2 Calibration 2, transient from 

12.9 to 53.2 A 

8 0.5 hr 31.5 300 5 211.5 hr 107.9 Calibration 3, transient from 

53.2 to 31.5 A 

9 0.5 hr 23.8 300 5 212 hr 81.5 Calibration 4 

10a 5 min 20.0 300 5 212 hr 

5 min 

68.5 Landing 

10b 23 hr 

50 min 

20.0 300 300 235 hr 

55 min 

68.5 Landing 

10c 5 min 20.0 300 5 236 hr 68.5 Landing 

11a 5 min 0.0 300 5 236 hr 

5 min 

0.0 Cooldown, transient from 20.0 

to 0.0 A 

11b 3 hr 

55 min 

0.0 300 300 240 hr 0.0 Cooldown 

C.4 Water Separator Test

Element 

no.

Increment 

time,

min

Current,

A

Teledyne data 

recording 

interval,

sec

GRC data 

recording 

interval,

sec

High speed 

data recording

rate,

kHz

Stack 

voltage,

V

Total time Current 

density,

mA/cm2

Comments

1 10 0 5 5

2 5 0 5 5 Collect water

3 60 5 5 5 Collect water

4 60 5 5 5 Collect water

5 10 0 5 5

6 5 0 5 5 Collect water

7 60 10 5 5 Collect water
NASA/TM—2011-216783 21

Element 

no.

Increment 

time,

min

Current,

A

Teledyne data 

recording 

interval,

sec

GRC data 

recording 

interval,

sec

High speed 

data recording

rate,

kHz

Stack 

voltage,

V

Total time Current 

density,

mA/cm2

Comments

8 60 10 5 5 Collect water

9 10 0 5 5

10 5 0 5 5 Collect water

11 60 15 5 5 Collect water

12 60 15 5 5 Collect water

13 10 0 5 5

14 5 0 5 5 Collect water

15 60 20 5 5 Collect water

16 60 20 5 5 Collect water

17 10 0 5 5

18 5 0 5 5 Collect water

19 60 25 5 5 Collect water

20 60 25 5 5 Collect water

21 10 0 5 5

22 5 0 5 5 Collect water

23 60 30 5 5 Collect water

24 60 30 5 5 Collect water

25 10 0 5 5

26 5 0 5 5 Collect water

27 60 35 5 5 Collect water

28 60 35 5 5 Collect water

29 10 0 5 5

30 5 0 5 5 Collect water

31 60 40 5 5 Collect water

32 60 40 5 5 Collect water

33 10 0 5 5

34 5 0 5 5 Collect water

35 60 45 5 5 Collect water

36 60 45 5 5 Collect water

37 10 0 5 5

38 5 0 5 5 Collect water

39 60 50 5 5 Collect water

40 60 50 5 5 Collect water

41 10 0 5 5

42 5 0 5 5 Collect water

43 60 55 5 5 Collect water

44 60 55 5 5 Collect water

45 10 0 5 5

46 5 0 5 5 Collect water
REPORT DOCUMENTATION PAGE Form Approved 

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PLEASE DO NOT RETURN YOUR FORM TO THE ABOVE ADDRESS. 

1. REPORT DATE (DD-MM-YYYY)

01-07-2011 

2. REPORT TYPE

Technical Memorandum 

3. DATES COVERED (From - To)

4. TITLE AND SUBTITLE

Characterization Testing of the Teledyne Passive Breadboard Fuel Cell Powerplant 

5a. CONTRACT NUMBER

5b. GRANT NUMBER

5c. PROGRAM ELEMENT NUMBER

6. AUTHOR(S)

Loyselle, Patricia; Prokopius, Kevin 

5d. PROJECT NUMBER

5e. TASK NUMBER

5f. WORK UNIT NUMBER

WBS 038957.04.06.03.03 

7. PERFORMING ORGANIZATION NAME(S) AND ADDRESS(ES)

National Aeronautics and Space Administration 

John H. Glenn Research Center at Lewis Field 

Cleveland, Ohio 44135-3191 

8. PERFORMING ORGANIZATION

 REPORT NUMBER

E-17411 

9. SPONSORING/MONITORING AGENCY NAME(S) AND ADDRESS(ES)

National Aeronautics and Space Administration 

Washington, DC 20546-0001 

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 ACRONYM(S)

NASA 

11. SPONSORING/MONITORING

 REPORT NUMBER

NASA/TM-2011-216783 

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Unclassified-Unlimited 

Subject Categories: 20 and 44 

Available electronically at http://gltrs.grc.nasa.gov 

This publication is available from the NASA Center for AeroSpace Information, 443-757-5802

13. SUPPLEMENTARY NOTES

14. ABSTRACT

NASA’s Exploration Technology Development Program (ETDP) is tasked with the development of enabling and enhancing technologies 

for NASA’s exploration missions. As part of that initiative, the return to the Moon requires a reliable, efficient, and lightweight fuel cell 

powerplant system to provide power to the Altair Lunar Lander and for lunar surface systems. Fuel cell powerplants are made up of two 

basic parts; the fuel cell itself and the supporting ancillary subsystem. This subsystem is designed to deliver reactants to the fuel cell and 

remove product water and waste heat from the fuel cell. Typically, fuel cell powerplant ancillary subsystems rely upon pumps and active 

water separation techniques to accomplish these tasks for closed hydrogen/oxygen systems. In a typical system, these components are the 

largest contributors to the overall parasitic power load of the fuel cell powerplant. A potential step towards the development of an efficient 

lightweight power system is to maximize the use of “passive” or low-power ancillary components as a replacement to these high-power load 

components. 

15. SUBJECT TERMS

Fuel cell powerplants; Electric power supplies; Energy sources; Spacecraft power supplies; Electric power; Energy storage; Fuel cells 

16. SECURITY CLASSIFICATION OF: 17. LIMITATION OF

 ABSTRACT

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