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: 11-Aug-2022
• Completion Date: 26-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

Overview

IEC 62282-4-101:2022 - Fuel cell technologies - Part 4-101 - defines safety requirements for fuel cell power systems used in electrically powered industrial trucks (as defined in ISO 5053-1). This second edition (2022) replaces the 2014 edition and focuses on gaseous hydrogen-fuelled and direct methanol fuel cell (DMFC) power systems of DC type with rated output voltages up to 150 V DC for indoor and outdoor use. It covers propulsion systems for industrial trucks (excluding several specialised truck types listed in the standard) and addresses design, construction, testing, marking and documentation necessary to manage hazards.

Key topics and technical requirements

• Scope & applicability: fuel cell power systems for electrically powered industrial trucks (not road vehicles or APU) and limited to specified truck types.
• Fuel types: gaseous hydrogen and direct methanol fuel cells (DMFC).
• Electrical limits: DC systems with rated output ≤ 150 V.
• Construction requirements: piping, pressure vessels, valves, regulators, venting, enclosures, electrostatic discharge prevention, and energy storage components.
• Control & safety functions: safety control circuits, emergency stop, manual shutoff access, and drive-off/start controls.
• Energy storage: requirements for battery terminals, double-layer capacitors and temperature limits for capacitors based on material ratings.
• Risk assessment: revised clause now titled Risk assessment and risk reduction - requires systematic hazard identification and mitigation.
• Type and performance tests: vibration, fuel container securement, endurance, external leakage, dilution tests, ultimate strength, temperature tests, touch current, dielectric withstand, limited power circuit tests, abnormal operation, emissions (for methanol), environmental and enclosure tests, plus emergency stop testing.
• Marking & instructions: updated marking requirements and mandatory operating/installation/maintenance instructions.
• Notable changes (2022 edition): title and reference revisions, new subclauses, revisions to leakage/strength tests, capacitor temperature limits, and an informative annex listing significant hazards.

Applications and practical value

• Ensures safe design and validation of fuel cell power systems for forklifts, pallet trucks and other electrically powered industrial trucks.
• Used to develop compliant systems for indoor warehouse environments (venting, leakage and emissions requirements are critical).
• Provides test protocols for manufacturers and test laboratories to demonstrate safety performance and regulatory compliance.
• Helps fleet operators and safety engineers assess risks and maintenance requirements for hydrogen or methanol fuel cell installations.

Who should use this standard

• Fuel cell system manufacturers and OEMs for industrial trucks
• Design and safety engineers
• Test labs and certification bodies
• Fleet operators, maintenance teams and compliance managers
• Standards writers and regulatory authorities

Related standards

• ISO 5053-1 (definition of electrically powered industrial trucks) - referenced for scope and vehicle definitions
• Other IEC fuel cell and electrical safety series standards (see normative references in IEC 62282-4-101:2022)

Keywords: IEC 62282-4-101, fuel cell safety, industrial trucks, hydrogen fuel cell, direct methanol fuel cell, DC ≤150 V, leakage test, ultimate strength test, risk assessment.

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

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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 External leakage . 49
6.2 Dielectric voltage-withstand test . 49
7 Markings. 50
8 Instructions . 50
8.1 General . 50
8.2 Maintenance instructions . 51
8.3 Operating instructions . 51
8.4 Installation instructions . 52
Annex A (informative) Comparison of pressure terms . 53
Annex B (informative) Significant hazards, hazardous situations and events dealt with
in this document . 54
Bibliography . 56

Figure 1 – Fuel cell power systems for industrial trucks . 10
Figure 2 – Example of a diagram with vent system covering components downstream

of the regulator . 24
Figure 3 – Example of a diagram with vent system covering all components . 25
Figure 4 – Example of a diagram with vent system covering all components in a
multiple storage tank vessel system . 26
Figure 5 – Measuring network, touch current weighted for perception or reaction .
Figure 6 – Diagram for touch current measurement test .

Table 1 – Appliance-wiring material . 31
Table 2 – Spacings . 35
Table 3 – Temperature rise limits . 41
Table 4 – Limits for inherently limited power sources . 45
Table 5 – Limits for power sources not inherently limited (overcurrent protection
required) . 45
Table 6 – Emission rate limits . 46
Table A.1 – Comparison table of pressure terms . 53

INTERNATIONAL ELECTROTECHNICAL COMMISSION
____________
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

FOREWORD
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This redline version of the official IEC Standard allows the user to identify the changes made to
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change has been made. Additions are in green text, deletions are in strikethrough red text.

– 6 – IEC 62282-4-101:2022 RLV © IEC 2022
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);
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.
IMPORTANT – The "colour inside" logo on the cover page of this document indicates that it
contains colours which are considered to be useful for the correct understanding of its
contents. Users should therefore print this document using a colour printer.

– 8 – IEC 62282-4-101:2022 RLV © IEC 2022
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 electric 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).

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

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 standard is limited to electrically powered industrial trucks and is applicable to material-
handling equipment, e.g. forklifts.
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;

– 10 – IEC 62282-4-101:2022 RLV © IEC 2022
– fuel cell power systems intended for operation in potentially explosive atmospheres;
– fuel storage systems using liquid hydrogen.

Fuel (hydrogen, methanol)
Coolant
System boundary
Excess/released fuel
Fuel storage
Thermal
Waste heat
(hydrogen,
management
Internal power needs
Fuel
Power
regulating & Fuel cell
Electrical
piping
power output
conditioning
module
Conditioner and
Oxidant (air)
processing
system (stack)
Energy
storage
Ventilation air
Ventilation
Exhaust gases
Discharge water
system
Water
Water
Control
treatment and
EMD
system
EMI
Vibration,
Noise,
wind, rain,
vibration
IEC
Key
EMD electromagnetic disturbance
EMI electromagnetic interference
NOTE A fuel cell power system may 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 insulated cables of rated voltages up to and including
450/750 V – Part 3: Non-sheathed cables for fixed wiring
IEC 60227-5, Polyvinyl chloride insulated cables of rated voltages up to and including
450/750 V – Part 5: Flexible cables (cords)
IEC 60335-2-41, Household and similar electrical appliances – Safety – Part 2-41: Particular
requirements for pumps
IEC 60335-2-80, Household and similar electrical appliances – Safety – Part 2-80: Particular
requirements for fans
IEC 60364-4-41:2005, Low-voltage electrical installations – Part 4-41: Protection for safety –
Protection against electric shock
IEC 60364-4-41:2005/AMD1:2017
IEC 60529, Degrees of protection provided by enclosures (IP Code)
IEC 60584-1, Thermocouples – Part 1: Reference tables EMF specifications and tolerances
IEC 60664-1, Insulation coordination for equipment within low-voltage systems – Part 1:
Principles, requirements and tests
IEC 60695 (all parts), Fire hazard testing
IEC 60695-1-30, Fire hazard testing – Part 1-30: Guidance for assessing the fire hazard of
electrotechnical products – Preselection testing process – General guidelines
IEC 60695-10-2, Fire hazard testing – Part 10-2: Abnormal heat – Ball pressure test method
IEC 60695-11-4, Fire hazard testing – Part 11-4: Test flames – 50 W flame – Apparatus and
confirmational test method
– 12 – IEC 62282-4-101:2022 RLV © IEC 2022
IEC 60695-11-10, Fire hazard testing – Part 11-10: Test flames – 50 W horizontal and vertical
flame test methods
IEC 60730-1:2013, Automatic electrical controls for household and similar use – Part 1: General
requirements
IEC 60730-1:2013/AMD1:2015
IEC 60730-1:2013/AMD2:2020
IEC 60730-2-17, Automatic electrical controls for household and similar use – Part 2-17:
Particular requirements for electrically operated gas valves, including mechanical requirements
IEC 60812, Failure modes and effects analysis (FMEA and FMECA)
IEC 60947-3, Low-voltage switchgear and controlgear – Part 3: Switches, disconnectors,
switch-disconnectors and fuse-combination units
IEC 60947-5-1, Low-voltage switchgear and controlgear – Part 5-1: Control circuit devices and
switching elements – Electromechanical control circuit devices
IEC 60950-1:2005, Information technology equipment – Safety – Part 1: General requirements
IEC 60950-1:2005/AMD1:2009
IEC 60950-1:2005/AMD2:2013
IEC 61025, Fault tree analysis (FTA)
IEC 61204-7, Low-voltage switch mode power supplies, d.c. output – Part 7: Safety
requirements
IEC TS 61430, Secondary cells and batteries – Test methods for checking the performance of
devices designed for reducing explosion hazards – Lead-acid starter batteries
IEC 61508 (all parts), Functional safety of electrical/electronic/programmable electronic safety-
related systems
IEC 61558-1, Safety os power transformers, power supplies, reactors and similar products of
transformers, reactors, power supply units and combinations thereof – Part 1: General
requirements and tests
IEC 62103, Electronic equipment for use in power installations
IEC 62477-1, Safety requirements for power electronic converter systems and equipment –
Part 1: General
IEC 62133-1, Secondary cells and batteries containing alkaline or other non-acid electrolytes –
Safety requirements for portable sealed secondary cells, and for batteries made from them, for
use in portable applications – Part 1: Nickel systems
IEC 62282-2-100, Fuel cell technologies – Part 2-100: Fuel cell modules – Safety
IEC 62391-1, Fixed electric double-layer capacitors for use in electric and electronic equipment
– Part 1: Generic specification
IEC 62391-2, Fixed electric double-layer capacitors for use in electronic equipment – Part 2:
Sectional specfication – Electric double layer capacitors for power application

IEC 62619, Secondary cells and batteries containing alkaline or other non-acid electrolytes –
Safety requirements for secondary lithium cells and batteries, for use in industrial applications
IEC/ISO 31010, Risk management – Risk assessment techniques
ISO 179 (all parts), Plastics – Determination of Charpy impact properties
ISO 180, Plastics – Determination of Izod impact strength
ISO 877 (all parts), Plastics – Methods of exposure to solar radiation
ISO 1419, Rubber- or plastics-coated fabrics – Accelerated-ageing tests
ISO 1421, Rubber- or plastics-coated fabrics – Determination of tensile strength and elongation
at break
ISO 1798, Flexible cellular polymeric materials – Determination of tensile strength and
elongation at break
ISO 2440, Flexible and rigid cellular polymeric materials – Accelerated ageing tests
ISO 2626, Copper – Hydrogen embrittlement test
ISO 3691-1, Industrial trucks – Safety requirements and verification – Part 1: Self-propelled
industrial trucks, other than driverless trucks, variable-reach trucks and burden-carrier trucks
ISO/TS 3691-7, Industrial trucks – Safety requirements and verification – Part 7: Regional
requirements for countries within the European Community
ISO/TS 3691-8, Industrial trucks – Safety requirements and verification – Part 8: Regional
requirements for countries outside the European Community
ISO 3864-1, Graphical symbols – Safety colours and safety signs – Part 1: Design principles
for safety signs and safety markings
ISO 3996, Road Vehicles – Brake hose assemblies for hydraulic braking systems used with a
non-petroleum-base brake fluid
ISO 4038, Road vehicles – Hydraulic braking systems – Simple flare pipes, tapped holes, male
fittings and hose end fittings
ISO 4080, Rubber and plastics hoses and hose assemblies – Determination of permeability to
gas
ISO 4675, Rubber- or plastics-coated fabrics – Low-temperature bend test
ISO 5053-1, Industrial trucks – Vocabulary – Part 1: Types of industrial trucks
ISO 7010, Graphical symbols – Safety colours and safety signs – Registered safety signs
ISO 7866:2012, Gas cylinders – Refillable seamless aluminum alloy gas cylinders – Design,
construction and testing
– 14 – IEC 62282-4-101:2022 RLV © IEC 2022
ISO 9809-1, Gas cylinders – Refillable seamless steel gas cylinders – Design, construction and
testing – Part 1: Quenched and tempered steel cylinders with tensile strength less than 1 100
MPa
ISO 10380, Pipework – Corrugated metal hoses and hose assemblies
ISO 10442, Petroleum, chemical and gas service industries – Packaged, integrally geared
centrifugal air compressors
ISO 10806, Pipework – Fittings for corrugated metal hoses
ISO 11114-4, Transportable gas cylinders – Compatibility of cylinder and valve materials with
gas contents – Part 4: Test methods for selecting metallic materials resistant to hydrogen
embrittlement
ISO 12100, Safety of machinery – General principles for design – Risk assessment and risk
reduction
ISO 13226, Rubber – Standard reference elastomers (SREs) for characterizing the effect of
liquids on vulcanized rubbers
ISO 13849-1, Safety of machinery – Safety-related parts of control systems – Part 1: General
principles for design
ISO 13849-2, Safety of machinery – Safety-related parts of control systems – Part 2: Validation
ISO 14113, Gas welding equipment – Rubber and plastics hose and hose assemblies for use
with industrial gases up to 450 bar (45 MPa)
ISO/TS 14687-2, Hydrogen fuel – Product specification – Part 2: Proton exchange membrane
(PEM) fuel cell applications for road vehicles
ISO 15500-12, Road vehicles – Compressed natural gas (CNG) fuel system components – Part
12: Pressure relief valve (PRV)
ISO 15649, Petroleum and natural gas industries – Piping
ISO/TS 15869:2009, Gaseous hydrogen and hydrogen blends – Land vehicle fuel tanks
ISO/TR 15916, Basic considerations for the safety of hydrogen systems
ISO 16010, Elastomeric seals – Material requirements for seals used in pipes and fittings
carrying gaseous fuels and hydrocarbon fluids
ISO 16111:20082018, Transportable gas storage devices – Hydrogen absorbed in reversible
metal hydride
ISO 17268, Compressed Gaseous hydrogen surface land vehicle refuelling connection devices
ISO 19881, Gaseous hydrogen – Land vehicle fuel containers
ISO 19882, Gaseous hydrogen – Thermally activated pressure relief devices for compressed
hydrogen vehicle fuel containers
ISO 20898, Industrial trucks – Electrical requirements

ISO 21927-3, Smoke and heat control systems – Part 3: Specifications for powered smoke and
heat exhaust ventilators
ISO 23551-1, Safety and control devices for gas burners and gas-burning appliances –
Particular requirements – Part 1: Automatic and semi-automatic valves
UN GTR No. 13, Global Technical Regulation concerning the hydrogen and fuel cell vehicles
UN Regulation No. 134, Uniform provisions concerning the approval of motor vehicles and their
components with regard to the safety- related performance of hydrogen-fuelled vehicles (HFCV)
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 60050-485 and the
following apply.
ISO and IEC maintain terminological databases for use in standardization at the following
addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
3.1
abnormal operation
operation of the fuel cell power system with any one mechanical, electrical or control component
malfunction or failure, in any failure mode regarded as reasonably probable in the failure mode
and effects analysis (FMEA) but excluding accidental rupture or breakdown of the containers of
flammable liquids, vapours and/or gases
3.2
equipotential bonding
permanent joining of metallic conductive parts to form a positive electrically conductive path
that provides electrical continuity between non-current carrying metal conductive parts and is
capable of conducting any fault current that may can occur
Note 1 to entry: This applies to bonding within the fuel cell power system and between the fuel cell power system
and truck and does not refer to the means to ground earth the truck itself, such as with a grounding an earthing strap
or with tires. Acceptable methods of bonding shall be by any positive means, such as by a clamp, rivet, bolt, screw,
welded joint, soldered or brazed joint, or a bonding jumper with a closed loop connector secured by a screw.
3.3
check-valve
fluid control device that allows fluids to flow in only one direction
3.4
circuit, limited power circuit
circuit involving a potential greater than 42,4 V peak (30 V RMS) or 60 V DC and whose power
after 60 s of operation complies with the values outlined in Table 2B and Table 2C of
IEC 60950-1:2005 and IEC 60950-1:2005/AMD2:2013
Note 1 to entry: A circuit that is low voltage under both normal and single fault conditions is referred to in
IEC 60950-1 as a safety extra low voltage (SELV).
3.5
low-voltage circuit
circuit involving a peak open-circuit potential of not more than 42,4 V (30 V RMS) or 60 V DC
supplied by a battery, a fuel cell, a transformer having a maximum volt-ampere (VA), rated
power output rating of less than 100 VA and a maximum secondary output of 30 V AC or by a

– 16 – IEC 62282-4-101:2022 RLV © IEC 2022
combination of a transformer and a fixed impedance that, as a system, complies with
IEC 61558-1
Note 1 to entry: A circuit derived by connecting a resistance in series with a voltage supply circuit as a means of
limiting the voltage and current is not considered to be a low-voltage circuit.
3.6
dilution boundary
extent of a flammable area or zone created by a limited release of flammable gas or vapour,
internal to the fuel cell power system or truck in which it is mounted, and controlled by
mechanical ventilation or other effective means
Note 1 to entry: This is outlined in IEC 60079-10-1.
3.7
electrostatic discharge
ESD
discharge created by static electricity
transfer of electric charge between bodies of different electrostatic potentials in proximity or
through direct contact
[SOURCE: IEC 60050-561:2014, 561-03-06]
3.8
fuel cell power system
generator system that uses one or more fuel cell modules to generate electric power and heat
Note 1 to entry: See Figure 1 for a block diagram of a fuel cell power system. A fuel cell power system may contain
all or some of the components shown in Figure 1. The fuel cell power system for use with industrial trucks will be in
one of the forms as outlined in 3.9 and 3.10.
[SOURCE: IEC TS 62282-1:2013, 3.49, modified – Addition of second sentence to the Note to
entry IEC 60050-485:2020, 485-09-01, modified – addition of the Note to entry.]
3.9
self-contained system
complete system incorporated into its own housing that is intended to replace or combine with
a battery system to power an industrial truck
Note 1 to entry: Display and control functions may can be located outside the system's housing in proximity to the
operator's compartment. However, if counterweight is required outside the system’s housing or direct communication
is required between the system and the truck controller, then it will be considered an integrated system (see 3.10).
3.10
integrated fuel cell power system
complete system of fuel cell components and parts that are incorporated into the industrial truck
with the various parts of the system potentially distributed throughout the truck
3.11
hazardous (classified) areas zone
any work area or space where combustible dust, ignitable fibres, or flammable, volatile liquids,
gases, vapours or mixtures are or may can be present in the air in quantities sufficient to
produce explosive or ignitable mixtures as defined by IEC 60079-10-1
3.12
integral
something that is either contained within the fuel cell power system or is external to it, but is a
part of the fuel cell power system

3.13
lower flammability limit
LFL
minimum concentration of fuel in a fuel-air mixture where a combustion can be ignited by an
ignition source
Note 1 to entry: A fuel-air mixture is flammable when combustion can be started by an ignition source. The main
component concerns the proportions or composition of the fuel-air mixture. A mixture that has less than a critical
amount of fuel, known as the lower flammability limit (LFL) or more than a critical amount of fuel, known as the rich
or upper flammability limit (UFL), will not be flammable.
3.14
maximum allowable working pressure
MAWP
maximum gauge pressure at wh
...

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
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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 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

– 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

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,
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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
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3) IEC Publications have the form of recommendations for international use and are accepted by IEC National
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services carried out by independent certification bodies.
6) All users should ensure that they have the latest edition of this publication.
7) No liability shall attach to IEC or its directors, employees, servants or agents including individual experts and
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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);

– 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.
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).

– 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.

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 insulated cables of rated voltages up to and including
450/750 V – Part 3: Non-sheathed cables for fixed wiring
IEC 60227-5, Polyvinyl chloride insulated cables of rated voltages up to and including
450/750 V – Part 5: Flexible cables (cords)

– 10 – IEC 62282-4-101:2022 © IEC 2022
IEC 60335-2-41, Household and similar electrical appliances – Safety – Part 2-41: Particular
requirements for pumps
IEC 60335-2-80, Household and similar electrical appliances – Safety – Part 2-80: Particular
requirements for fans
IEC 60364-4-41:2005, Low-voltage electrical installations – Part 4-41: Protection for safety –
Protection against electric shock
IEC 60364-4-41:2005/AMD1:2017
IEC 60529, Degrees of protection provided by enclosures (IP Code)
IEC 60584-1, Thermocouples – Part 1: EMF specifications and tolerances
IEC 60664-1, Insulation coordination for equipment within low-voltage systems – Part 1:
Principles, requirements and tests
IEC 60695 (all parts), Fire hazard testing
IEC 60695-1-30, Fire hazard testing – Part 1-30: Guidance for assessing the fire hazard of
electrotechnical products – Preselection testing process – General guidelines
IEC 60695-10-2, Fire hazard testing – Part 10-2: Abnormal heat – Ball pressure test method
IEC 60695-11-4, Fire hazard testing – Part 11-4: Test flames – 50 W flame – Apparatus and
confirmational test method
IEC 60695-11-10, Fire hazard testing – Part 11-10: Test flames – 50 W horizontal and vertical
flame test methods
IEC 60730-1:2013, Automatic electrical controls – Part 1: General requirements
IEC 60730-1:2013/AMD1:2015
IEC 60730-1:2013/AMD2:2020
IEC 60812, Failure modes and effects analysis (FMEA and FMECA)
IEC 60947-3, Low-voltage switchgear and controlgear – Part 3: Switches, disconnectors,
switch-disconnectors and fuse-combination units
IEC 60947-5-1, Low-voltage switchgear and controlgear – Part 5-1: Control circuit devices and
switching elements – Electromechanical control circuit devices
IEC 60950-1:2005, Information technology equipment – Safety – Part 1: General requirements
IEC 60950-1:2005/AMD1:2009
IEC 60950-1:2005/AMD2:2013
IEC 61025, Fault tree analysis (FTA)
IEC 61204-7, Low-voltage switch mode power supplies – Part 7: Safety requirements
IEC TS 61430, Secondary cells and batteries – Test methods for checking the performance of
devices designed for reducing explosion hazards – Lead-acid starter batteries
IEC 61508 (all parts), Functional safety of electrical/electronic/programmable electronic safety-
related systems
IEC 61558-1, Safety of transformers, reactors, power supply units and combinations thereof –
Part 1: General requirements and tests
IEC 62477-1, Safety requirements for power electronic converter systems and equipment –
Part 1: General
IEC 62133-1, Secondary cells and batteries containing alkaline or other non-acid electrolytes –
Safety requirements for portable sealed secondary cells, and for batteries made from them, for
use in portable applications – Part 1: Nickel systems
IEC 62282-2-100, Fuel cell technologies – Part 2-100: Fuel cell modules – Safety
IEC 62391-1, Fixed electric double-layer capacitors for use in electric and electronic equipment
– Part 1: Generic specification
IEC 62391-2, Fixed electric double-layer capacitors for use in electronic equipment – Part 2:
Sectional specfication – Electric double layer capacitors for power application
IEC 62619, Secondary cells and batteries containing alkaline or other non-acid electrolytes –
Safety requirements for secondary lithium cells and batteries, for use in industrial applications
IEC/ISO 31010, Risk management – Risk assessment techniques
ISO 179 (all parts), Plastics – Determination of Charpy impact properties
ISO 180, Plastics – Determination of Izod impact strength
ISO 877 (all parts), Plastics – Methods of exposure to solar radiation
ISO 1419, Rubber- or plastics-coated fabrics – Accelerated-ageing tests
ISO 1421, Rubber- or plastics-coated fabrics – Determination of tensile strength and elongation
at break
ISO 1798, Flexible cellular polymeric materials – Determination of tensile strength and
elongation at break
ISO 2440, Flexible and rigid cellular polymeric materials – Accelerated ageing tests
ISO 2626, Copper – Hydrogen embrittlement test
ISO 3691-1, Industrial trucks – Safety requirements and verification – Part 1: Self-propelled
industrial trucks, other than driverless trucks, variable-reach trucks and burden-carrier trucks
ISO/TS 3691-7, Industrial trucks – Safety requirements and verification – Part 7: Regional
requirements for countries within the European Community
ISO/TS 3691-8, Industrial trucks – Safety requirements and verification – Part 8: Regional
requirements for countries outside the European Community
ISO 3864-1, Graphical symbols – Safety colours and safety signs – Part 1: Design principles
for safety signs and safety markings
ISO 4038, Road vehicles – Hydraulic braking systems – Simple flare pipes, tapped holes, male
fittings and hose end fittings

– 12 – IEC 62282-4-101:2022 © IEC 2022
ISO 4080, Rubber and plastics hoses and hose assemblies – Determination of permeability to
gas
ISO 4675, Rubber- or plastics-coated fabrics – Low-temperature bend test
ISO 5053-1, Industrial trucks – Vocabulary – Part 1: Types of industrial trucks
ISO 7010, Graphical symbols – Safety colours and safety signs – Registered safety signs
ISO 10380, Pipework – Corrugated metal hoses and hose assemblies
ISO 10442, Petroleum, chemical and gas service industries – Packaged, integrally geared
centrifugal air compressors
ISO 10806, Pipework – Fittings for corrugated metal hoses
ISO 11114-4, Transportable gas cylinders – Compatibility of cylinder and valve materials with
gas contents – Part 4: Test methods for selecting metallic materials resistant to hydrogen
embrittlement
ISO 12100, Safety of machinery – General principles for design – Risk assessment and risk
reduction
ISO 13226, Rubber – Standard reference elastomers (SREs) for characterizing the effect of
liquids on vulcanized rubbers
ISO 13849-1, Safety of machinery – Safety-related parts of control systems – Part 1: General
principles for design
ISO 13849-2, Safety of machinery – Safety-related parts of control systems – Part 2: Validation
ISO 14113, Gas welding equipment – Rubber and plastics hose and hose assemblies for use
with industrial gases up to 450 bar (45 MPa)
ISO 15649, Petroleum and natural gas industries – Piping
ISO/TR 15916, Basic considerations for the safety of hydrogen systems
ISO 16010, Elastomeric seals – Material requirements for seals used in pipes and fittings
carrying gaseous fuels and hydrocarbon fluids
ISO 16111:2018, Transportable gas storage devices – Hydrogen absorbed in reversible metal
hydride
ISO 17268, Gaseous hydrogen land vehicle refuelling connection devices
ISO 19881, Gaseous hydrogen – Land vehicle fuel containers
ISO 19882, Gaseous hydrogen – Thermally activated pressure relief devices for compressed
hydrogen vehicle fuel containers
ISO 20898, Industrial trucks – Electrical requirements
ISO 21927-3, Smoke and heat control systems – Part 3: Specifications for powered smoke and
heat exhaust ventilators
ISO 23551-1, Safety and control devices for gas burners and gas-burning appliances –
Particular requirements – Part 1: Automatic and semi-automatic valves
UN GTR No. 13, Global Technical Regulation concerning the hydrogen and fuel cell vehicles
UN Regulation No. 134, Uniform provisions concerning the approval of motor vehicles and their
components with regard to the safety- related performance of hydrogen-fuelled vehicles (HFCV)
3 Terms and definitions
For the purposes of this document, the terms and definitions given in IEC 60050-485 and the
following apply.
ISO and IEC maintain terminological databases for use in standardization at the following
addresses:
• IEC Electropedia: available at http://www.electropedia.org/
• ISO Online browsing platform: available at http://www.iso.org/obp
3.1
abnormal operation
operation of the fuel cell power system with any one mechanical, electrical or control component
malfunction or failure, in any failure mode regarded as reasonably probable in the failure mode
and effects analysis (FMEA) but excluding accidental rupture or breakdown of the containers of
flammable liquids, and/or gases
3.2
equipotential bonding
permanent joining of conductive parts to form a positive electrically conductive path that
provides electrical continuity between non-current carrying conductive parts and is capable of
conducting any fault current that can occur
Note 1 to entry: This applies to bonding within the fuel cell system and between the fuel cell system and truck and
does not refer to the means to earth the truck itself, such as with an earthing strap or with tires.
3.3
check-valve
fluid control device that allows fluids to flow in only one direction
3.4
limited power circuit
circuit involving a potential greater than 42,4 V peak (30 V RMS) or 60 V DC and whose power
after 60 s of operation complies with the values outlined in Table 2B and Table 2C of
IEC 60950-1:2005 and IEC 60950-1:2005/AMD2:2013
Note 1 to entry: A circuit that is low voltage under both normal and single fault conditions is referred to in
IEC 60950-1 as a safety extra low voltage (SELV).
3.5
low-voltage circuit
circuit involving a peak open-circuit potential of not more than 42,4 V (30 V RMS) or 60 V DC
supplied by a battery, a fuel cell, a transformer having a rated power output rating of less than
100 VA and a maximum secondary output of 30 V AC or by a combination of a transformer and
a fixed impedance that, as a system, complies with IEC 61558-1
Note 1 to entry: A circuit derived by connecting a resistance in series with a voltage supply circuit as a means of
limiting the voltage and current is not considered to be a low-voltage circuit.

– 14 – IEC 62282-4-101:2022 © IEC 2022
3.6
dilution boundary
extent of a flammable area or zone created by a limited release of flammable gas, internal to
the fuel cell power system or truck in which it is mounted, and controlled by mechanical
ventilation or other effective means
Note 1 to entry: This is outlined in IEC 60079-10-1.
3.7
electrostatic discharge
ESD
transfer of electric charge between bodies of different electrostatic potentials in proximity or
through direct contact
[SOURCE: IEC 60050-561:2014, 561-03-06]
3.8
fuel cell power system
generator system that uses one or more fuel cell modules to generate electric power and heat
Note 1 to entry: See Figure 1 for a block diagram of a fuel cell power system. The fuel cell power system for use
with industrial trucks will be in one of the forms as outlined in 3.9 and 3.10.
[SOURCE: IEC 60050-485:2020, 485-09-01, modified – addition of the Note to entry.]
3.9
self-contained system
complete system incorporated into its own housing that is intended to replace or combine with
a battery system to power an industrial truck
Note 1 to entry: Display and control functions can be located outside the system's housing in proximity to the
operator's compartment. However, if counterweight is required outside the system’s housing or direct communication
is required between the system and the truck controller, then it will be considered an integrated system (see 3.10).
3.10
integrated fuel cell power system
complete system of fuel cell components and parts that are incorporated into the industrial truck
with the various parts of the system potentially distributed throughout the truck
3.11
hazardous zone
any work area or space where combustible dust, ignitable fibres, or flammable, volatile liquids,
gases, or mixtures are or can be present in the air in quantities sufficient to produce explosive
or ignitable mixtures as defined by IEC 60079-10-1
3.12
integral
something that is either contained within the fuel cell power system or is external to it, but is a
part of the fuel cell power system
3.13
lower flammability limit
LFL
minimum concentration of fuel in a fuel-air mixture where a combustion can be ignited by an
ignition source
Note 1 to entry: A fuel-air mixture is flammable when combustion can be started by an ignition source. The main
component concerns the proportions or composition of the fuel-air mixture. A mixture that has less than a critical
amount of fuel, known as the lower flammability limit (LFL) or more than a critical amount of fuel, known as the rich
or upper flammability limit (UFL), will not be flammable.

3.14
maximum allowable working pressure
MAWP
maximum gauge pressure at which a fuel cell or fuel cell power system can be operated
Note 1 to entry: See Annex A for a comparison table of pressure terms.
Note 2 to entry: The maximum allowable working pressure is expressed in Pa.
Note 3 to entry: The maximum allowable working pressure is the pressure used in determining the setting of
pressure limiting/relieving devices installed to protect a component or system from accidental over-pressuring.
[SOURCE: IEC 60050-485:2020, 485-17-03, modified – addition of new Note 1 to entry.]
3.15
maximum operating pressure
MOP
highest gauge pressure of a component or the system that is expected during normal operation
Note 1 to entry: See Annex A for a comparison table of pressure terms.
3.16
normal release
limited localized volumes of hydrogen concentrations released during normal operation that can
include fuel cell purge
3.17
normal operation
all operating and non-operating modes encountered during product use that are not the result
of a malfunction or failure
3.18
pressure relief device
PRD
pressure and/or temperature activated device used to prevent the pressure from rising above a
predetermined maximum and thereby prevent failure of a pressurized part or system
3.19
thermally activated pressure relief device
TPRD
pressure relief device (3.18) activated by temperature
3.20
risk assessment
overall process comprising a risk analysis and a risk evaluation
3.21
risk analysis
systemic use of available information to identify hazards and to estimate the risk
3.22
risk evaluation
procedure based on the risk analysis to determine whether a tolerable risk has been achieved
3.23
safety control
automatic controls and interlocks including relays, switches, sensors and other aux
...