UL SUBJECT 2265A-2004 OUTLINE OF INVESTIGATION FOR HAND-HELD OR HAND-TRANSPORTABLE FUEL CELL POWER UNITS WITH DISPOSABLE METHANOL FUEL CARTRIDGES FOR USE IN ORIGINAL EQUIPMENT MANU.pdf

1、November 19, 20041SUBJECT 2265AOUTLINE OF INVESTIGATIONFORHAND-HELD OR HAND-TRANSPORTABLE FUEL CELL POWER UNITS WITHDISPOSABLE METHANOL FUEL CARTRIDGES FOR USE IN ORIGINALEQUIPMENT MANUFACTURERS INFORMATION TECHNOLOGYEQUIPMENTIssue Number: 1NOVEMBER 19, 2004Summary of TopicsThis is the first issue o

2、f the Outline of Investigation for Hand-Held orHand-Transportable Fuel Cell Power Units with Disposable Methanol FuelCartridges for Use in Original Equipment Manufacturers InformationTechnology Equipment.The UL Foreword is no longer located within the UL Outline of Investigation. Forinformation conc

3、erning the use and application of the requirements contained inthis Outline of Investigation, the current version of the UL Foreword is located onULStandardsInfoNet at: http:/ 2004 UNDERWRITERS LABORATORIES INC.NOVEMBER 19, 2004SUBJECT 2265A2No Text on This PageCONTENTSINTRODUCTION1 Scope .52 Units

4、of Measurement .63 References .64 Glossary .6CONSTRUCTION5 General 86 Flammable/Hazardous Fluids .87 Enclosures .97.1 General .97.2 Fire enclosures .98 Electrical Circuits and Components 118.1 Internal wiring .118.2 Motors .118.3 Electromechanical components .128.4 Functional insulation .128.5 Batte

5、ries .128.6 Safety controls 138.7 Circuits .139 Hazard Analysis .1310 Cartridge 14PERFORMANCE11 Test Considerations .1411.1 General .1411.2 Simulated faults and abnormal conditions for limited power and SELV circuits .1512 Determination of SELV Reliability and Limited Power .1612.1 SELV reliability

6、.1612.2 Limited power source and circuits 1612.3 Maximum VA output .1813 Material Tests 1813.1 Accelerated aging 1813.2 Fuel gas compatibility .1814 Fuel Cell Power Unit Electrical 1914.1 Abnormal operations and fault conditions 1914.2 Normal use temperature 2115 Mechanical Tests .2315.1 General .23

7、15.2 Drop test 2315.3 Vibration test 2315.4 Steady force test .2415.5 Stress relief test 2616 Environmental Tests 2616.1 Temperature cycling 2616.2 Emissions test .2716.3 Pressure test 30NOVEMBER 19, 2004 SUBJECT 2265A 317 Cartridge Mechanical Tests 3017.1 Crush test .3017.2 Drop test 3118 Cartridge

8、 Environmental Tests 3118.1 Temperature cycling test 3118.2 Altitude simulation 32MANUFACTURING AND PRODUCTION TESTS19 Pressure Test 3220 Maximum VA Output 32MARKINGS21 General 3322 Markings for the Fuel Cell Power Unit .3323 Markings for the Fuel Cartridges 34INSTRUCTIONS24 Instructions 3424.1 Gene

9、ral .3424.2 Fuel cell power units 3524.3 Fuel cartridges .37APPENDIX A Fuel Cell Power Units Intended for Extended Outdoors UseNOVEMBER 19, 2004SUBJECT 2265A4INTRODUCTION1 Scope1.1 These requirements cover hand-held or hand-transportable fuel cell power units that use disposablemethanol fuel cartrid

10、ges. These requirements also cover the disposable fuel cartridges. Theserequirements apply to power units that provide dc outputs rated 60 Vdc or less and 240 VA or less. Assuch, the internal and external circuitry are considered secondary circuits that are “SELV.”1.2 The fuel cell power units cover

11、ed by these requirements are for use in unclassified (ordinary)locations in ambient temperatures that do not exceed 60C (140F). The fuel cell power units are to beintegrated into information technology equipment on the production line by the original equipmentmanufacturer. The fuel cartridges are to

12、 be installed and replaced by the end-product user.1.3 These requirements cover fuel cell power units that are electrical power sources that includeintegrated electrical connection means, integrated wiring material leads with or without electricalconnectors, or a combination of these arrangements fo

13、r single or multiple electrical loads. Additionalelectrical connection means may be provided to affect information exchange with the end-use product asdesigned.1.4 These requirements cover disposable fuel cartridges and fuel cell power units that are not intendedfor use with common consumer electron

14、ics appliances.1.5 Federal regulatory requirements pertaining to the shipment of fuel cartridges is outside the scope ofthis Outline of Investigation.1.6 This Outline of Investigation establishes requirements for disposable fuel cartridges limited inpressure to the vapor pressure of the methanol fue

15、l.1.7 Disposable cartridges with a fuel capacity greater than 950 mL and refillable cartridges are excludedfrom this Outline of Investigation.1.8 The technologies covered by these requirements include direct methanol fuel cell stacks and fuelsidentified as methanol, or methanol and water mixtures wi

16、th or without additives.NOVEMBER 19, 2004 SUBJECT 2265A 52 Units of Measurement2.1 Values stated without parentheses are the requirement. Values in parentheses are explanatory orapproximate information.3 References3.1 Any undated reference to a code or standard appearing in the requirements of this

17、Outline ofInvestigation shall be interpreted as referring to the latest edition of that code or standard.4 Glossary4.1 For the purpose of these requirements, the following definitions apply.4.2 DISPOSABLE FUEL CARTRIDGE A disposable container of fuel that is not refillable.4.3 ELECTRIC SHOCK Electri

18、c shock is due to current passing through the human body. Theresulting physiological effects depend on the value and duration of the current and the path it takesthrough the body. The value of the current depends on the applied voltage, the impedance of thesource and the impedance of the body. The b

19、ody impedance depends in turn on the area of contact,moisture in the area of contact and the applied voltage and frequency. Currents of approximately half amilliampere can cause a reaction in persons in good health and may cause injury indirectly due toinvoluntary reaction. Higher currents can have

20、more direct effects, such as burn, muscle tetanization orventricular fibrillation.4.4 EXPLOSION When the cell or fuel cell power unit contents are forcibly expelled and the cell orfuel cell power unit casing is torn or split into two or more pieces.4.5 EXTENDED OUTDOOR-USE PRODUCT A product that is

21、intended for use outdoors and used inlocations where it will be exposed to weather conditions as noted in Exception No. 2 of 22.1 andevaluated in accordance with Appendix A.4.6 FIRE ENCLOSURE The outer enclosure of the fuel cell power unit that is intended to minimizethe spread of fire or flames fro

22、m within.4.7 FUEL Any mixture of methanol with or without water and/or specified additives that is used toproduce electricity in a micro fuel cell unit.4.8 FUEL CARTRIDGES, NON-PRESSURIZED A cartridge in which the fuel vapor pressure does notexceed the surrounding ambient pressure during operation.4

23、.9 FUEL CARTRIDGES, PRESSURIZED A cartridge that is sealed and is suitable for safe shippingor transport. The internal cartridge pressure will be a factor of the surrounding ambient temperature andatmospheric pressure.4.10 FUNCTIONAL INSULATION Insulation that is necessary only for the correct funct

24、ioning of theequipment. Functional insulation is located between SELV circuits and between SELV circuits andconductive parts.Note: Functional insulation does not protect against electric shock but it may reduce the likelihood ofignition and fire.NOVEMBER 19, 2004SUBJECT 2265A64.11 IMPERMISSIBLE LEAK

25、AGE OF FUEL A release of methanol fuel in a vapor or non-vaporphase that results in one or a combination of the following situations that are deemed unsuitable:a) A fuel vapor in air mixture in excess of 25 percent of the lower flammability limit.b) A fuel vapor in air concentration in excess of the

26、 Occupational Safety and HealthAdministration (OSHA) 8-hour time-weighted-average permissible exposure limit, whichcorresponds to the National Institute of Safety and Health (NIOSH) 10-hour per day, 40 hour-per-week permissible exposure limit.c) A fuel vapor in air concentration in excess of 30-min

27、the Environmental Protection Agency(EPA) nondisabling Acute Exposure Guideline Levels.d) A non-vaporous fuel spillage in excess of an acute oral reference dose of 5 mg methanolper kilogram body weight per day.4.12 INDOOR-USE PRODUCT A product that is intended for use indoors only in environmentsprot

28、ected from weather and temperature extremes.4.13 OCCASIONAL OUTDOOR-USE PRODUCT A product that can be used outdoors but storedindoors. These products are not intended to be exposed to rain and are marked in accordance withException No. 1 of 22.1.4.14 OPERATIONAL PRESSURE The steady-state gauge press

29、ure at which a fuel cell unit normallyoperates. It shall not exceed the allowable working pressure and it is usually kept at a suitable levelbelow the setting of pressure-limiting/relieving devices to prevent their functioning under normaloperating conditions.4.15 OPERATIONAL TEMPERATURE RANGE The a

30、mbient air temperature range, defined herein as0C (32F) to 40C (104F), where the fuel cell power unit is expected to operate normally.4.16 SELV CIRCUIT (SAFETY EXTRA LOW VOLTAGE) A secondary circuit which is so designedand protected that, under normal and single fault conditions, its voltages do not

31、 exceed a safe value of60 Vdc.4.17 STORAGE TEMPERATURE RANGE The ambient air temperature range, defined herein asminus 20C (minus 4F) to 60C (140F), where the fuel cell power unit and/or fuel cartridge isexpected to be stored in a non-operational state without adverse impact.4.18 TOOL A screwdriver,

32、 coin, key, or any other object that is usable to operate a screw, latch, orsimilar fastening means.4.19 VALVE (SHUT-OFF) Component of a fuel cartridge or system that controls the release of fuel.NOVEMBER 19, 2004 SUBJECT 2265A 7CONSTRUCTION5 General5.1 Fuel cell power units and fuel cartridges may

33、be marked in accordance with 22.2 and 23.1(e) foroperating and storage temperature ranges. Absence of such markings shall result in a 0C to 40C (32Fto 104F) operational temperature range being applied for the test in Temperature Cycling, Section 16.1,and a minus 20C to 60C (minus 4F to 140F) storage

34、 temperature range applied for the Drop Test,Section 17.2, and Temperature Cycling Test, Section 18.1. If manufacturer specifications indicate a moresevere temperature range than the 0C to 40C operational and minus 20C to 60C storage ranges notedabove, the test parameters shall be adjusted to addres

35、s these more extreme ranges.5.2 Features of the product intended to limit the exposure of fuel to users or inhibit the amount of fuel thatcan be leaked under normal and abnormal conditions shall be judged based on the design andcorroborating evidence in the form of valid calculations, technical refe

36、rences and internal test data whendetermining the products compliance to this Outline of Investigation.6 Flammable/Hazardous Fluids6.1 Flammable fluids shall be kept within a closed containment system such as within fuel piping, in areservoir, a cartridge, or similar enclosure.6.2 Except under the c

37、onditions specified in 6.3, flammable liquid fuels shall have a flash point of 60C(140F) or higher, and shall not be under sufficient pressure to cause atomization.6.3 Flammable liquid fuels which have a flash point of less than 60C (140F) or which are undersufficient pressure to cause atomization a

38、re permitted provided that there is no likelihood of liquid spraysor build-up of flammable vapor-air mixtures which could cause an explosion or fire hazard.6.4 Under normal operating conditions, equipment using a flammable fluid shall not generate a mixturewith a concentration exceeding 25 percent o

39、f the lower flammable limit (LFL). The investigation shall alsotake into account the integrity of the flammable fluid handling system. The flammable fluid handlingsystem shall be housed or constructed so as to avoid the risk of fire or explosion, even under the testconditions specified in the applic

40、able tests of Performance, Sections 11 18.6.5 Electrical components, connections and connecting methods located in classified zones within theequipment shall be evaluated to the Standard for Electrical Equipment for Use in Class I and II, Division2, and Class III Hazardous (Classified) Locations, UL

41、 1604, Sections46,todetermine their potential toignite flammable vapors.6.6 Storage at the temperatures defined in 5.1 shall not cause impermissible leakage of fuel asdetermined by the temperature cycling tests outlined in Sections 16.1 and 18.1.6.7 Internal wiring and insulation, in general, shall

42、not be exposed to fuel, oil, grease or similarsubstances, unless the insulation has been evaluated for contact with these substances.NOVEMBER 19, 2004SUBJECT 2265A87 Enclosures7.1 General7.1.1 Equipment enclosures shall comply with the mechanical strength tests (drop, vibration, steady forceand stre

43、ss relief) of Sections 15.2 15.5. Steady Force Test, Section 15.4, and Stress Relief Test, Section15.5, are not required for handles, levers, knobs, transparent or translucent covers of indicating ormeasuring devices, internal barriers, screens or similar parts if the enclosure provides mechanicalpr

44、otection.7.1.2 The outer case of the fuel cell power unit shall be designed so that it is not able to be openedwithout the use of a tool.7.1.3 An edge projection or corner of a fuel cell power unit and of a fuel cartridge shall not be sufficientlysharp to result in a risk of injury to persons during

45、 intended use, or user maintenance. The Standard forTests for Sharpness of Edges on Equipment, IEC 1439, may be used to determine compliance with thisrequirement.7.2 Fire enclosures7.2.1 A fire enclosure is required when temperature of parts under fault conditions is sufficient for ignitionas descri

46、bed in Table 7.1.Table 7.1Summary of Material Flammability RequirementsParts Requiring a Fire Enclosure Parts Not Requiring a Fire EnclosureComponents in limited power circuits not mounted on ClassV-1 minimum rated materialsMotors (complying with Section 8.2) and otherelectromechanical components (c

47、omplying with Section 8.3)Non-limited power circuits Wires, Cables insulated with PVC, TFE, PTFE, FEP, neopreneor polyamideAreas that contain or process a flammable fluid Components in limited power circuits mounted on Class V-1minimum materialsComponents with unenclosed arcing parts such as a relay

48、contacts, commutators and open switchesConnectors in limited power circuitsInsulated wiring (not employing PVC, etc. insulation) Plugs and connectors forming part of an interconnecting cable7.2.2 Fire enclosure requirements are shown in Table 7.2.NOVEMBER 19, 2004 SUBJECT 2265A 9Table 7.2Summary of

49、Material Flammability RequirementsPart RequirementsFire EnclosureEnclosure V-1 (IEC 60695-11-10)1,or Test A2 of UL 60950-12,or Hot Wire Test of IEC 60695-2-203(if 3 mm, or HB75 (UL 60965-11-10) forthicknesses OSHA1Limits 200 ppm (260 mg/ m3) for chronic exposure EPA2AEGL-1 30-minute acute exposure of 670 ppm (880mg/m3)Direct contact or ingestion 56.8 mg (1.25 10-4lb) Oral reference dose based on a10 kg (22 lb) body weightFlammability 25 percent LFL (1.5 perce