Thermal Management & Coolant Testing for Fuel Cell Vehicles

Professionally test, analyze, and fill fuel cell cooling systems! Fuel cell vehicles generate the electrical energy needed to power the vehicle electrochemically from hydrogen and oxygen. In addition to electrical energy, this process also produces water and heat. Effective fuel cell thermal management therefore ensures that the fuel cell stack operates within its intended temperature range.

Particularly in liquid-cooled PEM fuel cells (PEMFC), the coolant must meet specific requirements. In addition to heat transfer, freeze protection, and corrosion protection, other important test parameters may include very low or precisely defined electrical conductivity, the chemical state of the coolant, and correctly adjusted freeze protection.

Autotestgeräte Leitenberger offers professional testing and service equipment for various tasks related to the fuel cell cooling circuit.

With the LWM 01_LR and LWM 02_LR conductivity meters, the electrical conductivity of suitable fuel cell coolants can be measured and documented. A conductivity value that deviates from the manufacturer’s specifications may indicate, among other things, aging, contamination, or changes within the cooling circuit.

In addition, the PHM 01_LR enables precise measurement of the pH value. This allows for the recording of another important parameter—in addition to electrical conductivity—for assessing the chemical condition of suitable coolants.

The RFM 05_RGM is also available—a refractometer specifically designed for ready-to-use PEMFC coolant mixtures to monitor antifreeze protection.

Leitenberger offers two different solutions for service and filling operations:

The KVB 01_BZ was developed specifically for the use of single-type fuel cell coolant. The cooling circuit is first evacuated and checked via a vacuum hold test. The intended coolant can then be drawn in quickly and largely bubble-free via the existing vacuum.

For larger, reproducible filling processes, the KVBW 01_230VAC_LR—a mobile evacuation, filling, and testing unit—is available. The system operates with a high-performance electric vacuum pump and is particularly suitable for rework, test benches, small-batch production, and professional service processes.

With this, Autotestgeräte Leitenberger covers key tasks related to fuel cell coolant and thermal management:

• Measuring electrical conductivity
• Checking the pH value
• Checking for antifreeze
• Evacuating the cooling circuit
• Checking for leaks via a vacuum hold test
• Filling the cooling system properly and largely free of air bubbles

Coolant type, permissible conductivity, pH range, antifreeze, replacement intervals, and requirements for the filling process vary among different fuel cell systems. Therefore, the specifications of the vehicle, fuel cell, or coolant manufacturer are always decisive.