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This document is developed in accordance with the rules given in GB/T 1.1-2020 Directives for standardization — Part 1: Rules for the structure and drafting of standardizing documents.
This document is Part 1 of GB/T 41134 Fuel cell power systems for industrial electric trucks. The following parts of GB/T 41134 have been issued:
——Part 1: Safety;
——Part 2: Performance test methods.
This document has been redrafted and modified in relation to IEC 62282-4-101: 2014 Fuel cell technologies — Part 4-101: Fuel cell power systems for propulsion other than road vehicles and auxiliary power unit (APU) — Safety of electrically powered industrial trucks.
The following structural changes have been made with respect to IEC 62282-4-101: 2014:
——Subclauses 4.16 and 4.17 have been added;
——Test conditions have been added into 5.1 c);
——Subclauses 5.11.1 and 5.11.2 have been added;
——Subclauses 7.1, 7.2, and 7.3 have been added;
——Subclauses 4.3.3 ~ 4.3.8, 4.9.1 ~ 4.9.10, 4.10.1 ~ 4.10.8, 4.13.10, 5.17.1 ~ 5.17.3 have been deleted, and 4.13.11 has been adjusted to 4.13.10 herein, 4.13.12 adjusted to 4.13.11 and 4.13.13 adjusted to 4.13.12;
——Subclause 5.20 in IEC 62282-4-101: 2014 has been deleted, and 5.21 has been adjusted to 5.20 herein, 5.22 adjusted to 5.21 and 5.23 adjusted to 5.22;
——Figures 2, 3 and 4 and Table 1 have been deleted, and Figure 5 in IEC 62282-4-101: 2014 has been changed to Figure 2 herein, Figure 6 changed to Figure 3, Table 2 changed to Table 1, Table 3 changed to Table 2 and Table 4 changed to Table 3;
——Annex A to IEC 62282-4-101: 2014 has been adjusted to Annex B hereto.
Technical differences between this document and IEC 62282-4-101: 2014 are marked with perpendicular single line (|) in the outside page margin of the provisions concerned.
The following main technical differences have been made with respect to IEC 62282-4-101: 2014 and the reasons are as follows:
——The normative references in the international standard have been added, deleted and replaced, and the differences between normative references of this document and normative references in IEC 62282-4-101: 2014 have been listed in Annex A hereto;
——The terms and definitions of modified check valves, maximum allowable working pressure, maximum operating pressure and zone system of classification have been modified (see 3.3, 3.14, 3.16 and 3.26);
——For convenience of use, the requirements for hydrogen pressure vessels metal hydride vessels, overvoltage protection, regulating valves, ventilation measures, electrostatic discharge, electrical components of fuel cell power system, internal wires, external wires, lamps and lampholders, etc. have been modified for compliance with the current national standards (see 4.2.3.2, 4.2.4, 4.3.2, 4.5.2, 4.9, 4.10, 4.13.1.3, 4.13.2, 4.13.3 and 4.13.8);
——The requirements for insulation resistance and vibration resistance have been added (see 4.16 and 4.17);
——The performance requirements for safety and test methods for generals for type test have been added [see 5.1 c)];
——For convenience of use, the contents of some tests have been modified, such as fuel container securement test, dielectric voltage-withstand test, rain test, enclosure loading test and needle flame test for thermoplastic materials, for compliance with the current national standards (see 5.3, 5.11, 5.17, 5.18.1, 5.19 and 6.1);
——For convenience of use, the logo has been modified for compliance with the current national standard (see Clause 7);
——For convenience of use, some requirements and test methods for overpressure and thermal protection, ventilation facilities to prevent combustible gas and vapor accumulation, electrostatic discharge, electrical insulation, environmental test and adhesion test of sign boards have been deleted (see 4.3.2 ~ 4.3.8, 4.9.1 ~ 4.9.10, 4.10.1 ~ 4.10.8, 4.13.10, 5.17.1 ~ 5.17.3 and 5.20 of IEC 62282-4-101: 2014).
The following editorial changes have been made in this document:
——To be consistent with the existing standard in China, this standard has been renamed "Fuel cell power systems for industrial electric trucks — Part 1: Safety";
——Annex A (Informative) "Differences between normative references of this document and normative references in IEC 62282-4-101: 2014" have been added; The Chinese documents consistent and corresponding with the international normative references in this document are as follows:
——GB/T 5169 (All Parts) Fire hazard testing for electric and electronic products [IEC 60695 (All Parts)]
——GB/T 14536.1-2008 Automatic electrical controls for household and similar use — Part 1: General requirements (IEC 60730-1: 2003, IDT)
——GB/T 18615-2002 Non-alloyed and stainless steel fittings for corrugated flexible metallic hoses (eqv ISO 10806: 1994)
——GB/T 29729-2013 Essential requirements for the safety of hydrogen systems (ISO/TR 15916: 2004, NEQ)
Attention is drawn to the possibility that some of the elements of this document may be the subject of patent rights. The issuing body of this document shall not be held responsible for identifying any or all such patent rights.
This document was proposed by the China Electrical Equipment Industry Association.
This standard is under the jurisdiction of National Technical Committee on Fuel Cell and Flow Battery of Standardization Administration of China (SAC/TC 342).
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Introduction
GB/T 41134 deals with categories such as safety, performance and interchangeability of fuel cell power systems for industrial electric trucks. This standard is applicable to industrial electric trucks with fuel cell power systems because such an application is urgently demanded in the world.
Fuel cell power systems for industrial electric trucks can work in hybrid mode or multiple modes. This standard breaks down their different modes and provides a clear framework for the design and test of fuel cell power systems for industrial electric trucks. It is used for evaluating the performance of different combined fuel cell modes of fuel cell power systems for industrial electric trucks.
Users of this standard may optionally carry out the test items, described in this standard, which are suitable for their purposes. This document does not exclude other test methods.
GB/T 41134 is proposed to consist of two parts.
——Part 1: Safety, which presents the safety requirements and test methods for structure, circuit and fuel of fuel cell power systems for industrial electric trucks.
——Part 2: Performance test methods, which presents a unified and repeatable test method related to the electrical, thermal and environmental performance of fuel cell power systems for industrial electric trucks.
Fuel cell power systems for industrial electric trucks — Part 1: Safety
1 Scope
This part of GB/T 41134 covers safety requirements for fuel cell power systems intended to be used in electrically powered industrial trucks.
This standard applies to gaseous hydrogen-fuelled fuel cell power systems and direct methanol fuel cell power systems for electrically powered industrial trucks.
This standard applies to fuel cell powered industrial trucks for handling, pushing, towing, lifting, stacking or placing goods, such as forklifts, single-bucket loaders.
This standard covers the fuel cell power system as defined in 3.8 and Figure 1.
This standard applies to d.c. type fuel cell power systems, with a rated output voltage not exceeding 150 V d.c. for indoor and outdoor use.
This standard covers fuel cell power systems whose fuel source container is permanently attached to either the industrial truck or the fuel cell power system.
The following fuels are considered within the scope of this standard:
——gaseous hydrogen;
——methanol.
The following are not included in the scope of this standard:
——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.
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Note: A fuel cell power system may contain all or some of the above components.
Figure 1 Fuel cell power systems for industrial electric trucks
2 Normative references
The following referenced documents are indispensable for the application 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.
GB 2894 Safety signs and guideline for the use
GB 3836.1-2010 Explosive atmospheres — Part 1: Equipment — General requirements (IEC 60079-0: 2007, MOD);
GB 3836.4-2010 Explosive atmospheres — Part 4: Equipment protection by intrinsic safety "i"
GB 3836.14-2014 Explosive atmospheres — Part 14: Classification of areas — Explosive gas atmosphere (IEC 60079-10-1: 2008, IDT);
GB/T 4208-2017 Degrees of protection provided by enclosure (IP code) (IEC 60529: 2013, IDT)
GB 4706.66-2008 Household and similar electrical appliance-safety — Particular requirements for pumps (IEC 60335-2-41: 2004, IDT)
GB 4943.1-2011 Information technology equipment — Safety — Part 1: General requirements (IEC 60950-1: 2005, MOD)
GB/T 5099.1-2017 Seamless steel gas cylinders — Part 1: Quenched and tempered steel cylinders with tensile strength less than 1100 MPa (ISO 9809-1: 2010, NEQ);
GB/T 5169.9-2013 Fire hazard testing for electric and electronic products — Part 9:Guidance for assessing the fire hazard — Preselection testing procedures — General guidelines (IEC 60695-1-30: 2008, IDT)
GB/T 5169.16-2017 Fire hazard testing for electric and electronic products — Part 16: Test flames — 50 W horizontal and vertical flame test methods (IEC 60695-11-10: 2013, IDT)
GB/T 5169.21-2017 Fire hazard testing for electric and electronic products — Part 21: Abnormal heat — Ball pressure test (IEC 60695-10-2: 2014, IDT)
GB/T 5169.22-2015 Fire hazard testing for electric and electronic products — Part 22: Test flames — 50 W flame — Apparatus and confirmational test method (IEC 60695-11-4: 2011, IDT)
GB/T 5226.1-2019 Electrical safety of machinery — Electrical equipment of machines — Part 1: General requirements (IEC 60204-1: 2016, IDT)
GB/T 7127.1-2000 Brake hose assemblies for hydraulic braking systems of road vehicles used with non-petroleum-base brake fluid (eqv ISO 3996: 1995)
GB/T 14048.3-2017 Low-voltage switchgear and controlgear — Part 3: Switches, disconnectors, switch-disconnectors and fuse-combination units (IEC 60947-3: 2015, IDT)
GB/T 14048.5-2017 Low-voltage switchgear and controlgear — Part 5-1: Control circuit devices and switching element — Electromechanical control circuit devices (IEC 60947-5-1: 2016, MOD)
GB/T 14536.19-2017 Automatic electrical controls for household and similar use — Particular requirements for electrically operated water valves including mechanical requirements (IEC 60730-2-17: 2007, IDT)
GB/T 16839.1-2018 Thermocouples — Part 1: EMF specifications and tolerances (IEC 60584-1: 2013, IDT)
GB/T 16855.1-2018 Safety of machinery — Safety-related parts of control systems — Part 1: General principles for design (ISO 13849-1: 2015, IDT)
GB/T 16895.21-2020 Low-voltage electrical installations — Part 4-41: Protection for safety — Protection against electric shock (IEC 60364-4-41: 2017, IDT)
GB/T 16935.1-2008 Insulation coordination for equipment within low-voltage systems — Part 1: Principles requirements and tests (IEC 60664-1: 2007, IDT)
GB/T 17799.1-2017 Electromagnetic compatibility — Generic standards — Immunity for residential, commercial and light-industrial environments
GB 17799.3-2012 Electromagnetic compatibility (EMC) — Generic standards — Emission standard for residential, commercial and light-industrial environments
GB 18384-2020 The safety requirement of electric vehicles
GB/T 18422-2013 Rubber and plastics hoses and hose assemblies — Determination of air permeability (ISO 4080: 2009, IDT)
GB/T 18426-2001 Rubber or plastics-coated fabrics — Low-temperature bend test (ISO 4675: 1990, IDT)
GB/T 19212.1-2016 Safety of transformers, reactors, power supply units and combinations thereof — Part 1: General requirements and tests (IEC 61558-1: 2009, MOD)
GB/T 23606-2009 Copper-hydrogen embrittlement test method (ISO 2626: 1973, MOD)
GB/T 23658-2009 Elastomeric seals — Material requirement for seals used in pipes and fittings carrying gaseous fuels and hydrocarbon fluid (ISO 16010: 2005, MOD)
GB/T 24135-2009 Rubber-or plastics-coated fabrics — Accelerated ageing tests (ISO 1419: 1995, IDT)
GB/T 27544-2011 Industrial trucks — Electrical requirements
GB/T 28164-2011 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 application (IEC 62133: 2002, IDT)
GB/T 29838-2013 Fuel cell modules (IEC 62282-2: 2012, MOD)
GB/T 30718-2014 Compressed hydrogen surface vehicle refueling connection devices (ISO 17268: 2006, NEQ)
GB/T 33292-2016 Metal hydride hydrogen storage system for fuel cells backup power
GB/T 35544-2017 Fully-wrapped carbon fiber reinforced cylinders with an aluminum liner for the on-board storage of compressed hydrogen as a fuel for land vehicles
GB/T 37499-2019 Safety and control devices for gas burners and gas-burning appliances — Particular requirements — Automatic and semi-automatic valves (ISO 23551-1: 2012, MOD)
ISO 1421 Rubber- or plastics-coated fabrics — Determination of tensile strength and elongation at break
ISO 4038 Road vehicles — Hydraulic braking systems — Simple flare pipes, tapped holes, male fittings and hose end fittings
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 1114-4 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 13226 Rubber — Standard reference elastomers (SREs) for characterizing the effect of liquids on vulcanized rubbers
ISO 14113 Gas welding equipment — Rubber and plastics hose and hose assemblies for use with industrial gases up to 450 bar (45MPa)
ISO 15500-12 Road vehicles — Compressed natural gas (CNG) fuel system components — Part 12: Pressure relief valve (PRV)
ISO/TR 15916 Basic considerations for the safety of hydrogen systems
ISO 15649 Petroleum and natural gas industries — Piping
IEC 60695 Fire hazard testing
IEC 60730-1: 2013 Automatic electrical controls — Part 1: General requirements
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 62103 Electronic equipment for use in power installations
3 Terms and definitions
For the purposes of this document, the following terms and definitions apply.
3.1
abnormal operation
operation of the fuel cell power system with any one electrical or control component malfunction or failure, in any failure mode regarded as reasonably probable in the FMEA; but excluding accidental rupture or breakdown of the containers of flammable liquids, vapours and/or gases
3.2
bonding
permanent joining of metallic parts to form a positive electrically conductive path that provides electrical continuity between non-current carrying metal parts and is capable of conducting any fault current that may occur
Note 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 the truck itself, such as with a grounding strap or with tyres. 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
valve that automatically prevents medium countercurrent through medium force by a disc (valve disc)
[Source: GB/T 21465-2008, 2.2.1.8]
3.4
circuit, limited power
circuit involving a peak voltage greater than 42.4 V a.c. (30 V r.m.s.) or 60 V d.c. and power after 60 s of operation comply with the values outlined in Tables 2B and 2C of GB 4943.1-2011
Note to entry: A circuit that is low voltage under both normal and single fault conditions is referred to in GB 4943.1-2011 as a safety extra low voltage (SELV).
3.5
low-voltage circuit
circuit involving a peak open-circuit voltage of less than 42.4 V a.c. (30 V r.m.s.) or 60 V d.c. supplied by a battery, a fuel cell, a transformer having a maximum volt-ampere (VA), rating of less than 100 VA and a maximum secondary output of 30 V a.c. or by a combination of a transformer and a fixed impedance that as a system, complies with GB/T 19212.1-2016
Note 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 to entry: This is outlined in GB 3836.14-2014.
3.7
electrostatic discharge; ESD
discharge created by static electricity
3.8
fuel cell power system
generator system that uses one or more fuel cell module(s) to generate electric power and heat
Note 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: GB/T 28816-2020, 3.49, modified]
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 to entry: Display and control functions may 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).
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3.10
integrated fuel cell power system
complete system of fuel cell modules and components that are incorporated into the industrial truck with the various components of the system potentially distributed throughout the truck
3.11
hazardous (classified) areas
any work area or space where combustible dust, ignitable fibres, or flammable, volatile liquids, gases, vapours or mixtures are or may be present in the air in quantities sufficient to produce explosive or ignitable mixtures as defined by GB 3836.14-2014
3.12
integral
something that is either contained within the fuel cell power system or is external, 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 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 pressure at which a fuel cell or fuel cell power system may be operated
Note 1 to entry: See Annex B 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: GB/T 28816-2020, 3.86.3, modified]
3.15
maximum continuous load rating
maximum continuous power that can be sustained by the fuel cell power system independent of any electrical energy storage device or storage component at 25°C and ambient pressure 0.1 MPa
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3.16
maximum operating pressure; MOP
maximum pressure, specified by part/system manufacturers, at which the part or system is designed to operate continuously
Note 1 to entry: The maximum operating pressure is expressed in Pa.
Note 2 to entry: See Annex B for a comparison table of pressure terms.
[Source: GB/T 28816-2020, Definition 3.86.4, modified]
3.17
normal release
limited internal localized volumes of flammable vapour concentrations released during normal operation that may include fuel cell purge
3.18
normal operation
all operating and non-operating modes encountered during product use that are not the result of a failure
3.19
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
3.20
thermally activated pressure relief device; TPRD
pressure relief device that activated thermally
3.21
safety control
automatic controls and interlocks including relays, switches, sensors and other auxiliary equipment used in conjunction therewith to form a safety control system, which is intended to prevent unsafe operation of the controlled equipment
3.22
safety critical component
component, device, circuit, software or similar part whose failure would affect the safety of the fuel cell power system as determined in 4.15
3.23
service pressure
nominal working pressure
pressure, as specified by the manufacturer, at a uniform gas temperature of 15°C and full gas content
Note 1 to entry: This term only relates to the hydrogen pressure vessel.
Note 2 to entry: See Annex B for a comparison table of pressure terms.
3.24
gas purge
protective operation to remove gases and/or liquids, such as fuel, hydrogen, air or water, from a fuel cell power system
3.25
touch current
electric current through a human body or an animal body when it touches one or more accessible parts
3.26
zone system of classification
means for classifying areas into hazardous areas and non-hazardous areas, based on the frequency and duration of flammable gas
Note 1 to entry: Hazardous areas include the following zones:
——Zone 0: A location in which explosive gases appears continuously or frequently or are present for long periods of time, e.g., hydrogen carrying devices in a power system
——Zone 1: A location in which explosive gases are likely to exist under normal operating conditions, e.g., the fuel cell stack, fuel supply system and exhaust gas (hydrogen) discharge port in a power system.
——Zone 2: A location in which explosive gases are impossible to exist or possible to exist in a short time under normal operating conditions.
Note 2 to entry: Except for the above-mentioned zones, other zones in a power system are non-hazardous areas.
4 Construction requirements for safety
4.1 General
4.1.1 Any component of a product covered by this document shall comply with the requirements for that component. Normative references for standards covering components used in the products covered by this document are given in Clause 2.
4.1.2 A component is not required to comply with a specific requirement of the normative referenced standards that:
a) involves a feature or characteristic not required in the application of the component in the product covered by this document, or
b) is superseded by a requirement in this document.
4.1.3 Any component shall be used in accordance with its rating established for the intended conditions of use.
4.1.4 Specific components are incomplete in construction features or restricted in performance capabilities. Such components are intended for use only under limited conditions, such as certain temperatures not exceeding specified limits, and shall be used only under those specific conditions.
Foreword i
Introduction iv
1 Scope
2 Normative references
3 Terms and definitions
4 Construction requirements for safety
4.1 General
4.2 Hydrogen and other fluid containing parts
4.3 Over-pressure and thermal protection
4.4 Regulators
4.5 Operating and shut-off valves
4.6 Filters
4.7 Pumps and compressors
4.8 Electrically operated pressure sensing and controlling devices
4.9 Ventilation measures
4.10 Electrostatic discharge (ESD)
4.11 Discharges including methanol emissions and waste materials
4.12 System enclosures (self-contained system)
4.13 Fuel cell power system electrical components
4.14 Control circuits
4.15 Safety/hazard analysis
4.16 Insulation resistance
4.17 Requirements for vibration resistance
5 Performance requirements for safety and type tests
5.1 General
5.2 Vibration test
5.3 Fuel container securement test
5.4 Endurance test
5.5 External leakage test
5.6 Ultimate strength test
5.7 Potential failure modes test
5.8 Temperature test
5.9 Continuity test
5.10 Touch current test
5.11 Dielectric voltage-withstand test
5.12 Non-metallic tubing test for accumulation of static electricity
5.13 Limited power circuit test
5.14 Maximum VA test
5.15 Abnormal operation test (electric equipment failures)
5.16 Emission of effluents test (only for methanol fuel cells)
5.17 Rain test
5.18 System enclosure test (self-contained system)
5.19 Needle flame test for thermoplastic materials
5.20 Test for elastomeric seals, gaskets and tubing
5.21 Test for permeation of non-metallic tubing and piping
5.22 Test for electrical output leads
6 Routine tests
6.1 Dielectric voltage-withstand test
6.2 External leakage test
7 Markings
7.1 General
7.2 Markings of fuel cell power system
7.3 Marking of components
8 Instructions
8.1 General
8.2 Maintenance instructions
8.3 Operating instructions
8.4 Installation instructions
Annex A (Informative) Differences between normative references of this document and normative references in IEC 62282-4-101:
Annex B (Informative) Comparison of pressure terms
Bibliography
