Fuel cell installation database

If the fuel cell is old or has not been removed in awhile it is going to be filthy. You will need to reuse the cover plate and fittings so it a good idea to block all the holes with plugs and give the plate a very good clean.

With the fuel cell out of the car, now is the perfect time to clean out all the old gunk that has collected over the years. I was replacing my fuel cell and installing the In-Tank Fuel Pump when doing the Gen3 Upgrade so it was a good time to clean out the entire engine bay and cockpit. Before installing the new fuel cell into the car you will want to protect it from any sharp elements that would rub against the fuel cell while driving such as rivet heads and sheet metal edges.

Better off using a little bit of tape now then putting a small hole in your very expensive new fuel cell. The new Fuel Cell comes with compliance documentation make sure to store this in a safe place. Depending on the fuel cell you buy it might come with foam that helps reduce the amount of fuel movement as you corner, brake and accelerate. You will need to cut the foam to fit the surge box in place. This can be accomplished with a hacksaw blade.

The surge box should sit at the lowest central point with about an inch of clearance all around. Otherwise continue on. Use a brand new gasket and replace the fuel cell cover plate. Just loosely thread all the fasteners in place. Make sure the plastic washers are all in place, you do not want any leaks. Do not tighten down yet we will torque them to the proper spec later.

If you are doing a Gen 3 conversion you might 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 to do oil changes. Use a brand new gasket if you do undo the fuel filler neck portion of the closeout plate.

Here you can see we clocked it two fastener position if you notice the black indicator lines. It depends on your car and hose routing on how many positions to clock it, one might be sufficient. We still have a hard time removing the filter in this position. For both the filler neck place and fuel cell cover lightly snug the bolts first using a star pattern criss crossing.

For the 3 fasteners with the locating tabs you will have to provide the final toque when the fuel cell is in place and the tabs are rotated into the correct position.

Then torque to the manufacturers recommendation 40 in-lbs. We did a two step process 20 in-lbs all around followed by 40 in-lbs. Be very careful not to over torque these bolts as you can easily strip them out ruining the fuel cell in the process.

The basics of the install are updating and modifying the surge box to house the new fuel pump and pick up mesh. Then modifying the fuel feed line to connect the to the pump and outlet of the fuel cell cover plate. You will also need to drill and secure an new pass through for the electrical connector and then terminate it to the engine harness.

With the new fuel cell all sorted it is time to get it back into the car. Place it in the cockpit and you will need to position it so that you can get the fuel cell cover plate in the hole of the engine bay bulkhead. Then rotate the three locating tabs into position and torque those bolts to the manufacturers recommendation, 40 in-lbs. Reconnect all the fuel hoses including the feed, return, vent and filler hose. Good thing you marked the Vent and Return line positions. Kind code of ref document : C1.

Ref document number : Country of ref document : EP. Country of ref document : US. Ref country code : JP. The invention relates to a fuel cell installation comprising a cascaded fuel cell block, for essentially waste gas-free operation. An installation of this type presents the problem that the cascaded fuel cell block is complex to produce and therefore expensive.

The aim of the invention is to solve this problem. To this end, the inventive fuel cell installation 1 has several steps 2, 4, 6, 8 which are arranged in a cascade, each of the steps 2, 4, 6, 8 comprising one or more non-cascaded similar fuel cell blocks 10, 12, 14, 16, 18, 20, Each step 2, 4 has at least one fuel cell block 10, 12, 14, 16 , an operating gas feed 24a, 24b, 30a, 30b and an operating gas outlet 26a, 26b, 32a, 32b , the operating gas outlet 26a, 26b of the first step 2 being connected to the operating gas feed 30a, 30b of the second step 4.

A fuel cell installation 1 construction consisting of modular similar fuel cell blocks 10, 12, 14, 16, 18, 20, 22 is economical and simple to produce in series. Fuel cell system 1 with a first 2 and, second stage 4 , each stage 2, 4 having at least one fuel cell block 10, 12, 14, 16 , an operating gas supply 24a, 24b , 30a, 30b and an operating gas discharge 26a, 26b, 32a, 32b , the operating gas discharge 26a, 26b of the first stage 2 being connected to the operating gas supply 30a, 30b of the second stage 4.

Fuel cell system 1 according to claim 1, with an additional third stage 6 , which has at least one fuel cell block 18 , an operating gas supply 36a, 36b and an operating gas discharge 38a, 38b , the operating gas discharge 32a , 32b of the second stage 4 is connected to the operating gas supply 36a, 36b of the third stage 6.

Fuel cell system 1 according to claim 1 or 2, wherein the steps 2,4,6 comprise similar fuel cell blocks 10, 12, 14, 16, More Less. Barrier: Identifying or evaluating energy-saving technologies. Tool type: Map. Technology: Combined Heat and Power System. Solutions at a Glance. Microgrid Installation Database. Showcase Project. Other: Report.