WIKA success story with Maximator

H₂ refuelling stations: A key technology for emission-free mobility

TC90 high-pressure thermocouple from WIKA in the MAX Dispenser 1.5 ensures smooth refuelling

Hydrogen is considered the key to emission-free mobility – especially in heavy goods transport. However, for widespread use, the infrastructure of H₂ filling stations must be expanded. With the MAX Dispenser 1.5, Maximator Hydrogen has developed an innovative solution that enables fast, safe and cost-effective hydrogen refuelling thanks to precise temperature monitoring with the TC90 high-pressure thermocouple from WIKA.

“The creation of a reliable infrastructure is crucial to accelerate the introduction of hydrogen-powered vehicles. We are working on the expansion and are also relying on cooperation with partners such as WIKA.”

Lukas Rainer
Executive Development Lead, Maximator Hydrogen

Challenge

Politics forces a change of course

Hydrogen is the smallest and lightest chemical molecule, but its role in the energy transition is huge. In the transport sector, hydrogen is seen as a promising alternative to fossil fuels – especially for heavy goods transport, which is one of the largest sources of CO₂ emissions. In order to reduce these emissions, politicians are planning a change of course: in accordance with EU guidelines, one -third of newly registered trucks should be equipped with electric drives or fuel cells by 2030.

The expansion of the hydrogen infrastructure as a key challenge

In accordance with the EU regulation on the deployment of alternative fuels infrastructure (AFIR), there must be at least one publicly accessible hydrogen refuelling station every 200 kilometres along the trans-European transport network (TEN-T) and at every urban node from 2030. The EU is currently providing 422 million euros in funding for projects that promote the refuelling and charging infrastructure for alternative fuels, including 35 hydrogen refuelling stations for trucks, buses and cars.

Solution

Hydrogen refuelling – a business for experts

For its solutions, Maximator Hydrogen utilises the knowledge and experience of WIKA, the world’s leading supplier of sensor solutions in pressure and temperature measurement. One example of the close cooperation is the use of the TC90 high-pressure thermocouple from WIKA in the MAX Dispenser 1.5, a technically sophisticated “dispenser” for filling hydrogen vehicles in accordance with the SAE J2601 refuelling standard.

TC90 high-pressure thermocouple

Precise monitoring of the hydrogen temperature prevents the tank from overheating and protects the system from damage. The MAX Dispenser 1.5 uses the TC90 high-pressure thermocouple from WIKA for this purpose. The temperature of the incoming hydrogen is recorded on the inlet side of the dispenser and the filling temperature is monitored redundantly with two TC90 sensors in the outlet assembly. Thus it is ensured that this remains between -40 °C and -17.5 °C in accordance with SAE J2601.

Benefits

“Three decisive factors spoke in favour of choosing the TC90 from WIKA: its pressure containment up to at least 1034 bar, the short response time and the ATEX certificate, which enables it to be used in hazardous areas.”

Maik Wenderott
Strategic buyer, Maximator Hydrogen

The product: TC90 high-pressure thermocouple

The TC90 is compact and designed for measuring tasks in small nominal pipe widths.
Its probe tip can withstand pressures of up to 1034 bar that occur at hydrogen refuelling stations, even when it is unprotected.
The version with high-pressure threaded connection, gives the TC90 the necessary strength and keeps the measuring location reliably sealed.
All wetted components are made of H₂-compatible materials.
ATEX certification, which allows the TC90 to be used in hazardous areas.

Interesting facts

Safe hydrogen refuelling – requirements and standards

■ High-pressure systems: Current fuel cell vehicles use tanks with an operating pressure of 350 or 700 bar
■ Safety requirements: Refuelling under high pressure demands the highest standards of safety
■ User-friendliness: The refuelling must be as easy as for petrol or diesel, in order to achieve wide acceptance
■ SAE J2601 standard: This standard regulates the highest pressure and maximum hydrogen temperature during the refuelling process.
■ Thermal control: Precise pressure and temperature control prevents material damage and ensures safe processes

Maximator Hydrogen – Infrastructure for hydrogen mobility

■ Company foundation: Founded 2019, headquarters in Nordhausen, Germany.
■ Core focus: Development and expansion of hydrogen refuelling stations worldwide.
■ International presence: Over 80 systems in use by the end of 2025 –- in Switzerland, 17 out of 18 are from Maximator Hydrogen
■ Goal: Contributing to the mobility transition by building a reliable H₂ infrastructure.

Hydrogen becomes a real alternative to diesel

Short refuelling times and a competitive price are crucial for acceptance by end customers. Thanks to innovative systems such as the MAX Dispenser 1.5, fast refuelling is already a reality. The price of hydrogen was also on a par with diesel before the pandemic. In the medium term, the technology can become competitive and make a significant contribution to emission-free mobility.

Read more success stories from WIKA customers.

Contact

If you would also like to optimise your H₂ infrastructure with the TC90 high-pressure thermocouple from WIKA, please feel free to contact us:

Maximator Hydrogen