GB/T 31037.2-2014Fuel cell power system used for industrial lift truck applications - Part 2: Technical specification (English PDF)

1.1 Overview

This Part of GB/T 31037 specifies the technical requirements, test methods, inspection rules, and technical documentation of the fuel cell power system used for industrial lift truck applications.

Fuel cell power systems that power electric industrial lift trucks for indoor or outdoor use include fuel cell power systems (referred to as power systems) and energy storage modules. An energy storage module refers to an electrical energy storage device that is used to start a power system, or to help or supplement a fuel cell power system to power internal or external loads. It consists of a lead-acid battery, a nickel-metal hydride battery, a lithium-ion battery, a super capacitor, or other energy storage modules with corresponding functions. This Part covers only the technical specification of the fuel cell power system and does not include the requirements for energy storage modules.

The industrial lift trucks involved in this Part include: counterbalanced fork lift truck, reach truck, straddle truck, pallet-stacking truck, platform truck, truck with elevatable operation position, side-loading truck, rough terrain truck, lateral stacking truck (both sides), lateral and front stacking truck, stacking high-lift straddle carrier, pallet truck, platform and stillage truck, non-stacking low-lift straddle carrier, and order picking truck.

This Part is applicable to proton exchange membrane (PEM) fuel cell power systems that use gaseous hydrogen as the fuel and air as the oxidant.

The dangerous situations considered in this Part are limited to the safety measures that shall be taken if the abnormal operation of the fuel cell power system may cause damage to the power system itself.

1.2 System boundary

The schematic diagram for the system boundary is shown in Figure 1. Among which, the components of the fuel cell power system are in the thick solid line frames, and the entry-exit arrows at the frame boundary represent the inputs and outputs for the fuel cell power system.

operating temperature range by heating or cooling or heat removal.

- Humidifying system: A device for humidifying fuel and oxidant (air) to increase relative humidity.

- Water treatment system: It includes, but is not limited to piping, circulating water pumps, valves, sensor devices, water storage and replenishment tanks, etc. When water generated by the power system is used for humidifying fuel or oxidant or other uses, the particles and metal ions that are harmful to the power system shall be removed.

- Control system: It consists of sensor devices, circuits, actuators, control devices, and software programs that are necessary for regulation and monitoring, so that the power system’s operating parameters are able to be kept within the manufacturer’s given limits without human intervention, thus ensuring the normal operation of the power system.

- Power regulating system: It includes, but is not limited to DC / DC or DC /

AC, circuits, etc. The output power of the fuel cell stack will, by regulating current and voltage according to the requirements for the power required for the internal device of the power system and the external output power, provide the power output that meets the requirements of use.

- Ventilation system: A system that achieves air exchange inside and outside the power system through forced or natural means.

- Fuel cell power system: It consists of all or part of the components in the schematic diagram for the boundary of the power system, and is combined with an energy storage module to form a fuel cell dynamic system.

According to its different structures, it can be divided into two types: all-in- one and integrated:

lambda All-in-one system: All the components of the power system are loaded into one shell; the display and control interface or function buttons can be installed in the place where the operator can conveniently operate according to the actual situation.

lambda Integrated system: All the components of the power system are dispersedly installed on an industrial lift truck in accordance with the structural space and the center of gravity of the industrial lift truck.

However, all the components are connected together through circuits or piping to form a complete set of fuel cell power system.

3.2 Maximum power

It refers to the electric power that is output by the fuel cell power system under peak operating conditions.

3.3 Idle conditions

The power system is in operating condition and is able to maintain its own operation, but does not output power externally.

3.4 Efficiency of power system

It refers to the share of the energy consumed by the power system per unit time converted into the effective electric power. It shall be calculated as the low heat value (LHV) of hydrogen as required.

3.5 Fuel consumption

The amount of fuel consumed by the power system within a specified period of time under specific conditions, in kilograms per hour (kg/h).

3.6 Fuel consumption rate

The amount of fuel consumed per unit time and unit power by the power system, in grams per kilowatt-hour [g/(kW·h)].

3.7 Balance weight

It refers to the auxiliary quality that is added inside or outside the power system to ensure the equilibrium and stable operation of the industrial lift truck.

4.1 Integrity requirements of the power system

4.1.1 Overview

The design of the power system shall be able to meet the needs of the set functions. Its composition may include the fuel cell module, fuel storage system, fuel supply system, oxidant supply system, thermal management system, humidifying system, water treatment system, control system, power regulating system, ventilation system, etc. In addition, all components used in the power system shall comply with the relevant national standards.

4.1.2 Fuel cell module

The fuel cell module shall meet the requirements of GB/T 29838-2013.

4.1.3 Fuel storage system

The connection device between the fuel storage system and the fuel cell module shall meet the safety requirements for use. When refueling, the method for fast fuel connector connection between the fuel storage system and the fuel supply station shall comply with relevant pressure and safety standards and regulations. The replenishment port of the non-standard fuel storage container and the connector of the standard fuel storage container shall not be matched.

The hydrogen storage device, whether stationary or replaceable, disposable or rechargeable, shall comply with relevant national standards of pressure and safe use as well as regulatory requirements.

4.2 Output voltage of the power system

The output voltage of the power system shall meet the electrical input voltage requirements of industrial lift trucks using the system, and comply with the provisions of GB/T 17938-1999. Alternatively, USE the DC or AC input voltage required by the industrial lift truck of the power system.

4.3 Safety protection

The automatic control system in the power system shall be able to automatically control the normal operation of each subsystem, and provide appropriate sound, light, or other equivalent methods in response to the abnormal changes in the operation of the power system to alert the operator or automatically turn on the interlocking device for safety protection, so as to ensure normal and safe operation of the power system.

4.4 Requirements for startup characteristics

When the power system is tested for startup characteristics in accordance with

6.3, the time from startup to idle conditions shall comply with the manufacturer’s regulations.

4.5 Power output characteristics

When tested in accordance with 6.4, the test results for the rated power, maximum power and overload capacity of the power system shall comply with the manufacturer’s regulations.

4.6 Dynamic response characteristics

The dynamic response characteristics mainly reflect the dynamic loading response of the power system and its ability to adapt to load impact. PERFORM a dynamic response test in accordance with 6.6. The response time of the power system from idle conditions to rated power conditions, and the response time from rated power conditions to maximum power conditions shall comply integrated system according to the following requirements:

- All-in-one system: MEASURE the mass of the power system and balance weight, respectively, including the mass of coolant and humidifying water.

Without affecting the equilibrium and stability of the industrial lift truck at rest or in operation, the mass of the display and control interface or function buttons located outside the enclosure of the power system may not be measured.

- Integrated system: MEASURE the mass of each discrete module of the power system, and the mass of the balance weight, respectively, including the mass of coolant and humidifying water. Without affecting the equilibrium and stability of the industrial lift truck at rest or in operation, the mass of the display and control interface or function buttons may not be measured.

6.1.2 Volume measurement of the power system

MEASURE the volumes of the all-in-one system and the integrated system according to the following requirements:

- All-in-one system: If the power system and the balance weight are in the same encapsulated enclosure, MEASURE the dimensions of the enclosure in three directions. If the power system and the balance weight are not in the same encapsulated enclosure, they must be measured separately. The sum of the two is the volume of the system. In the event that it is determined that the industrial lift truck has sufficient space to install a display and control interface or function buttons located outside of the enclosure of the power system, the volume of the display and control interface or function buttons may not be measured.

- Integrated system: MEASURE the volume of each discrete module of the power system and balance weight during installation, respectively. The total volume obtained by summation is the volume of the system.

6.2 Air tightness test

6.2.1 Air tightness test for piping, fittings and pressure-containing

members of fuel (hydrogen) and oxidant (air)

The power system starts operation according to the manufacturer’s prescribed procedures. After reaching the manufacturer specified normal operating conditions, STOP the operation, PURGE the power system, and CLOSE all gas outlets, leaving only one gas inlet, as shown in Figure 2. The temperature of the power system drops to ambient temperature. Nitrogen or helium passes through a gas pressure test device equipped with a pressure relief valve, a pressure sensor, a cut-off valve and a gas flow meter to enter the gas chamber inlet of the power system. Gradually PRESSURIZE within about 1min to (110 ± specified shutdown procedures.

6.6 Dynamic response characteristics test

6.6.1 Test requirements

FOLLOW the procedures listed in 6.6.2 successively to test the dynamic response characteristics of the power system. The dynamic response time in the test shall comply with the manufacturer’s regulations.

The data sampling equipment used in the test shall meet the requirements of

5.2.5.

In the test, it is necessary to continuously record the peak output voltage and output current of the power system during step loading, as well as the peak output voltage and output current of the fuel cell stack.

6.6.2 Test procedures

a) START the power system in accordance with the procedures in 6.3.2.2;

ENTER the idle conditions for at least 1min of steady operation;

b) SEND an operation command of dynamic step to the power system in accordance with the manufacturer’s regulations; rapidly LOAD-STEP the power system from the idle conditions to the rated power output state;

c) SEND an operation command of dynamic step to the power system in accordance with the manufacturer’s regulations, so as to directly LOAD-

STEP the power system from the rated power output state to the maximum power output state;

d) In the test, RECORD and CALCULATE the response time of the dynamic process in which the power system rapidly load-steps from the idle conditions to the rated power output state, and the response time of the process in which the power system directly load-steps from the rated power output state to the maximum power output state, respectively.

6.7 Energy efficiency test

Using the data obtained from the test in 6.4, CALCULATE the energy efficiency of the power system in accordance with the provisions in Annex A of GB/T

23645-2009. The calculation results shall meet the requirements of 4.8.

6.8 Temperature adaptability test

6.8.1 SHUT down the power system under normal operating conditions. Then

PLACE the power system in a low-temperature environment specified by the manufacturer for more than 12h. At this temperature, the power system shall be able to start and operate normally as specified by the manufacturer.

6.8.2 SHUT down the power system under normal operating conditions. Then

Unless otherwise agreed between the manufacturer and user of the power system, each power system shall have a complete set of technical documents.

If a set of files consists of multiple files, each file shall list the file codes and names of other files.

8.3.1 Product manual

At a minimum, the product manual shall give a detailed and clear description of the following:

- technical parameters, including:

lambda output voltage, V;

lambda rated power, kW;

lambda maximum power, kW;

lambda single duration of the maximum power, s;

lambda minimum interval of the maximum power, s;

lambda system weight, balance weight may be included, kg;

lambda weight of the balance weight, kg (if balance weight is not included in the system weight, it must be given separately);

lambda overall dimensions; the all-in-one system shall provide the overall dimensions of the system enclosure; if the balance weight is outside the enclosure, the overall dimensions of the balance weight shall also be provided; the integrated system gives the volume in accordance with the provisions of 6.1.2, mm × mm × mm;

lambda hydrogen storage capacity, kg;

lambda requirements for the technical parameters of energy storage modules, such as voltage, capacitance, overall dimensions, etc.

- introduction of various functional components of the power system, such as hydrogen charging interfaces, electric power output connectors, hydrogen storage devices, switches, etc.;

- types of fuels and oxidants (including gas composition, impurity content, etc.);

- fuel and oxidant consumption at rated and maximum power;

- maximum gas leakage limit;

- typical emissions;

- ambient conditions during normal startup and operation (permissible altitude, temperature range, and humidity range);

- ambient conditions during storage (permissible temperature, and humidity range);

- operating temperature range during normal operation of the power system;

- operating pressure range and maximum allowable operating pressure of the fuel, oxidant, and coolant during normal operation of the power system;

- coolant type and quality;

- noise;

- location of the grounding point.

8.3.2 Installation manual

The installation manual shall give detailed and clear instructions for the installation and fixing of the power system.

The installation manual includes at least the following:

- handling, transportation and storage requirements;

- preparations before installation;

- installation positions;

- fixing means;

- connection methods for piping, including the gas and liquid piping;

- connection methods for circuits and sensors;

- installation drawing;

- precautions and prohibited operations.

The installation manual of the integrated system needs to specify in detail the overall dimensions, piping and circuit connection methods of each component.

8.3.3 Operation manual

The operating manual shall detail the procedures for the proper startup and use of the power system. Special caution shall be given to safety measures and possible incorrect operations.

The operation manual shall include the following:

- hydrogen charging procedures and precautions;

- hydrogen storage device cleaning procedures and precautions; if a compressed hydrogen storage bottle is used, for transport safety, the hydrogen replacement and cleaning must be performed before filling the