Remove and replace components in a hydrogen fuel cell electric vehicle system
This standard covers the competence and knowledge technicians need to safely carry out the removal and replacement of components in hydrogen fuel cell electric vehicle (FCEV) systems. The unit also ensures that the technician is aware of the hazards posed by hydrogen fuel cell electric vehicle systems and the safe working practices to follow when carrying out removal and replacement activities.
Warning: It has been recommended by industry experts that only those with suitable training and experience on working with electric vehicles should carry out the functions below.
You must be able to:
P1 Identify that the vehicle has a hydrogen fuel cell electric vehicle system and collect relevant technical information
P5.1 system manufacturer's vehicle technical data
P5.2 removal and replacement proceduresP5.3 legal requirementsP6 Prepare, check and use all the appropriate equipment required following manufacturer's instructionsP7 Work in a way which minimises the risk of:P7.1 damage to other vehicle systems, components and unitsP7.2 damage to your working environmentP7.3 injury to yourself and othersP8 Select replacement components which meet the manufacturer's recommendations or conform to operating specificationP9 Carry out component removal and replacement activities following:
P9.1 manufacturers’ instructionsP9.2 industry recognised repair methodsP9.3 health, safety and environmental requirementsP10 Record and report any relevant/related faults you notice during the course of your workP11 Follow manufacturer’s instructions to test and evaluate the performance of the reassembled hydrogen fuel cell electric vehicle system accurately and ensure other associated systems operate correctlyP12 Ensure your records are accurate, complete and passed to the relevant person(s) promptly in the format required
Knowledge and Understanding
You need to know and understand:
Use of technical information
K8.1 referral/reporting of problems when working with hydrogen fuel cell electric vehiclesK8.2 how to make others aware that work is being carried out on a hydrogen fuel cell electric vehicleK9 The precautions necessary when using hydrogen re-fuelling equipmentK10 How to carry out a risk assessment on damaged and broken-down hydrogen fuel cell electric vehiclesK11 How to confirm a hydrogen fuel cell electric vehicle is safe to work onK12 Hazards associated with hydrogen and hydrogen under high-pressure, including the physiological, mechanical and chemical effects of hydrogenK13 The hazards associated with hydrogen fuel cell electric vehicles when exposed to extreme temperatures, impact and other adverse conditionsK14 The implications of electrical conductivity through the human body and the potential medical conditions that can occur regardless of voltage or current type present in a hydrogen fuel cell electric vehicleK15 How to dispose of, recycle and return any removed hydrogen fuel cell electric vehicle system components in line with legislative, environmental and organisational requirementsK16 How to work safely avoiding damage to other vehicle systems, components and units and contact with leakage and hazardous substances
Hydrogen fuel cell and the vehicle system principlesK17 The basic construction of a hydrogen polymer electrolyte/proton-exchange membrane (PEM) fuel cellK18 The electrochemical reactions in a PEM fuel cellK19 The purpose of the membrane in a PEM fuel cellK20 How a PEM fuel cell operatesK21 The by-products of the PEM fuel cell chemical reactionK22 The differences between PEM fuel cell and other alternative fuel cell technologies which may come into general useK23 The reasons for connecting PEM fuel cells into a stackK24 On-board hydrogen fuel storage and supply systemsK25 The types of hydrogen production
Vehicle equipment faults and their correction
K26 How to identify faults and damage in hydrogen fuel cell electric vehicle systems and componentsK27 How to remove, replace, test and evaluate the performance of components and the reassembled system against operating specifications and legal requirements
K28 The importance of ensuring components are functioning correctly before release to the customer
Hydrogen fuel cell electric vehicle systems and componentsK29 How hydrogen supply system components function and are constructedK30 How to identify the location of hydrogen and high-pressure hydrogen pipes and other system components, for example, by labelling or colourK31 The different pressures and voltages associated with components in hydrogen fuel cell electric vehiclesK32 How hydrogen fuel cell electric vehicle systems interact with other vehicle systemsK33 The manufacturers'sspecification for the type and quality of components to be used for replacementK34 The different types of energy storage systems and voltages associated with hydrogen fuel cell electric vehiclesK35 The ancillary components of alternative fuel sources and systems on hydrogen fuel cells
Use of tools and testing equipment and testing techniquesK36 How to select and use the testing equipment requiredK37 How to select, prepare, check and use all the repair and replacement equipment requiredK38 How to conduct tests on hydrogen fuel cell electric vehicle systems following safety and workplace proceduresK39 How to conduct a test on energy sources and systemsK40 How to determine the serviceability of a component in a hydrogen fuel cell electric vehicle systemK41 How to interpret the results of your tests and make recommendations based on these resultsK42 The importance of basing your recommendations on test results
Vehicle system operationK43 The main differences between a hydrogen fuel cell electric vehicle (FCEV) and a battery electric vehicle (BEV) and its operationK44 How to safely operate a hydrogen fuel cell electric vehicleK45 The specific manufacturer’s guidelines and the precautions necessary when charging, connecting an auxiliary power source to or towing/lifting an electric vehicleK46 The evacuation and re-fuelling systems associated with hydrogen fuel cell electric vehicles and how to operate them safely
This section contains examples and explanations of some of the terms used but does not form part of the standard.
Fuel cell system
Includes fuel cell and fuel cell stack, hydrogen storage and supply, on-board fuelling systems and safety and control systems
Hazards associated with high voltage electrical vehicle components - exist not only during work on high voltage systems, as specified above, but also on all other high-power electrical drive systems and high-pressure storage systems. Vehicle and equipment manufacturers’ guidance should be followed at all times.
Hazards associated with hydrogen and hydrogen fuel cell electric vehicle systems *Physiological (e.g. frostbite, respiratory ailments, injury from unexpected release of pressure and asphyxiation), mechanical (for example, embrittlement) and chemical (flammable - burns without visible flame, causes explosive atmospheres).
High voltage* – Regulation No 100 of the Economic Commission for Europe of the United Nations (UNECE) — Uniform provisions concerning the approval of vehicles with regard to specific requirements for the electric power train, states that: ‘High Voltage’ means the classification of an electric component or circuit, if its working voltage is > 60 V and ≤ 1 500 V DC or > 30 V and ≤ 1 000 V AC root mean square (rms). Electricity at Work Regulations (1989), and associated HSE guidance should be followed at all times.
Sensory testing methodsInclude looking, listening, smelling, touching for temperature or vibration.
Sources of information applicable to electric vehicles
Examples include hard copy manuals, data on computer and data obtained from on- board diagnostic displays.
*Vehicle *Fuel Cell Electric Vehicle (FCEV)