Fuel cells are an innovative technology with a wide range of applications, from powering vehicles to providing backup energy for buildings. They work similarly to batteries but have key differences, such as their ability to produce electricity continuously as long as they are fuelled. This article will provide a comprehensive guide on how to change a fuel cell, covering the necessary tools, steps, and safety precautions. By the end, you should have a clear understanding of the process and feel confident about tackling this task.
Characteristics | Values |
---|---|
Installation | Remove seat, hoses, and transfer equipment to a new bladder. |
Fuel Cell Types | Fuel bladder or hard-plastic fuel cell. |
Fuel Cell Use | To increase fuel supply and driving range. |
Fuel Cell Maintenance | Fuel cells should be inspected and serviced annually. |
Fuel Cell Parts | Proton Exchange Membrane, Electrode Backing Layers, Catalyst, Flowfield Plates, Gaskets, Current Collectors, End Plates, Clamping Mechanism. |
Fuel Cell Materials | Carbon fabric or paper, platinum, graphite, metal, etc. |
What You'll Learn
Removing the old fuel cell
The first step in removing the old fuel cell is to drain all the fuel from the car. This can be done by disconnecting a hose from the fuel rail and placing the end into a fuel jug. Next, disconnect the fuel filler hose from the fuel cell side.
Remove the seat from the car. For a ButlerBuilt Seat, you can refer to the installation guide. For a fiberglass seat, refer to the Spec Racer Ford Gen2 Manual.
Undo all the fasteners holding the Fuel Cell cover in place using a 5/16th inch nut driver, 3/8th inch wrench, socket, and ratchet, or impact driver. There should be four sets of fasteners: two on each side, and one each on the top and bottom rows.
You may need to use a pry bar or a blunt flat-blade screwdriver to help get the fuel cell cover loose. If your fuel cell cover panel isn't notched for the rear bulkhead mount, now is a good time to mark and notch it with a hacksaw and some sheet metal sheers.
Before disconnecting the fuel lines, it is important to mark which fitting is the Vent and which is the Return. Disconnect the fuel lines from the Fuel Cell closeout plate using a -6 AN wrench.
Loosen the closeout place bolts with locating tabs using a 7/16th inch wrench or socket and ratchet. Swing the tabs out of the way of the engine bay bulkhead and pull the fuel cell out through the driver's compartment.
The fuel cell will likely be filthy, so it is recommended to clean the cover plate and fittings before reusing them. Block all the holes with plugs and give the plate a good clean.
With the fuel cell out of the car, take the opportunity to clean out any old gunk that has collected over the years.
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Preparing the new fuel cell
The new fuel cell comes with compliance documentation, which should be stored in a safe place. The following steps outline the process of preparing the new fuel cell:
- The fuel cell should have foam inside it to prevent the fuel from sloshing around while the vehicle is in motion. This foam will need to be cut to fit the surge box in place. This can be done with a hacksaw blade. The surge box should sit at the lowest central point with about an inch of clearance all around.
- Install the internal vent line and ensure it is not kinked or blocked. If it is, the tank will not vent correctly, and you will have difficulty getting a full fuel load into the car as the air won't escape.
- If you are upgrading from an external fuel pump to an internal fuel pump, refer to the "In-Tank Fuel Pump" section before proceeding.
- Use a brand new gasket and replace the fuel cell cover plate. Thread all the fasteners loosely in place. Ensure the plastic washers are all in place to prevent leaks. Do not tighten yet, as you will torque them to the manufacturer's specifications later.
- Mark which fitting is which. For example, a "V" for vent and "R" for return.
- If you are doing a Gen 3 conversion, you may find it beneficial to slightly clock the fuel filler neck to curve the fuel filler hose. This will make it easier to remove the oil filter when it comes time for an oil change. Use a brand new gasket if you need to undo the fuel filler neck portion of the closeout plate.
- For both the filler neck place and fuel cell cover, lightly snug the bolts first using a star pattern. For the three fasteners with locating tabs, provide the final torque when the fuel cell is in place and the tabs are rotated into the correct position. Do not tighten one side straight away, as you don't want to pinch and ruin the gasket seal. You want to get an even crush across the entire surface area. Then torque to the manufacturer's recommendation of 40 in-lbs. A two-step process can be followed: first, 20 in-lbs all around, followed by 40 in-lbs. Be careful not to over-torque these bolts, as you can easily strip them and ruin the fuel cell.
Additional Considerations:
- If your old hoses are cracked, now is a great time to swap them out for a fresh set of AN hoses and fittings.
- Before installing the new fuel cell into the car, protect it from any sharp elements that could rub against it while driving, such as rivet heads and sheet metal edges. It is better to use a little bit of tape now than to put a small hole in your new fuel cell.
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Installing the new fuel cell
With the new fuel cell sorted, it's time to put it back into the car. Place it in the cockpit, ensuring that the fuel cell cover plate is positioned in the hole of the engine bay bulkhead. Rotate the three locating tabs into position and torque the bolts to the manufacturer's recommended 40 in-lbs.
Reconnect all the fuel hoses, including the feed, return, vent, and filler hose. It is important to mark the vent and return line positions to avoid confusion. Connect the fuel pump wiring to the engine harness.
Pour some fuel into the new fuel cell and check for any leaks on the cover plate, hoses, or filler neck. Turn on the ignition and check the fuel pressure before covering the fuel cell and reinstalling the seat. This way, you can address any issues without having to remove everything again.
If everything is functioning correctly, reposition the fuel cell cover and reinstall the fasteners and seat. Your vehicle is now ready for the next race weekend!
Additional tips and precautions
- It is recommended to protect the new fuel cell from any sharp elements that could cause damage during driving, such as rivet heads and sheet metal edges. Use tape as necessary.
- Ensure that the internal vent line is installed correctly and is not kinked or blocked. Otherwise, the tank will not vent correctly, and you may have difficulty filling the car with fuel.
- Use a new gasket and replace the fuel cell cover plate. Loosely thread all the fasteners in place, ensuring the plastic washers are in the correct position to prevent leaks. Do not tighten them yet; instead, follow the manufacturer's torque specifications.
- Mark the fittings to differentiate between the vent and return lines. This will make it easier during reconnection.
- Before installing the new fuel cell, it is crucial to block all the holes and thoroughly clean the cover plate to remove any old gunk or residue.
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Fuel cell maintenance
Regular Inspection and Servicing:
Fuel cells should be inspected and serviced annually. This includes replacing the pick-up screens and checking the proper operation of the check valves. It is also recommended to replace all gaskets and the cap during this annual service.
Fuel Type Considerations:
It is important to use the correct type of fuel for your fuel cell. Bladder fuel cells filled with foam should only be filled with regular gasoline. If you intend to use alcohol, the foam must be removed. Additionally, avoid using fuel additives as they can harm the fuel bladder over time by separating from the fuel and eating away at the bladder.
Storage and Drainage:
If your vehicle is going to be stored in a garage for an extended period, such as several months, it is crucial to drain the fuel cell completely. Store the fuel cell in a cool, dry environment to prevent any damage.
Grounding:
Always remember to add a ground strap to the fuel cell during installation. This is essential for safety. Fuel sloshing inside the cell can generate static electricity, which could lead to an explosion if the cell is not properly grounded to the chassis of the vehicle.
Foam Insert:
For off-road environments, consider using a fuel bladder with foam inside. The foam helps prevent fuel sloshing, which can lead to explosions. The foam absorbs the energy of any explosions and extinguishes the flames by burning off the oxygen within the cell. Ensure the fuel cell is 80% filled with foam for maximum effectiveness.
Ventilation and Temperature Management:
Fuel cells produce heat, and proper ventilation is necessary to prevent overheating. Additionally, maintain a consistent temperature throughout the cell to prevent destruction through thermal loading. This is particularly important as the fuel cell reaction is highly exothermic and generates significant heat.
Compatibility and Legal Considerations:
Always check the compatibility of your fuel cell with different fuel types. Some fuel cells are designed for specific fuels, such as hydrocarbon fuels like diesel or methanol. Additionally, be aware of local laws and regulations regarding fuel cell usage, especially for vehicles operated on public roads.
Cleaning and Maintenance:
Fuel cells should be kept clean and free of debris. This includes the fuel cell cover plate and the engine bay. Ensure all old gunk is removed, and the components are well-maintained.
Gaskets and Seals:
Inspect the gaskets and seals regularly for any signs of wear or damage. Replace them if necessary to prevent fuel leakage and maintain proper pressure in the stack.
Fuel Cell Cover Plate:
Before installing a new fuel cell, protect it from sharp elements that could cause damage during driving conditions, such as rivet heads and sheet metal edges. Additionally, ensure the fuel cell cover plate is clean and free of debris before installation.
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Safety considerations
Fuel cells are a powerful energy source but must be handled with caution to ensure safety. Here are some key safety considerations when working with fuel cells:
- Fuel and Chemical Handling: Fuel cells typically use flammable fuels like hydrogen, so proper fuel handling is crucial. Always work in a well-ventilated area to prevent the buildup of flammable gases. Store and handle fuels according to the manufacturer's instructions and local regulations.
- Personal Protective Equipment: When working with fuel cells, wear appropriate personal protective equipment (PPE), including safety goggles, gloves, and clothing that covers your skin. This will protect you from chemical splashes, sparks, and hot surfaces.
- Ventilation and Exhaust: Ensure that the work area has adequate ventilation to prevent the accumulation of hazardous gases and fumes. Use exhaust systems or fans to remove these gases from the workspace.
- Electrical Safety: Fuel cells produce electricity, so be mindful of electrical hazards. Ensure that all electrical connections are secure and properly insulated. Be cautious of high-voltage components, and never work on a fuel cell if you are not trained to do so.
- Spill and Leak Management: In the event of a fuel or chemical spill, have the necessary absorbent materials and spill kits readily available. Know how to properly clean and dispose of any spilled or leaked materials.
- Pressure and Temperature Control: Fuel cells operate under pressure and high temperatures. Always use appropriate pressure relief devices and temperature control mechanisms to prevent over-pressurization or overheating. Regularly inspect these components for proper functioning.
- Fire Safety: Keep fire extinguishers and other fire safety equipment nearby. Fuel cells and their fuels can be highly flammable, so it is essential to be prepared for any potential fire hazards.
- Isolation and Shutdown Procedures: Know how to safely isolate and shut down the fuel cell in case of an emergency. Develop standard operating procedures for these situations and ensure that all personnel are trained to follow them.
- Maintenance and Inspection: Regular maintenance and inspection of fuel cells are crucial for safety. Check for signs of wear, leaks, or damage, and replace any faulty components immediately. Follow the manufacturer's recommended maintenance schedule.
- Training and Education: Ensure that all personnel working with fuel cells are adequately trained and educated on safety procedures. This includes understanding the hazards, safe handling practices, and emergency response protocols associated with fuel cells.
These safety considerations provide a foundation for working with fuel cells safely. Always refer to the manufacturer's instructions, industry standards, and local regulations for comprehensive safety guidelines.
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Frequently asked questions
A fuel cell is an electrochemical cell that converts the chemical energy of a fuel (typically hydrogen) and an oxidising agent (typically oxygen) into electricity. Fuel cells differ from batteries in that they require a continuous source of fuel and oxygen to sustain the chemical reaction and produce electricity.
Fuel cells can be used to safely increase the fuel supply and driving range of a vehicle. They also do not need to be recharged and can theoretically last forever if they have a fuel supply. Additionally, their by-product is water, rather than pollution or smog.
The tools and materials required will depend on the type of fuel cell and vehicle. However, some common tools and materials include:
- Wrenches and spanners
- Sockets and ratchets
- Impact driver
- Coarse and fine files
- Gasket
- Clamping mechanism
- Hydrogen source