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FALEX 400 Operation And Maintenance Manual

Fuel thermal oxidation test machine
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Operation and Maintenance Manual
Falex Corporation
1020 Airpark Drive
VER 1.2 (1-1-13)
FALEX 400 Fuel
Thermal Oxidation
Test Machine
Sugar Grove, IL 60554
630.556.3669
www.falex.com

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Summary of Contents for FALEX 400

  • Page 1 FALEX 400 Fuel Thermal Oxidation Test Machine Operation and Maintenance Manual www.falex.com Falex Corporation 1020 Airpark Drive Sugar Grove, IL 60554 630.556.3669 VER 1.2 (1-1-13)

  • Page 2: Table Of Contents

    Getting To Know The Falex 400 . . . . . . . . . . . . . . . . .
  • Page 3 Table of Contents Section 8 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Software Accessible Service .

  • Page 4: Instructions-How To Use This Manual

    Manual Safety Callouts mal Oxidation Test Machine, in future referred to as Falex 400. For your own safety and protection from injury, care- The following are safety labels placed in areas on the fully read, understand and observe the safety instruc- test machine that may be hazardous to the operator.
  • Page 5 (SOP), and related instructions. Failure to comply important for protecting the equipment and performance. may result in personnel injury or death. A warning is important to protecting yourself, others, and the equipment. WARNING Falex 400 General Safety Warnings WARNING heater tube test section...

  • Page 6: Section 1: General Information

    ASTM D3241 Thermal Oxidation Stability of Aviation Turbine Fuels requires a strict conformance for the jet fuel industry for this critical test. The Falex 400 matches results due to the critical equipment specification that controls the heater test section and test conditions.

  • Page 7: Packing List

    Section 1: General Information 1.3 Packing List 1. The following items are included in the package: • 1 Falex 400 Thermal Oxidation Stability Tester • 1 Start-Up Kit Table 1: Start-Up Kit Contents Quantity Description Part Number Picture 1 Package of 2...
  • Page 8 400-105-005 output line assembly Pre-Filter assembly 400-105-010 Sample input line assembly 400-105-020 Lead calibration holder with 400-108-004 melted lead Falex 400 Manual CD 400-112-001 DP calibration bottle 400-200-005 Heater Tubes with DP filters 1 Package of 12 400-560-001 and O-rings...
  • Page 9 Part Number Picture 1 Package of 25 O-ring tubing 620-005-002 1 Package of 5 O-ring Pre-Filter 620-210-001 Beaker, 1000 ml 648-400-012 Funnel, large 648-400-003 1 Package of Funnel filter papers 648-400-004 1 Package of 25 Pre-Filter filter papers 648-400-005 Cleaning brush...
  • Page 10 650-204-065 Quality Control Certificate Oxidation Stability Apparatus Tube Kit 400-560-003 of Inspection Material: 316 Stainless Steel Form number: 400-111-006 Falex Corporation 1020 Airpark Drive, Sugar Grove, IL 60554 USA (630) 556-3669 f: (630) 556-3679 www.falex.com CERTIFICATE OF INSPECTION Tube Kit...

  • Page 11: Getting To Know The Falex 400

    Section 1: General Information 1.4 Getting To Know The Falex 400 Front USB Slot DP Calibration High Alignment Line Desiccant Chamber Door Fault Indicators (Resettable Fuses) Touch Screen On/Off Switch Interface Air Flow Meter Ring Stand Assembly Coolant Flow Meter...
  • Page 12 Fans — DO NOT BLOCK Interface Panel USB (2) Ethernet (1) Circuit Breaker Power Plug Receptacle Rear of the Falex 400 120V Unit Figure 2 Fans — DO NOT BLOCK Interface Panel USB (2) Ethernet (1) Circuit Breaker Power Plug...
  • Page 13 Section 1: General Information Sample input Sample output line assembly line assembly 400-105-020 400-105-028 Thermocouple Aeration line - fuel sample assembly 650-009-055 400-105-002 Beaker, 1000 ml Beaker, 1000 ml 648-400-012 648-400-012 Sample Container Area Figure 4 Aeration line assembly 400-105-002 Sample output...
  • Page 14 Thermocouple Retaining Clip DP Filter Housing (behind fuel out line) Fuel heater tube holder output line assembly 400-105-005 Fuel Bypass Line Part of 400-103-009 Heater tube holder assembly 400-103-009 Fuel heater tube holder input line assembly 400-105-004 Pre-Filter assembly 400-105-010...
  • Page 15 Section 1: General Information Heater Tube Holder Assembly Hex Nut 977-438-001 Upper insulation bushing 400-018-003 O-ring Fuel heater tube holder 650-008-002 output line assembly Lower insulation bushing 400-105-005 400-018-003 Bypass Line (part of heater tube holder assembly) Lower insulation bushing...

  • Page 16: Section 2: Setup

    Plug in the sample thermocouple and place the thermocouple Plug the Power Cord into the rear of the Falex 400. into the glass beaker. 2. Plug the power cord (120V, 60Hz, 220V, 50/60Hz) NoTe: The sample thermocouple can be stored in the hole at the left of the beaker area when not in use...
  • Page 17 Section 2: Setup New O-ring Damaged O-ring O-ring Inspection Figure 14a Beaker Filter/Funnel Filtering Fuel O-ring Placement Figure 13 Figure 14b funnel until all the fuel has been placed into the WARNING filter . Place the now empty beaker in the [Figure 13] sample-out position at the right of the sample container area.

  • Page 18: Instrument And Test Configuration

    Section 2: Setup 2.3 Instrument And Test Configuration NoTe: Before instrument setup, all components must the riveted end down and the tube ID number be clean. If the components are not clean, review the closest to the DP filter housing. Secure the heater Component Cleaning section .
  • Page 19 Section 2: Setup DP Filter DP Filter Housing 8. Using clean tweezers, install the DP filter supplied in the heater tube kit into the DP filter housing. Ensure the blue stripe is facing out. If the blue stripe is missing, then that filter has already been used so do not use it .
  • Page 20 Section 2: Setup NoTe: The bus bar caps and contacts are a matched set. If the caps are completely removed from the contacts, match the Bus Bar Caps number stamped on the inside of each cap to the number stamped on the end of the contact.
  • Page 21 Section 2: Setup 16. Begin assembling the pre-filter by placing the 19. Place the lower housing onto the upper housing. pre-filter O-ring on the lower housing Line up the screw holes on the upper and lower [Figure 23] housings and insert the screws through the lower 17.
  • Page 22 Section 2: Setup 22. Attach the pre-filter assembly to the assembled NoTe: The heater tube thermocouple can be stored in test section using the fuel input line the hole found on the top right of the beaker stand to [Figure 25] Inspect the O-rings on both ends of the sample the left of the bus bar area when not in use.

  • Page 23: Section 3: Software Operation

    In many instances the forward arrow will not appear until certain 3.1 Falex 400 Software Program conditions are met on the current screen (such as; man- datory test information entered, a button pushed, a tem- GeNeral NoTes: Various software screens have perature value reached).

  • Page 24: Run Test

    Section 3: Software Operation The ‘RUN TEST’ menu allows users to choose various test types. The test data can be viewed, printed, and/or stored after a successful test completion. Instructions 1. Accessing the Test Type screen: On the MAIN screen press the 'Run Test' button .
  • Page 25 Section 3: Software Operation 2. Test Type Screen: This screen has the possibility <3, 3, <4, 4, and [A] abnormal or [P] peacock of seven different test types to choose from are accepted for the breakpoint tube reading. . The D3241 ASTM test is always active [Figure 33] D.
  • Page 26 Section 3: Software Operation ____________________________________________________________________________________ Data File Root Name: The Data File Root Name can be entered (maximum of 8 characters) or left with the default value. Every time any configuration screen is entered the Data File Root Name is Data. This can be overwritten.
  • Page 27 1 hour prior to heating the sample. If the operator chooses to skip aeration a warning box will appear reminding of the 1 hour requirement. Be sure to properly assemble the Falex 400 before proceeding. Begin the aeration process by pressing the ‘Start’ button.
  • Page 28 Falex 420 Tube Rater and comparing it to the ASTM D3241 color comparison standard supplied with the Tube Rater. The Falex 420 Tube Rater System pressure and heater Figure 41b is specifically designed to meet ASTM D3241 tube temperature for tube rating.

  • Page 29: Data

    30 minutes during the test [Figure 47] NoTe: If the Falex 400 has had a power cycle since the last test, data transfer cannot be performed. The name of the last test run is on the top line on this screen.
  • Page 30 4. Copy: ‘Copy’ opens Windows Explorer. Navigate MUST be selected to move the test data to the to the “Data” folder under the root directory (400 computer. Upon transfer, data files reside in the (C:)). This folder contains all the data files that “Data”...

  • Page 31: Disassembly And Component Cleaning

    Section 4: Disassembly and Component Cleaning 9. Remove the test section assembly. WARNING 10. Remove the fuel-out line (J-line) from the heater tube housing and place in the pan provided. 11. Remove the O-ring and the DP filter from the DP filter housing using the extraction tool provided.

  • Page 32: Continued Unit Disassembly Cleaning

    Section 4: Disassembly and Component Cleaning 4.2 Continued Unit Disassembly 4.3 Component Cleaning 17. Use the hex wrench to remove the three screws in NoTe: The heater tube housing is the only component the pre-filter assembly. to be cleaned with Tri-Solvent. 18.

  • Page 33: Section 5: Software Preferences

    Section 5: Software Preferences 5.0 Software Preferences The Preferences menu allows authorized users to set up which test types can be run, the default ASTM D3241 test temperature, date/time display options (military or stan- dard time), and exit to Windows to install printer drivers. Only authorized users should be given the password to the Preference section.
  • Page 34 Falex Representative for more details. NoTe: Falex does not guarantee the use of any printer with its software other than the one shipped with the unit. D. Set PC Time: This button takes you out to Windows Control Panel that allows you to navigate to 'Date &...

  • Page 35: Section 6: Maintenance

    Failure to follow this warning may result in damage to equipment. 1. Ensure the Falex 400 is not performing a test. 2. Open the beaker cover by tilting it out towards you. 3. Slide the used charcoal filter out of the slot on the...
  • Page 36 Section 6: Maintenance 4. Grasp the desiccant cartridge with one hand and pull the desiccant cartridge straight out of the machine. If rubber bushings are attached to desiccant filter, remove and replace in machine . Properly dispose of used [Figure 55] desiccant cartridge.

  • Page 37: Pump Maintenance (Prime, Purge)

    Section 6: Maintenance 6.3 Pump Maintenance 6.3.1 Prime Pump Select the Prime Pump button on the maintenance screen WARNING . Before beginning the Prime Pump operation [Figure 58] be sure the sample beaker has plenty of fluid, 250 ml allows for 15 minutes of priming. Attach the sample-in line properly, placing the filter end into the beaker.
  • Page 38 Section 6: Maintenance 6.3.2 Priming Pump 4. On the Maintenance screen, select PRIME PUMP button. 6.3.2.1 Manual Method 5. Press the PRIME button. 6. Insert an empty, plastic 10 ml syringe into the Although not the recommended method, the pump and pump priming port at the center of the black lines may be primed manually.
  • Page 39 Before beginning the Purge Pump operation, [Figure 58]. be sure the sample beaker has at least 400 ml fluid and attach the sample-in line properly, placing the filter end into the beaker. Be sure there is a beaker under the prop- erly attached sample-out line.

  • Page 40: Section 7: Calibration

    Section 7: Calibration 7.1.1 Thermal Calibration Lo Check Calibrations should be preformed regularly on the 400 in accordance with the method. Refer to each method for it is required calibration schedule. Calibrations should 1. Prepare a low temperature standard, from an ice...

  • Page 41: Differential Pressure

    ‘OK’ button on the popup display. This will cause the popup to disappear. 1. Falex 400 must be on for at least 30 minutes The temperature will increase to melt the lead for before following this procedure.

  • Page 42: System Pressure

    14. Close the DP- vent on the screen by pressing the DP- button until it turns red. 15. Leave the bottle on top of the Falex 400. 16. Remove the nut from the DP+ port and set it aside. 17. Disconnect the bottle from the DP- port and attach the bottle to the DP+ port.

  • Page 43: Section 8: Service

    DP negative valve. This button is not interlocked with the bypass valve and On the front of the Falex 400 are 17 indicator lights. If should be used only if the operator has an a fuse trips an indicator light will be visible with the understanding of the system as not to damage the description of the problem area.

  • Page 44: Alarm And Warning Messages

    Section 8: Service 8.4 Alarm and Warning Messages...
  • Page 45 Section 8: Service...
  • Page 46 Section 8: Service...

  • Page 47: Addendum A Parts Listing

    Addendum A: Parts Listing FALEX 400 Thermal Oxidation Tester Parts Listing Part Number Description 400-018-003 Pack of insulation bushings (2 pairs/pack) 400-021-006 Bus bar drip pan 400-021-023 Bus bar cover 400-025-002 Charcoal filter (5 per pack) 400-027-003 Metal prefilter screen...

  • Page 48: Addendum B: Printed Report Example

    Addendum B: Printed Report Example...

  • Page 49: (Blank Page For Customer Notes)

    Notes issue date: 1/1/2013...

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