Fuel Safe Systems
Racing is our passion and Fuel Safe is committed to delivering the highest quality safety fuel cells to our customers.
If you have questions, please call 800-433-6524 or e-mail us at sales@fuelsafe.com. Our sales team is staffed by industry professionals and can assist with any questions you have.
Inspect & Prepare
Install Details
- Inspect all edges and surfaces inside your fuel cell compartment to ensure there are no rough spots that could cause puncture or abrasive damage to the fuel bladder.
- Ensure that the fuel cell compartment has adequate ventilation to account for any fuel vapor transfer through the bladder walls. Pockets of fuel vapor can present an ignitable and hazardous condition.
- Standard fuel cell setups usually include a normally-open vent / rollover valve. Ensure that this vent is plumbed to a location with free-flowing access to open air.
- Pad or tape the edges of any compartment opening in which the bladder will be installed so as to reduce the possibility of puncture or abrasion damage during installation.
- Static ground fuel cell fill plate to the vehicle's chassis.
Installation into tight spaces
- Remove the access plate and gasket and bag all hardware.
- Remove the internal baffling foam, numbering each piece with a sharpie so that reinstallation is completed in the correct order.
- Collapse the bladder in a way that will provide for the least amount of creasing, and gently feed the bladder through the access space. Expand the bladder into all corners of the container once through the access.
- Check the empty bladder for any signs of Foreign Object Debris (FOD).
- Reinstall the baffling foam in the reverse order of what was previously recorded.
- Reinstall the access plate and hardware, using the torque specifications noted below.
- Check to ensure that there are no fuel leaks during the first filling of the bladder at the access plate location.
Preparation
- If any cuts or abrasions are seen or occur during installation, DO NOT proceed with installation. Instead, contact Fuel Safe with pictures and information related to how the damage occurred and Fuel Safe representatives will instruct you how to proceed with returning the bladder for repair or replacement.
- Baby powder can be applied to the external faces of the bladder to reduce friction and while installing the bladder in the housing.
- Re-torque all screws after receiving the system to ensure nothing has come loose during shipping. See torque values below.
Torque Specifications
MAX TORQUE (IN.-LBS.)
70
25
15
10
20
40
70
Usage Instructions
- Anti-slosh baffling foam may have debris attached to it from the cutting process. It is recommended that a fuel filter be installed between the fuel cell and fuel pump, and that this filter be cleaned after the bladder has been filled twice.
- Racing fuel bladder materials degrade faster in high-moisture environments, so ensure that the bladder is not consistently exposed to high-humidity conditions or sitting water.
- Fuel Safe fuel bladders are approved only for use with hydrocarbon fuels. Neoprene bladders are the only exception and should be used solely with alcohol fuels or water. Fuel additives have not been tested by Fuel Safe and are therefore excluded from Fuel Safe’s limited warranty if damage occurs as a result of their use.
- When removing anti-slosh baffling foam after use with fuel, spray water on the foam before removal to prevent static ignition of fuel vapors.
- When not in use, empty the fuel bladder(s) and store in a cool, dry environment.
- Inspect the baffling foam after two years, and then annually thereafter for any signs of degradation.
- Periodically check and re-torque the screws on the system to ensure that all components are secured.
Things NOT to do
- Do NOT attempt to repair a Fuel Safe fuel bladder without consulting Fuel Safe Systems sales representatives.
- Do NOT weld, drill, cut, or otherwise modify the metal container while the bladder is still installed.
- Do NOT allow untested fuels or additives to be used in the fuel bladders without prior authorization from Fuel Safe sales representatives.
- Do NOT pressurize Fuel Safe fuel bladders above 1 psi unless otherwise authorized by Fuel Safe sales representatives.
- Do NOT expose the fuel bladders to consistent temperatures over 160°F (82°C) over extended periods of time or intermittent temperatures of 180°F (71°C)
Troubleshooting Guide
If you have questions, please call 800-433-6524 or e-mail us at sales@fuelsafe.com. Our sales team is staffed by industry professionals and can assist with any questions you have.
AVOIDING EXTERNAL FUEL PUMP CAVITATION
Avoiding cavitation issues with an external fuel pump is a must when you want to reach the finish line. We have included a couple steps below that will help mitigate the chances of external fuel pump cavitation from occurring.
- If possible, make sure that the external fuel pump is installed in a location that is at or below the bottom of the fuel cell. (Most external fuel pumps are meant to push fuel and not pull fuel. Having the pump positioned as low as possible helps create a gravity assist in the line, which will help mitigate the chances of the fuel pump overworking itself)
- The external fuel pickup / outlet line that goes between the fuel pickup / outlet fitting on the fuel cell and the external pump needs to be as short as possible. (The shorter the line, the less distance the pump has to pull fuel from inside of the fuel cell, which helps mitigate cavitation from occurring)
PLUMBING EXTERNAL VENT LINES
It is critically important to properly plumb the extenal ven line properly to avoid vacuums and fuel surge instances from occurring.
We have included a few steps below to ensure that your external vent line is plumbed properly.
- The external vent line must be plumbed vertically off the vent fitting so that there are no downward sags in it.
- Once you have plumbed the external vent line in a vertical direction that meets and or exceeds the tallest point in the fill system, you can then run the line downwards to where you want the line to vent to the atmosphere. (A fuel surge out of the vent line can occur if you run the line downwards before the line has met or exceeded the tallest point in the fill system.)
PROGRAMMABLE SENDING UNITS
ENSURE THERE ARE NO BROKEN WIRES AND THAT YOU HAVE 12 VOLTS AVAILABLE AT THE SENDER AND GAUGE.
ENSURE ALL WIRES ARE CONNECTED PROPERLY:
- POS terminal on sending unit connected to 12 Volt positive.
- NEG terminal on sending unit connected to 12 Volt negative (ground).
- SEND terminal on sending unit connected to Signal Input Terminal on gauge.
- POS terminal on gauge connected to 12 Volt positive.
- NEG terminal on gauge connected to 12 Volt negative (ground).
ENSURE THAT THE OHM RANGE SPECIFIED ON THE SENDER MATCHES THE OHM RANGE SPECIFIED FOR THE GAUGE. CONTACT THE GAUGE MANUFACTURER FOR THE PROPER OHM RANGE.
WHEN CALIBRATING THE SENDING UNIT TIMING IS CRITICAL. WHEN CALIBRATING EITHER EMPTY OR FULL A LITTLE LONGER IS BETTER THAN NOT LONG ENOUGH. IF YOU CANNOT CALIBRATE EMPTY OR FULL, ADD 2 SECONDS TO THE SPECIFIED NUMBER OF SECONDS AND TRY AGAIN.
YOU MUST PROCEED IN THIS EXACT ORDER FOR EMPTY OR FULL CALIBRATION:
- Start with the power off.
- Jumper the SEND terminal on the sending unit to the NEG terminal.
- Turn the power on.
- Remove jumper in the specified number of seconds (2 seconds for empty and 5 seconds for full). You must follow this procedure twice, once for empty and once for full.
SYMPTOMS AND POSSIBLE CAUSES
NEEDLE ON GAUGE DOES NOT MOVE AT ALL
- Positive and Ground Wire are switched at gauge or at sender.
- No Power at sending unit.
- Broken Wire
- No ground
- Ignition switch is off
>>Full was set at empty.
>>Positive 12-volt dc or ground are not connected at gauge
NEEDLE PEGS FULL
- Mismatched ohm range between sender and gauge
- 12-volt positive is connected to the send terminal on gauge or sending unit
NEEDLE PEGS EMPTY
- Mismatched ohm range between sender and gauge
- Sending unit probe tube is in contact with water
GAUGE NEEDLE DOES NOT TRAVEL FULL SCALE
- Mismatched ohm range between sender and gauge
- Calibration or re-calibration is required
FÉDÉRATION INTERNATIONALE DE I’AUTOMOBILE (FIA) CERTIFICATION
- Fuel bladders with FIA certification are qualified to race in sanctioned events for a period of up to five (5) years after the manufacturing date noted on the bladder, or to the expiration date shown on the FIA label.
- After the five-year certification window has closed, fuel bladders can be returned to Fuel Safe for inspection, and if the bladder is still in good working condition, the bladder can be recertified for a period of two (2) additional years.
- Fuel bladders involved in racing incidents should be inspected by the manufacturer before being used in any other capacity, as the integrity of the fuel bladder may have been compromised during the incident. Information about the incident should be supplied to Fuel Safe to ensure that all safety questions have been accounted for before the bladder is returned to the field.
Warranty
Fuel Safe’s limited warranty can be found at Warranty
For any warranty claims, please provide the following information to a Fuel Safe sales representative:
- Serial number
- A description of the problem and photos of the affected areas
- Information about how the bladder has been used
- Any information about modifications made to the system, as this will help Fuel Safe troubleshoot the issues
Warranty
Fuel Safe’s limited warranty can be found at Warranty
For any warranty claims, please provide the following information to a Fuel Safe sales representative:
- Serial number
- A description of the problem and photos of the affected areas
- Information about how the bladder has been used
- Any information about modifications made to the system, as this will help Fuel Safe troubleshoot the issues
Reordering Instructions
Contact a Fuel Safe sales representative at sales@fuelsafe.com with the following information:
- Serial number
- Photos of the bladder, including of all internal components (pumps, collectors, filters, etc.)
- Quantities and required timeline
Fuel Safe may issue a Return Material Authorization (RMA) number and ask you to ship the bladder in if previous design data is not available.
A quote may be provided after either stage in the process, depending on available information.
Reordering Instructions
Contact a Fuel Safe sales representative at sales@fuelsafe.com with the following information:
- Serial number
- Photos of the bladder, including of all internal components (pumps, collectors, filters, etc.)
- Quantities and required timeline
Fuel Safe may issue a Return Material Authorization (RMA) number and ask you to ship the bladder in if previous design data is not available.
A quote may be provided after either stage in the process, depending on available information.
Disposal Instructions
- Remove all fuel from inside of the bladder (drain or pump out).
- Remove access plates from bladder and allow all remaining fuel to evaporate.
- Disassemble the components from the access plates and reuse any desired undamaged hardware.
- Recycle the aluminum access plates.
- Drop off the fuel bladder at your local waste disposal site.
Fuel Safe Systems
Aircraft Rubber Manufacturing
dba Fuel Safe Systems
1550 NE Kingwood Ave
Redmond, OR 97756
Tel: (541) 923-6005
Fax: (541) 923-6015
Toll Free: (800) 433-6524
Contact: sales@fuelsafe.com
Products
1550 NE Kingwood Ave
Redmond, OR 97756
Tel: (541) 923-6005
Fax: (541) 923-6015
Toll Free: (800) 433-6524
Contact: sales@fuelsafe.com
Monday - Thursday:
6:00AM - 5:00PM (PST)
Friday - Sunday: Closed
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