ISO 12619-5:2016

Overview

ISO 12619-5:2016 - "Road vehicles - Compressed gaseous hydrogen (CGH2) and hydrogen/natural gas blends fuel system components - Part 5: Manual cylinder valve" specifies the general requirements, design principles, markings and test methods for manual cylinder valves used in vehicle compressed hydrogen and hydrogen/natural gas blend fuel systems. It applies to motor vehicles defined in ISO 3833 using CGH2 (per ISO 14687‑1/2) or hydrogen/natural gas blends (per ISO 15403‑1/2).

This part is focused on manual cylinder valves and complements the general and test-method requirements in ISO 12619‑1 and ISO 12619‑2.

Key topics and technical requirements

• Scope and applicability: For compressed gaseous hydrogen (CGH2) and H2/natural gas blends on road vehicles. Not applicable to liquefied hydrogen (LH2) upstream of the vaporizer, fuel containers, stationary engines, container mounting hardware, electronic fuel management, or refuelling receptacles.
• Marking: Components must be permanently marked (etched, stamped, moulded or permanent label) with manufacturer, part/model number, working pressure (or pressure/temperature range). Recommended markings include flow direction, fuel type, electrical ratings, certification symbol, approval number and serial/date code. Markings must remain legible for the component life.
• Construction and assembly: Valves must meet the general provisions of ISO 12619‑1 and ISO 12619‑2 and the specific tests in this part.
• Mandatory tests and acceptance criteria:
  • Hydrostatic strength: test at 2× working pressure (per ISO 12619‑2 procedure).
  • Leakage: tested at specified temperatures and pressures (Table 2): e.g., −40 or −20 °C, 20 °C, 85 °C with pressure factors relative to working pressure.
  • Continued operation (endurance): 2 000 cycles with downstream pressure lowered to < 0.5 MPa; re-test leakage. After cycling the valve must fully open/close under specified maximum torques.
  • Torque limits (Table 3): example values - inlet size 6 mm: max torque 1.7 N·m (ambient) and 3.4 N·m (−40 °C); 8/10 mm: 2.3 N·m and 4.5 N·m; 12 mm: 2.8 N·m and 11.3 N·m.
  • Additional applicable tests (listed): excess torque resistance, bending moment, corrosion resistance, oxygen/ozone/heat ageing, material compatibility, vibration, automotive fluid exposure, brass/hydrogen compatibility, pre-cooled hydrogen exposure, electrical overvoltages and non‑metallic immersion.
• Referencing normative documents: ISO 12619 parts 1–4, ISO 12619‑2 test methods, ISO 14687, ISO 15403, ISO 3833, ISO 15869, and relevant cable standards.

Applications and users

ISO 12619-5 is intended for:

• Vehicle manufacturers integrating CGH2 fuel systems
• Fuel-system component designers and valve manufacturers
• Test laboratories and certification bodies validating valve safety and durability
• Regulators and type‑approval authorities referencing harmonized safety criteria
• Suppliers of hydrogen fuel system components for light- and heavy-duty road vehicles

Using ISO 12619‑5 helps ensure safe, reliable manual cylinder valves for compressed hydrogen and H2/NG blends, supports regulatory compliance and reduces in-service risk.

Related standards

• ISO 12619‑1 (General requirements and definitions)
• ISO 12619‑2 (Performance and general test methods)
• ISO 12619‑3 (Pressure regulator) and ISO 12619‑4 (Check valve)
• ISO 14687‑1/2 (Hydrogen fuel quality)
• ISO 15403‑1/2 (Natural gas fuel quality)
• ISO 3833 (Vehicle types) and ISO 15869 (Hydrogen vehicle fuel tanks)

Keywords: ISO 12619-5:2016, manual cylinder valve, CGH2, compressed gaseous hydrogen, hydrogen/natural gas blends, fuel system components, road vehicles, valve testing, hydrostatic strength, leakage test.