IEC 62282-4-101:2022

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

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

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
• ICS: 27.070 - Fuel cells
• Technical Committee: TC 105 - Fuel cell technologies
• Drafting Committee: MT 301 - TC 105/MT 301
• Current Stage: PPUB - Publication issued
• Start Date: 26-Aug-2022
• Completion Date: 11-Aug-2022

Relations

• Revises: IEC 62282-4-101:2014 - Fuel cell technologies - Part 4-101: Fuel cell power systems for propulsion other than road vehicles and auxiliary power units (APU) - Safety of electrically powered industrial trucks
• Effective Date: 05-Sep-2023

Standards Content (Sample)

IEC 62282-4-101 ®
Edition 2.0 2022-08
REDLINE VERSION
INTERNATIONAL
STANDARD
colour
inside
Fuel cell technologies –
Part 4-101: Fuel cell power systems for propulsion other than road vehicles
and auxiliary power units (APU) – Safety of electrically powered industrial
trucks
Fuel cell power systems for electrically powered industrial trucks – Safety

All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form
or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from
either IEC or IEC's member National Committee in the country of the requester. If you have any questions about IEC
copyright or have an enquiry about obtaining additional rights to this publication, please contact the address below or
your local IEC member National Committee for further information.

IEC Secretariat Tel.: [phone]
3, rue de Varembé [e-mail]
CH-1211 Geneva 20 www.iec.ch
Switzerland
About the IEC
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International Standards for all electrical, electronic and related technologies.

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need further assistance, please contact the Customer Service
Centre: [e-mail].
IEC 62282-4-101 ®
Edition 2.0 2022-08
REDLINE VERSION
INTERNATIONAL
STANDARD
colour
inside
Fuel cell technologies –
Part 4-101: Fuel cell power systems for propulsion other than road vehicles
and auxiliary power units (APU) – Safety of electrically powered industrial
trucks
Fuel cell power systems for electrically powered industrial trucks – Safety
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
ICS 27.070 ISBN 978-2-8322-5589-6
– 2 – IEC 62282-4-101:2022 RLV © IEC 2022
CONTENTS
FOREWORD . 5
INTRODUCTION . 8
1 Scope . 9
2 Normative references . 11
3 Terms and definitions . 15
4 Construction requirements for safety . 19
4.1 General . 19
4.2 Hydrogen and other fluid containing parts . 20
4.2.1 General . 20
4.2.2 Piping, hoses, tubing and fittings . 20
4.2.3 Hydrogen pressure vessels . 21
4.2.4 Metal hydride container . 22
4.2.5 Methanol fuel tank . 22
4.3 Refueling . 23
4.4 Over-pressure and thermal protection . 23
4.5 Regulators . 26
4.6 Operating and shut-off valves . 26
4.7 Filters . 27
4.8 Pumps and compressors . 27
4.9 Electrically operated pressure sensing and controlling devices . 27
4.10 Ventilation to prevent the build up of flammable gases and vapours . 27
4.11 Electrostatic discharge (ESD) . 28
4.12 Discharges including methanol emissions and waste materials . 29
4.13 Enclosures . 29
4.14 Fuel cell power system electrical components Electrical system . 29
4.14.1 General . 29
4.14.2 Internal wiring . 30
4.14.3 External wiring . 31
4.14.4 Emergency switching off requirements (disconnection) for connections
for fuel cell power system . 31
4.14.5 Motors . 32
4.14.6 Switches and motor controllers . 32
4.14.7 Transformers and power supplies . 32
4.14.8 Inverters, converters and controllers . 32
4.14.9 Lamps and lampholders . 32
4.14.10 Energy storage components . 32
4.14.11 Electrical insulation. 33
4.14.12 Limited power circuit . 34
4.14.13 Electrical spacings . 34
4.14.14 Separation of circuits . 35
4.15 Control circuits . 36
4.15.1 Safety controls. 36
4.15.2 Start . 36
4.15.3 Drive off . 36
4.15.4 Emergency stop . 36
4.16 Safety/hazard analysis Risk assessment and risk reduction . 36

5 Performance requirements for safety and type tests . 37
5.1 General . 37
5.2 Vibration test . 37
5.2.1 General . 37
5.2.2 Vertical axis test . 37
5.2.3 Longitudinal and lateral axes tests . 37
5.3 Fuel container securement test . 37
5.4 Endurance test . 38
5.5 External leakage test . 38
External leakage – Hazardous gas containing portions (determination of
dilution boundary) .
External leakage – Hazardous liquid containing portions .
5.6 Dilution test . 38
5.6.1 Releases . 38
5.6.2 Setup and operation . 39
5.6.3 Exhaust dilution . 39
5.6.4 Dilution boundaries . 39
5.7 Ultimate strength test . 39
Ultimate strength – Hazardous liquids and pressurized parts .
Ultimate strength – Hazardous gas and pressurized parts.
Ultimate strength －Fuel cell modules .
5.8 Potential failure modes test . 40
5.9 Temperature test . 40
5.10 Touch current test .
5.10 Continuity test . 42
5.11 Non-metallic tubing test for accumulation of static electricity . 44
5.11.1 Passing criteria . 44
5.11.2 Test method . 44
5.12 Dielectric voltage – Withstand test . 44
5.13 Limited power circuit test . 44
5.14 Maximum VA test Rated power output test . 45
5.15 Abnormal operation test – Electric equipment failures . 45
5.16 Emission of effluents test (only for methanol fuel cells) . 46
5.17 Environmental test . 46
5.17.1 Rain test . 46
5.17.2 Test of equipment – Exposure to wind . 47
5.18 Enclosure tests . 47
5.18.1 Enclosure loading test . 47
5.18.2 Test for thermoplastic enclosures . 47
5.19 Marking plate adhesion test . 48
5.20 Test for elastomeric seals, gaskets and tubing . 48
5.20.1 General . 48
5.20.2 Accelerated air-oven ageing test . 48
5.20.3 Cold temperature exposure test . 48
5.20.4 Immersion test . 48
5.21 Test for permeation of non-metallic tubing and piping . 49
5.22 Test for electrical output leads . 49
5.23 Emergency stop . 49
6 Routine tests . 49

– 4 – IEC 62282-4-101:2022 RLV © IEC 2022
6.1
...

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
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized in any form
or by any means, electronic or mechanical, including photocopying and microfilm, without permission in writing from
either IEC or IEC's member National Committee in the country of the requester. If you have any questions about IEC
copyright or have an enquiry about obtaining additional rights to this publication, please contact the address below or
your local IEC member National Committee for further information.

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CH-1211 Geneva 20 www.iec.ch
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About the IEC
The International Electrotechnical Commission (IEC) is the leading global organization that prepares and publishes
International Standards for all electrical, electronic and related technologies.

About IEC publications
The technical content of IEC publications is kept under constant review by the IEC. Please make sure that you have the
latest edition, a corrigendum or an amendment might have been published.

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The advanced search enables to find IEC publications by a Discover our powerful search engine and read freely all the
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Stay up to date on all new IEC publications. Just Published
containing more than 22 300 terminological entries in English
details all new publications released. Available online and
and French, with equivalent terms in 19 additional languages.
once a month by email.
Also known as the International Electrotechnical Vocabulary

(IEV) online.
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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
INTERNATIONAL
ELECTROTECHNICAL
COMMISSION
COMMISSION
ELECTROTECHNIQUE
INTERNATIONALE
ICS 27.070 ISBN 978-2-8322-4167-7

– 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

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 t
...