ISO 16380:2014
(Main)Road vehicles — Blended fuels refuelling connector
Road vehicles — Blended fuels refuelling connector
ISO 16380:2014 applies to compressed blended fuels vehicle nozzles and receptacles hereinafter referred to as devices, constructed entirely of new, unused parts and materials. Compressed blended fuels fuelling connection nozzles consist of the following components, as applicable: a) Receptacle and protective cap (mounted on vehicle); b) Nozzle (mounted on dispenser side). ISO 16380:2014 applies to devices which have a service pressure of 20 MPa, 25 MPa, and 35 MPa hereinafter referred to as: a) size 1: M200, M250, and M350; b) size 2: N200 and N250. ISO 16380:2014 refers to service pressures of 20 MPa, 25 MPa, and 35 MPa for size 1 and 20 MPa and 25 MPa for size 2. ISO 16380:2014 applies to devices with standardised mating components. ISO 16380:2014 applies to connectors which a) prevent blended fuels vehicles from being fuelled by dispenser stations with working pressures higher than the vehicle fuel system working pressure, b) allow blended fuels vehicles to be fuelled by dispenser stations with working pressures equal to or lower than the vehicle fuel system working pressure, c) allow blended fuels vehicles to be fuelled by dispenser stations for compressed natural gas, d) allow blended fuels vehicles to be fuelled by compressed natural gas dispenser stations with working pressures equal to or lower than the vehicle fuel system working pressure, e) prevent blended fuels vehicles size 1 being refuelled on blended fuels dispenser stations equipped with a size 2 nozzle and vice versa, f) prevent natural gas vehicles from being fuelled by blended fuels station, and dispensers, and g) prevent pure hydrogen vehicles from being fuelled by blended fuels station dispensers. ISO 16380:2014 is applicable to mixtures of hydrogen from 2 % to 30 % in volume and compressed natural gas containing: a) natural gas in accordance with ISO 15403‑1 and ISO 15403‑2; b) pure hydrogen in accordance with ISO 14687‑1 or ISO/TS 14687‑2.
Véhicules routiers — Pistolet de remplissage pour les mélanges de carburants gazeux
ISO 16380:2014 s'applique aux injecteurs et réceptacles de véhicules utilisant des mélanges de carburants comprimés, ci-après appelés dispositifs, fabriqués avec des pièces et des matériaux neufs et non usagés. Les réceptacles de remplissage en mélanges de carburants comprimés sont constitués des composants suivants, selon le cas: a) Réceptacle et bouchon de protection (intégrés au véhicule) (voir l'Article 7); b) Injecteur (intégré côté distributeur) (voir l'Article 5). ISO 16380:2014 s'applique aux dispositifs ayant une pression de service de 20 MPa, 25 MPa et 35 MPa, ci-après appelés dans la présente Norme internationale [voir en 9.1 c)]: - taille 1: M200, M250 et M350; - taille 2: N200 et N250. ISO 16380:2014 concerne des pressions de service de 20 MPa, 25 MPa et 35 MPa pour la taille 1 et de 20 MPa et 25 MPa pour la taille 2. ISO 16380:2014 s'applique aux dispositifs ayant des composants de raccordement standardisés (voir en 5.8 et 7.7). La présente Norme internationale s'applique aux pistolets qui: a) empêchent les véhicules utilisant des mélanges de carburants d'être ravitaillés par des distributeurs dont les pressions de fonctionnement sont supérieures à la pression de fonctionnement du circuit carburant du véhicule, b) permettent aux véhicules utilisant des mélanges de carburants d'être ravitaillés par des distributeurs dont les pressions de fonctionnement sont inférieures ou égales à la pression de fonctionnement du circuit carburant du véhicule, c) permettent aux véhicules utilisant des mélanges de carburants d'être ravitaillés par des distributeurs de gaz naturel comprimé, d) permettent aux véhicules utilisant des mélanges de carburants d'être ravitaillés par des distributeurs de gaz naturel comprimé dont les pressions de fonctionnement sont inférieures ou égales à la pression de fonctionnement du circuit carburant du véhicule, e) empêchent les véhicules utilisant des mélanges de carburants de taille 1 d'être ravitaillés par des distributeurs de mélanges de carburants équipés d'un injecteur de taille 2 et inversement, f) empêchent les véhicules fonctionnant au gaz naturel d'être ravitaillés par des distributeurs de mélanges de carburants, et g) empêchent les véhicules fonctionnant à l'hydrogène pur d'être ravitaillés par des distributeurs de mélanges de carburants. La présente Norme internationale est applicable aux mélanges d'hydrogène de 2 % à 30 % en volume et au gaz naturel comprimé contenant: a) du gaz naturel conformément à l'ISO 15403‑1 et à l'ISO 15403‑2; b) de l'hydrogène pur conformément à l'ISO ISO 14687‑1 ou à l'ISO /TS 14687‑2. Sauf indication contraire, toutes les références aux pressions (MPa) de la présente Norme internationale doivent être considérées comme des pressions manométriques.
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INTERNATIONAL ISO
STANDARD 16380
First edition
2014-06-01
Road vehicles — Blended fuels
refuelling connector
Véhicules routiers — Pistolet de remplissage pour les mélanges
de carburants gazeux
Reference number
ISO 16380:2014(E)
©
ISO 2014
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ISO 16380:2014(E)
COPYRIGHT PROTECTED DOCUMENT
© ISO 2014
All rights reserved. Unless otherwise specified, no part of this publication may be reproduced or utilized otherwise in any form
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Published in Switzerland
ii © ISO 2014 – All rights reserved
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ISO 16380:2014(E)
Contents Page
Foreword .iv
Introduction .v
1 Scope . 1
2 Normative references . 2
3 Terms and definitions . 2
4 General construction requirements . 3
5 Nozzles . 5
6 Standard receptacle dimensions . 6
6.1 Standard receptacle dimensions Size 1 (M200, M250, M350) . 6
6.2 Standard receptacle dimensions size 2 (N200, N250) .10
7 Receptacles .12
8 Instructions .12
9 Marking .13
10 Tests .14
10.1 General requirements .14
10.2 User interface .14
10.3 Impact resistance .15
10.4 Receptacle protective caps.15
10.5 Leakage at room temperature .15
10.6 Valve operating handle .16
10.7 Abnormal loads .16
10.8 Rocking/twisting.17
10.9 Mounting hardware torque .18
10.10 Leakage test at low and high temperatures .18
10.11 Durability .19
10.12 Hydrostatic strength .22
10.13 Corrosion resistance .22
10.14 Deformation .23
10.15 Non-igniting evaluation .23
10.16 Vibration resistance .23
10.17 Hydrogen embrittlement .23
10.18 Pressure tight protective cap (PTPC) .24
Annex A (informative) Table of nozzle characteristics .32
Annex B (informative) Manufacturing and production test plan .33
Annex C (informative) Receptacle test fixture .34
Annex D (informative) Nozzle clearance dimensions .44
Bibliography .45
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ISO 16380:2014(E)
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out
through ISO technical committees. Each member body interested in a subject for which a technical
committee has been established has the right to be represented on that committee. International
organizations, governmental and non-governmental, in liaison with ISO, also take part in the work.
ISO collaborates closely with the International Electrotechnical Commission (IEC) on all matters of
electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are
described in the ISO/IEC Directives, Part 1. In particular the different approval criteria needed for the
different types of ISO documents should be noted. This document was drafted in accordance with the
editorial rules of the ISO/IEC Directives, Part 2 (see www.iso.org/directives).
Attention is drawn to the possibility that some of the elements of this document may be the subject of
patent rights. ISO shall not be held responsible for identifying any or all such patent rights. Details of
any patent rights identified during the development of the document will be in the Introduction and/or
on the ISO list of patent declarations received (see www.iso.org/patents).
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation on the meaning of ISO specific terms and expressions related to conformity
assessment, as well as information about ISO’s adherence to the WTO principles in the Technical Barriers
to Trade (TBT) see the following URL: Foreword - Supplementary information
The committee responsible for this document is ISO/TC 22, Road vehicles, Subcommittee SC 25, Vehicles
using gaseous fuel.
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ISO 16380:2014(E)
Introduction
A nozzle certified to this International Standard will be functionally compatible from a safety and
performance perspective with all listed receptacles of compatible profile and system pressure. Similarly,
a receptacle certified to this International Standard will be functionally compatible from a safety and
performance perspective with all listed nozzles of compatible profile and system pressure.
As there can eventually be many different kinds of nozzles and receptacles available from a variety
of manufacturers which, for safety reasons, shall all be compatible with each other, this International
Standard specifies a series of receptacle profiles. These standard profiles incorporate the design
specifications (mating materials, geometry, and tolerances) which can be considered in the certification
of a submitted nozzle or receptacle.
The construction and performance of nozzles and receptacles are based on the observation that four
main parameters affect user safety and system compatibility.
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INTERNATIONAL STANDARD ISO 16380:2014(E)
Road vehicles — Blended fuels refuelling connector
1 Scope
This International Standard applies to compressed blended fuels vehicle nozzles and receptacles
hereinafter referred to as devices, constructed entirely of new, unused parts and materials. Compressed
blended fuels fuelling connection nozzles consist of the following components, as applicable:
a) Receptacle and protective cap (mounted on vehicle) (see Clause 7);
b) Nozzle (mounted on dispenser side) (see Clause 5).
This International Standard applies to devices which have a service pressure of 20 MPa, 25 MPa, and
35 MPa hereinafter referred to in this International Standard as [see 9.1 c)]:
— size 1: M200, M250, and M350;
— size 2: N200 and N250.
This International Standard refers to service pressures of 20 MPa, 25 MPa, and 35 MPa for size 1 and
20 MPa and 25 MPa for size 2.
This International Standard applies to devices with standardised mating components (see 5.8 and 7.7).
This International Standard applies to connectors which
a) prevent blended fuels vehicles from being fuelled by dispenser stations with working pressures
higher than the vehicle fuel system working pressure,
b) allow blended fuels vehicles to be fuelled by dispenser stations with working pressures equal to or
lower than the vehicle fuel system working pressure,
c) allow blended fuels vehicles to be fuelled by dispenser stations for compressed natural gas,
d) allow blended fuels vehicles to be fuelled by compressed natural gas dispenser stations with working
pressures equal to or lower than the vehicle fuel system working pressure,
e) prevent blended fuels vehicles size 1 being refuelled on blended fuels dispenser stations equipped
with a size 2 nozzle and vice versa,
f) prevent natural gas vehicles from being fuelled by blended fuels station, and dispensers, and
g) prevent pure hydrogen vehicles from being fuelled by blended fuels station dispensers.
This International Standard is applicable to mixtures of hydrogen from 2 % to 30 % in volume and
compressed natural gas containing:
a) natural gas in accordance with ISO 15403-1 and ISO 15403-2;
b) pure hydrogen in accordance with ISO 14687-1 or ISO/TS 14687-2.
All references to pressures (MPa) throughout this International Standard are to be considered gauge
pressures unless otherwise specified.
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ISO 16380:2014(E)
2 Normative references
The following documents, in whole or in part, are normatively referenced in this document and are
indispensable for its application. For dated references, only the edition cited applies. For undated
references, the latest edition of the referenced document (including any amendments) applies.
ISO 1431-1, Rubber, vulcanized or thermoplastic — Resistance to ozone cracking — Part 1: Static and
dynamic strain testing
ISO 1817, Rubber, vulcanized or thermoplastic — Determination of the effect of liquids
ISO 9227, Corrosion tests in artificial atmospheres — Salt spray tests
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 14175, Welding consumables — Gases and gas mixtures for fusion welding and allied processes
ISO 14687-1, Hydrogen fuel — Product specification — Part 1: All applications except proton exchange
membrane (PEM) fuel cell for road vehicles
ISO/TS 14687-2, Hydrogen Fuel — Product Specification — Part 2: Proton exchange membrane (PEM) fuel
cell applications for road vehicles
ISO 15500-2:2012, Compressed natural gas (CNG) fuel system components — Part 2: Performance and
general test methods
ISO 15403-1, Natural gas — Natural gas for use as a compressed fuel for vehicles — Part 1: Designation of
the quality
ISO/TR 15403-2, Natural gas — Natural gas for use as a compressed fuel for vehicles — Part 2: Specification
of the quality
EN 10204, Metallic products — Types of inspection documents
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
air, dry
air with moisture content such that the dew point of the air at the required test pressure is at least 11 °C
below the ambient test temperature
3.2
hydrostatic pressure
pressure to which a component is tested to verify the structural strength of the component
3.3
working pressure
maximum pressure that the blended fuels refuelling connector can be expected to withstand in actual
service (calculatory base: service pressure times 1,25)
3.4
service pressure
settled pressure of 20 MPa, 25 MPa, and 35 MPa at a uniform gas temperature of 15 °C
3.5
positive locking means
feature which requires actuation of an interlocking mechanism to allow connection/disconnection of
the nozzle from the receptacle
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ISO 16380:2014(E)
3.6
compressed blended fuels refuelling nozzle
device which permits quick connection and disconnection of fuel supply hose to the compressed blended
fuels receptacle in a safe manner, hereafter referred to as compressed blended fuels nozzle
3.7
compressed blended fuels refuelling receptacle
device connected to a vehicle or storage system which receives the compressed blended fuels nozzle and
permits safe transfer of fuel, hereafter referred to as receptacle
3.8
compressed blended fuels refuelling connector
joint assembly of compressed blended fuels nozzle and receptacle, hereafter referred to as connector
3.9
hydrogen embrittlement
process by which various metals, most importantly high-strength steel, become brittle and crack
following exposure to hydrogen
3.10
compressed blended fuels
blended fuel is a mixture out of hydrogen from 2 % to 30 % in volume and natural gas which is used as
a vehicular fuel at a specified pressure as in the Introduction point 2
3.11
leak test gas
gas used for leak testing purposes
3.12
cycle life
connections and disconnections to a nozzle
3.13
service life
operations of the check valve
4 General construction requirements
a) There are two different sizes of refuelling systems, size 1 and size 2.
Size 1 should suit the need of smaller vehicles with a limited tanks size. Therefore, the flow diameter is
limited by the inner front diameter of the receptacle – in this case ⌀ 7,8 mm ± 0,2 mm.
Size 2 should suit the need of commercial vehicles like busses and trucks. Therefore, the flow diameter
is limited by the inner front diameter of the receptacle – in this case ⌀ 12 mm ± 0 2mm.
Also, the profile of the two different sizes is so different that no cross connection between the sizes is
possible.
b) Working pressure (= 1,25 times service pressure). All nozzles and receptacles are designed to have
a working pressure of:
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ISO 16380:2014(E)
Code Service pressure Working pressure
Size 1
M200 20 MPa 25 MPa
M250 25 MPa 31,25 MPa
M350 35 MPa 43,75 MPa
Size 2
N200 20 MPa 25 MPa
N250 25 MPa 31,25 MPa
c) Design life. Frequency of use is the second parameter to be considered. Since frequency of use will
differ with the nozzle/receptacle application (i.e. public sector, fleet employee, and residential),
all receptacles will be tested at 10 000 connect/disconnect cycles for compliance with this
International Standard. In addition, all nozzles shall be tested according to the following frequency
use classifications, as applicable.
— Class A Nozzle - This class specifies high frequency use, with a cycle life of 100 000. This equates
to approximately 100 fills per day for three years.
— Class B Nozzle - This class specifies medium frequency use, with a cycle life of 20 000 cycles.
This equates to approximately 10 fills per day for five years.
d) Training. Operator. Training required is in accordance with national requirements.
4.1 Compressed blended fuels nozzles and receptacles shall be well fitted and manufactured in
accordance with good engineering practice. All construction requirements can be met by either the
construction specified in this International Standard or another construction that gives at least equivalent
performance.
4.2 Compressed blended fuels nozzles and receptacles shall be:
— designed to minimize the possibility of incorrect assembly;
— designed to be secure against displacement, distortion, warping, or other damage;
— constructed to maintain operational integrity under normal and reasonable conditions of handling
and usage.
4.3 Nozzles and receptacles shall be manufactured of materials suitable and compatible for use with
compressed blended fuels at the pressure and the temperature ranges to which it will be subjected.
4.3.1 The temperature ranges shall be:
Table 1 — Temperature ranges
Location on board
Location a Location b
Cold −40 °C to 120 °C −40 °C to 85 °C
Moderate −20 °C to 120 °C −20 °C to 85 °C
Location a — Inside the engine compartment in case of internal combustion engine vehicle. The
receptacle shall be installed far from either heat or sparking sources and in a vented area.
Location b — Elsewhere in case of internal combustion engine vehicle.
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ISO 16380:2014(E)
4.4 Compressed blended fuels nozzles and receptacles shall be constructed out of materials which have
to be proven for the intent of withstanding a blended fuels mixture at the given pressures, temperatures,
and contents of the fuel that can be expected in this system.
4.5 Separate external three-way valves shall be constructed and marked so as to indicate clearly the
open, shut, and vent positions.
4.6 Compressed blended fuels nozzles and receptacles shall be operated either to connect or disconnect
without the use of tools.
4.7 Jointing components shall provide gas tight sealing performance.
Unless otherwise specified, all tests shall be conducted using dry hydrogen, helium, or blends of nitrogen
with a minimum 5 % of hydrogen. Test shall be performed by qualified personnel and appropriate safety
measures shall be taken. The dew point of the test gas at the test pressure shall be at the temperature at
which there is no icing, or hydrate or liquid formation. The dew point of the test gas at the test pressure
shall be at the temperature at which there is no icing, or hydrate or liquid formation.
5 Nozzles
5.1 Nozzles shall be one of three types as described in a) to c). (See also Annex A)
a) Type 1, which is a nozzle for use with dispensing hoses that remain fully pressurized at dispenser
shutdown. The nozzle shall not allow gas to flow until a positive connection has been achieved. The
nozzle shall be equipped with an integral valve or valves, incorporating an operating mechanism
which first stops the supply of gas and safely vents the trapped gas before allowing the disconnection
of the nozzle from the receptacle. The operating mechanism shall ensure the vent valve is in the
open position before the release mechanism can be operated and the gas located between the
nozzle shut-off valve and the receptacle check valve is safely vented prior to nozzle disconnection
(see 10.2).
b) Type 2, which is a nozzle for use with dispensing hoses that remain fully pressurized at dispenser
shutdown. A separate three-way valve connected directly, or indirectly, to the inlet of the nozzle is
required to safely vent trapped gas prior to nozzle disconnection. The nozzle shall not permit the
flow of gas if unconnected. Venting is required prior to disconnection of the nozzle (see 10.2).
c) Type 3, which is a nozzle for use with dispensing hoses which are automatically depressurised
(0,5 MPa and below) at dispenser shutdown (see 10.2).
In addition, nozzles shall be classified in terms of cycle life as follows:
— Class A - This class specifies high frequency use, with a cycle life of 100 000.
— Class B - This class specifies low frequency use, with a cycle life of 20 000.
5.2 Venting or de-pressurization of all nozzle types is required prior to disconnection. Disconnection of
all nozzles shall be capable of being accomplished in accordance with 10.2.
5.3 The method for attaching the nozzle to the fuel dispensing system hose shall not rely on the joint
threads between the male and female threads for sealing, such as conical threads.
5.4 The three-way valve vent port of Type 1 and Type 2 nozzles shall be protected from the ingress of
foreign particles and fluid which would hamper the operation of the valve. It has to be considered that the
vented gas has to be lead into a safe direction.
5.5 The portions of a nozzle which are held by the user for connection or disconnection can be thermally
insulated or it shall be ensured that no abnormal dangerous temperatures can be transferred to the user.
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ISO 16380:2014(E)
5.6 A Type 1 nozzle shall bear a marking in accordance with Clause 9, indicating the direction of the
open and shut operation of the actuating mechanism, if necessary.
5.7 The interface surface of the nozzle shall be constructed of material having a hardness > 75 Rockwell
B (HRB 75) and shall be non-sparking and conductive (see 10.11.5 and 10.15).
A proof for adequate hardness shall be either a Mill Sheet or an EN 10204-3.1 certificate or a similar
acceptable certificate if hardness is mentioned on there.
The exposed surfaces of the nozzles shall be made of non-sparking materials (see 10.11.5 and 10.15).
5.8 Nozzles shall comply with the performance requirements of Clause 10 to ensure interchangeability.
5.9 The vent line of Type 1 and Type 2 nozzles must withstand the maximum working pressure at full
flow conditions.
6 Standard receptacle dimensions
6.1 Standard receptacle dimensions Size 1 (M200, M250, M350)
A receptacle size 1 shall comply with the design specifications detailed in Figures 1 to 3.
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ISO 16380:2014(E)
Key
this area shall be kept free of all components
1 sealing surface equivalent to No. 110 O-ring of dimensions:
9,19 mm ± 0, 127 mm ID
2,62 mm ± 0, 076 mm width
sealing surface finish 0,8 μm to 0, 05 μm
material hardness 75 Rockwell B (HRB 75) minimum
Figure 1 — Size 1 — M200 Receptacle
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ISO 16380:2014(E)
Key
this area shall be kept free of all components
1 sealing surface equivalent to No. 110 O-ring of dimensions:
9,19 mm ± 0, 127 mm ID
2,62 mm ± 0, 076 mm width
sealing surface finish 0,8 μm to 0, 05 μm
material hardness 75 Rockwell B (HRB 75) minimum
Figure 2 — Size 1 — M250 Receptacle
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ISO 16380:2014(E)
Key
this area shall be kept free of all components
1 sealing surface equivalent to No. 110 O-ring of dimensions:
9,19 mm ± 0, 127 mm ID
2,62 mm ± 0, 076 mm width
sealing surface finish 0,8 μm to 0, 05 μm
material hardness 75 Rockwell B (HRB 75) minimum
Figure 3 — Size 1 — M350 Receptacle
Depending on the pressure range, M200 and M250 receptacles have to have a minimum length of 42 mm
and M350, 48,5 mm which is clear of provisions for attachment of receptacle or protective caps.
NOTE This space can be used from nozzle manufacturers for coding purposes.
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ISO 16380:2014(E)
6.2 Standard receptacle dimensions size 2 (N200, N250)
A receptacle size 2 shall comply with the design specifications detailed in Figures 4 to 5.
Key
1 sealing ID = ⌀15,47 ± 0,1 width = ⌀3,53 ± 0,2
this area shall be kept free of all components
surface roughness < Ra 3,2 μm
sealing surface finish 0,8 μm to 0,05 μm
material hardness 75 Rockwell B (HRB 75) minimum
Figure 4 — Size 2 N200 Receptacle
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ISO 16380:2014(E)
Key
1 sealing ID = ⌀15,47 ± 0,1 width = ⌀3,53 ± 0,2
this area shall be kept free of all components
surface roughness < Ra 3,2 μm
sealing surface finish 0,8 μm to 0,05 μm
material hardness 75 Rockwell B (HRB 75) minimum
Figure 5 — Size 2 — N250 Receptacle
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ISO 16380:2014(E)
Depending on the pressure range, N200 and N250 receptacles have to have a minimum length of 60,5 mm
which is clear of provisions for attachment of receptacle or protective caps.
NOTE This space can be used from nozzle manufacturers for coding purposes.
7 Receptacles
7.1 Receptacles shall comply with Clauses 1 to 10 of this International Standard and shall be evaluated
with at least two different test nozzles which are already certified to this International Standard – if
available in the market - each nozzle representing a different locking technology. If in future other locking
mechanisms will be invented the amount of nozzle types tested to shall reflect the actual technology.
The failure of any test conducted with the receptacle and nozzle test samples shall constitute a failure of
the submitted receptacle, unless the manufacturer can prove the problem was caused by the test nozzle.
7.2 Receptacle designs which employ means on the position of the back side ring as specified in
Figures 1 to 3 to accommodate mounting, or for mounting accessories or marking purposes, shall not
have such means extend beyond the back diameter dimensions of the profile as specified in Figures 1
to 3, as applicable. Acceptable means include wrench flats, dust cap anchoring grooves, use of hex stock,
undercutting for marking, and threads for pressure tight caps. Receptacle designs shall not compromise
the interchangeability requirements specified in Annex C.
7.3 The receptacle shall be equipped with an internal check valve to prevent the escape of gas. The
check valve shall be of the non-contact type, opening by differential pressure only.
7.4 The use of threaded connections which rely on the joint between the m
...
DRAFT INTERNATIONAL STANDARD ISO/DIS 16380
ISO/TC 22/SC 25 Secretariat: UNI
Voting begins on Voting terminates on
2013-01-12 2013-04-12
INTERNATIONAL ORGANIZATION FOR STANDARDIZATION • МЕЖДУНАРОДНАЯ ОРГАНИЗАЦИЯ ПО СТАНДАРТИЗАЦИИ • ORGANISATION INTERNATIONALE DE NORMALISATION
Road Vehicles — Blended Fuels Refuelling Connector
Véhicules routiers — Pistolet de remplissage pour les mélanges de carburants gazeux
ICS 75.200
To expedite distribution, this document is circulated as received from the committee
secretariat. ISO Central Secretariat work of editing and text composition will be undertaken at
publication stage.
Pour accélérer la distribution, le présent document est distribué tel qu'il est parvenu du
secrétariat du comité. Le travail de rédaction et de composition de texte sera effectué au
Secrétariat central de l'ISO au stade de publication.
THIS DOCUMENT IS A DRAFT CIRCULATED FOR COMMENT AND APPROVAL. IT IS THEREFORE SUBJECT TO CHANGE AND MAY NOT BE
REFERRED TO AS AN INTERNATIONAL STANDARD UNTIL PUBLISHED AS SUCH.
IN ADDITION TO THEIR EVALUATION AS BEING ACCEPTABLE FOR INDUSTRIAL, TECHNOLOGICAL, COMMERCIAL AND USER PURPOSES, DRAFT
INTERNATIONAL STANDARDS MAY ON OCCASION HAVE TO BE CONSIDERED IN THE LIGHT OF THEIR POTENTIAL TO BECOME STANDARDS TO
WHICH REFERENCE MAY BE MADE IN NATIONAL REGULATIONS.
RECIPIENTS OF THIS DRAFT ARE INVITED TO SUBMIT, WITH THEIR COMMENTS, NOTIFICATION OF ANY RELEVANT PATENT RIGHTS OF WHICH
THEY ARE AWARE AND TO PROVIDE SUPPORTING DOCUMENTATION.
© International Organization for Standardization, 2013
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ISO/DIS 16380
Copyright notice
This ISO document is a Draft International Standard and is copyright-protected by ISO. Except as permitted
under the applicable laws of the user’s country, neither this ISO draft nor any extract from it may be
reproduced, stored in a retrieval system or transmitted in any form or by any means, electronic,
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Reproduction may be subject to royalty payments or a licensing agreement.
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ii © ISO 2013 – All rights reserved
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ISO/DIS 16380
Contents Page
Foreword . iv
Introduction . v
1 Scope . 1
2 Normative references . 2
3 Terms and definitions . 3
4 General construction requirements . 4
5 Nozzles . 5
6 Standard receptacle dimensions . 6
7 Receptacles . 12
8 Instructions . 12
9 Marking . 13
10 Tests . 14
Annex A (informative) Table of Nozzle Characteristics . 32
Annex B (informative) Manufacturing and production test plan . 33
B.1 Acceptance of the manufacturing and production plan . 33
B.2 Qualification . 33
B.3 Leakage test . 33
B.4 Additional tests . 33
B.5 Evaluation . 33
Annex C (normative) Receptacle Test fixture . 34
Annex D (informative) Nozzle clearance dimensions . 44
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ISO/DIS 16380
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards bodies
(ISO member bodies). The work of preparing International Standards is normally carried out through ISO
technical committees. Each member body interested in a subject for which a technical committee has been
established has the right to be represented on that committee. International organizations, governmental and
non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely with the
International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.
International Standards are drafted in accordance with the rules given in the ISO/IEC Directives, Part 2.
The main task of technical committees is to prepare International Standards. Draft International Standards
adopted by the technical committees are circulated to the member bodies for voting. Publication as an
International Standard requires approval by at least 75 % of the member bodies casting a vote.
Attention is drawn to the possibility that some of the elements of this International Standard may be the
subject of patent rights. ISO shall not be held responsible for identifying any or all such patent rights.
ISO 16380 was prepared by Technical Committee ISO/TC 22, Road vehicles, Subcommittee SC 25, Vehicles
using gaseous fuel, JWG5 Fuel system components of vehicles propelled by gaseous hydrogen or by blends
of hydrogen and methane
Annexes A and B are for information only. Annex C forms an integral part of this part of ISO 16380.
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ISO/DIS 16380
Introduction
A nozzle certified to this International Standard will be functionally compatible from a safety and performance
perspective with all listed receptacles of compatible profile and system pressure. Similarly, a receptacle
certified to this standard will be functionally compatible from a safety and performance perspective with all
listed nozzles of compatible profile and system pressure.
A there may eventually be many different kinds of nozzles and receptacles available from a variety of
manufacturers which, for safety reasons, shall all be compatible with each other, this International Standard
specifies a series of receptacle profiles. These standard profiles incorporate the design specifications (mating
materials, geometry and tolerances) which may be considered in the certification of a submitted nozzle or
receptacle.
The construction and performance of nozzles and receptacles are based on the observation that four main
parameters affect user safety and system compatibility.
1) There exist two different sizes of refuelling systems. As there is the size1 and size 2.
Size 1 should suit the need of smaller vehicles with a limited tanks size. Therefore the flow diameter
is limited by the inner front diameter of the receptacle – in this case Ø7.8mm +-0.2mm.
Size 2 should suit the need of commercial vehicles like busses and trucks. Therefore the flow
diameter is limited by the inner front diameter of the receptacle – in this case Ø12mm+-0.2mm.
Also the profile of the two different sizes is so different that no cross connection between the sizes is
possible.
2) Working Pressure (=1.25 times Service Pressure). All nozzles and receptacles are designed to have
a working pressure of:
Code Service Pressure Working Pressure
Size 1
M200 20 MPa 25 MPa
M250 25 MPa 31.25 MPa
M350 35 MPa 43.75 MPa
Size 2
N200 20 MPa 25 MPa
N250 25 MPa 31.25 MPa
3) Design Life. Frequency of use is the second parameter to be considered. Since frequency of use will
differ with the nozzle/receptacle application (i.e., public sector, fleet employee and residential), all
receptacles will be tested at 10 000 connect/disconnect cycles for compliance with this standard. In
addition, all nozzles shall be tested according to the following frequency use classifications, as
applicable:
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ISO/DIS 16380
Class A Nozzle - This class specifies high frequency use, with a cycle life of 100 000. This
equates to approximately 100 fills per day for three years.
Class B Nozzle - This class specifies medium frequency use, with a cycle life of 20 000 cycles.
This equates to approximately 10 fills per day for five years.
4) Training. Operator training required is in accordance with national requirements.
vi © ISO 2012 – All rights reserved
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DRAFT INTERNATIONAL STANDARD ISO/DIS 16380
Road Vehicles — Blended Fuels Refuelling Connector
1 Scope
1.1 This International Standard applies to Compressed Blended Fuels vehicle nozzles and receptacles
hereinafter referred to as devices, constructed entirely of new, unused parts and materials. Compressed
Blended Fuels fuelling connection nozzles consist of the following components, as applicable:
a) Receptacle and protective cap (mounted on vehicle) (see clause 7).
b) Nozzle (mounted on dispenser side) (see clause 5).
1.2 This International Standard applies to devices which have a Service Pressure of 20MPa, 25MPa and
35MPa hereinafter referred to in this International Standard as (see 9.1c):
Size 1: M200, M250 and M350
Size 2: N200 and N250
1.2.1 This standard refers to Service Pressures of 20MPa, 25MPa and 35MPa for size 1 and 20MPa and
25MPa for size 2.
1.3 This International Standard applies to devices with standardised mating components (see subclause 5.8
and subclause 7.7).
1.4 This International Standard applies to connectors which:
1) prevent blended fuels vehicles from being fuelled by dispenser stations with Working Pressures
higher than the vehicle fuel system Working Pressure, and
2) allow blended fuels vehicles to be fuelled by dispenser stations with Working Pressures equal to or
lower than the vehicle fuel system Working Pressure, and
3) allow blended fuels vehicles to be fuelled by dispenser stations for compressed natural gas
4) allow blended fuels vehicles to be fuelled by compressed natural gas dispenser stations with Working
Pressures equal to or lower than the vehicle fuel system Working Pressure.
5) prevent blended fuels vehicles size 1 being refuelled on blended fuels dispenser stations equipped
with a size 2 nozzle and vice versa.
6) prevent Natural Gas vehicles from being fuelled by blended fuels station dispensers
7) prevent Pure Hydrogen vehicles from being fuelled by blended fuels station dispensers
1.5 This International Standard is applicable to:
Mixtures of Hydrogen from 2% to 30% in volume and compressed natural gas containing:
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ISO/DIS 16380
1) natural gas in accordance with ISO15403 Part 1 and 2
2) pure Hydrogen as per ISO 14687-1 or ISO/TS 14687-2
1.6 All references to pressures (MPa) throughout this International Standard are to be considered gauge
pressures unless otherwise specified.
2 Normative references
The following normative documents contain provisions which, through reference in this text, constitute
provisions of this International Standard. For dated references, subsequent amendments to, or revisions of,
any of these publications do not apply. However, parties to agreements based on this International Standard
are encouraged to investigate the possibility of applying the most recent editions of the normative documents
indicated below. For undated references, the latest edition of the normative document referred to applies.
Members of ISO and IEC maintain registers of currently valid International Standards.
EN 10204, Metallic products - Types of inspection documents
ISO 188, Rubber vulcanized — Accelerated ageing or heat-resistance tests.
ISO 1431-1, Rubber, vulcanized or thermoplastic - Resistance to ozone cracking - Part 1: Static and dynamic
strain testing
ISO 1817, Rubber vulcanized — Determination of the effect of liquids.
ISO 9227, Corrosion tests in artificial atmospheres — Salt spray tests.
ISO 14687-1, Hydrogen fuel - Product specification - Part 1: All applications except proton exchange
membrane (PEM) fuel cell for road vehicles.
ISO/TS 14687-2, Hydrogen Fuel — Product Specification — Part 2: Proton exchange membrane (PEM) fuel
cell applications for road vehicles.
ISO 15403-1, Natural gas - Natural gas for use as a compressed fuel for vehicles - Part 1: Designation of the
quality
ISO TR 15403-2, Natural gas - Natural gas for use as a compressed fuel for vehicles - Part 1: Specification of
the quality
ISO 15501-1, Road vehicles — Compressed natural gas fuelling systems — Part 1: Safety requirements.
ISO 15501-2, Road vehicles - Compressed natural gas (CNG) fuel systems - Part 2: Test methods
ISO TR 15916, Basic considerations for the safety of hydrogen systems
ISO CD 17268, Compressed hydrogen surface vehicle refuelling connection devices
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 14175, Welding consumable - Gases and gas mixture for fusion welding and allied processes
SAE J2600, Compressed Hydrogen Surface Vehicle Refuelling Connection Devices
SAE J2601, Fueling Protocols for Light Duty Gaseous Hydrogen Surface Vehicles
SAE J2719, Information Report on the Development of a Hydrogen Quality Guideline for Fuel Cell Vehicles
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ISO/DIS 16380
SAE J2799, 70 MPa Compressed Hydrogen Surface Vehicle Fueling Connection Device and Optional Vehicle
to Station Communications
3 Terms and definitions
For the purposes of this International Standard, the following terms and definitions apply.
3.1 air, dry
air with moisture content such that the dew point of the air at the required test pressure is at least 11 °C below
the ambient test temperature.
3.2 hydrostatic pressure
pressure to which a component is taken to verify the structural strength of the component
3.3 working pressure
maximum pressure that a connector may be expected to withstand in actual service (calculatory base: Service
Pressure times 1.25)
3.4 service pressure
settled pressure of 20MPa, 25MPa and 35MPa at a uniform gas temperature of 15 °C
3.5 positive locking means
feature which requires actuation of an interlocking mechanism to allow connection/disconnection of the nozzle
from the receptacle
3.6 compressed blended fuels refuelling nozzle
device which permits quick connection and disconnection of fuel supply hose to the Compressed Blended
Fuels receptacle in a safe manner, hereafter referred to as Compressed Blended Fuels nozzle
3.7 compressed blended fuels refuelling receptacle
device connected to a vehicle or storage system which receives the Compressed Blended Fuels nozzle and
permits safe transfer of fuel, hereafter referred to as receptacle
3.8 compressed blended fuels refuelling connector
joint assembly of Compressed Blended Fuels nozzle and receptacle, hereafter referred to as connector
3.9 non-sparking materials:
A stainless steel material can be considered as non-sparking when the alloy content of Chromium and Nickel
is above 22%.
3.10 hydrogen embrittlement
is the process by which various metals, most importantly high-strength steel, become brittle and crack
following exposure to hydrogen.
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ISO/DIS 16380
3.11 compressed blended fuels
A blended fuel is a mixture out of Hydrogen from 2% to 30% in volume and Natural Gas which is used as a
vehicular fuel at a specified pressure as in the Introduction point 2.
3.12 leak test gas
Gas used for leak testing purposes.
3.13 cycle life
connections and disconnections to a nozzle
3.14 service life
operations of the check valve
4 General construction requirements
4.1 Compressed blended fuels nozzles and receptacles shall be well fitted and manufactured in accordance
with good engineering practice. All construction requirements may be met by either the construction specified
in this International Standard or another construction that gives at least equivalent performance.
4.2 Compressed blended fuels nozzles and receptacles shall be:
designed to minimise the possibility of incorrect assembly;
designed to be secure against displacement, distortion, warping or other damage;
constructed to maintain operational integrity under normal and reasonable conditions of handling and
usage.
4.3 Nozzles and receptacles shall be manufactured of materials suitable and compatible for use with
compressed blended fuels at the pressure and the temperature ranges to which it will be subjected.
4.3.1 The temperature ranges shall be:
Table 1 — Temperature ranges
Location on board
Location a Location b
Cold - 40°C to 120°C - 40°C to 85°C
Moderate - 20°C to 120°C - 20°C to 85°C
Location a: inside the engine compartment in case of Internal Combustion engine vehicle.
Location b: elsewhere in case of Internal Combustion engine vehicle.
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ISO/DIS 16380
4.4 Compressed Blended Fuels nozzles and receptacles shall be constructed out of materials which have to
be proven for the intend of withstanding a blended fuels mixture at the given pressures, temperatures and
contents of the fuel that can be expected in this system.
4.5 Separate external three-way valves shall be constructed and marked so as to indicate clearly the open,
shut, and vent positions.
4.6 Compressed Blended Fuels nozzles and receptacles shall be operated either to connect or disconnect
without the use of tools.
4.7 Jointing components shall provide gas tight sealing performance.
4.8 Unless otherwise specified, all tests shall be conducted using dry hydrogen, helium or blends of
nitrogen with a minimum 5% of hydrogen. Test shall be performed by qualified personnel and appropriate
safety measures shall be taken. The dew point of the test gas at the test pressure shall be at the temperature
at which there is no icing, or hydrate or liquid formation. The dew point of the test gas at the test pressure
shall be at the temperature at which there is no icing, or hydrate or liquid formation.
5 Nozzles
5.1 Nozzles shall be one of three types as described in a) to c). (Also see Annex A)
a) Type 1, which is a nozzle for use with dispensing hoses that remain fully pressurised at dispenser
shutdown. The nozzle shall not allow gas to flow until a positive connection has been achieved. The
nozzle shall be equipped with an integral valve or valves, incorporating an operating mechanism which
first stops the supply of gas and safely vents the trapped gas before allowing the disconnection of the
nozzle from the receptacle. The operating mechanism shall ensure the vent valve is in the open position
before the release mechanism can be operated and the gas located between the nozzle shut-off valve
and the receptacle check valve is safely vented prior to nozzle disconnection (see subclause 10.2).
b) Type 2, which is a nozzle for use with dispensing hoses that remain fully pressurised at dispenser
shutdown. A separate three-way valve connected directly, or indirectly, to the inlet of the nozzle is
required to safely vent trapped gas prior to nozzle disconnection. The nozzle shall not permit the flow of
gas if unconnected. Venting is required prior to disconnection of the nozzle (see subclause 10.2).
c) Type 3, which is a nozzle for use with dispensing hoses which are automatically depressurised (0,5 MPa
and below) at dispenser shutdown (see subclause 10.2).
In addition, nozzles shall be classified in terms of cycle life as follows:
CLASS A - This class specifies high frequency use, with a cycle life of 100 000.
CLASS B - This class specifies low frequency use, with a cycle life of 20 000.
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ISO/DIS 16380
5.2 Venting or de-pressurisation of all nozzle types is required prior to disconnection. Disconnection of all
nozzles shall be capable of being accomplished in accordance with subclause 10.2.
5.3 The method for attaching the nozzle to the fuel dispensing system hose shall not rely on the joint
threads between the male and female threads for sealing, such as conical threads.
5.4 The three-way valve vent port of Type 1 and Type 2 nozzles shall be protected from the ingress of
foreign particles and fluid which would hamper the operation of the valve. It has to be considered that the
vented gas has to be lead into a safe direction.
5.5 The portions of a nozzle which are held by the user for connection or disconnection may be thermally
insulated or it shall be assured that no abnormal dangerous temperatures can be transferred to the user.
5.6 A Type 1 nozzle shall bear a marking in accordance with clause 9, indicating the direction of the open
and shut operation of the actuating mechanism, if necessary.
5.7 The interface surface of the nozzle shall be constructed of material having a hardness > 75 Rockwell B
(HRB 75) and shall be non-sparking and conductive (see subclause 10.11.5 and subclause 10.15).
A proof for adequate hardness can be a Mil Sheet or an EN10204-3.1 certificate or a similar acceptable
certificate if hardness is mentioned on there.
The exposed surfaces of the nozzles shall be made of non-sparking materials (see subclause 10.11.5 and
subclause 10.15).
5.8 Nozzles shall comply with the performance requirements of clause 10 to ensure interchangeability.
5.9 The vent line of Type 1 and 2 nozzles must withstand max. working pressure at full flow conditions.
6 Standard receptacle dimensions
6.1 Standard receptacle dimensions Size 1 (M200, M250; M350)
A receptacle size 1 shall comply with the design specifications detailed in Figures 1-3.
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ISO/DIS 16380
Figure 1 — Size 1 - M200 Receptacle
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ISO/DIS 16380
.
Figure 2 — Size 1 - M250 Receptacle
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ISO/DIS 16380
Figure 3 — Size 1 - M350 Receptacle
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ISO/DIS 16380
Depending on the pressure range M200 and M250 receptacles have to have a minimum length of 42 mm and
M350 48,5mm which is clear of provisions for attachment of receptacle or protective caps.
NOTE This space may be used from nozzle manufacturers for coding purposes
6.2 Standard receptacle dimensions size 2 (N200, N250)
A receptacle size 2 shall comply with the design specifications detailed in Figures 4-5.
Figure 4 — Size 2 N200 Receptacle
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ISO/DIS 16380
Figure 5 — Size 2 - N250 Receptacle
Depending on the pressure range N200 and N250 receptacles have to have a minimum length of 60.5 mm
which is clear of provisions for attachment of receptacle or protective caps.
NOTE This space may be used from nozzle manufacturers for coding purposes
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ISO/DIS 16380
7 Receptacles
7.1 Receptacles shall comply with clauses 1 to 10 of this standard and shall be evaluated with at least two
different test nozzles which are already certified to this standard – if available in the market - each nozzle
representing a different locking technology. If in future other locking mechanisms will be invented the amount
of nozzle types tested to shall reflect the actual technology.
The failure of any test conducted with the receptacle and nozzle test samples shall constitute a failure of the
submitted receptacle, unless the manufacturer can prove the problem was caused by the test nozzle.
7.2 Receptacle designs which employ means on the position of the back side ring as specified in figure 1-3
to accommodate mounting, or for mounting accessories or marking purposes, shall not have such means
extend beyond the back diameter dimensions of the profile as specified in figure 1-3, as applicable.
Acceptable means include wrench flats, dust cap anchoring grooves, use of hex stock, undercutting for
marking, and threads for pressure tight caps. Receptacle designs shall not compromise the interchangeability
requirements specified in Annex C.
7.3 The receptacle shall be equipped with an internal check valve to prevent the escape of gas. The check
valve shall be of the non-contact type, opening by differential pressure only.
7.4 The use of threaded connections which rely on the joint between the male and female threads for
sealing is prohibited.
7.5 The interfacing surface of the receptacle shall be constructed of material having a hardness > 75
Rockwell B (HRB 75) and shall be non-sparking and conductive (see subclauses 10.11.5 and 10.15).
The exposed surfaces of devices shall be made of non-sparking materials. (see subclause 10.11.5)
7.6 Receptacles shall have a means to prevent the ingress of fluids and foreign matter.
7.7 The function described in subclause 7.6 may also be met by either a protective cap (see subclause
10.4) or a pressure tight protective cap (see subclause 10.19).
7.8 Additionally a filter of adequate size should be integrated.
7.9 The receptacle shall have provisions to be firmly attached to the vehicle and shall comply with
applicable abnormal load tests (see subclause 10.7).
7.10 The receptacle shall not be installed in an area that exceeds a temperature of 85 °C. But it is to consider
that out of safety reasons the receptacle shall be tested for temperatures up to +120°C.
7.11 Receptacles shall have a cycle life of > 10 000 cycles but a service life of > 100 000 cycles.
8 Instructions
Information required under this section for instructions and provisions specified are required to be in an easily
understood form.
Special tools required for connection of receptacles to tubing and assembly and disassembly of three-way
valve parts shall be clearly identified in the instructions.
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ISO/DIS 16380
Manufacturers of receptacles, nozzles and three-way valves shall provide clear and concise printed instruction
and diagrams in a form that can be easily understood and adequate for
1) proper field assembly,
2) installation,
3) maintenance,
4) replacement of components as appropriate,
5) for safe operation by all users
6) suitability and use, and
7) storage and handling.
9 Marking
Information required under this section for marking, provisions specified are required to be in a form easily
understood. Marking should be embossed, cast, stamped or otherwise formed in the part. This includes
markings baked into an enamelled surface.
9.1 Nozzles and receptacles shall bear the following information
a) The manufacturer's or dealer's name, trademark or symbol
b) The model designation
c) M200 or M250 or M350 or N200 or N250
d) The applicable Type and Class (see subclause 5.1) and
e) If required - a certification mark
Marking shall remai
...
NORME ISO
INTERNATIONALE 16380
Première édition
2014-06-01
Véhicules routiers — Pistolet de
remplissage pour les mélanges de
carburants gazeux
Road vehicles — Blended fuels refuelling connector
Numéro de référence
ISO 16380:2014(F)
©
ISO 2014
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ISO 16380:2014(F)
DOCUMENT PROTÉGÉ PAR COPYRIGHT
© ISO 2014, Publié en Suisse
Droits de reproduction réservés. Sauf indication contraire, aucune partie de cette publication ne peut être reproduite ni utilisée
sous quelque forme que ce soit et par aucun procédé, électronique ou mécanique, y compris la photocopie, l’affichage sur
l’internet ou sur un Intranet, sans autorisation écrite préalable. Les demandes d’autorisation peuvent être adressées à l’ISO à
l’adresse ci-après ou au comité membre de l’ISO dans le pays du demandeur.
ISO copyright office
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CH-1214 Vernier, Geneva, Switzerland
Tel. +41 22 749 01 11
Fax +41 22 749 09 47
copyright@iso.org
www.iso.org
ii © ISO 2014 – Tous droits réservés
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ISO 16380:2014(F)
Sommaire Page
Avant-propos .v
Introduction .vi
1 Domaine d’application . 1
2 Références normatives . 2
3 Termes et définitions . 2
4 Exigences générales de construction . 3
5 Injecteurs . 5
6 Dimensions standards du réceptacle . 7
6.1 Dimensions standards du réceptacle de taille 1 (M200, M250, M350) . 7
6.2 Dimensions standards du réceptacle de taille 2 (N200, N250) .10
7 Réceptacles .12
8 Instructions .13
9 Marquage .13
10 Essais .14
10.1 Exigences générales .14
10.2 Interface utilisateur .14
10.3 Résistance au choc .15
10.4 Bouchons de protection du réceptacle .15
10.5 Fuite à température ambiante .16
10.5.1 Injecteur .16
10.5.2 Réceptacle .16
10.6 Poignée de manœuvre de la vanne .16
10.7 Charges exceptionnelles .16
10.7.1 Essai en atmosphère non pressurisée .17
10.7.2 Essai en atmosphère pressurisée .17
10.8 Oscillation/Torsion .18
10.9 Couple du matériel de fixation .18
10.10 Essai d’étanchéité à basse et haute températures .18
10.10.1 Essai d’étanchéité .18
10.10.2 Essai .19
10.10.3 Exigences .19
10.10.4 Essai de fonctionnement .19
10.11 Durabilité .19
10.11.1 Cyclage de durabilité .19
10.11.2 Vieillissement à l’ozone.21
10.11.3 Compatibilité du matériau d’étanchéité .21
10.11.4 Fissuration sous contrainte avec un mélange ammoniac-air humide
pendant dix jours.22
10.11.5 Résistance électrique .22
10.12 Résistance hydrostatique .22
10.13 Résistance à la corrosion .23
10.13.1 Injecteurs .23
10.13.2 Réceptacles .23
10.14 Déformation .23
10.15 Évaluation d'ininflammabilité .23
10.16 Résistance aux vibrations .24
10.17 Fragilisation par l’hydrogène .24
10.18 Bouchon de protection étanche à la pression (PTPC) .24
10.18.1 Étanchéité .24
10.18.2 Cyclage de durabilité .25
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ISO 16380:2014(F)
10.18.3 Usage inapproprié .25
10.18.4 Résistance au choc . .26
10.18.5 Résistance à la corrosion .26
10.18.6 Résistance hydrostatique .26
Annexe A (informative) Tableau des caractéristiques de l’injecteur .32
Annexe B (informative) Plan d’essai de fabrication et de production .33
Annexe C (informative) Montage d’essai du réceptacle .34
Annexe D (informative) Dimensions de l'espace mort de l’injecteur .44
Bibliographique .45
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ISO 16380:2014(F)
Avant-propos
L’ISO (Organisation internationale de normalisation) est une fédération mondiale d’organismes
nationaux de normalisation (comités membres de l’ISO). L’élaboration des Normes internationales est
en général confiée aux comités techniques de l'ISO. Chaque comité membre intéressé par une étude
a le droit de faire partie du comité technique créé à cet effet. Les organisations internationales,
gouvernementales et non gouvernementales, en liaison avec l'ISO participent également aux travaux.
L'ISO collabore étroitement avec la Commission électrotechnique internationale (IEC) en ce qui
concerne la normalisation électrotechnique.
Les procédures utilisées pour élaborer le présent document et celles destinées à sa mise à jour sont
décrites dans les Directives ISO/IEC, Partie 1. Il convient, en particulier de prendre note des différents
critères d'approbation requis pour les différents types de documents ISO. Le présent document a été
rédigé conformément aux règles de rédaction données dans les Directives ISO/IEC, Partie 2 (voir www
.iso .org/directives).
L’attention est appelée sur le fait que certains des éléments du présent document peuvent faire l’objet de
droits de propriété intellectuelle ou de droits analogues. L'ISO ne saurait être tenue pour responsable
de ne pas avoir identifié de tels droits de propriété et averti de leur existence. Les détails concernant
les références aux droits de propriété intellectuelle ou autres droits analogues identifiés lors de
l'élaboration du document sont indiqués dans l'Introduction et/ou dans la liste des déclarations de
brevets reçues par l'ISO (voir www .iso .org/brevets).
Les appellations commerciales éventuellement mentionnées dans le présent document sont données
pour information, par souci de commodité, à l’intention des utilisateurs et ne sauraient constituer un
engagement.
Pour une explication de la signification des termes et expressions spécifiques de l’ISO liés à
l’évaluation de la conformité, ou pour toute information au sujet de l’adhésion de l’ISO aux principes
de l’OMC concernant les obstacles techniques au commerce (OTC), voir le lien suivant: Avant-propos —
Informations supplémentaires.
Le comité chargé de l’élaboration du présent document est l’ISO/TC 22, Véhicules routiers, sous-comité
SC 25, Véhicules utilisant des carburants gazeux.
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ISO 16380:2014(F)
Introduction
Un injecteur certifié selon la présente Norme internationale sera fonctionnellement compatible, du
point de vue de la sécurité et de la performance, avec tous les réceptacles énumérés ayant un profil et
une pression système compatibles. De la même façon, un réceptacle certifié selon la présente Norme
internationale sera fonctionnellement compatible, du point de vue de la sécurité et de la performance,
avec tous les injecteurs énumérés ayant un profil et une pression système compatibles.
Étant donné qu'il peut exister de très nombreux types d'injecteurs et de réceptacles disponibles auprès
de différents fabricants qui, pour des raisons de sécurité, doivent tous être compatibles les uns avec les
autres, la présente Norme internationale spécifie une série de profils de réceptacle. Ces profils standards
incluent les spécifications de conception (matériaux de raccordement, géométrie et tolérances) qui
peuvent être prises en compte lors de la certification d'un injecteur ou d'un réceptacle soumis.
La construction et les performances des injecteurs et des réceptacles reposent sur l’observation selon
laquelle quatre principaux paramètres affectent la sécurité de l'utilisateur et la compatibilité du
système.
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NORME INTERNATIONALE ISO 16380:2014(F)
Véhicules routiers — Pistolet de remplissage pour les
mélanges de carburants gazeux
1 Domaine d’application
La présente Norme internationale s’applique aux injecteurs et réceptacles de véhicules utilisant des
mélanges de carburants comprimés, ci-après appelés dispositifs, fabriqués avec des pièces et des
matériaux neufs et non usagés. Les réceptacles de remplissage en mélanges de carburants comprimés
sont constitués des composants suivants, selon le cas:
a) Réceptacle et bouchon de protection (intégrés au véhicule) (voir l’Article 7);
b) Injecteur (intégré côté distributeur) (voir l’Article 5).
La présente Norme internationale s’applique aux dispositifs ayant une pression de service de 20 MPa,
25 MPa et 35 MPa, ci-après appelés dans la présente Norme internationale [voir en 9.1 c)]:
— taille 1: M200, M250 et M350;
— taille 2: N200 et N250.
La présente Norme internationale concerne des pressions de service de 20 MPa, 25 MPa et 35 MPa pour
la taille 1 et de 20 MPa et 25 MPa pour la taille 2.
La présente Norme internationale s’applique aux dispositifs ayant des composants de raccordement
standardisés (voir en 5.8 et 7.7).
La présente Norme internationale s’applique aux pistolets qui:
a) empêchent les véhicules utilisant des mélanges de carburants d’être ravitaillés par des distributeurs
dont les pressions de fonctionnement sont supérieures à la pression de fonctionnement du circuit
carburant du véhicule,
b) permettent aux véhicules utilisant des mélanges de carburants d’être ravitaillés par des
distributeurs dont les pressions de fonctionnement sont inférieures ou égales à la pression de
fonctionnement du circuit carburant du véhicule,
c) permettent aux véhicules utilisant des mélanges de carburants d’être ravitaillés par des
distributeurs de gaz naturel comprimé,
d) permettent aux véhicules utilisant des mélanges de carburants d’être ravitaillés par des
distributeurs de gaz naturel comprimé dont les pressions de fonctionnement sont inférieures ou
égales à la pression de fonctionnement du circuit carburant du véhicule,
e) empêchent les véhicules utilisant des mélanges de carburants de taille 1 d’être ravitaillés par des
distributeurs de mélanges de carburants équipés d’un injecteur de taille 2 et inversement,
f) empêchent les véhicules fonctionnant au gaz naturel d’être ravitaillés par des distributeurs de
mélanges de carburants, et
g) empêchent les véhicules fonctionnant à l’hydrogène pur d’être ravitaillés par des distributeurs de
mélanges de carburants.
La présente Norme internationale est applicable aux mélanges d’hydrogène de 2 % à 30 % en volume et
au gaz naturel comprimé contenant:
a) du gaz naturel conformément à l’ISO 15403-1 et à l’ISO 15403-2;
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b) de l’hydrogène pur conformément à l’ISO ISO 14687-1 ou à l’ISO /TS 14687-2.
Sauf indication contraire, toutes les références aux pressions (MPa) de la présente Norme internationale
doivent être considérées comme des pressions manométriques.
2 Références normatives
Les documents ci-après, dans leur intégralité ou non, sont des références normatives indispensables à
l’application du présent document. Pour les références datées, seule l'édition citée s'applique. Pour les
références non datées, la dernière édition du document de référence s'applique (y compris les éventuels
amendements).
ISO 1431-1, Caoutchouc vulcanisé ou thermoplastique — Résistance au craquelage par l'ozone — Partie 1:
Essais sous allongement statique et dynamique
ISO 1817, Caoutchouc vulcanisé ou thermoplastique — Détermination de l'action des liquides
ISO 9227, Essais de corrosion en atmosphères artificielles — Essais aux brouillards salins
ISO 11114-4, Bouteilles à gaz transportables — Compatibilité des matériaux et des robinets avec les
contenus gazeux — Partie 4: Méthodes d'essai pour le choix des aciers résistants à la fragilisation par
l'hydrogène
ISO 14175, Produits consommables pour le soudage — Gaz et mélanges gazeux pour le soudage par fusion
et les techniques connexes
ISO 14687-1, Carburant hydrogène — Spécification de produit — Partie 1: Toutes applications à l'exception
des piles à combustible à membrane d'échange de protons (MEP) pour les véhicules routiers
ISO/TS 14687-2, Carburant hydrogène — Spécification de produit — Partie 2: Applications des piles à
combustible à membrane à échange de protons (MEP) pour les véhicules routiers
ISO 15500-2:2012, Composants des systèmes de combustible gaz naturel comprimé (GNC) — Partie 2:
Performances et méthodes d’essai générales
ISO 15403-1, Gaz naturel — Gaz naturel pour usage comme carburant comprimé pour véhicules — Partie 1:
Désignation de la qualité
ISO/TR 15403-2, Gaz naturel — Gaz naturel pour usage comme carburant comprimé pour véhicules —
Partie 2: Spécification de la qualité
EN 10204, Produits métalliques — Types de documents de contrôle
3 Termes et définitions
Pour les besoins du présent document, les termes et définitions suivants s'appliquent.
3.1
air sec
air ayant un taux d'humidité tel que le point de rosée de l’air à la pression d’essai requise est au moins
11 °C au-dessous de la température d’essai ambiante
3.2
pression hydrostatique
pression à laquelle un composant est soumis à essai pour vérifier la résistance structurelle du
composant
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3.3
pression de fonctionnement
pression maximale qu'un pistolet de remplissage en mélanges de carburants peut supporter dans des
conditions réelles de fonctionnement (base de calcul: pressure de service multipliée par 1,25)
3.4
pression de service
pression établie de 20 MPa, 25 MPa et 35 MPa à une température gazeuse uniforme de 15 °C
3.5
moyen d’autoverrouillage
élément nécessitant l'actionnement d'un mécanisme d'interverrouillage pour connecter/déconnecter
l'injecteur au/du réceptacle
3.6
injecteur de remplissage en mélanges de carburants comprimés
dispositif permettant de connecter et déconnecter rapidement et sans danger le tuyau d'alimentation
en carburant au/du réceptacle de mélanges de carburants comprimés, ci-après appelé injecteur de
mélanges de carburants comprimés
3.7
réceptacle de remplissage en mélanges de carburants comprimés
dispositif connecté à un véhicule ou à un système de stockage qui reçoit l’injecteur de mélanges de
carburants comprimés et permet un transfert sans danger du carburant, ci-après appelé réceptacle
3.8
pistolet de remplissage en mélanges de carburants comprimés
assemblage de l’injecteur et du réceptacle de mélanges de carburants comprimés, ci-après appelé
pistolet
3.9
fragilisation par l’hydrogène
procédé par lequel plusieurs métaux, notamment l’acier à haute résistance, deviennent cassant et se
fissurent après exposition à l’hydrogène
3.10
mélanges de carburants comprimés
mélange constitué d’hydrogène de 2 % à 30 % en volume et de gaz naturel, qui est utilisé comme
carburant pour véhicules à une pression spécifiée comme dans le point 2 de l’Introduction
3.11
gaz d’essai d’étanchéité
gaz utilisé pour l’essai d’étanchéité
3.12
durée de vie
connexions et déconnexions à/d’un injecteur
3.13
durée de vie en service
actionnements du clapet antiretour
4 Exigences générales de construction
a) Il existe différentes tailles de système de remplissage, la taille 1 et la taille 2.
Il convient que la taille 1 réponde aux besoins des petits véhicules dont la capacité du réservoir est
limitée. Par conséquent, le diamètre de débit est limité par le diamètre avant intérieur du réceptacle –
dans ce cas ⌀ 7,8 mm ± 0,2 mm.
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Il convient que la taille 2 réponde aux besoins des véhicules commerciaux tels que les bus et les camions.
Par conséquent, le diamètre de débit est limité par le diamètre avant intérieur du réceptacle – dans ce
cas ⌀ 12 mm ± 2mm.
De plus, le profil des deux différentes tailles est tellement différent qu’aucune interconnexion entre les
tailles n’est possible.
b) Pression de fonctionnement (= 1,25 fois la pression de service). Tous les injecteurs et les réceptacles
sont conçus pour présenter une pression de fonctionnement de:
Pression de fonc-
Code Pression de service
tionnement
Taille 1
M200 20 MPa 25 MPa
M250 25 MPa 31,25 MPa
M350 35 MPa 43,75 MPa
Taille 2
N200 20 MPa 25 MPa
N250 25 MPa 31,25 MPa
c) Durée de vie nominale. La fréquence d'utilisation est le deuxième paramètre à prendre en compte.
Étant donné que la fréquence d'utilisation sera différente selon l'application de l'injecteur/du
réceptacle (c'est-à-dire, secteur public, parc automobile et secteur résidentiel), tous les réceptacles
seront soumis à essai à raison de 10 000 cycles de connexion/déconnexion pour déterminer la
conformité à la présente Norme internationale. De plus, tous les injecteurs doivent être soumis à
essai selon les classifications de fréquence d’utilisation suivantes, selon le cas.
— Injecteur de classe A – Cette classe spécifie une fréquence d’utilisation élevée, avec une durée
de vie de 100 000 cycles. Cela équivaut à environ 100 pleins par jour pendant trois ans.
— Injecteur de classe B – Cette classe spécifie une fréquence d’utilisable moyenne, avec une durée
de vie de 20 000 cycles. Cela équivaut à environ 10 pleins par jour pendant cinq ans.
d) Formation. Opérateur. La formation requise est conforme aux exigences nationales.
4.1 Les injecteurs et les réceptacles de mélanges de carburants comprimés doivent être correctement
équipés et fabriqués conformément aux bonnes pratiques d’ingénierie. Toutes les exigences de
construction peuvent être satisfaites soit par la construction spécifiée dans la présente Norme
internationale soit par une autre construction permettant d’obtenir des performances au moins
équivalentes.
4.2 Les injecteurs et les réceptacles de mélanges de carburants comprimés doivent être:
— conçus pour réduire le plus possible le risque d'assemblage incorrect;
— conçus pour être protégés contre la déformation, la distorsion, le voilage ou d'autres dommages;
— conçus pour préserver l'intégrité opérationnelle dans des conditions normales et raisonnables de
manipulation et d'utilisation.
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4.3 Les injecteurs et les réceptacles doivent être fabriqués avec des matériaux adaptés et compatibles
avec les mélanges de carburants comprimés dans les gammes de pression et de température auxquelles
ils seront soumis.
4.3.1 Les gammes de température doivent être:
Tableau 1 — Gammes de température
Emplacement à bord
Emplacement a Emplacement b
Températures
−40 °C à 120 °C −40 °C à 85 °C
froides
Températures
−20 °C à 120 °C −20 °C à 85 °C
modérées
Emplacement a — Intérieur du compartiment moteur dans le cas d’un véhicule équipé d’un moteur à
combustion interne. Le réceptacle doit être installé à distance de sources de chaleur ou d’explosion et
dans une zone ventilée.
Emplacement b — Ailleurs dans le cas d’un véhicule équipé d’un moteur à combustion interne.
4.4 Les injecteurs et les réceptacles de mélanges de carburants comprimés doivent être fabriqués avec
des matériaux qui doivent être prouvés capables de supporter un mélange de carburants comprimés
aux pressions, aux températures et à la composition indiquées du carburant qui peut être prévu dans ce
système.
4.5 Des vannes à trois voies externes séparées doivent être construites et marquées de façon à indiquer
clairement les positions d’ouverture, de fermeture et de mise à l’air libre.
4.6 Les injecteurs et les réceptacles de mélanges de carburants comprimés doivent pouvoir être
connectés ou déconnectés sans avoir recours à des outils.
4.7 Les composants pour joint doivent être étanches aux gaz.
Sauf indication contraire, tous les essais doivent être réalisés en utilisant de l’hydrogène sec, de l’hélium
ou des mélanges d’azote avec au moins 5 % d’hydrogène. L’essai doit être effectué par un personnel
qualifié et des mesures de sécurité appropriées doivent être prises. Le point de rosée du gaz d’essai à la
pression d’essai doit être établi à la température à laquelle il n’y a pas de formation de glace, d’hydrate
ou de liquide. Le point de rosée du gaz d’essai à la pression d’essai doit être établi à la température à
laquelle il n’y a pas de formation de glace, d’hydrate ou de liquide.
5 Injecteurs
5.1 Les injecteurs doivent être l’un des trois types décrits de a) à c). (Voir également l’Annexe A)
a) Le type 1, qui est un injecteur utilisable avec des flexibles distributeurs qui restent entièrement
pressurisés à l’arrêt du distributeur. L’injecteur doit empêcher le gaz de circuler tant qu’une
connexion positive n’a pas été obtenue. L’injecteur doit être équipé d’une ou de plusieurs vannes
intégrées comprenant un mécanisme de manœuvre qui stoppe d’abord l’alimentation en gaz et
met à l’air libre en toute sécurité le gaz piégé avant de permettre la déconnexion de l’injecteur
du réceptacle. Le mécanisme de manœuvre doit s’assurer que la vanne de mise à l’air libre est en
position ouverte avant de pouvoir actionner le mécanisme de libération et que le gaz situé entre
la vanne d’arrêt de l’injecteur et le clapet anti-retour est mis à l’air libre en toute sécurité avant la
déconnexion de l’injecteur (voir en 10.2).
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b) Le type 2, qui est un injecteur utilisable avec des flexibles distributeurs qui restent entièrement
pressurisés à l’arrêt du distributeur. Une vanne à trois voies séparée, connectée directement ou
indirectement à l’orifice d’entrée de l’injecteur, est nécessaire pour mettre à l’air libre en tout
...
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