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This SAE Information Report is intended to be used for routine (or periodic) monitoring of filling station performance. It is not intended to provide process quality control requirements for any portion of the product delivery cycle.

This SAE Technical Information Report (TIR) provides test methods for evaluating hydrogen sensors when the hydrogen system integrator and/or vehicle manufacturer elect to use such devices on board their hydrogen vehicles, including hydrogen fuel cell electric vehicles (FCEV). The tests described in 5.1 of this document are performance-based and were developed to assess hydrogen sensor metrological parameters. These tests were designed to accommodate a wide range of environmental and operating conditions based on different possible situations and sensor implementations within the vehicle. Section 5.2 covers supplemental electrical safety and physical stress tests. These are based upon standard tests developed for qualifying electrical and other components for use on vehicles and do not explicitly pertain to gas sensor metrological performance assessment.

Electric and alternative fueled vehicles present different hazards for first and second responders than conventional gasoline internal combustion engines. Hydrogen vehicles (H2V) including Fuel Cell Vehicles (FCVs) involved in incidents may present unique hazards associated with the fuel storage and high voltage systems. The electrical hazards associated with the high voltage systems of hybrid-electric vehicles and FCVs are already addressed in the parent document, SAE J2990. This Recommended Practice therefore addresses electric issues by reference to SAE J2990 and supplements SAE J2990 to address the potential consequences associated with hydrogen vehicle incidents and suggest common procedures to help protect emergency responders, tow and/or recovery, storage, repair, and salvage personnel after an incident has occurred. Industry design standards and tools were studied and where appropriate, suggested for responsible organizations to implement.

Electric and alternative fueled vehicles present different hazards for first and second responders than conventional gasoline internal combustion engines. Hydrogen vehicles (H2V) including Fuel Cell Vehicles (FCVs) involved in incidents may present unique hazards associated with the fuel storage and high voltage systems. The electrical hazards associated with the high voltage systems of hybrid-electric vehicles and FCVs are already addressed in the parent document, SAE J2990. This Recommended Practice therefore addresses electric issues by reference to SAE J2990 and supplements SAE J2990 to address the potential consequences associated with hydrogen vehicle incidents and suggest common procedures to help protect emergency responders, tow and/or recovery, storage, repair, and salvage personnel after an incident has occurred. Industry design standards and tools were studied and where appropriate, suggested for responsible organizations to implement.

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.

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 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.

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.

This document establishes safety limits and performance requirements for gaseous hydrogen fuel dispensers used to fuel Hydrogen Powered Industrial Trucks (HPITs). It also describes several example fueling methods for gaseous hydrogen dispensers serving HPIT vehicles. SAE J2601-3 offers performance based fueling methods and provides guidance to fueling system builders as well as suppliers of hydrogen powered industrial trucks and operators of the hydrogen powered vehicle fleet(s). This fueling protocol for HPITs can support a wide range of hydrogen fuel cell hybrid electric vehicles including fork lifts, tractors, pallet jacks, on and off road utility, and specialty vehicles of all types. The mechanical connector geometry for H25 and H35 connectors are defined in SAE J2600 Compressed Hydrogen Surface Vehicle Refueling Connection Devices.

This document establishes safety limits and performance requirements for gaseous hydrogen fuel dispensers used to fuel Hydrogen Powered Industrial Trucks (HPITs). It also describes several example fueling methods for gaseous hydrogen dispensers serving HPIT vehicles. SAE J2601-3 offers performance based fueling methods and provides guidance to fueling system builders as well as suppliers of hydrogen powered industrial trucks and operators of the hydrogen powered vehicle fleet(s). This fueling protocol for HPITs can support a wide range of hydrogen fuel cell hybrid electric vehicles including fork lifts, tractors, pallet jacks, on and off road utility, and specialty vehicles of all types. The mechanical connector geometry for H25 and H35 connectors are defined in SAE J2600 Compressed Hydrogen Surface Vehicle Refueling Connection Devices.

The purpose of this document is to provide performance requirements for hydrogen dispensing systems used for fueling 35 MPa heavy duty hydrogen transit buses and vehicles (other pressures are optional). This document establishes the boundary conditions for safe heavy duty hydrogen surface vehicle fueling, such as safety limits and performance requirements for gaseous hydrogen fuel dispensers used to fuel hydrogen transit buses. For fueling light-duty vehicles SAE J2601 should be used. SAE J2601-2 is a performance based protocol document that also provides guidance to fueling system builders, manufacturers of gaseous hydrogen powered heavy duty transit buses, and operators of the hydrogen powered vehicle fleet(s). This fueling protocol is suitable for heavy duty vehicles with a combined vehicle CHSS capacity larger than 10 kilograms aiming to support all practical capacities of transit buses.

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.

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.

SAE J2600 applies to the design and testing of Compressed Hydrogen Surface Vehicle (CHSV) fueling connectors, nozzles, and receptacles. Connectors, nozzles, and receptacles must meet all SAE J2600 requirements and pass all SAE J2600 testing to be considered as SAE J2600 compliant. This document applies to devices which have Pressure Classes of H11, H25, H35, H50 or H70. 1.1 Purpose SAE J2600 is intended to: • Prevent vehicles from being fueled with a Pressure Class greater than the vehicle Pressure Class; • Allow vehicles to be fueled with Pressure Class equal to or less than the vehicle Pressure Class, • Prevent vehicles from being fueled by other compressed gases dispensing stations; • Prevent other gaseous fueled vehicles from being fueled by hydrogen dispensing stations.

SAE J2600 applies to the design and testing of Compressed Hydrogen Surface Vehicle (CHSV) fueling connectors, nozzles, and receptacles. Connectors, nozzles, and receptacles must meet all SAE J2600 requirements and pass all SAE J2600 testing to be considered as SAE J2600 compliant. This document applies to devices which have Pressure Classes of H11, H25, H35, H50 or H70.

SAE J2600 applies to the design and testing of Compressed Hydrogen Surface Vehicle (CHSV) fueling connectors, nozzles, and receptacles. Connectors, nozzles, and receptacles must meet all SAE J2600 requirements and pass all SAE J2600 testing to be considered as SAE J2600 compliant. This document applies to devices which have Pressure Classes of H11, H25, H35, H50 or H70.

This SAE Recommended Practice identifies and defines requirements relating to the safe integration of the fuel cell system, the hydrogen fuel storage and handling systems (as defined and specified in SAE J2579) and high voltage electrical systems into the overall Fuel Cell Vehicle. The document may also be applied to hydrogen vehicles with internal combustion engines. This document relates to the overall design, construction, operation and maintenance of fuel cell vehicles.

SAE TIR J2601 establishes safety limits and performance requirements for gaseous hydrogen fuel dispensers. The criteria include maximum fuel temperature at the dispenser nozzle, the maximum fuel flow rate, the maximum rate of pressure increase and other performance criteria based on the cooling capability of the station’s dispenser. This document establishes fueling guidelines for “non-communication fueling” in the absence of vehicle communication and guidelines for “communication fueling” when specified information is transmitted from the vehicle and verified at the dispenser. The process by which fueling is optimized using vehicle-transmitted information is specified. This document provides details of the communication data transmission protocol. The mechanical connector geometry is not covered in this document. SAE J2600 defines the connector requirements for fueling vehicles operating with a nominal working pressure of 35 MPa.

SAE J2601 establishes the protocol and process limits for hydrogen fueling of light duty vehicles. These process limits (including fuel temperature, the maximum fuel flow rate, and rate of pressure increase and end pressure) are affected by factors such as ambient temperature, fuel delivery temperature and initial pressure in the vehicle’s compressed hydrogen storage system. SAE J2601-2014 establishes standard fueling protocols based on a look-up table approach with performance targets. The current standard is table-based and provides concise performance targets for both communications and non-communications fueling as described in Sections 7 through 10. An important factor in the performance of hydrogen fueling is the station’s dispensing equipment cooling capability and the resultant fuel delivery temperature “T” rating. SAE J2601 has a reference fueling target of 3 minutes with 95-100% SOC (with communications) with a T40 rated dispenser as specified in section 6.1.

SAE J2601 establishes the protocol and process limits for hydrogen fueling of light duty vehicles. These process limits (including the fuel delivery temperature, the maximum fuel flow rate, the rate of pressure increase and the ending pressure) are affected by factors such as ambient temperature, fuel delivery temperature and initial pressure in the vehicle’s compressed hydrogen storage system. SAE J2601 establishes standard fueling protocols based on either a look-up table approach utilizing a fixed pressure ramp rate, or a formula based approach utilizing a dynamic pressure ramp rate continuously calculated throughout the fill. Both protocols allow for fueling with communications or without communications. The table-based protocol provides a fixed end-of-fill pressure target, whereas the formula-based protocol calculates the end-of-fill pressure target continuously.