Method for running a fuel cell system with a failed stack health monitor

1. A method for operating a fuel cell system including a fuel cell stack, said fuel cell stack including a plurality of fuel cells electrically coupled in series, said method comprising:

monitoring a voltage of the fuel cells in the fuel cell stack using a cell voltage monitor;

determining that a voltage signal from one or more of the fuel cells in the fuel cell stack is lost and not being received by the cell voltage monitor;

performing one or more remedial actions in response to the loss of the voltage signal where the remedial actions cause the fuel cell stack to operate in a condition more favorable for stack durability, wherein performing one or more remedial actions includes preventing stack coolant pulsing;

determining whether the cell or cells whose voltage signal is lost were healthy prior to the voltage signal being lost;

operating the fuel cell stack under the remedial actions if the cell or cells were healthy; and

operating the fuel cell stack in a power limitation mode where a power output of the stack is limited if the voltage of the cell or cells were not healthy.

2. The method according to claim 1 wherein performing one or more remedial actions includes operating an anode hydrogen input to the fuel cell stack at an increased hydrogen dry mole fraction set-point.

3. The method according to claim 1 wherein performing one or more remedial actions includes increasing the time for start-up of the fuel cell system.

4. The method according to claim 1 wherein performing one or more remedial actions includes operating the fuel cell stack at a relative humidity that helps cells remain stable.

5. The method according to claim 1 wherein performing one or more remedial actions includes increasing a stack warm-up time before allowing system operation after system start-up.

6. The method according to claim 1 wherein performing one or more remedial actions includes preventing a stack voltage recovery operation.

7. The method according to claim 1 wherein performing one or more remedial actions includes preventing the fuel cell stack from going into a stand-by mode.

8. The method according to claim 1 wherein performing one or more remedial actions includes limiting stack power up transients.

9. The method according to claim 1 further comprising preventing the system from entering run mode if it is determined that the voltage signal from one or more of the fuel cells in the fuel cell stack is lost and not being received by the cell voltage monitor during a start-up routine of the system unless the voltage signal was lost during a previous run when cells were healthy.

10. The method according to claim 1 wherein determining whether the cell or cells whose voltage signal is lost were healthy includes using one or more of an absolute value of a minimum cell voltage, a difference between the minimum cell voltage and an average cell voltage, a difference between the minimum cell voltage and a maximum cell voltage, and a standard deviation of the cell voltages.

11. The method according to claim 1 wherein determining whether the cell or cells whose voltage signal is lost were healthy includes determining whether a voltage of the cell or cells whose voltage signal is lost was operating above a predetermined voltage threshold prior to the voltage signal being lost.

12. The method according to claim 11 wherein the voltage threshold is about 450 mV.

13. A method for operating a fuel cell system including a fuel cell stack, said fuel cell stack including a plurality of fuel cells electrically coupled in series, said method comprising:

monitoring a voltage of the fuel cells in the fuel cell stack using a cell voltage monitor;

determining that a voltage signal from one or more of the fuel cells in the fuel cell stack is lost and not being received by the cell voltage monitor;

performing one or more remedial actions in response to loss of the voltage signal where the remedial actions cause the fuel cell stack to operate in a condition more favorable for stack durability;

determining whether a voltage of the cell or cells whose voltage signal is lost was operating above a predetermined voltage threshold prior to the voltage signal being lost;

operating the fuel cell stack under the remedial actions if the cell or cells was above the voltage threshold; and

operating the fuel cell stack in a power limitation mode where a power output of the stack is limited if the voltage of the cell or cells was below the voltage threshold; and

preventing the system from entering run mode if it is determined that the voltage signal from one or more of the fuel cells in the fuel cell stack is lost and not being received by the cell voltage monitor during a start-up routine of the system unless the voltage signal was lost during a previous run when cells were healthy.

14. The method according to claim 13 wherein performing one or more remedial actions includes performing one or more remedial actions selected from the group consisting of operating an anode hydrogen input to the fuel cell stack at an increased hydrogen dry mole fraction set-point, increasing start-up time of the fuel cell system, operating the fuel cell stack at a relative humidity that helps cells remain stable, increasing a stack warm-up time before allowing system operation after system start-up, preventing stack coolant pulsing, preventing a stack voltage recovery, preventing the fuel cell stack from going into a stand-by mode and limiting stack power-up transients.

15. The method according to claim 13 wherein the voltage threshold is about 450 mV.

16. A control system for operating a fuel cell system including a fuel cell stack, said fuel cell stack including a plurality of fuel cells electrically coupled in series, said system comprising:

a cell voltage monitor for monitoring a voltage of fuel cells in the fuel cell stack using a cell voltage monitor;

a controller programmed to provide:

means for determining that a voltage signal from one or more of the fuel cells in the fuel cell stack is lost and not being received by the cell voltage monitor;

means for performing one or more remedial actions in response to loss of the voltage signal where the remedial actions cause the fuel cell stack to operate in a more stack safe condition;

means for determining whether a voltage of the cell or cells whose voltage signal is lost was operating above a predetermined voltage threshold prior to the voltage signal being lost;

means for operating the fuel cell stack under the remedial actions if the voltage of the cell or cells was above the voltage threshold; and

means for operating the fuel cell stack in a power limitation mode where a power output of the stack is limited if the cell or cells was below the voltage threshold.

17. The control system according to claim 16 wherein the means for performing one or more remedial actions performs one or more remedial actions selected from the group consisting of operating an anode hydrogen input to the fuel cell stack at an increased hydrogen dry mole fraction set-point, increasing start-up time of the fuel cell system, operating the fuel cell stack at a relative humidity that helps cells remain stable, increasing a stack warm-up time before allowing system operation at system start-up, preventing stack coolant pulsing, preventing a stack voltage recovery, preventing the fuel cell stack from going into a stand-by mode and limiting stack power-up transients.

18. The control system according to claim 16 further comprising means for preventing the fuel cell system from entering a run mode if it is determined that the voltage signal from one or more of the fuel cells in the fuel cell stack is lost and not being received by the cell voltage monitor during a start-up routine of the system unless the voltage signal was lost during a previous run when cells were healthy.