Katerina Swanson
When it comes to choosing the right wire for a fuel tank, there are several factors to consider to ensure safety and functionality. The wire must be compatible with the fuel type and resistant to fuel saturation, as fuel can wick up the wire insulation like a candle. Additionally, it is crucial to consider the wire gauge and ensure proper grounding and bonding. While sparks can occur from sliding contacts over open coils, the lack of oxygen in fuel tanks prevents explosions. The placement of the wires and connections is also important, with recommendations to avoid running electrical and fuel lines through the same hole.
| Characteristics | Values |
|---|---|
| Wire type | PTFE, M22759/16 (tefzel), FLRY automotive wires (DIN ISO 6722 / LV112) |
| Wire gauge | 10AWG, 12AWG, 18AWG, 20AWG |
| Other materials | Thermoplastic PVC, nylon, viton o-ring, bare metal terminals, grommets, adell clamps |
| Additional considerations | Ensure wires are fuel-resistant and gas submersible approved, avoid heat shrink and sheathing inside the fuel tank, seal wiring to prevent leaking |
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What You'll Learn
The wire should be fuel-resistant to prevent fuel saturation
When choosing a wire to use in a fuel tank, it is important to select one that is fuel-resistant. This is because, without fuel resistance, the wire's insulation can become saturated with fuel and wick like a candle, creating a hazardous situation. To prevent this, look for wires that state they are oil and gas-resistant.
One option for fuel-resistant wire is the FLRY automotive wire (DIN ISO 6722 / LV112), which has insulation made of Thermoplastic PVC type (ISO 6722) and can be safely submerged in fuel. Another option is to use M22759/16 wire, also known as Tefzel, which will not break down in fuel. If you need heatshrink, DR25 heatshrink is a good choice as it holds up well in fuel.
It is also important to consider the wire's gauge when selecting a fuel-resistant wire. For external grounding and bonding the fuel filler, a ten-gauge wire is suitable. For a fuel gauge, a 20-gauge wire is commonly used as the fuel gauge draws very little current, so wire size is not critical.
Additionally, it is recommended to seal the wire to prevent fuel wicking. This can be done by using a nylon/stud/viton o-ring solution or epoxy. However, some epoxies, like JB Weld, may be too permanent, so choose a sealing method that suits your needs.
By selecting a fuel-resistant wire, such as FLRY or Tefzel, and considering the appropriate gauge and sealing methods, you can help ensure the safety and functionality of your fuel tank wiring.
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Use bare metal terminals instead of heat shrink or sheathing
When choosing the type of wire to use in a fuel tank, it is important to opt for bare metal terminals instead of heat shrink or sheathing. This is because fuel can saturate the wire insulation and cause it to wick like a candle, which can lead to dangerous consequences.
Bare metal terminals are recommended for use inside fuel tanks as they do not involve the use of any insulation that can be compromised by the fuel. This is a safer option as it eliminates the risk of fuel wicking and the potential hazards associated with it.
Heat shrink tubing and sheathing are commonly used to insulate and protect electrical wires, but they are not suitable for use in fuel tanks. When exposed to fuel, the heat shrink and sheathing can break down and become ineffective, leaving the wires exposed. This can lead to electrical shorts, arcing, or other failures that may compromise the safety of the system.
By using bare metal terminals, you avoid the risk of insulation breakdown and the potential hazards associated with it. This helps to ensure the integrity and safety of the electrical connections within the fuel tank.
Additionally, when selecting the wire for your fuel tank, it is crucial to choose a type that is specifically designed to be oil and gas-resistant. This will ensure that the wire can withstand the fuel environment without degradation, further enhancing the safety and reliability of your fuel tank system.
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PTFE is used for plastic hoses in modern fuel tanks
When it comes to fuel tanks, safety is paramount. The wrong type of wire or hose can lead to fuel leaks, which are dangerous and can cause extensive damage. It is important to use fuel-resistant wire to prevent fuel from saturating the wire insulation and wicking up the core of the wire.
PTFE is used for the white plastic convoluted hoses in many modern fuel tanks. PTFE hoses are an essential component in managing fuel transportation safely and efficiently. They offer superior containment due to their low permeability to vapors, which is crucial for high-performance vehicles.
PTFE is smooth and non-stick, which reduces friction loss and fuel flow restriction. This results in improved fuel flow and a reduced chance of vapor lock, ensuring optimal engine performance and longevity. PTFE hoses are also resistant to chemical degradation, making them ideal for vehicles using ethanol-blended fuels.
Additionally, PTFE hoses can withstand a broad temperature range, making them well-suited for applications where space is tight and high temperatures are prevalent. PTFE's ability to withstand high temperatures also makes it a good choice for heatshrink, as it will not break down in fuel.
In summary, PTFE is an excellent choice for plastic hoses in modern fuel tanks due to its safety, efficiency, and durability. It improves fuel flow, reduces friction loss, and resists chemical degradation, ensuring optimal engine performance and safety.
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Avoid chafing when routing wires past Z brackets
To prevent chafing when routing wires past Z brackets, it is important to first understand the causes of wire chafing. Wire chafing can occur due to various factors, including vibration, thermal expansion and contraction, resistive heating, and pinching of the wire. Therefore, when routing wires past Z brackets, consider the following:
Firstly, evaluate the environment and identify potential sources of vibration, thermal fluctuations, and abrasion. Ensure that the wires are not resting on surfaces that vibrate or move relative to the wire insulation, as this can cause insulation breakdown and electrical faults. Use cable clamps or other restraining devices to secure the wires and minimise movement. Avoid routing wires in areas with high personnel traffic, such as under carpets, to reduce the risk of accidental damage.
Secondly, properly manage the routing of the wires. Separate the wires from other components to prevent rubbing and chafing. Route the wires away from hot surfaces, moving parts, and areas prone to mud, debris, and road splash. Ensure that the wires do not come into contact with metallic debris or other particulates that can accelerate chafing. Use wire looms, hold downs, or plastic tube chases to guide and protect the wires.
Thirdly, minimise the effects of chafing by reducing movement and friction. Secure the wires frequently along their run to prevent them from vibrating or moving excessively. Use well-secured cable ties, zip ties, or wire wraps in areas of abrasion concern. Consider using epoxy to fill in new holes and soften the edges to prevent chafing on sharp surfaces. Additionally, evaluate the use of fuel-resistant wires, as fuel can saturate standard wire insulation and compromise its integrity.
Finally, regularly inspect and maintain the wiring to identify and address any signs of chafing early on. Replace any worn or damaged wire coverings and ensure proper insulation. By following these guidelines, you can effectively reduce the risk of wire chafing when routing wires past Z brackets.
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Use a wire that is oil and gas-resistant
When selecting a wire for a fuel tank, it is crucial to prioritise safety and durability by opting for a wire that is specifically designed to withstand oil and gas exposure. Using a wire that is not fuel-resistant can lead to dangerous consequences, as fuel can saturate the wire insulation and wick like a candle, posing a fire hazard.
To prevent such issues, it is highly recommended to use wires with insulation made from polytetrafluoroethylene (PTFE). PTFE is commonly used in modern fuel tanks and is known for its excellent resistance to fuel and heat. It is often used in white plastic convoluted hoses and can also be found in wire form, sometimes referred to as M22759/16 wire or Tefzel. This type of wire will not break down in fuel and is a reliable choice for fuel tank applications.
Another option for oil and gas-resistant wire is to use Thermoplastic Polyvinyl Chloride (PVC) insulation. This type of insulation has been observed to hold up well, even when submerged in fuel. It is a common choice for automotive wiring and can be sourced from various suppliers, such as Waytec. PVC heat shrink tubing can also be used over existing wire insulation to provide added protection.
When selecting a wire for your fuel tank, it is essential to consult with specialists or experienced individuals to ensure that your chosen product meets the necessary safety standards. It is also worth noting that, in some cases, wires with standard PVC cover wire and heat shrink may not be sufficient to withstand prolonged exposure to oil and gas.
Additionally, it is worth mentioning that, while not directly related to wire selection, some individuals have suggested using epoxy, such as JB Weld, to seal the wiring from leaking gas. However, this may not be a preferred option due to the permanent nature of such solutions.
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Frequently asked questions
It is recommended that you use fuel-resistant wire for your fuel tank. Wires that are not fuel-resistant can be saturated with fuel, which can lead to dangerous consequences.
The gauge of wire you use will depend on the specific application. For example, for a fuel gauge and low fuel light thermistor, a 20AWG wire should be sufficient. For external grounding and bonding the fuel filler, a ten-gauge wire should work.
No, it is not recommended to use heat shrink or sheathing on wires inside a fuel tank. Instead, use bare metal terminals.
While it may seem dangerous, it is common to have electrical wires and pumps inside fuel tanks. The lack of oxygen in the tank prevents the fuel from igniting. However, it is important to ensure that all wires are fuel-resistant to prevent any potential hazards.
