ISO 19880-5:2025

International
Standard
ISO 19880-5
Second edition
Gaseous hydrogen — Fuelling
2025-07
stations —
Part 5:
Dispenser hoses and hose
assemblies
Carburant d'hydrogène gazeux — Stations de ravitaillement —
Partie 5: Flexibles et assemblages flexibles pour distributeurs
Reference number
© ISO 2025
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Published in Switzerland
ii
Contents Page
Foreword .v
Introduction .vi
1 Scope . 1
2 Normative references . 1
3 Terms and definitions . 2
4 Classification . 5
5 Materials and construction . 6
5.1 General .6
5.2 Lining .6
5.3 Reinforcement .6
5.4 Cover .7
5.5 Static electricity dissipation .7
5.5.1 General .7
5.5.2 External surface . .7
5.5.3 Internal surface .7
6 Dimensions and tolerances . 7
7 Performance requirements and testing . 7
7.1 General .7
7.2 Leakage test .8
7.2.1 General .8
7.2.2 Type tests - Method A.8
7.2.3 Routine tests - Method B .9
7.3 Hydrostatic strength .10
7.3.1 Proof pressure test .10
7.3.2 Ultimate strength .10
7.4 Electrical conductivity .10
7.5 Tensile test of hose assembly .10
7.5.1 General .10
7.5.2 Test method .11
7.6 Vertical load strength .11
7.6.1 General .11
7.6.2 Test method .11
7.7 Torsion strength . 12
7.7.1 General . 12
7.7.2 Test method . 12
7.8 Pressure cycle test (Hydraulic-pressure impulse test) . 13
7.8.1 General . 13
7.8.2 Apparatus . 13
7.8.3 Test fluid . 13
7.8.4 Test temperature . 13
7.8.5 Test piece . 13
7.8.6 Procedure .14
7.9 Hydrogen impulse test . 15
7.10 Corrosion test . 15
7.10.1 General . 15
7.10.2 Test conditions .16
7.11 Minimum bend radius .16
7.12 Hose permeation .16
7.12.1 General .16
7.12.2 Test Method 1 .16
7.12.3 Test Method 2 .17
7.13 Ozone resistance .17

iii
7.14 Ultraviolet light and water exposure test .18
7.14.1 Applicability and verification .18
7.14.2 Test conditions .18
7.14.3 Length of exposure.18
7.15 Crush test .18
7.15.1 General .18
7.15.2 Test method .18
7.16 Abrasion resistance test .18
7.17 Marking material legibility .19
7.17.1 General .19
7.17.2 Test method .19
7.18 Electrical properties of lining material .19
7.18.1 General .19
7.18.2 Electric strength .19
7.18.3 Volume resistivity .19
7.18.4 Criteria of electric properties of lining materials .19
8 Marking . .20
8.1 General . 20
8.2 Hoses .21
8.3 Hose end fittings or couplings .21
8.4 Hose assemblies .21
9 Instruction manual .21
9.1 General .21
9.2 Selection . 22
9.3 Installation . 22
9.4 Inspection and maintenance . 22
9.5 Safety precautions and usage . . 22
10 Test report .23
Annex A (normative) Type tests and routine tests .24
Annex B (informative) Production acceptance tests .25
Annex C (normative) Hydrogen impulse test .26
Bibliography .29

iv
Foreword
ISO (the International Organization for Standardization) is a worldwide federation of national standards
bodies (ISO member bodies). The work of preparing International Standards is normally carried out through
ISO technical committees. Each member body interested in a subject for which a technical committee
has been established has the right to be represented on that committee. International organizations,
governmental and non-governmental, in liaison with ISO, also take part in the work. ISO collaborates closely
with the International Electrotechnical Commission (IEC) on all matters of electrotechnical standardization.
The procedures used to develop this document and those intended for its further maintenance are described
in the ISO/IEC Directives, Part 1. In particular, the different approval criteria needed for the different types
of ISO document should be noted. This document was drafted in accordance with the editorial rules of the
ISO/IEC Directives, Part 2 (see www.iso.org/directives).
ISO draws attention to the possibility that the implementation of this document may involve the use of (a)
patent(s). ISO takes no position concerning the evidence, validity or applicability of any claimed patent
rights in respect thereof. As of the date of publication of this document, ISO had not received notice of (a)
patent(s) which may be required to implement this document. However, implementers are cautioned that
this may not represent the latest information, which may be obtained from the patent database available at
www.iso.org/patents. ISO shall not be held responsible for identifying any or all such patent rights.
Any trade name used in this document is information given for the convenience of users and does not
constitute an endorsement.
For an explanation of the voluntary nature of standards, the meaning of ISO specific terms and expressions
related to conformity assessment, as well as information about ISO's adherence to the World Trade
Organization (WTO) principles in the Technical Barriers to Trade (TBT), see www.iso.org/iso/foreword.html.
This document was prepared by ISO/TC 197, Hydrogen technologies.
This second edition cancels and replaces the first edition (ISO 19880-5:2019), which has been technically
revised.
The main changes are as follows:
— subclause 7.2.3 revised test gas and pass/fail criteria;
— subclause 7.7.2 revised to add temperature tolerance;
— editorial changes.
A list of all parts in the ISO 19880 series can be found on the ISO website.
Any feedback or questions on this document should be directed to the user’s national standards body. A
complete listing of these bodies can be found at www.iso.org/members.html.

v
Introduction
This document specifies the implementation of performance-based testing for components of dispensing
systems and fuelling stations that are based on proven engineering principles, research and the combined
expertise of gas utilities, fuel providers, manufacturers, users, and others having specialized experience.
The successful commercialization of hydrogen vehicle technologies requires codes and standards pertaining
to fuelling stations, vehicle fuel system components, and the global homologation of standards requirements
for technologies with the same end use. Essentially this will allow manufacturers to achieve economies of
scale by producing one product for use globally.
International harmonization contributes to reducing technical barriers and stimulates related markets. A
series of documents that address hydrogen-fuelled vehicles and fuelling stations is being developed. These
documents will provide internationally homologized minimum safety performance criteria at the component
level, thus providing a foundation to build a safe “fuelling system”.
This document is based on ANSI/CSA HGV 4.2-2022.
This document was developed based on five pressure classes of wire or textile reinforced hoses and hose
assemblies suitable for use with gaseous hydrogen for hydrogen dispensing. This is based on technologies in
use at the time of the development of the requirements.
In the future, other types and classes of hoses and hose assemblies will need to be evaluated to determine
the suitability of requirements in this document.
This document applies to newly manufactured hoses and hose assemblies for connecting a dispenser to a
high-pressure fuelling nozzle.
A nozzle vent hose is included in this document; however; the pressure rating may be lower than the nozzle
rating, based on the nozzle and dispenser design.
For general hydrogen safety information, see ISO/TR 15916.

vi
International Standard ISO 19880-5:2025(en)
Gaseous hydrogen — Fuelling stations —
Part 5:
Dispenser hoses and hose assemblies
1 Scope
This document specifies the requirements for wire or textile reinforced hoses and hose assemblies suitable
for dispensing hydrogen up to 70 MPa nominal working pressure, in the operating temperature range of
−40 °C to 65 °C.
This document specifies safety requirements for material, design, manufacture and testing of gaseous
hydrogen hose and hose assemblies for hydrogen fuelling stations.
This document does not apply to the following hoses and hose assemblies:
a) those used as part of a vehicle high pressure on-board fuel storage system;
b) those used as part of a vehicle low pressure fuel delivery system; and
c) flexible metal hoses.
NOTE 1 This document was developed primarily for hoses and hose assemblies for dispensing high-pressure
hydrogen from refuelling dispensers to hydrogen vehicles. ISO 16964 addresses hoses used to deliver hydrogen from a
transportable vessel (e.g. trailer) into a buffer storage of a station.
NOTE 2 Hose assemblies include a hose with connectors on each end (see Figure 1). Each connector has two basic
functional elements that are addressed as described below.
a) Coupling to hose. This function is defined by requirements and verified (along with the hose itself) by
performance-based tests in this document.
b) Fitting for transition and connection to the piping system or equipment. This function is addressed by reference
to appropriate hydrogen equipment standards and piping codes.
2 Normative references
The following documents are referred to in the text in such a way that some or all of their content constitutes
requirements of this document. For dated references, only the edition cited applies. For undated references,
the latest edition of the referenced document (including any amendments) applies.
ISO 1402, Rubber and plastics hoses and hose assemblies — Hydrostatic testing
ISO 4671, Rubber and plastics hoses and hose assemblies — Methods of measurement of the dimensions of hoses
and the lengths of hose assemblies
ISO 6802, Rubber or plastics hoses and hose assemblies — Hydraulic impulse test with flexing
ISO 6803, Rubber or plastics hoses and hose assemblies — Hydraulic-pressure impulse test without flexing
ISO 7326:2016, Rubber and plastics hoses — Assessment of ozone resistance under static conditions
ISO 8031:2020, Rubber and plastics hoses and hose assemblies — Determination of electrical resistance and
conductivity
ISO 8330, Rubber and plastics hoses and hose assemblies — Vocabulary
ISO 8331, Rubber and plastics hoses and hose assemblies — Guidelines for selection, storage, use and maintenance
ISO 9227, Corrosion tests in artificial atmospheres — Salt spray tests
ISO 15649, Petroleum and natural gas industries — Piping
ISO 16964, Gas cylinders — Flexible hoses assemblies — Specification and testing
ISO 19880-1, Gaseous hydrogen — Fuelling stations — Part 1: General requirements
ISO 20485, Non-destructive testing — Leak testing — Tracer gas method
ISO 30013, Rubber and plastics hoses — Methods of exposure to laboratory light sources — Determination of
changes in colour, appearance and other physical properties
IEC 60243-1, Electric strength of insulating materials — Test methods — Part 1: Tests at power frequencies
IEC 62631-3-1, Dielectric and resistive properties of solid insulating materials — Part 3-1: Determination of
resistive properties (DC methods) — Volume resistance and volume resistivity — General method
3 Terms and definitions
For the purpose of this document, the terms and definitions given in ISO 8330, ISO 19880-1 and the
following apply.
ISO and IEC maintain terminology databases for use in standardization at the following addresses:
— ISO Online browsing platform: available at https:// www .iso .org/ obp
— IEC Electropedia: available at https:// www .electropedia .org/
3.1
connector
mating parts that can be put together to form a "connection" which permits the transfer of fluids, electric
power, or control signals
Note 1 to entry: Fittings (3.4) are a type of connector used in piping systems.
EXAMPLE Connectors commonly used in hydrogen systems are as follows:
a) The fuelling nozzle “connector” mates with the receptacle “connector” on the vehicle to form the
connection for transfer of compressed hydrogen between the dispenser and the vehicle, as defined in
ISO 17268 for this specific application.
b) The hose assemblies have connectors on each end that allow coupling (3.2) to the hoses and connection
to the piping system (e.g. hose breakaway device or fuelling nozzle).
c) Control systems often use electrical connectors to allow rapid and secure assembly or replacement.
3.2
connection fitting
connection part consisting of a fitting inserted into a hose and a mechanical joint
3.3
coupling
integrated structure of nipple (3.9) and socket with end portion of a hose crimped together
Note 1 to entry: See Figure 1
3.4
socket shell
portion of a hose fitting that is compressed by swaging or crimping to seat the hose on to the fitting
serrations and create a permanent attachment
Note 1 to entry: ISO 8330 provides the following names for socket shell: collar and ferrule.
3.5
dispenser hose assembly
hose assembly (3.7) used for dispensing gaseous hydrogen to vehicles through a nozzle
Note 1 to entry: See Figure 2.
Key
1 hose assembly
2 mechanical joint
3 connection fitting (key 2+ key 4)
4 nipple
5 coupling (key 4 + key 6)
6 socket shell
7 hose
8 fitting (key 2 + key 4+ key 6)
NOTE Definition of the terms used in the key table and how they are defined under ISO 8330 are explained in
Clause 3, terms and definitions.
Figure 1 — Conceptual diagram of hose assembly and fitting

Key
1 dispenser
2 breakaway device
3 connection fitting
4 hose assembly
5 connector
6 nozzle
7 receptacle
8 vehicle
NOTE Definition of the terms used in the key table are explained in Clause 3.
Figure 2 — Components connecting a dispenser to a vehicle
3.6
fitting
connector (3.1) used to join any pressure retaining components in the system, and in the case of the hose
assembly (3.7), device, usually made of metal, attached to the end of a hose to facilitate connection to
equipment or other hose
Note 1 to entry: Other hoses are shown in Figure 1.
Note 2 to entry: Fittings can be used in a finished hose assembly (3.7); however; requirements for fittings are out of
scope of this document.
3.7
hose assembly
assembly which includes the hose and end connections, including any necessary fittings (3.6), bend
restrictors, and appropriate markings

3.8
breakaway device
device on the fuelling hose that disconnects the hose from the dispenser when a tension limit is exceeded
and blocks the flow of hydrogen from the dispenser
Note 1 to entry: An example application is if the vehicle moves away with the fuelling hose connected to the vehicle.
Note 2 to entry: Figure 2 shows the breakaway device connected directly to the dispenser.
Note 3 to entry: A breakaway device placed between two hose assemblies is called a “hose breakaway device", which is
designed to separate when a given pull force is applied in order to cut off the flow of hydrogen to prevent gas leakage
and protect the dispenser from damage from vehicles driving away.
[SOURCE: ISO 19880-1: 2020, 3.5, modified — added Notes 2 and 3 to entry.]
3.9
nipple
section of the fitting that is inserted into the hose
Note 1 to entry: ISO 8330 provides the following names for nipple: spigot, hose nipple, hose fitting stem, insert,
hosetail, tail and shank.
3.10
nozzle vent hose
hose used to depressurize the fuelling nozzle and vent the hydrogen to an approved location
Note 1 to entry: See ISO 17268 for type B nozzle definition.
3.11
minimum bend radius
smallest specified radius to which a hose may be bent in service
Note 1 to entry: The minimum bend radius is shown in Table 3.
3.12
pressure rating
maximum pressure at which it is permissible to operate a component as specified by the manufacturer at
the maximum temperature expected during service
3.13
proof pressure
pressure applied during a non-destructive test and held for a specified period of time to prove the integrity
of the construction
4 Classification
This clause applies to newly manufactured hoses and hose assemblies for dispenser hoses connecting the
dispenser to the fuelling nozzle supply port.
This document is intended for new hose and hose assembly designs and existing designs made with new
materials. It is not intended for existing hose designs with history of use, hoses made of existing materials
with history of use, or hoses qualified by industry-recognized organizations for use in compressed gaseous
hydrogen applications.
NOTE The exclusions in this clause do not preclude manufacturers from using this document for certification
purposes for existing hoses and hose assemblies with history of use.
Hoses and couplings shall meet the requirements in this document with end fittings selected by the
manufacturer, customer, or testing agency as required to connect to the test equipment. Fittings shall be
in accordance with the requirements of the appropriate documents in the ISO 19880 series, ISO 17268, or
ISO 15649.
The connection fitting of the hose assembly (see Figure 1) may be changed to another type that meets
requirements defined above without the need to repeat the performance tests for verification of the hose
assembly and its coupling as long as the hose coupling remains unchanged.
Some newly manufactured hoses and hose assemblies include vent lines required by some fuelling nozzles.
Nozzle vent hose assemblies shall meet the requirements of ISO 16964 or the requirements in this document
and be appropriately rated for operation in the vent system that has been defined based on the nozzle
manufacturer instructions and the dispenser design.
Table 1 converts hydrogen service levels (HSL), as defined in ISO 19880-1, to pressure levels.
When using ISO 16964, the hose rating is 125 % of the working pressure, which is 10 % lower than the
pressure ratings in Table 1.
A hose assembly shall be designated according to the pressure classes defined in Table 1 or by the
manufacturer’s stated pressure rating. The information in Table 1 is taken from ISO 19880-1 (and pressure
class H11 is added). The pressure rating of the hose assembly shall be equal to or above the dispenser pressure
ratings. For further information regarding the relationships between pressure terms, see ISO 19880-1.
When the nozzle vent hose is part of dispensing system, the nozzle vent hose shall have means to ensure that
the vent hose is not inadvertently connected to the fuelling ports of the breakaway or the nozzle.
NOTE Examples of such means include having different end fitting sizes or different end fitting threads.
Table 1 — Hose assembly pressure levels
Maximum allowable
working pressure (MAWP)
Pressure level (HSL) Pressure class
(1,375 × HSL)
(MPa) (MPa)
11 H11 15,13
25 H25 34,38
35 H35 48,13
50 H50 68,75
70 H70 96,25
The hoses and hose assemblies shall be designed to operate at temperatures ranging from −40 °C to 65 °C.
5 Materials and construction
5.1 General
The hose and lining shall be constructed with materials that are resistant to corrosion and exposure to
hydrogen.
5.2 Lining
The lining shall be of uniform thickness and free from defects. Defects are defined as but are not limited to
bubbles, thinning, gouging, or discoloration.
The lining may also consist of multiple material layers.
5.3 Reinforcement
The reinforcement consists of one or more layers of suitable wire or textile material applied by any suitable
technique.
5.4 Cover
The cover shall be resistant to abrasion, cracking, crazing, the effects of exposure to ultraviolet light and
ozone, be of uniform thickness, and free from defects. Defects can include but are not limited to bubbles,
thinning, gouging, or discoloration. All outer covering shall either be of a permeable material or sufficiently
pricked to avoid diffused gas build up.
5.5 Static electricity dissipation
5.5.1 General
Static electricity can be generated on the external and interior surface of a hose assembly.
5.5.2 External surface
The hose assembly shall be constructed so as to provide an external, electrically conductive, bonding path
between the end couplings to dissipate external static electric charges.
5.5.3 Internal surface
The hose assembly shall be constructed so that the liner provides an adequate internal layer of prevention to
avoid dielectric breakdown by static electricity in the fluid during normal use.
6 Dimensions and tolerances
The measurement shall be in accordance with ISO 4671, typical diameters and concentricity of hoses are
given in Table 2.
Table 2 — Typical diameters and concentricity of hoses
Inside diameter Concentricity
Maximum outside (Maximum variation in wall
mm
Nominal size
diameter of hose thickness between inside
Minimum maximum diameter and outside diameter)
mm mm
6,3 5,9 7,0 25 0,8
8 7,7 8,5 30
10 9,3 10,1 35 1,0
13 12,3 13,5 40
7 Performance requirements and testing
7.1 General
Performance requirements shall be determined by the following tests and carried out by type tests, routine
tests and production acceptance tests.
Hose assemblies shall meet the requirement of each performance test.
When hydrogen or helium is used for conducting the tests the gas purity shall be 99,9 % or greater.
Type tests are those required to confirm that a particular hose or hose assembly design, manufactured
by a particular method from particular materials, meets all the requirements of this document. The tests
shall be repeated whenever a change in the method of manufacture or materials used occurs. They shall be
performed on all sizes and types except those of the same size and construction.

Routine tests are those required to be carried out on each length of a finished hose or hose assembly prior to
dispatch.
Type tests and routine tests shall be carried out as specified in Annex A.
Production acceptance tests are those required to control the quality of the manufacturing. The frequencies
specified in Annex B are given as a guide only and determined by the interested parties.
7.2 Leakage test
7.2.1 General
Leakage tests shall be conducted in accordance with Method A (7.2.2) for type tests, Method B (7.2.3) for routine
tests and after relevant performance tests. Method A is also recommended for production acceptance tests.
7.2.2 Type tests - Method A
The hose assembly shall be tested with the following conditions and procedures using the apparatus as
shown in Figure 3. Use hydrogen as a test gas
The leakage rate of the hose assembly shall be less than 20 Nml/h under normal pressure and temperature
conditions measured with an accuracy of ±10 %.
NOTE Nml/h indicates flow rate at 0 °C and 1 atm.
The test can be done at room temperature. This temperature shall be converted to 15 °C.
The test piece shall have a free length of 0,5 m ± 1 % tolerance between the couplings. Connect the test piece
to the hydrogen gas supply with a suitable connector and purge the test assembly with hydrogen gas. Adjust
the temperature of the water bath to the specified value.
Immerse the test assembly and its end connections in the water bath.
Apply the gas pressure of 1,375 × HSL and maintain it for 10 min. This is the time necessary for releasing
trapped air in the reinforcement layer to the outside of the hose through pricked holes. Then, position the
two measuring cylinders and the collection funnels as shown in Figure 3 so as to collect and measure the
gas which escapes from the two ends of the test piece for a period of 5 min while maintaining the pressure.
Leakage can be tested using the same apparatus shown in Figure 9 for hose permeation with the above
conditions and procedures.
The measuring apparatus shall have a means capable of measuring the gas with a tolerance of at least ±10 %.
This amount shall be converted to an amount per hour.

Key
1 gas supply
2 collecting funnels
3 measuring cylinder
4 test piece
a
5 test length
6 water bath
a
0,5 m of free length ±1 % tolerance.
Figure 3 — Schematic apparatus for Method A
7.2.3 Routine tests - Method B
Use hydrogen or helium as a test gas. Connect the test piece to the test gas supply with a suitable connector
and purge the test assembly with the test gas. Apply the gas pressure of 1,375 × HSL and maintain it for
10 min to release trapped air in the reinforcement layer. Then, still maintaining the pressure, the fittings of
the test piece shall be checked for 5 min for leakage by one of the following options.
For this test, a length of any assembly hose can be used.
a) Option 1: The leakage shall be checked under water by immersing the test piece in a water bath shown
in Figure 3. No bubbles shall be visible. Collecting funnels and measuring cylinders are possibly not
necessary for this test.
b) Option 2: This check may also be performed by applying leak detection fluid on the fittings in the air. No
bubbles shall be visible.
The air contained in the reinforcement layer (trapped air), which comes out from pricked holes, can be
omitted unless they are abnormal.
c) Option 3: The leakage shall be checked by using a gas leak detector in accordance with ISO 20485. The
-4 3 -1 -3 -1
leakage rate shall be less than 1∙10 Pa∙m ∙s (1∙10 mbar∙l∙s , corresponds to smallest detectable
leakage rate with bubble test).

7.3 Hydrostatic strength
7.3.1 Proof pressure test
When tested in accordance with ISO 1402, a hose assembly shall withstand a pressure of at least 2,1 × HSL
for 5 min without bursting or visible loss of fluid.
As a test fluid, water or a mixture of water and glycol or oil can be used.
This is a non-destructive test.
7.3.2 Ultimate strength
When tested in accordance with ISO 1402, a hose assembly shall withstand without bursting or visible loss
of fluid with a pressure of a minimum of 5 times of HSL for 5 min.
As a test fluid, water or a mixture of water and glycol or oil can be used.
Following this test, the sample shall be discarded.
7.4 Electrical conductivity
When determined in accordance with ISO 8031:2020, 4.8, the bonding resistance of fuelling hose assembly,
from end fitting to end fitting, shall be no greater than 100 kΩ, for any length of assembled hose in order to
dissipate static electricity.
This test shall be conducted with the hose un-pressurized.
7.5 Tensile test of hose assembly
7.5.1 General
This test is modelling the scenario of the fuelling nozzle being connected to the vehicle while driving away.
This provision applies to a single hose assembly only. For an integrated supply and vent line hose assembly,
only the supply portion of the hose assembly shall be tested.
A hose assembly having a free length of 100 mm or longer shall withstand a longitudinal pull force of 3 000 N,
as shown Figure 4, without structural damage or leakage. The hose shall comply with 7.2.3 and 7.4 after the
tensile test.
For safety reasons, before performing 7.2.3 leakage test - Method B, it is recommended to run 7.3.1 proof
pressure test.
Key
1 hose assembly
a
Direction of force.
Figure 4 — Tensile test of hose assembly

7.5.2 Test method
The tensile test shall be conducted at room temperature.
The hose assembly is to be placed in a tensile testing machine and connected so that the end couplings and
hose are subjected to 3 000 N. With the testing machine adjusted for a rate of travel of 0,2 mm/s or slower,
the pull force is to be applied until 3 000 N is attained.
At the completion of this test, hose assemblies shall comply with 7.2.3 and 7.4.
7.6 Vertical load strength
7.6.1 General
This test models the scenario of a person falling against the hose while the fuelling nozzle is connected to
the vehicle receptacle, as shown Figure 5.
The hose shall comply with 7.2.3 and 7.4 after the vertical strength test.
Key
1 hose assembly
a
Direction of force.
Figure 5 — E
...