Fuel cell technologies - Part 4-101: Fuel cell power systems for electrically powered industrial trucks - Safety

IEC 62282-4-101:2022 is available as IEC 62282-4-101:2022 RLV which contains the International Standard and its Redline version, showing all changes of the technical content compared to the previous edition.
IEC 62282-4-101:2022 deals with safety of fuel cell power systems for propulsion other than road vehicles and auxiliary power units (APU). This part of IEC 62282 covers safety requirements for fuel cell power systems intended to be used in electrically powered industrial trucks as defined in ISO 5053-1.except for: rough-terrain trucks; non-stacking low-lift straddle carriers; stacking high-lift straddle carriers; rough-terrain variable-reach trucks; slewing rough-terrain variable-reach trucks; variable-reach container handlers; pedestrian propelled trucks. This document applies to gaseous hydrogen-fueled fuel cell power systems and direct methanol fuel cell power systems for electrically powered industrial trucks. This document applies to DC type fuel cell power systems, with a rated output voltage not exceeding 150 V DC for indoor and outdoor use.This second edition cancels and replaces the first edition published in 2014.This edition includes the following significant technical changes with respect to the previous edition:
- revision of the title of this document;
- revision of reference standards;
- addition of new subclauses (4.3, 4.14.5, 4.15.3, 4.15.4, 4.16, 5.6, and 5.23);
- previous 4.15 was revised as “4.16 Risk assessment and risk reduction”;
- revision of 4.6 3), access to the manual shutoff valve;
- revision of requirements for battery terminals that are threaded (4.14.10.1);
- revision of requirements for double layer capacitors (4.14.10.2);
- revision of external leakage test (5.5) and ultimate strength test (5.7);
- revision of temperature limits on capacitors depending on the temperature rating of the material (Table 3);
- revision of markings that are not relevant (Clause 7);
- added “Significant hazards, hazardous situations and events dealt with in this document” as a new informative annex

Technologies des piles à combustible - Partie 4-101: Systèmes à pile à combustible pour chariots de manutention électriques - Sécurité

IEC 62282-4-101:2022 est disponible sous forme de IEC 62282-4-101:2022 RLV qui contient la Norme internationale et sa version Redline, illustrant les modifications du contenu technique depuis l'édition précédente.
L'IEC 62282-4-101:2022 traite des systèmes à piles à combustible pour la propulsion, autres que les véhicules routiers et groupes auxiliaires de puissance (GAP). La présente partie de l’IEC 62282 couvre les exigences de sécurité relatives aux systèmes à pile à combustible destinés à être utilisés sur des chariots de manutention électriques, définies dans l’ISO 5053-1 à l’exception des chariots suivants: chariots tout-terrain; chariots cavaliers élévateurs non gerbeurs; chariots cavaliers élévateurs gerbeurs; chariots tout-terrain à portée variable; chariots tout-terrain rotatifs à portée variable; chariots porte-conteneur à portée variable; chariots à propulsion manuelle. Le présent document s’applique aux systèmes à pile à combustible utilisant de l’hydrogène gazeux et à ceux utilisant du méthanol direct pour les chariots de manutention électriques.Le présent document s’applique aux systèmes à pile à combustible de type à courant continu, d’une tension de sortie assignée d’au maximum 150 V en courant continu pour utilisation à l’intérieur et à l’extérieur. Cette deuxième édition annule et remplace la première édition parue en 2014.Cette édition inclut les modifications techniques majeures suivantes par rapport à l’édition précédente:
- révision du titre du présent document;
- révision des normes de référence;
- ajout de nouveaux paragraphes (4.3, 4.14.5, 4.15.3, 4.15.4, 4.16, 5.6 et 5.23);
- renumérotation du paragraphe 4.15 de la version précédente en "4.16 Appréciation du risque et réduction du risque";
- révision de 4.6 3) concernant l’accès au robinet d’arrêt manuel;
- révision des exigences relatives aux bornes filetées de la batterie (4.14.10.1);
- révision des exigences relatives aux condensateurs à double couche (4.14.10.2);
- révision de l’essai de fuites externes (5.5) et de l’essai de résistance à la rupture (5.7);
- révision des limites de température des condensateurs dépendant des caractéristiques assignées de tenue en température du matériau (Tableau 3);
- révision des marquages non pertinents (Article 7);
- ajout d’une nouvelle annexe informative (Annexe B) "Phénomènes dangereux significatifs, situations et événements dangereux traités dans le présent document".

General Information

Status
Published
Publication Date
10-Aug-2022
Current Stage
PPUB - Publication issued
Completion Date
11-Aug-2022
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IEC 62282-4-101
Edition 2.0 2022-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Fuel cell technologies –
Part 4-101: Fuel cell power systems for electrically powered industrial trucks –
Safety
Technologies des piles à combustible –
Partie 4-101: Systèmes à pile à combustible pour chariots de manutention
électriques – Sécurité
IEC 62282-4-101:2022-08(en-fr)
---------------------- Page: 1 ----------------------
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---------------------- Page: 2 ----------------------
IEC 62282-4-101
Edition 2.0 2022-08
INTERNATIONAL
STANDARD
NORME
INTERNATIONALE
Fuel cell technologies –
Part 4-101: Fuel cell power systems for electrically powered industrial trucks –
Safety
Technologies des piles à combustible –
Partie 4-101: Systèmes à pile à combustible pour chariots de manutention
électriques – Sécurité
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 27.070 ISBN 978-2-8322-4167-7

Warning! Make sure that you obtained this publication from an authorized distributor.

Attention! Veuillez vous assurer que vous avez obtenu cette publication via un distributeur agréé.

® Registered trademark of the International Electrotechnical Commission
Marque déposée de la Commission Electrotechnique Internationale
---------------------- Page: 3 ----------------------
– 2 – IEC 62282-4-101:2022 © IEC 2022
CONTENTS

FOREWORD ........................................................................................................................... 5

INTRODUCTION ..................................................................................................................... 7

1 Scope .............................................................................................................................. 8

2 Normative references ...................................................................................................... 9

3 Terms and definitions .................................................................................................... 13

4 Construction requirements for safety ............................................................................. 16

4.1 General ................................................................................................................. 16

4.2 Hydrogen and other fluid containing parts ............................................................. 17

4.2.1 General ......................................................................................................... 17

4.2.2 Piping, hoses, tubing and fittings ................................................................... 17

4.2.3 Hydrogen pressure vessels ............................................................................ 18

4.2.4 Metal hydride container ................................................................................. 19

4.2.5 Methanol fuel tank ......................................................................................... 19

4.3 Refueling .............................................................................................................. 19

4.4 Over-pressure and thermal protection ................................................................... 19

4.5 Regulators ............................................................................................................ 21

4.6 Operating and shut-off valves ............................................................................... 21

4.7 Filters ................................................................................................................... 21

4.8 Pumps and compressors ....................................................................................... 21

4.9 Electrically operated pressure sensing and controlling devices ............................. 22

4.10 Ventilation to prevent the build up of flammable gases .......................................... 22

4.11 Electrostatic discharge (ESD) ............................................................................... 23

4.12 Discharges including methanol emissions and waste materials ............................. 23

4.13 Enclosures ............................................................................................................ 23

4.14 Electrical system ................................................................................................... 24

4.14.1 General ......................................................................................................... 24

4.14.2 Internal wiring ................................................................................................ 24

4.14.3 External wiring ............................................................................................... 25

4.14.4 Emergency switching off requirements (disconnection) for connections

for fuel cell power system .............................................................................. 25

4.14.5 Motors ........................................................................................................... 26

4.14.6 Switches and motor controllers ...................................................................... 26

4.14.7 Transformers and power supplies .................................................................. 26

4.14.8 Inverters, converters and controllers .............................................................. 26

4.14.9 Lamps and lampholders ................................................................................. 26

4.14.10 Energy storage components .......................................................................... 27

4.14.11 Electrical insulation........................................................................................ 27

4.14.12 Limited power circuit ...................................................................................... 28

4.14.13 Electrical spacings ......................................................................................... 28

4.14.14 Separation of circuits ..................................................................................... 29

4.15 Control circuits ...................................................................................................... 30

4.15.1 Safety controls............................................................................................... 30

4.15.2 Start .............................................................................................................. 30

4.15.3 Drive off ......................................................................................................... 30

4.15.4 Emergency stop ............................................................................................. 30

4.16 Risk assessment and risk reduction ...................................................................... 30

---------------------- Page: 4 ----------------------
IEC 62282-4-101:2022 © IEC 2022 – 3 –

5 Performance requirements for safety and type tests ...................................................... 31

5.1 General ................................................................................................................. 31

5.2 Vibration test ........................................................................................................ 31

5.2.1 General ......................................................................................................... 31

5.2.2 Vertical axis test ............................................................................................ 31

5.2.3 Longitudinal and lateral axes tests ................................................................. 31

5.3 Fuel container securement test ............................................................................. 31

5.4 Endurance test ...................................................................................................... 32

5.5 External leakage test ............................................................................................ 32

5.6 Dilution test .......................................................................................................... 32

5.6.1 Releases ....................................................................................................... 32

5.6.2 Setup and operation ...................................................................................... 32

5.6.3 Exhaust dilution ............................................................................................. 32

5.6.4 Dilution boundaries ........................................................................................ 32

5.7 Ultimate strength test ............................................................................................ 32

5.8 Potential failure modes test ................................................................................... 33

5.9 Temperature test .................................................................................................. 33

5.10 Continuity test ....................................................................................................... 35

5.11 Non-metallic tubing test for accumulation of static electricity ................................. 35

5.11.1 Passing criteria .............................................................................................. 35

5.11.2 Test method .................................................................................................. 35

5.12 Dielectric voltage – Withstand test ........................................................................ 36

5.13 Limited power circuit test ...................................................................................... 36

5.14 Rated power output test ........................................................................................ 37

5.15 Abnormal operation test – Electric equipment failures ........................................... 37

5.16 Emission of effluents test (only for methanol fuel cells) ......................................... 38

5.17 Environmental test ................................................................................................ 38

5.17.1 Rain test ........................................................................................................ 38

5.17.2 Test of equipment – Exposure to wind ........................................................... 39

5.18 Enclosure tests ..................................................................................................... 39

5.18.1 Enclosure loading test ................................................................................... 39

5.18.2 Test for thermoplastic enclosures .................................................................. 39

5.19 Marking plate adhesion test .................................................................................. 40

5.20 Test for elastomeric seals, gaskets and tubing ...................................................... 40

5.20.1 General ......................................................................................................... 40

5.20.2 Accelerated air-oven ageing test .................................................................... 40

5.20.3 Cold temperature exposure test ..................................................................... 40

5.20.4 Immersion test ............................................................................................... 40

5.21 Test for permeation of non-metallic tubing and piping ........................................... 41

5.22 Test for electrical output leads .............................................................................. 41

5.23 Emergency stop .................................................................................................... 41

6 Routine tests ................................................................................................................. 41

6.1 External leakage ................................................................................................... 41

6.2 Dielectric voltage-withstand test ............................................................................ 41

7 Markings........................................................................................................................ 41

8 Instructions .................................................................................................................... 42

8.1 General ................................................................................................................. 42

8.2 Maintenance instructions ...................................................................................... 43

---------------------- Page: 5 ----------------------
– 4 – IEC 62282-4-101:2022 © IEC 2022

8.3 Operating instructions ........................................................................................... 43

8.4 Installation instructions ......................................................................................... 44

Annex A (informative) Comparison of pressure terms ........................................................... 45

Annex B (informative) Significant hazards, hazardous situations and events dealt with

in this document ................................................................................................................... 46

Bibliography .......................................................................................................................... 48

Figure 1 – Fuel cell power systems for industrial trucks .......................................................... 9

Figure 2 – Example of a diagram with vent system covering components downstream

of the regulator ..................................................................................................................... 20

Figure 3 – Example of a diagram with vent system covering all components ......................... 20

Figure 4 – Example of a diagram with vent system covering all components in a

multiple storage vessel system ............................................................................................. 21

Table 1 – Appliance-wiring material ...................................................................................... 25

Table 2 – Spacings ............................................................................................................... 29

Table 3 – Temperature rise limits .......................................................................................... 34

Table 4 – Limits for inherently limited power sources ............................................................ 37

Table 5 – Limits for power sources not inherently limited (overcurrent protection

required) ............................................................................................................................... 37

Table 6 – Emission rate limits ............................................................................................... 38

Table A.1 – Comparison table of pressure terms ................................................................... 45

---------------------- Page: 6 ----------------------
IEC 62282-4-101:2022 © IEC 2022 – 5 –
INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
FUEL CELL TECHNOLOGIES –
Part 4-101: Fuel cell power systems for
electrically powered industrial trucks – Safety
FOREWORD

1) The International Electrotechnical Commission (IEC) is a worldwide organization for standardization comprising

all national electrotechnical committees (IEC National Committees). The object of IEC is to promote international

co-operation on all questions concerning standardization in the electrical and electronic fields. To this end and

in addition to other activities, IEC publishes International Standards, Technical Specifications, Technical Reports,

Publicly Available Specifications (PAS) and Guides (hereafter referred to as “IEC Publication(s)”). Their

preparation is entrusted to technical committees; any IEC National Committee interested in the subject dealt with

may participate in this preparatory work. International, governmental and non-governmental organizations liaising

with the IEC also participate in this preparation. IEC collaborates closely with the International Organization for

Standardization (ISO) in accordance with conditions determined by agreement between the two organizations.

2) The formal decisions or agreements of IEC on technical matters express, as nearly as possible, an international

consensus of opinion on the relevant subjects since each technical committee has representation from all

interested IEC National Committees.

3) IEC Publications have the form of recommendations for international use and are accepted by IEC National

Committees in that sense. While all reasonable efforts are made to ensure that the technical content of IEC

Publications is accurate, IEC cannot be held responsible for the way in which they are used or for any

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4) In order to promote international uniformity, IEC National Committees undertake to apply IEC Publications

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8) Attention is drawn to the Normative references cited in this publication. Use of the referenced publications is

indispensable for the correct application of this publication.

9) Attention is drawn to the possibility that some of the elements of this IEC Publication may be the subject of patent

rights. IEC shall not be held responsible for identifying any or all such patent rights.

International Standard IEC 62282-4-101 has been prepared by IEC technical committee 105:

Fuel cell technologies.

This second edition cancels and replaces the first edition published in 2014. This edition

constitutes a technical revision.

This edition includes the following significant technical changes with respect to the previous

edition:
a) revision of the title of this document;
b) revision of reference standards;

c) addition of new subclauses (4.3, 4.14.5, 4.15.3, 4.15.4, 4.16, 5.6, and 5.23);

d) previous 4.15 was revised as “4.16 Risk assessment and risk reduction”;
e) revision of 4.6 3), access to the manual shutoff valve;
f) revision of requirements for battery terminals that are threaded (4.14.10.1);
---------------------- Page: 7 ----------------------
– 6 – IEC 62282-4-101:2022 © IEC 2022
g) revision of requirements for double layer capacitors (4.14.10.2);
h) revision of external leakage test (5.5) and ultimate strength test (5.7);

i) revision of temperature limits on capacitors depending on the temperature rating of the

material (Table 3);
j) revision of markings that are not relevant (Clause 7);

k) added “Significant hazards, hazardous situations and events dealt with in this document” as

a new informative annex (Annex B).
The text of this International Standard is based on the following documents:
Draft Report on voting
105/912/FDIS 105/922/RVD

Full information on the voting for its approval can be found in the report on voting indicated in

the above table.
The language used for the development of this International Standard is English.

This document was drafted in accordance with ISO/IEC Directives, Part 2, and developed in

accordance with ISO/IEC Directives, Part 1 and ISO/IEC Directives, IEC Supplement, available

at www.iec.ch/members_experts/refdocs. The main document types developed by IEC are

described in greater detail at www.iec.ch/standardsdev/publications.

A list of all parts of IEC 62282 series, published under the general title Fuel cell technologies,

can be found on the IEC website.

The committee has decided that the contents of this document will remain unchanged until the

stability date indicated on the IEC website under webstore.iec.ch in the data related to the

specific document. At this date, the document will be
• reconfirmed,
• withdrawn,
• replaced by a revised edition, or
• amended.
---------------------- Page: 8 ----------------------
IEC 62282-4-101:2022 © IEC 2022 – 7 –
INTRODUCTION
The IEC 62282-4 series deals with categories such as safety, performance and

interchangeability of fuel cell power systems for propulsion other than road vehicles and

auxiliary power units (APU). Among the categories mentioned above, this document,

IEC 62282-4-101, focuses on safety of electrically powered industrial trucks with fuel cell power

systems because such applications are urgently demanded in the world. Future documents in

this part of IEC 62282-4 will deal with other applications related to onboard vehicles other than

road vehicles and auxiliary power units (APU).
---------------------- Page: 9 ----------------------
– 8 – IEC 62282-4-101:2022 © IEC 2022
FUEL CELL TECHNOLOGIES –
Part 4-101: Fuel cell power systems for
electrically powered industrial trucks – Safety
1 Scope

This document deals with safety of fuel cell power systems for propulsion other than road

vehicles and auxiliary power units (APU).

This part of IEC 62282 covers safety requirements for fuel cell power systems intended to be

used in electrically powered industrial trucks as defined in ISO 5053-1, except for:

– rough-terrain trucks;
– non-stacking low-lift straddle carriers;
– stacking high-lift straddle carriers;
– rough-terrain variable-reach trucks;
– slewing rough-terrain variable-reach trucks;
– variable-reach container handlers;
– pedestrian propelled trucks.

This document applies to gaseous hydrogen-fuelled fuel cell power systems and direct methanol

fuel cell power systems for electrically powered industrial trucks.
The following fuels are considered within the scope of this document:
– gaseous hydrogen;
– methanol.
This document covers the fuel cell power system as defined in 3.8 and Figure 1.

This document applies to DC type fuel cell power systems, with a rated output voltage not

exceeding 150 V DC for indoor and outdoor use.

This document covers fuel cell power systems whose fuel source container is permanently

attached to either the industrial truck or the fuel cell power system.

In accordance with IEC Guide 116, significant hazards, hazardous situations and events dealt

with in this document are shown in Annex B.
The following are not included in the scope of this document:
– detachable type fuel source containers;
– hybrid trucks that include an internal combustion engine;
– reformer-equipped fuel cell power systems;

– fuel cell power systems intended for operation in potentially explosive atmospheres;

– fuel storage systems using liquid hydrogen.
---------------------- Page: 10 ----------------------
IEC 62282-4-101:2022 © IEC 2022 – 9 –
Key
EMD electromagnetic disturbance
EMI electromagnetic interference
NOTE A fuel cell power system can contain all or some of the above components.
Figure 1 – Fuel cell power systems for industrial trucks
2 Normative references

The following documents are referred to in the text in such a way that some or all of their content

constitutes requirements of this document. For dated references, only the edition cited applies.

For undated references, the latest edition of the referenced document (including any

amendments) applies.

IEC 60050-485, International Electrotechnical Vocabulary (IEV) – Part 485: Fuel cell

technologies
IEC 60079-0, Explosive atmospheres – Part 0: Equipment – General requirements

IEC 60079-10-1, Explosive atmospheres – Part 10-1: Classification of areas – Explosive gas

atmospheres
IEC 60079-29-1, Explosive atmospheres – Part 29-1: Gas detectors – Performance
requirements of detectors for flammable gases
IEC 60079-29-4, Explosive atmospheres – Part 29-4: Gas detectors – Performance
requirements of open path detectors for flammable gases

IEC 60204-1, Safety of machinery – Electrical equipment of machines – Part 1: General

requirements
IEC 60227-3, Polyvinyl chloride ins
...

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