Ref No: N05-045 Date: May 25, 2005 GAS PRODUCTS NO. 64 Effective Date: May 1, 2006 Call us today! We can help you stay on top of changes that will affect your Certification! 1-866-797-4272 Announcing: ANSI/CSA America FC 3-2004 Portable Fuel Cell Power Systems Class No:2725 85 : POWER GENERATORS-Portable Fuel Cell Power Systems-Certified to U.S. Standards Who is affected? Manufacturers of portable fuel cell power systems What do you do? 1. Testing may be required to comply with these revisions. Please contact CSA engineering staff to arrange for testing of your products. 2. If none of the revisions are applicable to your product designs, please notify your CSA engineering staff or the listed Technical Contact to update your Certification Records to show compliance with the new requirements. Approvals: - American National Standards Institute, Inc.: October 22, 2004 - Revisions to this standard supersede any corresponding revisions of CSA International Requirement 3.01 U.S. Major Revisions: The major revisions are shown on the following pages. See attachment 1 3. Please respond no later than November 1, 2005. When responding, please include the appropriate supporting documentation*. If testing is needed, we will inform you of the samples required. *Technical information and materials as well as company name, address, factory locations and CSA file number or master contract number (if assigned) when applying. Need additional technical information? Contact Greg Chirdon by phone 704.552.2919, fax 704.552.0683 or e-mail greg.chirdon@csa-international.org Apply Before November 1, 2005 In the event your models do not comply with the effective standards, arrangements must be made to bring them into compliance. In the event we do not receive a response as to your currently certified models, prior to the above applicable effective date(s), the certification of such models will be discontinued. Visit us at www.csa-international.org Click on "Contact Us" for the online phone listing of our Offices and Partners Visit us at www.shopcsa.ca to purchase a Standard! DQD 529.01e Rev 2004-09-30 Page 1 of 5
ATTACHMENT 1 Major Revisions 1. Expanded the requirements pertaining to flammable atmospheres, clause 1.2.2. The revisions emphasize that: a) Equipment within the dilution boundary shall be suitable for the classification. Guidance for such equipment in the dilution boundary can be found in two additional documents: Article 500-4 of the National Electrical Code, ANSI/NFPA 70, and Electrical apparatus for explosive gas atmospheres Part 0: General Requirements IEC 60079-0. [Refer to clause 1.2.2.c1]. b) When detection is used to prevent the accumulation of flammable fuel above 25% of the lower flammability limit within the fuel cell power system, the system must be compliant with section 1.4.7, and the control circuit and logic must be compliant with the requirements outlined in section 1.34, Safety Analysis. [Refer to clause 1.2.2.2]. 2. Expanded the requirement pertaining to fuel supply, clause1.2.3c. There is now a lateral force test determining whether the fuel container is secure and cannot be dislodged. 3. For material other than glass employed as a sole covering over an opening forming part of the enclosure and relied upon to prevent contact with bare live parts, such material shall now comply with the requirements of the flame test specified in section 2.19, flaming Oil, Perforated Panels. [Refer to clause 1.5.6.k]. 4. Expanded the requirement to specify that the flexible cords on cord-connected portable fuel cell power systems shall be one of the following types: S, SO, SOO, SE, SEO, SEOO, SJ, SJE, SJEO, SJEOO, SJO, SJOO, SJT, SJTO, SJTOO, ST, STO, OR STOO. [Refer to clause 1.7.1]. 5. Added the requirement: When within a control, fan or similar compartment, factory wiring, involving voltage of not more than 300 volts between parts attached to the same assembly with a predetermined fixed relationship one to the other, may be done with Type SJO, SJT or SPT03 cord or appliance3 wiring material having neoprene, thermoplastic or equally durable insulation of a thickness no less than that specified in Group B of Table VI, or Group A of Table VI. [Refer to clause 9.9]. 6. Added the requirement that electrolytic or other special types of capacitors and capacitors intended for connection directly across the line shall be made the subject of investigation by the certifying agency. [Refer to clause 1.13.3]. 7. Added the requirement: printed circuit boards involving primary circuits or those located in secondary circuits where failure of the bond between the conductor and the base material could result in contact with uninsulated primary circuit parts, shall be of a type that is acceptable for the application. 8. Section 1.24, Grounding and Bonding has been entirely revised. Clause 1.24.1 gives requirements for Portable Standby Fuel Cell Power Systems. Clause 1.24.2 gives requirements for Portable Stand-Alone Fuel Cell Power Systems. Clause 1.24.3 gives requirements for Portable Uninterruptible Fuel Cell Power Supplies. Clause 1.24.4 emphasizes that all exposed non-current-carrying metal parts within the fuel cell power systems shall be electrically bonded to the frame of the fuel cell power unit. Clause 1.24.5 gives requirements for protective bonding, with emphasis on determining the impedance between the protective conductor terminal and each accessible part for which protective bonding is specified. [Refer to all clauses in section 1.24]. DQD 529.01e Rev 2004-09-30 Page 2 of 5
9. Added the requirement: when internal to the portable fuel cell power system and not capable of affecting the potable water supply, any means of heat transfer, commensurate with the chemistry of the affected fluids or gases is acceptable. 10. Added requirements for non-metallic piping systems. [Refer to section 1.28.2]. 11. Added the requirement: for piping applications below the limits described in 1.28.1-b, materials shall be investigated and tested to determine that components are safe and suitable for the proposed service temperatures, pressures, and material exposure, and shall be demonstrated to be in compliance with 2.1, Ultimate Strength. [Refer to clause 1.28.2b]. 12. Added requirement for liquid fuel filters. [Refer to clause 1.29.4]. 13. Added the requirement: a fractional horsepower motor provided with inherent overload protection complying with either ANSI/UL 2111 or ANSI/UL 1020 meets the intent of electric motors shall be designed for continuous duty and shall be provided with overload protection. [Refer to clause 1.31.1b]. 14. Added the requirement: The use of field performance data to demonstrate compliance with the software analysis and test, off-the-shelf software, and tool validation requirements of UL 1998 shall be considered where the period since the initial release of the product software to the field is three years or more. Compliance using field data is limited to the following paragraphs from UL 1998, Edition 2: 11.1.1 and 11.1.2, Software Analysis, 11.2.1, Software Testing. 11.3.1, Failure Mode and Stress Testing, and 13.2, Off-the-Shelf (OTS) Software. [Refer to clause 1.34.3e]. 15. Added the marking requirement: the nameplate shall show the minimum operating hours at full load on one tank of fuel. [Refer to clause 1.36.2o]. 16. Added the marking requirement: the polarity of the output leads shall be plainly marked unless the portable fuel cell power system is provided with a polarized termination. [Refer to clause 1.36.4] 17. Added the marking requirement: Unless the proper wiring connections are plainly evident, wiring terminals shall be marked, or the device shall be provided with a suitable wiring diagram to indicate the connections. If information is necessary for the proper operation of the device, it shall be provided with the device (e.g. in an accompanying booklet.). [Refer to clause 1.36.5] 18. Modified the (marking) caution statement, which now says: Caution: * is an electrically energized (live) part. There is a risk of electric shock. Disconnect power before servicing. [Refer to clause 1.36.9]. 19. Modified the (marking) warning statement, which now says: Warning: More than one electrically energized (live) circuit. See diagram. [Refer to clause 1.36.10]. 20. Modified the (marking) caution statement, which now says: Caution: this cabinet (compartment) contains vented wet cell batteries. Use only in a well ventilated area. [Refer to clause 1.36.11]. 21. Modified the marking statement, which now says: Floating neutral neutral not grounded. [Refer to clause 1.36.13]. DQD 529.01e Rev 2004-09-30 Page 3 of 5
22. Added the marking requirement pertaining to battery safety instructions: portable fuel cell power system intended for use with batteries to be located in a remote battery room when the batteries are furnished with the portable fuel cell power system. [Refer to clause 1.36.15c]. 23. Added the marking requirement: A multiple voltage portable fuel cell power system shall have a marking (e.g. paper tag) stating the particular voltage for which the portable fuel cell power system has been wired when shipped from the factory. [Refer to clause 1.36.17]. 24. Added the marking requirement: A motor that complies with 1.31.1a or 2.5.3a shall be marked with a Class IIIA marking material that it is impedance protected. [Refer to clause 1.36.22]. 25. Added the requirement that the leakage test for liquid fueled systems be conducted after section 2.35, Drop Test. [Refer to section 2.2, first paragraph] 26. The Allowable Leakage Test for a flammable gas system, which is section 2.2.2 in CSA requirement 3.01 is now replaced by the Flammable Gas Concentration Test. [Refer to section 2.3]. 27. The Component Temperatures Test is now moved to section 2.5.2 in ANSI/CSA America FC 3. Previously, CSA 3.01 contained this test under the title Temperature (Normal) under section 2.8. 28. Added a rain test. [Refer to section 2.7.1]. 29. The Bonding Impedance Test in ANSI/CSA America FC 3, section 2.6.1 replaces the requirements of CSA 3.01, section 2.24 Bonding Continuity and section 2.11 Impedance. 30. Added maximum allowable temperature rises for liquid-filled equipment. [Refer to section 2.10.6]. 31. For liquid filled equipment, added the abnormal operation test: 7 hours at rated output with no oil in the main tank. [Refer to clause 2.13.1.f]. 32. The Container Pressure Test is now renamed the Tank Pressure Test. This test now states that all tanks shall withstand a hydrostatic pressure test of 150 percent of their maximum allowable working pressure, as opposed to the previous requirement of 150 percent of the maximum storage pressure. Moreover, this clause now states that appropriate relief valve protection shall be provided and set at less than the maximum allowable working pressure during use. [Refer to section 2.25]. 33. Added a mounting bracket vertical loading test [Refer to section 2.26]. 34. The Flammable Gas Accumulation test (section 2.29) has been revised. The test methodology now includes two measuring points. The unit shall operate until the fuel gas concentration reaches a steady state, or a safety device activates, prior to reaching 25 percent of the lower flammability limit at 1) within 10 cm of the ceiling of the room and 2) 50 percent of the lower flammability limit at the appliance vent outlet. The flammable gas accumulation test no longer includes testing the portable fuel cell power system at normal operation. The flammable gas concentration within the portable fuel cell power system, when the appliance is under normal operation, is now determined under the Flammable Gas Concentration Test, section 2.3. DQD 529.01e Rev 2004-09-30 Page 4 of 5
Also, the flammable gas accumulation test now includes a shutdown and purging test condition. Where the portable fuel cell power system shall be shutdown from full power under a normal shutdown mode and while under an emergency shutdown mode and determining the flammable gas accumulation. [Refer to section 2.29]. 35. The Drop Test has been revised. The height from which the portable power systems are dropped, and the weight categories are now different. [Refer to section 2.35]. DQD 529.01e Rev 2004-09-30 Page 5 of 5