400 - Jet Fuel Oxidation Tester Manual Ver 1.2
400 - Jet Fuel Oxidation Tester Manual Ver 1.2
400 - Jet Fuel Oxidation Tester Manual Ver 1.2
Thermal Oxidation
Test Machine
Operation and Maintenance Manual
www.falex.com
Table of Contents
Page
Forward
General Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.1
Technical Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5
1.2
1.3
Packing List . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6
1.4
Section 2 Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.1
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15
2.2
2.3
Section 3
Software Operation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22
3.1
3.2
Run Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28
Section 4
4.1
4.2
4.3
Component Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31
Section 5
Software Preferences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32
Section 6 Maintenance . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 34
6.1
6.2
6.3
Section 7 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.1
Thermocouple. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39
7.2
Differential Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40
7.3
System Pressure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
7.4
Factors . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41
Table of Contents
Section 8 Service . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.1
8.2
Alarm Log . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.3
Fault Indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42
8.4
Safety Introduction
The following safety precautions are published for your
information. This manual does not purport to detail
all of the safety concerns, if any, associated with the
equipments use. It is the responsibility of the user of this
equipment to establish appropriate safety and health
practices and determine the applicability of regulatory
limitations prior to use.
This machine is built with user safety in mind; however,
it can present hazards if improperly operated and
serviced. Follow operating instructions carefully! If
you have questions about operating or servicing this
equipment, please contact Falex Corporation.
This equipment should only be operated by personnel trained by Falex or a Falex approved distributor.
This operation manual contains HAZARD, WARNING,
and CAUTION callouts, which must be followed to
reduce the possibility of personal injury, damage to the
equipment, or improper service.
The Falex 400 must be electronically grounded. Do not
change the grounding requirements of the instrument.
CAUTION
Hot Surface.
Do NOT touch.
or
WARNING
ELECTRIC SHOCK
HAZARD.
This equipment is to be
serviced by trained
personnel only.
or
WARNING
FLAMMABLE HAZARD: This symbol indicates the
products used are flammable.
WARNING
WARNING
Fuels and solvents are flammable and may cause irritation to the eyes or skin. Wear protective goggles and
gloves; avoid contact with skin, eyes, and clothing. Use in
well ventilated areas and keep away from heat or flame.
Follow all Material Safety Data Sheet (MSDS), Hazardous Materials Identification System (HMIS), ISO 9000,
Lab Standard Operating Procedures (SOP), and related
instructions. Failure to comply may result in personnel
injury or death.
Quantity
1 Package of 2
Description
Part Number
400-018-003
400-021-006
1 Package of 5
Charcoal filter
400-025-002
1 Package of 2
400-027-003
400-103-009
400-105-002
Picture
Quantity
Description
Part Number
400-105-028
400-105-004
400-105-005
Pre-Filter assembly
400-105-010
400-105-020
400-108-004
400-112-001
DP calibration bottle
400-200-005
400-560-001
1 Package of 12
Picture
Quantity
Description
Part Number
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
648-400-004
648-400-005
Cleaning brush
648-400-006
Hex wrench
648-400-007
Cleaning pan,
stainlesssteel
648-400-008
Ceramic insulator
removaltool
648-400-009
1 Package of
100
1 Package of 25
Picture
Quantity
Description
Part Number
Tweezers
648-400-010
Thermocouple - fuel
sample
650-009-055
650-009-064
Power cord
650-204-048
Stylus
650-204-065
Picture
650-030-140 (120VAC)
or 650-030-150 (220VAC)
650-049-021B
Oxidation
Stability Apparatus
Tube Kit
p/n
400-560-003
CERTIFICATE OF INSPECTION
Tube Kit
p/n
400-560-003
F10617_PackagingInsert.indd 1
ISO 9001:2000
3/1/11 10:09 AM
Touch Screen
Interface
On/Off Switch
Air Flow Meter
Ring Stand
Assembly
Coolant
Flow Meter
DP+
Calibration
Alignment
Line
Sample
Container
Area
Sample
Test Area
Pump Priming
Door
Figure 1
10
11
Figure 2
Figure 3
Sample input
lineassembly
400-105-020
Sample output
line assembly
400-105-028
Thermocouple
- fuel sample
650-009-055
Aeration line
assembly
400-105-002
Beaker, 1000 ml
648-400-012
Beaker, 1000 ml
648-400-012
Figure 4
Aeration line
assembly
400-105-002
Sample output
line assembly
400-105-028
Sample input
lineassembly
400-105-020
12
13
Thermocouple
- heater tube
650-009-064
DP Filter Housing
(behind fuel out
line)
Pre-Filter Bulkhead
Figure 6
DP Filter Housing
(part of heater tube
holder assembly)
O-ring
650-008-002
Upper insulation bushing
400-018-003
Heater Tube Holder
Assembly Hex Nut
977-438-001
Figure 7
Pre-Filter Screws
870-190-063
Lower Pre-Filter Cover Assembly
400-105-014
O-ring Pre-Filter
620-210-001
Pre-Filter filter paper
648-400-005
Metal Pre-Filter screen
400-027-003
Upper Pre-Filter Cover Assembly
400-105-021
Fuel heater tube holder
input line assembly
400-105-004
Figure 8
14
15
Section 2: Setup
2.1 Initial Setup
1. Plug the Power Cord into the rear of the Falex 400.
2. Plug the power cord (120V, 60Hz, 220V, 50/60Hz)
into an appropriate outlet. Electrical source must have
a good ground or an isolated power withground.
3. Connect the keyboard to one of the USB ports on the
back of the machine.
4. If the machine was shipped with a printer, the user
interface is already configured for the printer. If the
machine was not shipped with a printer and a printer
is to be configured, refer to section 5.0 for printer
configuration details.
5. Turn the unit on (by the rocker switch on the front of
the unit) and allow to warm up for 15 minutes prior to
use.
6. The Falex 400 is shipped with a charcoal filter
located in the beaker stand. Remove the shipping
filter by sliding the filter out of the opening on the left
side of the beaker stand and replace with a new filter.
It is recommended that this filter be replaced every 2
weeks to 1 month depending on usage. See section
6.1 for charcoal filter replacement instructions.
Sample
Thermocouple
Sample-In Line
Aeration Line
Glass Beaker
Figure 10
Thermocouple Storage
Filter Paper
Figure 9
Figure 11a
Figure 11b
Funnel
Ring Stand
Figure 12
Funnel/Filter Setup
Section 2: Setup
New O-ring
Damaged O-ring
Figure 14a
O-ring Inspection
Figure 14b
O-ring Placement
Beaker
Filter/Funnel
Figure 13
Filtering Fuel
WARNING
funnel until all the fuel has been placed into the
filter [Figure13]. Place the now empty beaker in the
sample-out position at the right of the sample
container area.
5. Place an O-ring on the sample-out line. O-rings
are required on all tubing lines except the aeration
and sample-in lines. Place a clean small O-ring
(650-005-002) at the end of each line before
securing the line in place [Figure14a and 14b]. Inspect
the O-rings and replace if damaged or missing.
6. Connect the sample-out line to the appropriate
fitting on the front panel [Figure4].
7. Once the fuel has been filtered, remove the filter
and dispose of it according to local regulations.
8. Remove, clean, and store the funnel.
9. Rotate the ring stand assembly to the left and
store into the ring stand housing of test machine
[Figure11a].
16
17
Section 2: Setup
2.3 Instrument And Test Configuration
Note: Before instrument setup, all components must
be clean. If the components are not clean, review the
Component Cleaning section [section 4.3]. A new heater
tube, DP test filter and three O-rings are required for
each test.
1. Retrieve a new heater tube kit from the box of
specimens.
2. Carefully remove the new heater tube from the
container. Wear gloves and handle the heater tube
by the ends only. Do not touch the center section
of the tube.
3. Inspect the center section of the tube for
scratches, unpolished areas, or other visual
defects. Ensure the tube is not bent by rolling it
on a flat surface. If the tube is bent or has other
defects, discard that tube and retrieve another kit.
It is advisable to write the tube number down as
this number is a required entry value on the test
configuration setup.
4. Assemble the test section. Insert the heater
tube into the heater tube housing so that it is
approximately in the center of the housing with
Hex Nut
Heater Tube
Figure 15
Figure 16
Section 2: Setup
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 [Figure17a]. A new DP filter
must be used for each test. Place a new O-ring,
supplied in the heater tube kit, on top of the DP
filter and push into place [Figure17b].
DP Filter
DP Filter Housing
Figure 17a
O-ring
DP Filter Installation
DP Filter Housing
O-ring
Figure 17b
Figure 18
DP O-ring Installation
Figure 19
18
19
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
number stamped on the inside of each
cap to the number stamped on the end of
the contact.
Heater Tube
Assembled
Test Section
Fuel-Out
Line To
DP- Fitting
Fuel Bypass
Line To DP+
Fitting
Figure 21
BusBar
Figure 22
Section 2: Setup
16. Begin assembling the pre-filter by placing the
pre-filter O-ring on the lower housing [Figure23].
17. Place the pre-filter screen into the upper housing
[Figure23].
Pre-Filter Screws
Lower Pre-Filter
Housing
Pre-Filter O-ring
Pre-Filter
Bulkhead Fitting
Pre-Filter Assembly
Upper Pre-Filter
Housing
Figure 23
Pre-Filter Components
Figure 24
20
21
Section 2: Setup
22. Attach the pre-filter assembly to the assembled
test section using the fuel input line [Figure25].
Inspect the O-rings on both ends of the sample
line union. Replace if missing or damaged.
Assembled
Test Section
Fuel Input Line
Pre-Filter Assembly
Figure 25
Thermocouple
Retaining Clip
Figure 26a
Insert Thermocouple
into top of Tube
Retaining
Bus Bar Screws Clip in Place
Heater Tube
Thermocouple
Installed
Figure 26b
Screen Title
Lower right corner buttons: Usually there is a backward arrow, forward arrow or both [Figure 29]. The backward arrow directs the user to the previous screen and
the forward arrow advances to the next screen. In many
instances the forward arrow will not appear until certain
conditions are met on the current screen (such as; mandatory test information entered, a button pushed, a temperature value reached).
Lower left corner buttons: Buttons in the lower left are
for user assistance [Figure 29]. Various screens during a
running test have a 'Status button which activates a Status screen. The Status screen shows live feedback of
critical test data and where that data is taken from.
Aborts test or
procedure
Figure 27
Header Bars
Figure 28
Software Build
Help Location
in Operation
Manual
22
23
Instructions
Forward
screen
and back
screen
buttons
Figure 29
The Instructions button pops up a window to help explain how the current procedure is run [Figure30]. These
instructions are basic and the user should refer to other
sections in this manual for a more detailed explanation
on that particular procedure. Some instructions may
have multiple pages and the arrow in the lower right corner takes you to additional instructions. Press the Close
button to exit the instructions and return to the program.
Access
Test
Selection
Screen
Additional
pages
Main Screen In
Ready State
Figure 31
Figure 30
Temperature
must be
below 40C
before Run
Test button
appears
Figure 32
Figure 33
Test Selections
Figure 34
24
25
Single Configuration
Figure 36
Breakpoint Configuration
Figure 37
Figure 38
Custom Configuration
Aeration Screen
Aeration
Flow Meter
Coolant
Flow Meter
Figure 39
Figure 40
Status Screen
26
27
Figure 41a
Figure 41b
Figure 42
A. Tube Rating: Upon a successful test completion, a tube rating screen appears following
the cool down. Follow the heater tube disassembly procedure (Section 4) to prepare the
tube for rating. The operator must enter a
value for the tube rating (pumped fuel volume
optional) [Figure43]. All entries are stored in
the data file. The tube rating is derived from
placing the specimen tube in the Falex 420
Tube Rater and comparing it to the ASTM
D3241 color comparison standard supplied
with the Tube Rater. The Falex 420 Tube Rater
is specifically designed to meet ASTM D3241
for tube rating. Any characters can be entered
for a tube rating. However, it is recommended
that the individual test method for procedure
and instructions on how to rate a tube be used
(ASTM D3241).
Figure 43
B. Aborted Tests: A test is terminated by the operator pressing any abort button during a test
or from the test itself failing to reach defined
parameters. Refer to the Alarm section of this
manual to see which alarms cause an immediate test termination and which alarms initiate
only a warning message.
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. This is the file that the first three buttons refer to
[Figure45]. The user can view the test data on the touch
screen, transfer the data from the PLC storage onto the
computer, print this report and/or copy files from the
touch screen to a USB device or Ethernet connection.
Complete data records of DP mmHg, heater tube temperature and system pressure are taken every minute
during a test and are stored in the data file. To retrieve
the data file the operator needs to Transfer the data file
and then Copy the file to an external device. Data files
are saved in .csv format and can be viewed using appropriate software.
Figure 46
Viewing Data
Page 1 - Test Information
Figure 47
Viewing Data
Page 2 - DP Values
Access
the data
Figure 44
How To Access
Test Data
Figure 45
Name of
data file
that View,
Transfer
and Print
refer to
28
29
Figure 48
WARNING
The heater tube test section can reach high temperatures of 180 380 C during operation. Always
place bus bar cover over the heater tube test area
when running test to prevent contact with the test
section. When the bus bar cover is removed, always assume the heater tube test section is hot
and use caution when operating around this area.
Upper And
Lower
Bus Bar
Screws
Figure 49
30
31
Access
Preferences
Figure 51
Preferences Screen
A. Test Selection: This section is on the lefthand side of the screen containing six boxes
with respective titles on their right. Clicking
on these boxes will put an 'X' in the box and
activate the different test buttons available on
the TEST TYPE screen. To deactivate a test
type, click the boxes once more so that the 'X'
disappears from the box.
Figure 50
Accessing
Preferences
B. Time: On the right-hand side of the Preferences screen, there is a box labeled 'Time.' In
this box, there are two buttons 'Mil' and 'Std.'
These stand for 'Military' and 'Standard' time
respectively and will change the format of the
time display on the machine.
C. Install Printer: Pressing the Install Printer
button will initiate the Windows Control Panel.
Select the 'Printers and Faxes' icon in the
Windows Control Panel and then select 'Add
Printer.' Users can install a printer driver from a
flash drive or a portable USB disk drive.
32
33
Section 6: Maintenance
6.1 Charcoal Filter Replacement
Desiccant Cover
Figure 52
Charcoal Filter
34
35
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 [Figure 55]. Properly dispose of used
desiccantcartridge.
5. Obtain a new desiccant cartridge [Figure 56].
6. Align the new desiccant cartridge with the
desiccant cartridge inlet/outlet ports. Push
the desiccant cartridge straight into the F400
desiccant housing until the cartridge snaps into
the retainer clips.
7. Power on the machine, and proceed to
maintenance screen. Push the aeration button.
Verify the humidity level is dropping. If it is not,
the desiccant is not seated correctly in the rubber
bushing. Remove desiccant cartridge, reposition
rubber bushing and reinstall cartridge.
Figure 56
Desiccant Cartridge
Desiccant Housing
Retainer Clips
Desiccant Cartridge Inlet/Outlet Ports
Rubber Bushings
Figure 55
Section 6: Maintenance
6.3 Pump Maintenance
WARNING
Figure 58
Maintenance Screen
Figure 59
Access
Maintenance
Screen
Figure 57
Accessing The
Maintenance Screen
36
Section 6: Maintenance
37
Black Handle
Opening the Door
to Prime the Pump
Figure 60
Plastic Syringe
Section 6: Maintenance
38
6.3.3Purge
The Purge cycle should be performed the first time the
Falex 400 is started, whenever the unit has sat unused for
15 days or more or whenever there is air in the lines and
the prime pump sequence failed to remove all theair.
Select the Purge button from the maintenance screen
[Figure 58]. Before beginning the Purge Pump operation,
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 properly attached sample-out line. Pressing the Start button
begins an automated prime pump sequence that cannot
be stopped once started [Figure 62]. It's purpose is to flush
every line in the system with new fuel and expel any air
pockets. The purge sequence runs 21 minutes. Valves
are open and closed in sequence as can be seen by the
lighted Digital Points. The pump is adjusted to a flow rate
of 9 ml/minute. The Status bar returns feedback of the
purge sequence and the timer bar gives feedback on
how much time is remaining.
Following a successful purge, all air should be removed
from the lines. Dispose of used fuel properly and begintests.
Figure 62
Purge Screen
39
Section 7: Calibration
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
be performed on the heater tube thermocouple, the differential pressure transducer and the system pressure.
Thermocouple allows for a calibration of the temperature
control system using ice and the eutectic temperature of
lead to calibrate the heater tube thermocouple. The differential pressure is the measurement across the DP test
filter. Excessive differential pressure (DP) is an indication
of poor fuel quality. Diff Press provides a calibration of
the differential pressure transducer. Sys Press allows for
adjustment of the pressure measurement against a NIST
certified reference pressure gauge.
Select
Thermocouple
Current
Thermocouple
Reading
Figure 63
7.1Thermocouple
The auto calibration performs a calibration of the heater
tube thermocouple by a low calibration check using an
ice bath and a high calibration procedure using the lead
calibration assembly. It is critical that the following steps
be followed carefully. Failure to have the thermocouple in
the correct position during each step can cause the unit
to continue to apply heat to the bus bars or fail to heat the
bus bars. Should a step not complete as documented
within seven minutes of initiation, shut the unit off
from the power switch on the front, allow the unit to
cool for a minimum of 20 minutes before restoring
power and re-initiating calibration.
1.
Figure 64
Thermocouple Lo
Check Screen
Section 7: Calibration
3. Push the Start button to begin the heat cycle
that will raise the lead assembly temperature
to 350C. Once pushed, the Heat button
willdisappear.
4. The lead temperature will begin to rise. The
thermocouple must maintain contact with the
lead. An occasional light pressure on the top of
the thermocouple wires may be required. Once
the temperature is above 327.5 C, the lead will
melt down into the fixture cup. Make sure that the
thermocouple remains in contact with the lead
by pushing it down to the lowest position with the
tip centered in the cup (do not let thermocouple
touch the sides of the lead cup).
The Following steps are automated:
Real-Time
Temperature
Figure 67
40
41
Section 7: Calibration
7. Open the Bypass valve by pushing the Bypass
Valve button on the screen until it appears green.
8. Close the System Vent by pushing the System
Vent button on the screen until it appears red.
9. Attach the calibration bottle to the DP- port on the
Falex 400.
10. Set and leave the bottle on the top of the machine.
Live DP
Reading
Figure 68
DP Calibration Screen
7.4Factors
Factors displays the most recent values and date for the
last calibration of the heater tube thermocouple, differential pressure and system pressure [Figure 69].
Figure 69
Section 8: Service
8.1 Software Accessible Service
Obtaining manual access to machines functionalities is
done through the Service screen accessed from the
maintenance screen [Figure 70]. The user has access to
various controls so operation should only be undertaken
by someone with understanding of the system.
1. I/O & Vars: [Figure 71] Manual operation of different
controls can be accessed by pressing the large
green or red buttons under Digital Points. The
HPLC pump can manually be set to flow at either 3
or 9 ml/min for this service screen. Live feedback is
shown in the Data section of this screen.
2. Close DP Neg: Pressing this button manually
operates the DP negative valve. This button
is not interlocked with the bypass valve and
should be used only if the operator has an
understanding of the system as not to damage the
pressuretransducer.
Figure 70
[Figure 72]
Figure 71
42
Operator Abort
Pump Communication
Failure
Abort
Alarm
Description
> 32 C
Aeration
active
< 15 C
3.1 Mpa
3 min after
test start
< SP - 2 C > SP + 2 C
300 sec
after press
achieved
Hi Limit
Lo Limit
5 C in 10
sec after press
achieved
Condition
Comments
43
Section 8: Service
Alarm
High Humidity
Description
Abort
Test active
Test active
Test active
Test active
Aeration
time > 30
sec
Condition
-100 C
2.5 C
from setpoint
3.1 Mpa
Lo Limit
2.5 C
from setpoint
3.8 Mpa
60 C
80 C
425 C
21%
Hi Limit
Checked after 30 seconds of
aeration. Temperature must be at
high level for 1 sec.
Possible Cause: Air pump failure,
humidity sensor failure.
Comments
High Humidity
Section 8: Service
44
Alarm
Description
Abort
Sample Thermocouple
Failure
Data xfer
button
selected
Hi Limit
-100 C
-100 C
Lo Limit
Test active
Test active
Test active
Condition
Warning only.
Possible Cause: Cover removed
during test, photo eye failure.
Comments
45
Section 8: Service
Description
400-018-003
400-021-006
400-021-023
400-025-002
400-027-003
400-097-005
400-103-009
400-105-002
400-105-004
400-105-005
400-105-010
Pre-filter assembly
400-105-020
400-105-028
400-108-004
400-200-005
DP calibration bottle
400-560-001
620-005-002
620-210-001
648-400-003
Funnel, large
648-400-005
648-400-006
Cleaning brush
648-400-007
Hex wrench
648-400-008
648-400-009
648-400-010
Tweezers
648-400-004
648-400-012
Beaker, 1000 ml
650-009-055
650-009-064
650-030-140
650-030-150
650-049-021B
657-400-001
Desiccant cartridge
698-400-006
46
47
Notes
48