ReliOn Fuel Cell
Solutions
Guide to Fuel Cell
Permitting
Copyright
Information in this document is subject to change without notice. No part of this publication
may be reproduced by any means without prior written consent of ReliOn. Part No. 640-108793 Rev 5.
Printed August 2013. © ReliOn, Inc. All rights reserved.
Trademarks & Patents
E-200™, E-1100™, E-1100v™, E-1000x™, E-2500™ and E-2200x™ are trademarks of ReliOn, Inc. Other
product and company names mentioned herein may be the trademarks of their respective owners. ReliOn
retains all rights to the patents, patent applications, or other intellectual property rights covering the E-200™,
E-1100™, E-1100v™, E-1000x™, E-2500™ and E-2200x™ fuel cell systems, which include U.S. Patent Nos.
6,030,718; 6,096,449; 6,218,035; 6,387,556; 6,428,918; 7,833,645, 8,192,889 and other patents pending.
Product Certification
E-1100™, E-1100v™, E-1000x™, E-2500™ and E-2200x™ fuel cell systems are CSA certified to
ANSI/CSA America FC1-2012 (formerly ANSI Z21.83) American National Standard For Fuel Cell Power
Systems.
Note: Hydrogen storage does not fall under the scope of ANSI/CSA FC1. For installation requirements of
hydrogen storage, see 2009 International Fire Code Chapters 27 & 35 or NFPA 2 / NFPA55.
Telcordia®
When installed in ReliOn-supplied enclosures, the E-series fuel cell systems have been tested to Telcordia
standards and have been determined to be suitable for installation in an Outside Plant (OSP) environment.
For non-residential use only.
Contact Information
ReliOn
15913 East Euclid Avenue
Spokane, Washington 99216 USA
US Toll Free: 877.474.1993
Tel: +1 (509) 228-6500
Fax: +1 (509) 228-6510
techsupport@relion-inc.com
For 24 hour emergency customer service:
1-866-661-0020
Table of Contents
1.0 Introduction
4
1.1 PEM Fuel Cell Theory
1.2 The ReliOn Solution
1.3 Fuel Cell Applications
1.4 Example Sites
12
4
5
11
2.0 Certifications
13
2.1 CE
13
2.2 CSA America
13
2.3 NEBS / Telcordia 13
3.0 Hydrogen Fuel Safety
16
4.0 ReliOn Design Safety Features 19
4.1 Outdoor Enclosure Design
19
4.2 Hydrogen Storage Cabinet
19
4.3 Hydrogen Fuel Delivery System Diagram
4.4 Main Equipment Cabinet 21
4.5 Hydrogen Storage Module (HSM)
21
4.6 Operation 23
4.7 ReliOn Safety Record
24
5.0 Codes & Standards
25
5.1 Recommended Setback Distances
5.2 Websites for Other Siting References
Appendix A: Proof of Performance 29
Appendix B: Hydrogen Safety Data Sheet
Appendix C: Certification Documents
21
27
27
37
40
1.0 Introduction
ReliOn is committed to providing safe, cost-effective, versatile backup power solutions. The purpose of this
guide is to provide a high level overview of fuel cell technology, ReliOn fuel cell products, and hydrogen safety
in general. This information is provided as reference material for consideration by authorities having jurisdiction
(AHJs), installation providers and end-user customers. This document will assist decision-makers in determining the applicability of permitting for fuel cell system siting and installation. Additional information on the detailed features and specifications of the E-200™, E-1000x™, E-1100™, E-1100v™, E-2200x™ and E-2500™
fuel cell systems can be found in the separate E-200™ and E-series Operator Manuals.
1.1 PEM Fuel Cell Technology
A fuel cell is a device that converts the chemical energy of a fuel (hydrogen, natural gas, methane, alcohol,
gasoline, etc.) and an oxidant (air or oxygen) directly into electricity. This process happens without combustion.
A fuel cell operates electrochemically through the use of an electrolyte, just like a battery, but it does not run
down or require recharging. It is like a generator in that it operates as long as the fuel is supplied, but unlike a
generator, it is simple, quiet, clean and has few moving parts.
While there are a number of fuel cell technologies available, the most common and practical technology for
standby power is the proton exchange membrane, or PEM, fuel cell. PEM is the fuel cell technology preferred
by ReliOn and is used within all of its commercial products. In a PEM fuel cell, the electrolyte is a thin sheet of
a special polymer which resembles a sheet of plastic wrap. The only inputs to the PEM fuel cell are industrial
grade hydrogen as fuel and ambient air as a source of oxygen. The only by-products are DC electricity, pure
water/vapor and a small amount of heat (Figure 1-1).
Figure 1-1. PEM Fuel Cell: How It Works
The reaction that creates electricity takes place at room temperature. No special cooling systems are required
in ReliOn’s patented design. Since the fuel cell outputs are clean, fuel cells are considered a green technology, making them an attractive solution for installations with low emissions restrictions. ReliOn fuel cells are
so clean that they are certified by the California Air Resources Board (CARB) as a zero emissions technology,
making them exempt from air permitting requirements.
1.2 The ReliOn Solution
ReliOn’s modular design provides redundancy, scalability, and ease of service. ReliOn fuel cell systems are
air-cooled, eliminating the need for liquid pumps and heat exchangers. Unlike other PEM fuel cells, the fuel cell
system is self-hydrating, eliminating the need for a separate source of water. These features, combined with
ReliOn’s modular, redundant architecture, provide long term reliability and significantly reduced maintenance.
ReliOn fuel cell systems are available in both indoor and outdoor configurations. These configurations include
rack-mount solutions and environmentally hardened cabinets for outdoor use.
E-200 Fuel Cell System
The E-200 fuel cell system is designed specifically for small-scale backup power applications within
the telecommunications, transportation, security and government sectors. The E-200 fuel cell provides up to
175W in a single 2U (3.38” tall) chassis capable of being rack-mounted in a 19” or 23”rack. Multiple units may
be used together in order to provide higher levels of power. The E-200 is air-cooled and fueled by hydrogen.
The E-200 may be used indoors (Figure 1-2) or outdoors in multiple cabinet configurations (Figures 1-3 and
1-4).
Tables 1.1, 1.2 and 1.3 detail specifications of this fuel cell system and its outdoor cabinet configurations.
E-1000x, E-1100, E-1100v, E-2200x and E-2500 Fuel Cell Systems
The E-series fuel cell systems each provide a single, fully integrated system that fits within a standard equipment rack. Each chassis includes two parallel fuel cell modules and integrated control and power electronics for
a complete system in a single chassis. The two parallel fuel cell modules provide fault tolerance; the system
tests the condition of both modules upon each startup. Should one module have a fault, it is disabled, and an
alarm is issued to the user, allowing the system to deliver partial power, rather than having to disable the entire
system as is the case with a single fuel cell stack.
Figure 1-5 shows each of the fuel cell systems. Figure 1-6 shows the outdoor cabinets in which they may be
housed.
Tables 1.1, 1.2 and 1.3 detail specifications of these fuel cell systems and their outdoor cabinet configurations.
1.3 Fuel Cell Applications
ReliOn fuel cell systems provide backup or grid-supplement power for communications, signalling and
surveillance applications within a variety of markets. ReliOn fuel cell systems are intended to augment
traditional
DC power systems and connect directly to the DC bus. A simplified DC connection diagram is shown in Figure
1-7. See Appendix A for “Proof of Performance”.
1.4 Example Sites
2.0 Certifications
ReliOn is committed to providing safe, cost effective, versatile backup power solutions. A key component to the
production of safe and reliable commercial systems is product certification to industry-established standards.
ReliOn deploys fuel cell systems which meet the demanding criteria developed by industry standards
associations. ReliOn systems are designed and tested to meet the stringent inspections by CSA (Canadian
Standards Association) and Telcordia standards and have obtained the CE Mark. The standards developed by
these organizations govern system design and operation. Additionally, they provide necessary independent
regulatory verification that commercial systems are safe and reliable and meet or exceed required performance
minimums. Certification documents are shown in Appendix C.
2.1 CE
The CE Mark identifies equipment as complying with all the safety requirements established by the European
Union and is a requirement for products sold to the European Market. It identifies a product as complying with
the health and safety requirements spelled out in European legislation (Directives) and is mandatory for
equipment operating in the European Union (EU). ReliOn fuel cell systems obtained the CE Mark through
certification by GASTEC Certifications BV to European electromagnetic and safety standards, IE EN50165,
clause 19.101, EN61000-6-2, EN61000-6-3, and EN60204-1 Part 1 edition 4.1.
2.2 CSA America
CSA America has developed “ANSI/CSA America FC 1-2012, Stationary Fuel Cell Power Systems (FC 1)”.
This standard outlines requirements for the operation, construction, and performance of stationary fuel cell
power systems. ReliOn fuel cell systems are designed and/or certified to ANSI/ CSA FC 1-2012.
2.3 Network Equipment Building System (NEBS) / Telcordia
Network Equipment Building System (NEBS) as specified in FR2063 is a group of standards developed by
Telcordia for the telecommunications industry. These standards are stringent testing performance requirements
that go above and beyond the safety requirements of FC-1 to provide operational verification of systems to be
deployed into telecommunications infrastructure. The subset of standards found in NEBS and applicable to
PEM fuel cells are GR 78, GR 63 and GR 1089. GR 487 is applied for outside plant cabinets but not explicitly
part of NEBS. These Generic Requirements (GR) provide testing criteria for all conceivable environmental conditions ranging from electromagnetic interference to extreme environmental conditions. There are three levels
of NEBS testing, specified in SR3500, with Level 3 being the most stringent. ReliOn systems are tested and
compliant to applicable sections of NEBS Level 3. A summary of the applicable NEBS tests and
requirements pertaining to the ReliOn solution is provided below.
GR 63 – Physical Protection
GR 63 pertains to equipment reliability and performance in adverse environments that may see extreme
environmental variations related to temperature, humidity, altitude and airborne contaminants. The standard
provides guidelines for testing to the following topics.
· Low Temperature Exposure & Thermal Shock
· High Temperature Exposure & Thermal Shock
· High Relative Humidity Exposure
· Operating Temperature & Relative Humidity
· Altitude
· Airborne Contaminate
GR 1089 – Electromagnetic Compatibility and Electrical Safety
GR 1089 addresses the electromagnetic and electrical safety necessary for equipment to perform reliably and
safely in a telecommunications network environment. The standard includes testing pertaining to the following
topics:
· Radiated Emissions & Immunity
· Conducted Emissions (AC & DC)
· Short Circuit Tests
· Lightning Surge Immunity
· Electrical Safety
· Grounding & Bonding
GR 487 – General Requirements for Electronic Equipment Cabinets
GR 487 governs the testing of the integrated ReliOn integrated cabinet solutions. The standard provides a
template for testing of outdoor cabinets that will be utilized in a telecommunications environment. These
cabinets are exposed to earthquakes, fires, severe weather, etc. General tests covered under this standard
include the following:
· Earthquake Resistance – Seismic Zone IV
· Temperature Cycling (16 day cycle from -40ºC to +50ºC w/varying relative humidity)
· Solar load
· Wind Driven Rain & Rain Intrusion
· Weather Tightness
· Wind Resistance
· Corrosion – High Humidity/Salt Fog
· Fire Resistance (Operate before, during, and after the Brushfire Test without manual intervention)
· Firearms Resistance
· Impact Resistance
· Transportation Shock & Vibration
· Metallic & Polymeric & Other Non-Metallic Materials (Flammability, Corrosion, UV Degradation,
Fugus, Chemical Exposure, Etc.)
· Lifting Details
· Hinged Doors, Fans, Screens & Filters
· Security & Alarms
· Grounding & Bonding
The combination of the FC-1 listing, NEBS Level 3 compliance, and the CE Mark provides customers with the
necessary assurances that ReliOn’s commercial products are both safe and reliable. Additionally, ReliOn
systems are tested and certified to the harshest operational conditions (Figure 2-1). Regardless of the
environment, -40º C, an earthquake, or a brushfire, ReliOn equipment performs safely and reliably by design.
Figure 2-1. ReliOn NEBS Testing.
3.0 Hydrogen Fuel Safety
The fuel for ReliOn’s fuel cells is industrial-grade hydrogen gas. Compressed, bottled hydrogen is the most
readily available commercial source of industrial grade hydrogen and can be found throughout the world and at
over 2,500 locations in the U.S. alone. Compressed hydrogen gas is also stored in larger Hydrogen Storage
Modules (HSMs) which are filled onsite by special bulk delivery trucks. Compressed hydrogen is a versatile
fuel having a wide operating temperature range.
ReliOn deploys fuel cell systems to the field that incorporate a hydrogen storage and delivery system.
This system is provisioned for use with compressed hydrogen gas cylinders or bulk fuel. When designing
systems which store, distribute and utilize hydrogen gas it is imperative to address the characteristics of hydrogen to ensure a safe operating environment. Hydrogen is the lightest gas known, with a flammable range from
4% - 74% by concentration (Figure 3-1). It is useful to compare this to a known quantity. By way of comparison, propane has a flammable range from 2.4% - 9.6%. Propane’s flammability concentration is nearly 2 times
lower than that of hydrogen. While hydrogen has a wider flammability range, it can be argued that the more
important metric is the lower flammability limit. A second comparison of hydrogen to propane and diesel can
be seen in Figure 3-2.
Figure 3-1. Gas Flammability.
Figure 3-2. Hydrogen Fuel Comparisons.
The hydrogen storage cabinet designed for replacable cylinders, as well as the HSMs, are passively ventilated
cabinets open to outside air. The electrical equipment installed within is designed for use in a hydrogen environment. While a leak is not likely to occur, the system is designed to ensure a safe operation if one were to
occur.
Hydrogen is 0.0695 the density of air, or 14 times lighter than air. ReliOn cabinets are designed to ensure that
in the event of a hydrogen leak, the hydrogen gas is vented to atmosphere and allowed to disperse. Hydrogen’s dispersion characteristics will ensure that as distance from the leak source increases, the density of hydrogen will quickly drop below the flammable limit. By comparison, Propane is denser than air at 1.5 times the
density of air and will tend to “pool” or settle. Propane may not disperse without the use of forced ventilation.
Figure 3-3. NFPA 704 Hazard Diamond for Hydrogen.
Hydrogen is colorless, odorless, tasteless and non-toxic. Therefore, it is necessary to utilize gas detection
equipment when using or handling hydrogen gas. The NFPA 704 Hazard Diamond classification for hydrogen
is shown in Figure 3-3. Each ReliOn fuel cell contains one or more hydrogen safety sensors. These sensors
activate and shut the systems down at 7,500 ppm, or less than 1/5th the Lower Flammable Limit of hydrogen,
which is 40,000 ppm. When replacing gas cylinders in the fuel storage cabinet, ReliOn recommends the use of
a hand-held combustible gas detector to verify that there is no leakage. Hydrogen gas detectors are commercially available and affordable. Liquid soap solution also works effectively to locate any leaks.
The ReliOn outdoor cabinets utilize stainless steel and/or brass tank connection fittings. ReliOn recommends
the use of non-sparking cylinder wrenches for connecting the gas cylinder fittings. See Appendix B for more
information about hydrogen safety.
4.0 ReliOn Design Safety Features
Safe operation of the fuel cell system and all ancillary components including piping and cabinetry is of the highest importance to ReliOn. ReliOn takes great measures to design safety features into the fuel cell unit itself and
into the supporting components. ReliOn also ensures safety by using commercial-quality materials combined
with proper manufacturing processes and material/build inspection programs.
4.1 Outdoor Cabinet Designs
ReliOn’s outdoor cabinets are designed to account for hazardous area classification and are constructed of
rugged 1/8” thick aluminum with a baked on powder-coat finish that resists solar loading and heat build up
within the cabinets. All access doors use standard telecommunications style hex ‘can wrench’ locking
mechanisms to provide controlled access and will accommodate additional padlocks, provided by the end
user, as well. When installed per factory specifications, the cabinets have been tested to withstand wind
speeds up to 150 mph.
The outdoor cabinets may be comprised of two separate compartments: the hydrogen storage cabinet and the
fuel cell equipment cabinet. The hydrogen storage cabinet houses the hydrogen cylinders and hydrogen fuel
delivery system. The fuel cell equipment cabinet houses one or more fuel cells. Outdoor systems using an
HSM (Section 4.5) as the fuel supply will not generally include a hydrogen storage cabinet.
4.2 Hydrogen Storage Cabinet
The hydrogen storage cabinet holds steel compressed gas cylinders, which provide industrial-grade hydrogen
fuel for the ReliOn fuel cell(s). These cylinders are not provided by ReliOn; rather, they are sourced by the enduser customer from the same commercial compressed gas suppliers that would typically deliver other
compressed gasses, such as oxygen, acetylene, carbon dioxide, argon, air or helium. NFPA 704 safety decals
(Figure 3-3) are shipped with the system by code and are affixed by the installer or end-user customer after the
cabinet is installed and the fuel is delivered to the site. All ReliOn hydrogen storage cabinets are also labeled
by code with standard hydrogen safety placards (Figure 4-1).
Figure 4-1. Hydrogen Safety Placard.
The standard ReliOn hydrogen storage cabinet is not designed to be a sealed “gas cabinet” as defined by IFC
2703.8.6.1 and is intended for outdoor use only. ReliOn can provide third party “gas cabinets” for indoor fuel
storage applications as required.
The standard ReliOn hydrogen storage cabinet holds up to six (6) cylinders for a maximum combined total of
1,500 ft3 of hydrogen gas, if populated with the larger “series 300” or “T” tanks. The equivalent liquid volume of
all six cylinders combined is about 77 gallons. To put this energy storage into perspective, it is important to
understand that the BTU energy in one full tank of gaseous hydrogen is equivalent to about 1/2 gallon of diesel
fuel; therefore, the BTU energy of the entire hydrogen storage cabinet is about the same as 3 gallons of diesel
fuel or a 5 gallon propane tank.
The hydrogen cylinders connect to a common manifold where they feed through a •” O.D. piping to the regulators and then to 3/8” O.D. piping at lower pressure to the fuel cells. The hydrogen fuel is controlled by a
normally-closed fuel shut off safety solenoid valve that is only activated when the fuel cells are operating and
generating power. One or more hydrogen sensors within the fuel cell enclosure monitor the ambient air and will
shut down the system if hydrogen is detected at a level approaching 7,500 ppm, or 1/5th the lower flammability
limit of hydrogen.
A hydrogen storage cabinet contains the following:
· Hydrogen cylinders
· High pressure hydrogen feed hoses
· Check valves
· High pressure manifold
· 2 ea. single-stage regulators and a pressure relief valve
· Manual shut off ball valve
· High-pressure transducer (0-3000 psi)
· Normally-closed fuel control solenoid valve.
Details are shown in section 4.3 Hydrogen Delivery System.
The area within the hydrogen storage cabinet is designed for the potential presence of hydrogen. As such, the
normally-closed solenoid valve installed on the feed line and the high-pressure transducer installed on the high
pressure manifold are both intrinsically safe and sealed components. The cabinet doors have a hole pattern
which promotes passive ventilation, preventing a build up of hydrogen gas should a leak occur in the hydrogen
fuel delivery system.
Each of the hydrogen cylinders are secured in place with restraining straps. Each cylinder is plumbed to a
common manifold and each hydrogen feed hose incorporates a check valve to prevent reverse flow to the
cylinders. This safety feature provides the user the ability to replace a cylinder while the system is pressurized
and running, without interruption of service. The common manifold is attached to a high-pressure, single-stage
regulator which steps the delivery pressure to 50-80 PSI. Downstream is a low-pressure, single-stage regulator
which steps the delivery pressure to 10 PSI. Integral to this single stage regulator is a pressure relief valve that
will operate at 1.5x operating pressure, protecting downstream equipment. At this point the hydrogen piping
enters the main equipment cabinet providing low pressure fuel to the fuel cell(s).
4.3 Hydrogen Fuel Delivery System Diagram
4.4 Fuel Cell Equipment Cabinet
The fuel cell equipment cabinet houses the low-pressure hydrogen piping delivery system and the fuel
cell(s). The following components and measures are employed to ensure safety within the main equipment
cabinet:
· Low H2 pressure (10 psi gas)
· System compliant with ASME/ANSI B31.3, Process Piping Code
· No NPT threaded connections
· One or more hydrogen sensor(s) which interlock the hydrogen feed solenoid
· No AC power brought into either cabinet (low voltage DC power only)
· No incendive circuitry / ignition sources within the fuel cell chassis or cabinet
4.5 Optional Hydrogen Storage Module (HSM)
The optional Hydrogen Storage Modules (HSM) are bulk gaseous hydrogen fuel supply cabinets designed with
permanently mounted cylinders, which are connected to a common manifold and refueling port. Unlike the cylinder replacement methodology required with the standard 6-cylinder hydrogen storage cabinet, the HSM unit
is refueled in place by a mobile refueling truck in the same fashion as a permanently-mounted propane tank.
The large capacity HSM provides more energy storage and therefore longer fuel cell back up run time which is
desirable for certain applications.
The HSM is offerred in two configurations. The HSM9 is a 9-cylinder unit as shown in Figure 4-2. The HSM16
is a 16-cylinder unit as shown in figure 4-3. Whereas replaceable cylinders are limited to 2,400 psi maximum
pressure, the HSM is designed to be pressurized to 3,000 psi maximum. Each of the cylinders within the HSM
can hold a maximum of 500 standard cubic feet (scf) of gas; therefore, at full pressure, the HSM9 contains
4,500 scf and the HSM16 contains 8,000 scf of hydrogen gas. It is important to consider the total quantity of
gas stored on site when preparing the appropriate permit and/or hazmat reporting documents for the AHJ.
The HSM can be applied in series with the standard 6-cylinder hydrogen storage cabinet, or it can be used
independently to function as the sole supply of fuel for the fuel cell. Multiple HSM units can be combined in
series to provide larger amounts of fuel storage which may be needed to serve large electrical loads or to
provide increased runtimes. The HSM typically connects to the fuel cell equipment enclosure, a standard hydrogenstorage cabinet or another HSM using a short stainless steel tie tube which runs between the bulkhead
fittings on each corresponding cabinet (see example drawing Figure 4-4). In most cases, the cabinets are
adjoined and the tubing is unexposed, but in cases where the cabinets cannot be physically located adjacent
to each other, the tie tube should be protected from impact by a piece of uni-strut or a typical “ice bridge” used
to protect outdoor telecommunications equipment. The HSM is labeled with code compliant hydrogenflammable-gas signage/placards (Figure 4-1) as well as the NFPA 704 diamond for hydrogen (Figure 3-3). A
detailed hydrogen piping schematic of the HSM is shown in Figure 4-5.
Figure 4-4. Typical HSM connection to fuel cell equipment cabinet
Figure 4-5. HSM Hydrogen Supply Schematic
4.6 Operation
In the standby state, ReliOn fuel cell(s) are not operational. In this state, the normally-closed hydrogen feed
solenoid valve is de-energized (closed) and fuel is only present in the piping up to this point. When the fuel
cell(s) are activated, they provide a signal which energizes the hydrogen feed solenoid valve. As mentioned
previously, there is one or more hydrogen sensor(s) installed in each fuel cell, depending on the product. When
the fuel cells are operational, the system is utilizing air drawn into the equipment cabinet and is exhausting this
air out of the cabinet. All air drawn into the cabinet is filtered to remove dirt, insects, and other possible
contaminants. The internal hydrogen sensor(s) are exposed to the air pulled into the fuel cells. As mentioned
previously, the lower flammability limit (LFL) for hydrogen is 40,000 ppm in air which equates to a 4% concentration. If the system detects a very small hydrogen leak (1,800 ppm), the system will issue a minor alarm but
will continue to operate. If the system detects a more substantial leak (7,500-10,000 ppm), then the system will
shut down and issue a major alarm which, in turn, deactivates power to the hydrogen feed solenoid and shuts
down the flow of hydrogen fuel. This ensures that if a leak were to occur, the concentration of gas could not
exceed 20-25% of the LFL which provides for a safety factor of 4-5.
During operation, the fuel cell consumes hydrogen fuel and a small amount of oxygen from the ambient air
stream. The fuel cell produces electricity and its byproducts are simply warm moist air and a small amount of
pure liquid water which evaporates as it exits the bleed system. Signal and control wires can be connected to
receive alarms and to provide control through contact I/O. Local and remote communications are supported at
each fuel cell.
4.7 ReliOn Safety Record
ReliOn holds safety in the highest regard. There are over 5,000 kilowatts of ReliOn commercial fuel
cell systems deployed at over 1,600 sites in the field. These system designs comply with the requirements of
such industry-leading organizations as the American Society of Mechanical Engineers (ASME), Compressed
Gas Association (CGA), American National Standards Institute (ANSI, FC1), Canadian Standards Association
(CSA), European Community Trade Group (CE) and the Telcordia generic criteria for Telecommunication
Equipment. Many of these organizations have directly tested, evaluated, and approved or certified the ReliOn
fuel cell and hydrogen storage systems as safe commercial products. By design, these systems are safer than
other fuel consuming appliances such as a common household propane grill or natural gas hot water tank.
ReliOn’s Applications Engineers are available for consultation to discuss such topics as proposed installation
sites, codes and standards, and general hydrogen safety. ReliOn’s Applications Engineers teach hydrogen
safety as part of our Training Services and Commissioning Assistance Services. Hydrogen safety video tapes
and DVDs are available from an independent third party by calling Hydrogen 2000, Inc at 303-530-0336.
5.0 Codes & Standards
Standards Relevant to the Installation of Hydrogen Fuel Cell Systems
ReliOn products are engineered to meet many safety codes and standards, which are listed below.
IFC ch. 27
2009 International Fire Code: Hazardous Materials - General Provisions
IFC ch. 30
2009 International Fire Code: Compressed Gases
IFC ch. 35
2009 International Fire Code: Flammable Gases
*NFPA 2
Hydrogen Technologies Code, 2011
*NFPA 55
Compressed Gases and Cryogenic Fluids Code, 2013
*NFPA 853
Standard for Installation of Stationary Fuel Cell Power Plants, 2003
*NFPA 70
National Electric Code
*NFPA 496
Standard for Purged & Pressurized Enclosures for Electrical Equipment, 1998
*NFPA 497
Recommended Practice for the Classification of Flammable Liquids, Gases,
or Vapors and of Hazardous (Classified) Locations for Electrical Installations
in Chemical Process Areas, 2012.
CGA E-11
Standard for Stationary Compressed Gas Cylinder Discharging Manifolds for
Working Pressures up to 3000 PSI.
CGA – G-5.4 Standard for Hydrogen Piping Systems at Consumer Locations
ASME/ANSI B31.3 Process Piping Code
ANSI/CSA FC1-2012 Standard for Stationary Fuel Cell Power Systems
Telcordia GR-63
NEBS Requirements – Physical Protection (sections as deemed applicable
by RBOC)
Telcordia GR-1089 Electromagnetic Compatibility and Electrical Safety - Generic Criteria for
Network Telecommunications Equipment (sections as deemed applicable by
RBOC)
Telcordia GR- 487
Generic Requirements for Electronic Equipment Cabinets (sections as
deemed applicable by RBOC)
EN 60204-1 Safety of Machinery - Electrical equipment of machines. Part 1: General
Requirements
EN 50165
Electrical equipment of non-electric heating appliances for household and
similar purpose clause 19.101 EMC phenomena only
EN 61000-6-2 Electromagnetic compatibility (EMC) – Part 6.2 Generic standards for industrial
environments
EN 61000-6-3 Electromagnetic compatibility (EMC) – Part 6.3 Generic standards for residential,
commercial and light industrial environments
98/37/EC
EU Machinery Directive
89/336/EEC EU EMC Directive
*Note: The NFPA standards are developed by committee and are designed as guidelines, and the NFPA does not approve, inspect, or certify any installations, procedures, equipment, or materials. In determining the acceptability of installations, procedures, equipment, or materials, the authority having jurisdiction (AHJ) may base acceptance on compliance
with NFPA or other standards, or the said authority may use their own judgment or refer to the listings or labeling practices
of an organization that is concerned with product evaluations and is thus in a position to determine compliance with appropriate standards for the current production of listed items.
While all of the codes and standards listed above are valid for the design and manufacture of all ReliOn products, the documents which are most relevant to the installation of hydrogen fuel cell systems are the 2009 International Fire Code (chapters 27 and 35), which governs the fuel storage, and NFPA 853 which governs the
installation of the fuel cell equipment. The IFC is recognized as the primary reference document for the safe
storage and use of the fuel.
These references will aid in the selection of a site location which should be acceptable to the authority having
jurisdiction (AHJ). Where public safety is primary, the AHJ may be a federal, state, local, or other regional department or individual such as a fire chief, fire marshal, or permitting agency. Experience has shown that this
authority is generally a county or city fire chief/marshal, or local permitting agency.
Rooftop Installation of Hydrogen Fuel Cell Systems
Though a rooftop application may not be ideal for a diesel or propane generator, due to the possibility of liquid
fuel spillage issues, this application is ideal for a hydrogen fuel cell, since the hydrogen fuel is much lighter
than air. Any unintentional release or seepage of the fuel dissipates rapidly and simply escapes into the upper
atmosphere.
A ReliOn fuel cell system can be installed on a rooftop as a complete unit including the fuel storage, or alternately, can be installed with the fuel cell equipment cabinet located on the rooftop and the fuel storage cabinet
or HSM located on the ground as a “split” system. ReliOn Application Guide, “AG07-08: Guidelines for Remote
Fuel Storage Solutions Serving ReliOn Fuel Cells,” provides additional details on this type of a split system.
This design may be preferred in some instances where delivery of the hydrogen fuel to the rooftop is unfeasible or where the rooftop cannot bear the additional weight of the fuel storage vessels. ReliOn Applications
Engineers are available to provide technical assistance in these matters.
Figure 5-1. ReliOn Fuel Cell Rooftop Example.
In addition to the codes and standards that are relevant in general site selection and installation, the document,
NFPA 853, Standard for the Installation of Stationary Fuel Cell Power Systems, specifically addresses rooftop
installations in Chapter 5, “Siting and Interconnections, Section 5.4, Rooftop Installation”. The extent of the
NFPA reference is to ensure that the rooftop material under the fuel cell system and within 12 inches horizontally is non-combustible, or that it has a Class A rating. ReliOn suggests a metal plate, grate or raised platform,
concrete or other such stable and nonflammable base be used beneath the fuel cell system when installed on a
rooftop to meet this requirement. Beyond this, the installation is considered an outdoor installation. The 2009
International Fire Code (IFC) and 2009 International Building Code (IBC) consider this an outdoor application
with setback to exposure requirements listed in table 3504.2.1 of Chapter 35 of the IFC.
Another important consideration is the delivery of the hydrogen cylinders to the system by the gas supplier. In
our experience, the use of a service elevator is the preferred method for delivering compressed gases to rooftops. Compressed gases are delivered in this fashion on a regular basis to laboratories, medical offices, and
other commercial facilities located above the ground floor. If a service elevator is not available, a public elevator or other similar means is generally acceptable. Contact the local gas provider for additional recommendations. As stated in the general discussion on installation of fuel cells, the final decision regarding acceptable
placement of a fuel cell system and hydrogen storage ultimately resides with the customer and the local AHJ.
5.1 Recommended Setback Distances
ReliOn offers hydrogen storage setback distance/clearance recommendations shown in Figure 5-1 which are
based on fuel cell industry recognized practices and cross-referenced with the 2009 International Fire Code
Chapter 35. The IFC is recognized by most AHJs to be the controlling code for flammable gases. These manufacturer’s recommendations are also in alignment with the Hydrogen Executive Leadership Panel (HELP)
document titled, “Site Evaluation Worksheet for Flammable Gas Storage; Stationary Fuel Cells”. The Hydrogen
Executive Leadership Panel is a joint initiative of the National Association of State Fire Marshals (NASFM), the
Research and Innovative Technologies Administration of the U.S. Department of Transportation, and the International Consortium for Fire, Safety, Health and the Environment and can be found at the following website:
http://www.nasfmhydrogen.com/.
These recommendations are offered by ReliOn for the convenience of the customer; however, ultimately it is
the responsibility of the customer and/or the AHJ to select the setback distances which are both appropriate
and reasonable.
Note: The recommended setback distances shown in Figure 5-1 extend from the hydrogen storage cabinet
and/or HSM to the type of exposure.
In issuing and making this document available, ReliOn is not undertaking to render professional or other
services for or on behalf of any person or entity. ReliOn makes no guarantee or warranty as to the accuracy
or completeness of any information within.
5.2 Websites for other siting references
U.S. DOE - Safety, Codes & Standards
www1.eere.energy.gov/hydrogenandfuelcells/codes
U.S. Department of Energy - www.hydrogen.energy.gov/permitting
Permitting Hydrogen Facilities
www.hydrogen.energy.gov/pdfs/44520.pdf
Fuel Cell & Hydrogen Energy Association www.fchea.org
Figure 5-1. Hydrogen Setback Distances.
Appendix A: Proof of Performance
Figure 1-2. E-200™ Rack-mount solution
Figure 1-4. E-200™ 1 meter outdoor enclosure
Figure 1-3. E-200™ extended run outdoor enclosure
E-1100™ fuel cell system
E-1000x™ fuel cell system
E-1100v™ fuel cell system
E-2200x™ fuel cell system
Figure 1-5. E-series™ fuel cell systems.
E-2500™ fuel cell system
16U23 cabinet
16U20 cabinet with 6Cyl300 fuel storage
16U23 cabinet with 6Cyl300 fuel storage
Figure 1-6. E-series™ fuel cell cabinets.
32U23 cabinet
Table 1.1 E-series Specifications.
Table 1.2 E-series Common Specifications.
Table 1.3 E-series Cabinet Specifications.
Figure 1-7. DC Connection Diagrams
Figure 4-2. HSM9
Figure 4-3. In service HSM16 being refueled
Appendix B: Hydrogen Safety Data Sheet
Appendix C: Certification Documents