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This Information Report provides interim background information and an interim specification of hydrogen fuel quality for commercial proton exchange membrane (PEM) fuel cell vehicles. This Report also provides background information on how this interim specification was developed by the Hydrogen Quality Task Force (HQTF) of the Interface Working Group (IWG) of the SAE Fuel Cell Standards Committee. The constituents and thresholds listed in Table 1 are based on a survey of the industry, the published literature and reflects current and draft analytical test methods. Some of the allowable constituent levels are higher than desired because a published detection method is not available for the desired threshold. Some of the allowable constituent levels may be lower than desired due to incomplete evaluations and/or an attempt to minimize testing costs (such as including methane in total hydrocarbons).

The purpose of this document is to define design, construction, operational, and maintenance requirements for hydrogen fuel storage and handling systems in on-road vehicles. Performance-based requirements for verification of design prototype and production hydrogen storage and handling systems are also defined in this document. Complementary test protocols (for use in type approval or self-certification) to qualify designs (and/or production) as meeting the specified performance requirements are described. Crashworthiness of hydrogen storage and handling systems is beyond the scope of this document. SAE J2578 includes requirements relating to crashworthiness and vehicle integration for fuel cell vehicles. It defines recommended practices related to the integration of hydrogen storage and handling systems, fuel cell system, and electrical systems into the overall Fuel Cell Vehicle.

This recommended practice is intended to serve as a procedure to verify the functional performance, design specifications or vendor claims of any PEM (Proton Exchange Membrane) type fuel cell stack sub-system for automotive applications. In this document, definitions, specifications, and methods for the functional performance characterization of the fuel cell stack sub-system are provided. The functional performance characterization includes evaluating electrical outputs and controlling fluid inputs and outputs based on the test boundary defined in this document. In this document, a fuel cell stack sub-system is defined to include the following: Fuel cell stack(s) – An assembly of membrane electrode assemblies (MEA), current collectors, separator plates, cooling plates, manifolds, and a supporting structure. Connections for conducting fuels, oxidants, cooling media, inert gases and exhausts. Electrical connections for the power delivered by the stack sub-system.

This technical information report specifies a guideline for the hardware requirements for fueling a Hydrogen Surface Vehicle (HSV) with compressed hydrogen storage rated at a Nominal Working Pressure of 70 MPa. It contains a description of the receptacle geometry and optional communication hardware and communications protocol to refuel the HSV. The intent of this document is to enable harmonized development and implementation of the hydrogen fueling interfaces. It is intended to be utilized for hydrogen vehicle field evaluations until enough information is collected to enable standardization. The receptacle portion of this document is to be reevaluated utilizing international field data in approximately two (2) years and subsequently superseded by SAE J2600 in the 2009 timeframe.

This SAE Recommended Practice establishes uniform procedures for testing fuel cell and hybrid fuel cell electric vehicles, excluding low speed vehicles, designed primarily for operation on the public streets, roads and highways. The procedure addresses those vehicles under test using compressed hydrogen gas supplied by an off-board source or stored and supplied as a compressed gas onboard. This practice provides standard tests that will allow for determination of fuel consumption and range based on the US Federal Emission Test Procedures, using the Urban Dynamometer Driving Schedule (UDDS) and the Highway Fuel Economy Driving Schedule (HFEDS). Chassis dynamometer test procedures are specified in this document to eliminate the test-to-test variations inherent with track testing, and to adhere to standard industry practice for fuel consumption and range testing.

SAE J2579 is being developed by the SAE Fuel Cell Vehicle (FCV) Standards Committee to provide recommended practices for Fuel Systems in Fuel Cell and Other Hydrogen Vehicles. As part of this work, definitions for pressurized systems and containers were developed. The purpose of this document is to disseminate these definitions prior to the release of SAE J2579 such that other technical groups are aware of the information.

This Information Report provides interim background information and an interim specification of hydrogen fuel quality for commercial proton exchange membrane (PEM) fuel cell vehicles. This Report also provides background information on how this interim specification was developed by the Hydrogen Quality Task Force (HQTF) of the Interface Working Group (IWG) of the SAE Fuel Cell Standards Committee. The constituents and thresholds listed in table 1 are based on a survey of the industry, the published literature and reflects current and draft analytical test methods. Some of the allowable constituent levels are higher than desired because a published detection method is not available for the desired threshold. Some of the allowable constituent levels may be lower than desired due to incomplete evaluations and/or an attempt to minimize testing costs (such as including methane in total hydrocarbons).

This recommended practice is intended to serve as a design verification procedure and not a product qualification procedure. It may be used to verify design specifications or vendor claims. Test procedures, methods and definitions for the performance of the fuel processor subsystem (FPS) of a fuel cell system (FCS) are provided. Fuel processor subsystems (FPS) include all components required in the conversion of input fuel and oxidizer into a hydrogen-rich product gas stream suitable for use in fuel cells. Performance of the fuel processor subsystem includes evaluating system energy inputs and useful outputs to determine fuel conversion efficiency and where applicable the overall thermal effectiveness. Each of these performance characterizations will be determined to an uncertainty of less than ± 2% of the value. The method allows for the evaluation of fuel processor subsystems for two general cases.

Electric, Fuel Cell and Hybrid vehicles may contain many types of high voltage systems. Adequate barriers between occupants and the high voltage systems are necessary to provide protection from potentially harmful electric current and materials within the high voltage system that can cause injury to occupants of the vehicle during a crash. This SAE Recommended Practice is applicable to all Electric, Fuel Cell and Hybrid vehicle designs that are comprised of at least one voltage bus with a nominal voltage greater than or equal to 60 Volts DC or 30 VAC. This Recommended Practice addresses electrical isolation integrity, electrolyte spillage, and retention of the battery system.

This recommended practice is intended to provide a framework for performance testing of fuel cell systems (FCS’s) designed for automotive applications with direct current (DC) output. The procedures described allow for measurement of performance relative to claims by manufacturers of such systems with regard to the following performance criteria. — Power — Efficiency — Transient Response — Start and Stop Performance — Physical Description — Environmental Limits — Operational Requirements — Integration Since this recommended practice is based on the principal of performance measurement relative to a claim, the testing parties should take care to include any qualifying or unique circumstances leading to the test results reported in order to achieve full disclosure. For example, efficiency as defined in section 3.1.9 allows for the inclusion of thermal output benefit.

While there are various types of Fuel Cell architectures being developed, the focus of this document is on Proton Exchange Membrane (PEM) fuel cell stacks and ancillary components for automotive propulsion applications. Within the boundaries of this document are the: Fuel Supply and Storage, Fuel Processor, Fuel Cell Stack, and Balance of Plant, as shown in Figure 1.

This SAE Recommended Practice identifies and defines the preferred technical guidelines relating to the safe integration of fuel cell system, fuel storage, and electrical systems into the overall Fuel Cell Vehicle.

SAE J2600 applies to design, safety and operation verification of Compressed Hydrogen Surface Vehicle (CHSV) refuelling connection devices hereinafter referred to as nozzle and receptacle. CHSV Refuelling nozzles and receptacles shall consist of the following components, as applicable. Alternatives may be used as long as the alternative geometries shall not be interchangeable with the standard geometry specified in this SAE Standard and the standard geometry in Section 6 provides insufficient flow rates: a Receptacle and protective cap (mounted on vehicle) (see Section 6 and 7); b Nozzle (see Section 5).

This SAE Information Report contains definitions for hydrogen fuel cell powered vehicle terminology. It is intended that this document be a resource for those writing other hydrogen fuel cell vehicle documents, specifically, Standards or Recommended Practices.

Electric and Hybrid Electric Vehicles contain many types of battery systems. Adequate barriers between occupants and battery systems are necessary to provide protection from potentially harmful factors and materials within the battery system that can cause injury to occupants of the vehicle during a crash. This SAE Recommended Practice is applicable to all Electric Vehicle and Hybrid Electric Vehicle battery designs, including those described in SAE J1797. The potentially harmful factors and materials addressed by this document include electrical isolation integrity, electrolyte spillage, and retention of the battery system.

Electric and Hybrid Electric Vehicles contain many types of battery systems. Adequate barriers between occupants and battery systems are necessary to provide protection from potentially harmful factors and materials within the battery system, which can cause injury to occupants of the vehicle during different crash scenarios. This SAE Recommended Practice is applicable to all Electric Vehicle and Hybrid Electric Vehicle battery designs including those in SAE J1797. The potentially harmful factors and materials include electrical isolation integrity, electrolyte spillage and liquid interactions, and retention of the battery system. Maintaining electrical isolation of the system is important to prevent hazardous shock of vehicle occupants. Electrolyte spillage and battery fluid interactions should be minimized to prevent chemical reactions and electrical conductance. The latter could lead to an electrical shock hazard.