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PAC Alcor JFTOT II Manual

Jet fuel thermal oxidation tester
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59297
JFTOT II
J
F
T
O
T
ET
UEL
HERMAL
XIDATION
ESTER
October 2003
Version 2.1 or later
300 BAMMEL WESTFIELD ROAD • HOUSTON, TEXAS 77090 USA
TELEPHONE: 281-580-0339 • FAX: 281-580-0719

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Summary of Contents for PAC Alcor JFTOT II

  • Page 1 59297 JFTOT II HERMAL XIDATION ESTER October 2003 Version 2.1 or later 300 BAMMEL WESTFIELD ROAD • HOUSTON, TEXAS 77090 USA TELEPHONE: 281-580-0339 • FAX: 281-580-0719...
  • Page 2 THIS MANUAL CONTAINS CONFIDENTIAL AND PROPRIETARY INFORMATION… …which is the property of PAC. This manual and all information disclosed herein shall not be used to manufacture, construct, or fabricate the goods disclosed herein; shall not be exploited or sold; shall not be copied or otherwise reproduced in whole or in part and shall not be revealed or disclosed to others or in any manner made public without the express written permission of PAC.
  • Page 3 BOUT ANUAL Two very powerful features of the JFTOT-II are This User’s Manual is suitable for JFTOT 230 the REFRESH and PRINT SCREEN buttons on and 240 models for S/N 477 and beyond, until the keypad. Whenever you are looking at a superseded.
  • Page 4 clean the glass jar, remove any loose depos- This symbol (three wavy lines over a its from the oven, lid or exhaust tubes. Pack straight line in a triangle) indicates a hot any accessories on top of the MCRT between surface.
  • Page 5 REFACE The Jet Fuel Thermal Oxidation Tester (JFTOT) ABOUT THIS MANUAL has been designed to produce an accelerated This manual is applicable to both the JFTOT 230 (higher temperature) version of conditions that and JFTOT 240. Therefore, references and displays showing a second ∆P appear. If a test is might be experienced by a flowing fuel in a made using only a single ∆P, the operator should typical engine system.
  • Page 6 ABBREVIATIONS AND GLOSSARY These manuals use certain units abbreviations shown: amps WARNING HOT SURFACES - during ° degrees operation, the bus bars and lines are grams heated surfaces. Do not touch. hours Hertz kilo = x 10 PRESSURE REGULATOR - liters (mL = milliliters) indicates the adjusting control for the mega = x 10...
  • Page 7 Instruments to be free from defects in material and workmanship under use and service for a period of one (1) year of operation. The obligation of API/PAC under the warranty is limited to the repair or replace- ment, at API/PAC's option, of any part, component or JFTOT II which, in the opinion of API/PAC, is defective and which has been returned transportation prepaid.
  • Page 8 THIS PAGE INTENTIONALLY BLANK. Page viii JFTOT II User’s Manual Rev. C...
  • Page 9 JFTOT II HERMAL XIDATION ESTER Operation Manual / October 2003 Version 2.1 or later 300 BAMMEL WESTFIELD ROAD • HOUSTON, TEXAS 77090 USA TELEPHONE: 281-580-0339 • FAX: 281-580-0719...
  • Page 10 THIS PAGE INTENTIONALLY BLANK. Page 2 JFTOT II Operation Manual Rev. C JFTOT II Operation Manual Rev. C...

  • Page 11: Table Of Contents

    ABLE ONTENTS 1. INTRODUCTION ........................... 1 1.1 Basic Design ..........................1 1.2 Basic Principle ..........................1 1.3 Model Types ........................... 1 1.4 Optional Operation of Time Reactor System ................. 1 1.5 Optional Time Reactor Insulation ....................2 1.6 Deposit Measurements ........................2 2.
  • Page 12 5. HEATER TUBE DEPOSIT RATING ..................29 5.1 Visual Method ..........................29 6. APPENDICES ..........................31 A1. Precautionary Statements For Hazardous Materials ..............31 A2. JFTOT Equipment Description .....................32 A3. Heater Tube Temperature Profile ....................41 A4. Routine Maintenance ........................41 A5. Materials, Supplies, and Spares .....................41 Alcor JFTOT-230/240 Parts List ......................44 Supplies, Spares And Accessories ......................44 Page ii...

  • Page 13: Introduction

    1. INTRODUCTION 1.1 BASIC DESIGN other test setup data into the computer. The JFTOT stores this information and uses it whenever that The JFTOT is a fully integrated bench top instrument particular test is called for. This setup simplifies that provides everything needed to safety study the operation when performing the same test.

  • Page 14: Optional Time Reactor Insulation

    By eliminating the time reactor and substituting a ments and specifications on operation. Currently it is supplied outlet line from the heater section, the an option for use in research investigations. system can be run as a Model 230. A diagram in the Appendix shows the two alternative systems.

  • Page 15: Installation

    2. I NSTALLATION 2.1 INSTALLATION 2.2 COMPONENTS Place the tester on a level laboratory bench. Allow 2.2.1 JFTOT cabinet ready access to the rear of the tester for normal maintenance and service requirements. Ensure that See Figure 2.1 for front view of cabinet; see the vent on the right side of the cabinet in not ob- Figure 2.2 for rear view of cabinet.
  • Page 16 FIG 2.1 - FRONT VIEW OF THE JFTOT FIG 2.2 - LOWER RIGHT HAND SIDE VIEW OF THE JFTOT Page 4 JFTOT II Operation Manual Rev. C...
  • Page 17 FIG 2.3 - ACCESSORY COMPONENTS PACKAGED WITH JFTOT II JFTOT II Operation Manual Rev. C Page 5...

  • Page 18: Rear Panel Inspection

    Accessories: 1. Power Cord 2. Filter/aeration funnel 3. Tin AutoCal Calibrator 4. Lead AutoCal Calibrator 5. Aeration dryer assembly 6. Thumb-nut Cap 7. Standardization Kit • Check for coolant leakage, clean any spills. 8. Reservoir Stand • Check for loose parts and connectors. (The JFTOT model 230 has two unused electrical connectors 9.

  • Page 19: Assemble Sliding Scale Assembly And Thermocouple

    2.5 ASSEMBLE SLIDING SCALE 2.6 INSTALL AERATION TUBE AND ASSEMBLY AND THERMOCOUPLE DRYER • Place the sliding scale assembly on the top bus bar, Connect the fitting of the aeration dryer assembly to and push back against stop. Tighten the set screw the cabinet.
  • Page 20 THIS PAGE INTENTIONALLY BLANK. Page 8 JFTOT II Operation Manual Rev. C...

  • Page 21: General Operational Information

    3. GENERAL OPERATIONAL INFORMATION NOTE - All operators must read all of Section 3 selections from being made and prevents messages before using the JFTOT II. or values from scrolling too quickly. When making a menu selection, the display will normally change when a key is pressed.

  • Page 22: Main Operations

    • STEP = step or move forwards or backwards. For example, when viewing the CUSTOM SETUP screen, pressing STEP will display the secondary CUSTOM SETUP screen which allows changing flow rates and test times. Currently, this key is only active: a.
  • Page 23 When JFTOT power is switched ON, the computer The MAIN MENU is displayed when the JFTOT is performs a self-test. If the self-test passes, the idle, and all operations are off*: MAIN MENU is displayed. If the self-test does not Aeration Pump OFF pass, then an appropriate message is displayed.
  • Page 24 When a test is selected from the MAIN MENU, a. the maximum DP1 value seen during the test, the SETUP screen is displayed. Assemble the b. elapsed time before the DP1 bypass valve apparatus and adjust the test parameters. opened, •...
  • Page 25 NOTE - when the JFTOT is shipped there are a. Ice at 0°C several tests already in memory. These tests were b. Freezing point of Tin, 232°C performed at ALCOR as part of the operational checkout procedure. c. Freezing point of Lead, 327.5°C To perform the thermocouple Autocal go to the 3.2.3 Maintenance Operation CALIBRATION Manual.
  • Page 26 operating on an internal battery. If the clock is on When the clock is off and the JFTOT is powered and the JFTOT is never powered on the battery on, the clock will start automatically and the will last about 3.3 years. The more the JFTOT is CLOCK MENU will be displayed.
  • Page 27 FIGURE 3.1 - EXAMPLE OF TEST DATA WHEN REAL-TIME TRANSMIT IS SET TO “TIMED.” JFTOT II Operation Manual Rev. C Page 15...
  • Page 28 THIS PAGE INTENTIONALLY BLANK. Page 16 JFTOT II Operation Manual Rev. C...

  • Page 29: Performing A Test

    4. PERFORMING A TEST The following is general information describing how WARNING: These solvents will irritate the skin to setup and run a test and generate a test report. For after a short time. Use rubber gloves. It is specific step-by-step procedures for the D3241 test, recommended that gloves not be reused.

  • Page 30: Assembly Of Heater Tube Section

    WRENCH. Install a new test filter with RED WARNING - Trisolvent is a blend of acetone, COLORED SIDE OUT, and O-ring. toluene and isopropanol. It is extremely flammable and the vapors are harmful. See Appendix A1. Flush the heater tube housing with solvent and blow dry with a squeeze bulb.
  • Page 31 The contact area of bus bars must be clean to provide good electrical contact with the heater tube. This is very important since the bus bars must deliver about 200 Amps to heat the tube to 260°C. Before each test, wipe the contact area with a paper tissue that is wet with solvent.

  • Page 32: Assembly And Installation Of Pre-Filter

    until seated. A “snap” will be heard when seated. Connect the INLET and VENT lines and finger tighten snugly. NOTE - A quick connect hose fitting is provided for those who would rather fill an assembled reservoir. 4.6 ASSEMBLY OF AIR TRAP Fill glass jar with distilled water then attach to air trap assembly.
  • Page 33 primary CUSTOM SETUP screen. The ASTM- lipseal. Place the O-ring in the reservoir groove in the D3241 SETUP screen only allows adjustment of the top of the reservoir. Put the reservoir into a pan to temperature setpoint (flowrate, test time, and number catch the runoff from later procedures.

  • Page 34: Fuel Reservoir Section

    a. Press ENTER to see an error information reservoir outlet line to the top of the prefilter and screen. This will prevent the timer from finger tighten snugly. Attach the reservoir outlet line shutting off the air pump. to the heater tube housing inlet and finger tighten snugly.

  • Page 35: Venting Fuel System

    4.10 VENTING FUEL SYSTEM 4.11 START-UP Turn the top FLOW CONTROL SELECTOR Press ENTER for the TEST RUNNING display. VALVE to the SYSTEM VENT position and the Turn the FLOW CONTROL SELECTOR bottom valve (240 only) to the RUN position. The VALVE(s) to the RUN position.
  • Page 36 The JFTOT will record automatically the ∆P. If the After the temperature has stabilized at the specified ∆P exceeds 250mmHg the JFTOT will open the Setpoint: appropriate bypass valve. When a bypass valve is a. the bypass valve(s) will CLOSE automatically, open, “bypass”...

  • Page 37: Shutdown

    4.12 SHUTDOWN • If an abnormal problem is detected by the JFTOT, the test is terminated automatically. A message is The test ends when the Test Timer = 0:00 or other- displayed explaining why the test was terminated. wise terminated. The heater and drive pump will turn Then the save test information message will appear off automatically.

  • Page 38: Disassembly

    Measure and record the amount of water collected in housing. Do not touch the tube in the area that the the beaker from the air trap drip line (graduated fuel contacts. Remove and discard the O-rings. Save cylinder, nearest 1 mL). This amount is equal to the the insulators for use later.

  • Page 39: Complete Test Report

    Remove the water reservoir from the apparatus and 4.15 COMPLETE TEST REPORT place it in a cleaning pan. Remove the water reser- The completed report shall include the following: voir cover and empty the fuel and water in the reservoir into the appropriate waste container. •...
  • Page 40 Page 28 JFTOT II Operation Manual Rev. C...

  • Page 41: Heater Tube Deposit Rating

    5. HEATER TUBE DEPOSIT RATING 5.1 VISUAL METHOD 5.1.5 Insert the ASTM Color Standard horizontally into the back of the Tuberator in the slot 5.1.1 Use the Visual Tuberator light box equipped provided. with a magnifying glass assembly. NOTE - the Color Standard is known to fade upon 1.
  • Page 42 NOTE - abnormal is a tube deposit color such as blue or grey which is neither peacock nor does it match the color standard. 5.1.9 When reporting the overall rating, report the maximum rating as described in 5.1.7, and if there are present colors which do not match the Color Standard, report these as well.

  • Page 43: Appendices

    6. APPENDICES A1. PRECAUTIONARY STATEMENTS • Avoid buildup of vapors and eliminate sources of ignition, especially nonexplosion FOR HAZARDOUS MATERIALS proof electrical apparatus and heaters. NOTE - The precautionary statements listed might • Avoid prolonged or repeated breathing of not reference all aspects of the material. For vapor or spray mist.

  • Page 44: A2. Jftot Equipment Description

    • Avoid prolonged or repeated breathing of A2.3 Fuel System vapor or spray mist. • The syringe drive pump uses the hydraulic • Avoid prolonged or repeated contact with action of the reservoir piston to produce skin pressure on the fuel system. A regulator at the outlet of the system maintains the pressure at a constant value by maintaining A1.6 Aviation Turbine Fuel...
  • Page 45 regulator, then drips from a line into an open indication (MAN mode) and automatic container. The drip line allows visual control (AUTO mode). The input signal to monitoring of the flow rate. the JFTOT computer is from a thermo- couple inserted through the top of the A2.4 Cooling System heater tube and positioned at the point of maximum temperature.
  • Page 46 manometer. This bias is predictable, based Thermocouple calibration standards: on the density of mercury and the test 0°C ice bath fuel. A factory calibrated DPT checked 232°C freezing point of pure Tin (Sn) against an absolute standard, such as a 327.5°C freezing point of pure Lead (Pb) dead weight tester or air/mercury manom- Thermocouple type: J (Iron/Constantan)
  • Page 47 Aeration Flow Meter Water Reservoir Inlet Line (43930) Aeration Air Outlet Additional Fitting (Model 240 Only) Cooling Flow Meter Heater Section Outlet Line (43765) Thermocouple Reference Line Filter Bypass Line (part of 35291) Thermocouple Position Indicator Lower Floating Bus (part of Thermocouple Position Control 10830) Thermocouple (86300)
  • Page 48 FIGURE A2.2.1 - ASSEMBLY DRAWING OF HEATER TUBE TEST SECTION Page 36 JFTOT II Operation Manual Rev. C...
  • Page 49 FIGURE A2.2.2 - HEATER SECTION WITH NO TIME REACTOR, (1 P, MODEL 230 OR 240) FIGURE A2.2.3 - HEATER SECTION AND TIME REACTOR, WITHOUT INSULATION (2 P, 240 ONLY) JFTOT II Operation Manual Rev. C Page 37...
  • Page 50 FIGURE A2.2.4 - TIME DELAY REACTOR, MODEL 240 ONLY (35375) PLUS LINE (43925) Page 38 JFTOT II Operation Manual Rev. C...
  • Page 51 FIGURE A2.3 - SYRINGE PUMP AND FUEL RESERVOIR JFTOT II Operation Manual Rev. C Page 39...
  • Page 52 FIGURE A2.4 - WATER RESERVPOR (63320) Page 40 JFTOT II Operation Manual Rev. C...

  • Page 53: A3. Heater Tube Temperature Profile

    A3. HEATER TUBE TEMPERATURE PRO- A3.6 Press F1 to switch the Heater Mode to AUTO. FILE A3.7 Continue the test. A3.1 To measure the heater tube tempera- ture profile, the following procedure (test is running, heater in automatic mode) should be followed after the second half hour of the test but before a significant DP has been obtained.
  • Page 54 most spares and supplies are provided • Silicone Grease with the JFTOT to run 20 tests. • Gearbelt However, other items are not provided with the JFTOT but are required for • Beaker, 1000 ml plastic normal operation; these are specified A5.3 The following items are required to be below.
  • Page 55 • Printer ribbon • Solvent; may be technical grades of n-heptane, or 2,2,4-trimethyl pen- • Printer Paper (8.5 x 11) tane technical grade (95 mol percent minimum purity) • Water Pump Repair Kit • Trisolvent (equal parts of toluene, • Gear Belt acetone, and isopropyl alcohol, 99% •...

  • Page 56: Alcor Jftot-230/240 Parts List

    ALCOR JFTOT-230/240 PARTS LIST JFTOT-230, Universal Fuel Thermal Oxidation Tester ................85410 Single ∆P Model, 120/230V - 50/60 Hz JFTOT-240, Universal Fuel Thermal Oxidation Tester ................85411 Double ∆P Model, 120/230V - 50/60 Hz Visual Tuberator 115V 50/60 Hz with ASTM Color Standard ..............85417 and Magnifying Assembly Visual Tuberator 230V 50/60 Hz with ASTM Color Standard ..............
  • Page 57 JFTOT II HERMAL XIDATION ESTER D3241 Manual / October 2003 Version 2.1 or later 300 BAMMEL WESTFIELD ROAD • HOUSTON, TEXAS 77090 USA TELEPHONE: 281-580-0339 • FAX: 281-580-0719...
  • Page 58 THIS PAGE INTENTIONALLY BLANK. Page 2 JFTOT II D3241 Manual Rev. C...
  • Page 59 ABLE ONTENTS 1. INTRODUCTION ........................... 1 2. PREPARATION FOR TEST ......................3 2.1 Disassembly ........................... 3 2.2 Inspection of Components ......................3 2.3 Cleaning ............................3 2.4 Assembly of Heater Tube Test Section ..................6 2.5 Assembly and Installation of Pre-Filter ..................9 2.6 Assembly of Water Reservoir .......................10 2.7 Assembly of Air Trap ........................10 Preparation of Test Fuel .......................10...
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  • Page 61: Introduction

    1. INTRODUCTION This D3241 manual provides step by step procedures NOTE – Being able to perform an ASTM D3241 in setting up and performing an ASTM D3241 test on test using the CUSTOM test is important. If a test the JFTOT II. ASTM D3241 requires the use of the is accidentally terminated after aerating the fuel appropriate manual for the JFTOT being used.
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  • Page 63: Preparation For Test

    2. PREPARATION FOR TEST Protection provided by this equipment may be dry reservoir up to a light and look through it to impaired if used with accessories not provided detect any scratches. To prevent leaks, there or recommended by the manufacturer or used in must also be a proper seal between the reservoir a manner not specified by the manufacturer.
  • Page 64 4. Flush all inside surfaces of the fuel reservoir with 8. Using a squeeze bulb, blow out the fuel reservoir solvent while scrubbing the surfaces with a nylon cover outlet fitting to remove solvent. brush. Note - Do not use a metal brush which may damage the operating characteristics of the device.
  • Page 65 12. Using a squeeze bulb, blow out the quick connect 15. Flush the reservoir outlet line with solvent and fitting on the water reservoir to remove any thoroughly blow dry using a squeeze bulb. solvent. 16. Flush the heater section outlet line with solvent 13.

  • Page 66: Assembly Of Heater Tube Test Section

    19. Flush the glass aeration tube with solvent. 2.4 ASSEMBLY OF HEATER TUBE TEST SECTION 20. Using a brush (preferably metal) saturated with 1. A new ALCOR heater tube, test filter, and three trisolvent, brush the inside surfaces of the heater high temperature O-rings are required for each tube housing.
  • Page 67 b. Also examine the tube for straightness by 5. Repeat the above procedure for the other end of rolling the tube on a flat surface. As the the heater tube. tube is rolled, note any variation in the gap 6. Observe the heater tube through the fuel dis- between the surface and the tube center charge hole as shown below.
  • Page 68 9. Connect the fuel outlet line assembly to the 13. If the bus caps have been removed, check for heater tube housing outlet. Finger tighten lightly. proper mating. Numbers are stamped on the inside faces and these must be the same and face each other.

  • Page 69: Assembly And Installation Of Pre-Filter

    3. Using a clean tweezers, place the 0.45 µm white membrane filter element on the back-up screen, then install the O-ring on the other half of the pre-filter housing. 17. Insert the thermocouple into the upper end of the heater tube and lower to the 39 mm position (each line is 2 mm).

  • Page 70: Assembly Of Water Reservoir

    2.6 ASSEMBLY OF WATER RESERVOIR 1. Remove the quick connect fitting from the bottom of the water reservoir outlet fitting by sliding collar toward fitting. Then place the water reservoir on the reservoir stand. 6. Connect the INLET line and VENT line and snugly finger-tighten four knurled fittings.
  • Page 71 1. If the power to the JFTOT is not on, press 4. Lubricate the lip seal with fuel. Place the piston POWER to turn the JFTOT ON (“I” = on, “O”= in the center of fuel reservoir stand. Press the off).
  • Page 72 NOTE — Because it is necessary to have the test 13. Press F1 to turn Aeration ON. fuel at 15 to 32°C after filtration, it is desirable to have the test fuel within that temperature range at this time. 8. Put the reservoir into a pan to catch any spillage from this step.

  • Page 73: Assembly Of Fuel Reservoir Section

    2.9 ASSEMBLY OF FUEL RESERVOIR SECTION 1. Remove the filter/aeration funnel from the fuel reservoir. Some fuel may spill over the top of the reservoir, but the amount will be small and can be caught by wrapping a rag or towel around the cylinder.
  • Page 74 JFTOT II READY FOR D3241 TEST Page 14 JFTOT II D3241 Manual Rev. C...

  • Page 75: Test Procedure

    3. TEST PROCEDURE 3.1 SETTING THE CONTROLS 3. Observe the air trap jar for flow of air bubbles. Wait about one minute to see if air bubbles 1. Press F8 or F9 to set the Setpoint to the specified appear. Then wait until the air bubbles disappear heater tube temperature.
  • Page 76 3. The system fuel pressure will increase. As the 8. After the temperature has stabilized at the pressure builds up, no water will drip from the air specified Set Point: trap assembly drip line. At about 300 psig a. the bypass valve will automatically CLOSE, (2 MPa), the bypass valve will cycle (close and open).

  • Page 77: Shutdown

    3.4 SHUTDOWN 4. A message will be displayed to vent the system pressure below 0.35MPa (50 psig). 1. Test ends when the Test Timer = 0:00. The heater and drive pump will automatically turn off. A message will be displayed indicating the test has finished.

  • Page 78: Print Report

    3.5 PRINT REPORT NOTE – The test data from this test will be re- tained in memory after power is turned off. 1. Press F3 for the VIEW TEST HISTORY Reports from the six most recently saved test data display. can be printed from memory.

  • Page 79: Disassembly

    4. DISASSEMBLY 4.1 STEPS FOR DISASSEMBLY 1. Disconnect the fuel reservoir outlet line fitting from the heater tube housing. 5. Raise the heater tube thermocouple to the top of the sliding scale assembly. 2. Disconnect the reservoir outlet line from the prefilter.
  • Page 80 8. Rotate the bus caps and remove the heater tube test section. 13. After the solvent has evaporated from the heater tube, place the heater tube in the original plastic container and seal it with a cap. Mark it with the 9.
  • Page 81 18. Disconnect the water reservoir INLET and VENT lines. 16. Using a piston puller, remove the piston from the reservoir. Push the piston and piston puller out of the top of the reservoir. Do not pull the piston. 19. Disconnect the water reservoir, push down the This could damage the lip seal.

  • Page 82: Report

    NOTE - The tube rating and ∆P criteria are a 4.2 REPORT means of deciding whether a pass or fail result The report shall include the following: has been obtained at the test temperature. • The maximum heater tube temperature. •...
  • Page 83 JFTOT II HERMAL XIDATION ESTER Calibration Manual / October 2003 Version 2.1 or later 300 BAMMEL WESTFIELD ROAD • HOUSTON, TEXAS 77090 USA TELEPHONE: 281-580-0339 • FAX: 281-580-0719...
  • Page 84 THIS PAGE INTENTIONALLY BLANK. Page 2 JFTOT II Calibration Manual Rev. C JFTOT II Calibration Manual Rev. C...
  • Page 85 ABLE ONTENTS 1. INTRODUCTION .......................... 1 2. CALIBRATION OF HEATER TUBE TEMPERATURE CONTROLLER ........3 3. CHECKING VALIDITY OF ∆P TRANSDUCER (DPT) .............. 13 4. CHECKING VALIDITY OF FUEL FLOW RATE ................ 17 5. CHECKING AERATION FLOW, TIMER, AND COOLANT FLOW ......... 19 JFTOT II Calibration Manual Rev.
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  • Page 87: Introduction

    1. INTRODUCTION Bureau of Standards procedures and specially 1.1 The Calibration Manual provides procedures to calibrated instruments (calibrating). For our calibrate or check three major components. purposes, standardizing is sufficiently accurate to Examples of displays are shown to illustrate the determine if there is a problem with a transducer.
  • Page 88 SAMPLE OF QUICK REFERENCE CARD Page 2 JFTOT II Calibration Manual Rev. C...

  • Page 89: Calibration Of Heater Tube Temperature Controller

    2. CALIBRATION OF HEATER TUBE TEMPERATURE CONTROLLER The AUTOCAL procedure is used for cali- Press F6 AUTOCAL TC for the “PERFORM brating the temperature controller and heater CALIBRATION?” screen. The display will tube thermocouple. Three standards are used, indicate if the 20 minute warm-up period has utilizing the freezing points of water (H been completed and if the JFTOT is already 0°C, Tin (Sn), 232°C, and Lead (Pb), 327°C.
  • Page 90 After the JFTOT warm-up period is complete, Press any key except EXIT to keep press ENTER to begin the calibration proce- the temperature value. If you keep the dure. value, you will proceed with the Tin Calibration, as outlined in 2.9. A detected value of 1°C is used here as an example.
  • Page 91 2.7.3 TEMPERATURE DID NOT STABI- 2.10 Install the Tin (Sn) AutoCal Calibrator by LIZE. If the measured temperature placing the hollow end of the calibrator flush does not remain stable for at least 5 with the top surface of the upper bus and seconds, the JFTOT will display a tighten both Allen screws.
  • Page 92 2.13 Lower the thermocouple into the well so that it presses lightly against upper surface of the solid Tin. CAUTION: The thermocouple must be touch- ing the Tin. Varlen Instrum arlen Instruments Inc. ENTER ENTER EXIT Carefully lower the thermocouple to the bottom TOGGLE STEP PRINT...
  • Page 93 2.19 The temperature will drop, then abruptly 2.20 The thermocouple may be removed when the increase (to about 232°C), and then pause a temperature reaches 262°C. The display will few seconds. This pause period constitutes the display the prompt “REMOVE THERMO- freezing point, the change of state from liquid COUPLE”...
  • Page 94 perature value is kept, proceed to 2.24. NOTE – if a valid temperature was not detected The detected value of 231°C is used here and kept (retained), pressing ENTER will return as an example. you to the “PERFORM CALIBRATION?” (AUTOCAL TC) display. You must keep a valid Tin Calibration temperature to continue to the next calibration (Lead) point.
  • Page 95 2.27 Secure the plugged end of the calibrator by 2.30 Press ENTER to heat the Lead. The tempera- raising the lower floating bus bar to the upper ture will increase as the Lead is heated. The limit and tightening both Allen screws. screen will display “Please wait”...
  • Page 96 2.32.1 The heater stays on and controls the temperature at 357°C for no more than 2.5 minutes. If the next step (2.33) is not started within the 2.5 minutes, an error message is displayed and the Lead Calibration procedure must be repeated (proceed to step 2.39).
  • Page 97 keep the value. Press any key. Check the WARNING HOT SURFACES - the lead Lead Calibrator then repeat the AUTOCAL calibrator and thermocouple tip will be TC. The value of 341°C is used here as an hot. To prevent burns, handle with example.
  • Page 98 2.41 After all three calibration points have been 2.42.1 If the thermocouple was not properly performed successfully and the detected removed and is still inserted (stuck) in temperatures kept the temperatures can be solid Tin or Lead, then press F1 to turn saved in memory as the new calibration data.

  • Page 99: Checking Validity Of ∆P Transducer (Dpt)

    ∆ 3. CHECKING VALIDITY OF P TRANSDUCER (DPT) The calibration of the transducer system is Perform the test with the heater test section internal and not normally accessible to the user. disconnected. Wear gloves to protect fingers The following procedure can be used to ensure from fuel.
  • Page 100 3.10 Turn the FLOW CONTROL SELECTOR VALVE to the ∆P -VENT position and raise the bottle. The bottle will push fuel and any air through the system to the air trap drip tube. Press F2 to CLOSE the bypass valve(s). (Each time F2 is pressed, the bypass valves will change position.) 3.11 Hold the bottle up for about a minute.
  • Page 101 3.13 Lower bottle until the level of the fuel is at the same level as the -∆P fitting. 3.17 Lower the bottle so that the level of the fuel is level with the middle of the -∆P port. 3.14 Remove the fitting and reattach to the ∆P+ port.
  • Page 102 system should be checked a second time to be sure that there is no entrained air that might alter the standardization value. Return to Step 3.8. Air is the most likely cause of a suspected calibration drift. 3.23 Press EXIT to return to the MAIN MENU. 3.24 For JFTOT 240 only: Perform a similar test on Observe to confirm that the reading is steady.

  • Page 103: Checking Validity Of Fuel Flow Rate

    4. CHECKING VALIDITY OF FUEL FLOW RATE The calibration of the flow rate is internal and Pour the water into a clean graduated cylinder. not accessible to the user. The following Measure the volume to the nearest mm. procedure can be used to ensure that the flow Calculate the flow rate: rate is within the limits required for the test.
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  • Page 105: Checking Aeration Flow, Timer, And Coolant Flow

    5. CHECKING AERATION FLOW, TIMER, AND COOLANT FLOW Check the aeration flowmeter once every six 5.2.3 While running a D3241 or CUSTOM months. test, use a calibrated timer (or stop- watch) to time how long the heater is 5.1.1 While aerating fuel during a D3241 or on.
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  • Page 107 JFTOT II HERMAL XIDATION ESTER Maintenance Manual / October 2003 Version 2.1 or later 300 BAMMEL WESTFIELD ROAD • HOUSTON, TEXAS 77090 USA TELEPHONE: 281-580-0339 • FAX: 281-580-0719...
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  • Page 109 ABLE ONTENTS 1. INTRODUCTION ......................... 1 2. TECHNICAL SPECIFICATIONS ....................3 3. ROUTINE MAINTENANCE ....................... 5 3.1 AutoCal Calibrator Tin Replacement ..................... 5 3.2 AutoCal Calibrator Lead Replacement ..................5 3.3 Thermocouple Replacement and Position Adjustment ..............6 3.4 Cleaning Bus Bar Contacts ......................6 3.5 Aeration Dryer Replacement ......................
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  • Page 111: Introduction

    1. INTRODUCTION The JFTOT (Jet Fuel Thermal Oxidation Tester) is The maintenance (routine and repair) of the used for the thermal oxidation stability test of turbine JFTOT II ranges from simple to very complicated. fuels. It consists essentially of a fuel system with a This maintenance manual will attempt to provide heater tube test section (including a test filter), adequate information to maintain the JFTOT in...
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  • Page 113: Technical Specifications

    2. TECHNICAL SPECIFICATIONS Setpoint range: 180°C to 380°C Aeration Flowrate: 1.5 L/Min (Green) Flowrate range: 1 to 10 mL/min Coolant Flowrate: 10 Gal/Hr (Green) Flowrate accuracy: ±0.1 mL/min for 2 to 10 mL/min Heater tube temperature profile timer: 30 min. after heater tube temperature is stable Thermocouple calibration standards: Printer interface: Serial RS232, 19200, 9600, 4800 or...
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  • Page 115: Routine Maintenance

    3. ROUTINE MAINTENANCE 3.1 AUTOCAL CALIBRATOR TIN RE- display the initial AutoCal screen. Clean the tip of the thermocouple to remove any Tin. PLACEMENT Let the AutoCal Calibrator cool, then re- 1. The Tin in the Tin AutoCal Calibrator should move.

  • Page 116: Thermocouple Replacement And Position Adjustment

    8. While viewing the initial AutoCal display “PERFORM CALIBRATION?” press F1 (remove stuck thermocouple) to apply power to melt the Lead. When the Lead has melted, raise the thermocouple to remove it from the Lead. The JFTOT will turn the heater off and display the initial AutoCal screen.

  • Page 117: Aeration Dryer Replacement

    3.5 AERATION DRYER REPLACEMENT 3. If the fuel leaks into the bottom bearings of the drive pump assembly, replace the drive 1. The silica gel, located inside the aeration column o-ring. Turn the plunger shaft dryer, must be replaced when it is no longer counter-clockwise (ccw) to unscrew the blue in color.

  • Page 118: Cleaning The Display And Keypad

    3.8 CLEANING THE DISPLAY AND KEY- 1. Clean the display once a month, or as needed, with a clean dry soft cloth to remove any dust from: a. the blue-green display screen, b. the keypad 3.9 CLEANING THE JFTOT-II (CABINET) 1.

  • Page 119: Troubleshooting

    4. TROUBLESHOOTING JFTOT II Maintenance Manual Rev. C Page 9...
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  • Page 121 JFTOT II HERMAL XIDATION ESTER ISO 9000 Manual / October 2003 Version 2.1 or later 300 BAMMEL WESTFIELD ROAD • HOUSTON, TEXAS 77090 USA TELEPHONE: 281-580-0339 • FAX: 281-580-0719...
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  • Page 123 ABLE ONTENTS 1. INTRODUCTION ......................... 1 2. PREPARATION FOR TEST ......................4 JFTOT II ISO 9000 Manual Rev. C Page i...
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  • Page 125 1. INTRODUCTION This ISO 9000 section provides recommended Heater Tube rating results on the Log provided with documentation needed for installing the JFTOT into the Heater Tubes. Store the Log and Heater Tubes an ISO 9000 certified Lab. These forms provide for for six (6) months or as specified by your quality recording of Calibration/Verification and Mainte- system.
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