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1. owy dw j Jeg sng uonduasag 2 3 12 9 13 AM F10572_F400Manual indd 45 Addendum A Parts Listing TN 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 400 097 005 Screw Replacement Kit 400 103 009 Heater tube holder assembly 400 105 002 Aeration line assembly 400 105 004 Fuel heater tube holder input line assembly 400 105 005 Fuel heater tube holder output line assembly 400 105 010 Pre filter assembly 400 105 020 Sample input line assembly 400 105 028 Sample output line assembly 400 108 004 Lead calibration holder with melted lead 400 200 005 DP calibration bottle 400 560 001 Heater tubes with DP filters and O rings 12 tube assy box 620 005 002 O ring tubing bag of 25 620 210 001 O ring pre filter bag of 5 648 400 003 Funnel large 648 400 005 Pre filter filter papers 25 filters box 648 400 006 Cleaning brush 648 400 007 Hex wrench 648 400 008 Cleaning pan stainless steel 648 400 009 Ceramic insulator removal tool 648 400 010 Tweezers 648 400 01 1 Funnel filter papers 100 filters box 648 400 012 Beaker 1000 ml 650 009 055 Thermocouple fuel sample 650 009
2. FALEX 400 Fuel Thermal Oxidation Test Machine aT CO PLAT MUNUN Falex Corporation 1020 Airpark Drive Sugar Grove IL 60554 630 556 3669 www falex com VER 1 1 1 6 12 F10572 F400Manual indd 1 D 2 3 12 9 12 AM Forward Section 1 1 1 1 2 13 1 4 Section 2 2 1 2 2 2 3 Section 3 3 1 3 2 3 3 Section 4 4 1 4 2 4 3 Section 5 Section 6 6 1 6 2 6 3 Section 7 7 1 7 2 7 3 7 4 F10572 F400Manual indd 1 Table of Contents Page Instructions How to Use This Manual 3 Safety Safety Label Descriptions and Hazardous Areas of Test Machine 3 General Information 5 Technical Specifications 5 Brief Description of Equipment 5 Packing EISI PP 6 Getting To Know The Falex 400 10 Setup 15 lube UE IA ea hes ee AA 15 Sample Area and Fuel Preparation 15 Instrument and Test Configuration 17 Software Operation 22 Falex 400 Software Program 22 Run Test 23 WONG RSR 28 Disassembly and Component Cleaning 30 Heater Tube Disassembly 30 Continued Unit
3. 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 F10572 F400Manual indd 3 Machine Safety Labels and Manual Safety Callouts The following are safety labels placed in areas on the test machine that may be hazardous to the operator These same symbols may be used in the manual to bring attention to safety concerns Please take caution and understand what these labels indicate before operating the test equipment Hot Surface Do NOT touch Allow to cool before servicing HOT SURFACE HAZARD This symbol indicates hot surface areas on the test machine Use caution when working in these areas where components could be hot ELECTRIC SHOCK HAZARD This equipment is to be serviced by trained personnel only ELECTRICAL SHOCK HAZARD This symbol indicates hazardous voltage is present when opening the electrical cabinet This unit is to be serviced by trained personnel only WEAR SAFETY GLOVES This symbol indicates chemicals that may be hazardous to handle Wear safety gloves WEAR BREATHING PROTECTION This symbol indicates fumes that may be hazardous to inhale Wear breathing protection WEAR EYE PROTECTION This symbol indicates eye protection need during operation 2 3 12 9 12 AM Forward Instruct
4. catch solvent during the component cleaning 2 Ihe heater tube must be removed and rated Allow the heater tube assembly to cool for 15 minutes before continuing 3 Lift and rotate the heater tube thermocouple retaining clip off the thermocouple and carefully remove the thermocouple tip from the hole on the top of the heater tube taking care not to bend the thermocouple 4 Wipe down the thermocouple using a be Upper And ermicidal wipe j Lower 5 Remove the fuel out line from the DP fitting and Bus Bar the fuel bypass lines from the DP fittings Screws 6 Remove the prefilter assembly from the cabinet bulkhead 7 Remove the right upper and lower bus bar screws with the hex wrench provided Figure 49 8 Loosen the left hand screws on the upper and lower bus bars but do not remove Figure 49 Removal of the Test Section F10572 FA00Manual indd 30 e 2 3 12 9 13 AM 4 2 17 18 19 20 21 22 23 Continued Unit Disassembly Use the hex wrench to remove the three screws In the pre filter assembly Disassemble the pre filter Remove and discard the white pre filter element Place the remaining components of the pre filter assembly into the provided pan The prefilter O ring is reusable afer proper cleaning Open the cover from the sample container area Remove the aeration line and the sample in line and place them in the pan provided Remove the fuel thermocouple from the b
5. 12 9 13 AM Notes issue date 1 6 2012 F10572 F400Manual indd 48 D 2 342 9 13 AM
6. JOUE LOGY aun iej ejdnoo OLulau eqni 19jeaH agn 191284 UO jisodap 8AISS82X3 asneg 9Igissog puoo8s JOUE LOGY 08 lt due seg sng oJn re IH ejdnoo Ouueu egn J9JE0H Oo 08 Oo SCV dws uDiH veg sng due u6iH eqn 18788H anjiej JOSUAS A IPILUNY ane dund ut Sn a qissod 09S JO AO UBIU ye 9g snu eJnjeJjeduue uonejee JO spuooes CEE Jeye peyoouy Apiun yH HEC 09S Og lt SU uoneJov AWPIWNH uid HUIT TH TORIO IPRETTO 2 3 12 9 13 AM F10572 F400Manual indd 44 ice Serv Section 8 jdnuoo uomgeoiadde dl SIKO jou seop AIO IP ejep pajeaJo poloo es OU djl eq esne 9 qISSO ene uon X oJn ie J9JsueJ ere JJ EJec D 9 9ISS0d uonoy uedo wwo d nq IE JojsuEJ eyed pojoe es uo 19Jx eje jnq 19JsueJ ejep sale pexo9u aunjiej 04o ojoud se Ouunp Dp9 OLU8I JOAOD 8sne e qissog GUISSIN JOAOD Jeg sng JA 1S9 X BUISSIN 18109 Aleyes AJUO BuiuJeA pajoau uoo JOU ejdnooouueu njej ane ne WA eJn re ej dnooouJ ejdnooouuaeu esne e gissogd jdnooow y ejduueg Jo 00 49e el J9u due jan4 ejduueg PUO98S Joe 1oqy oeloeu uoo JOU ejdnooouueu njej oJn re J D 001 cause sel eJn re ejdnoo ejdnooouuaeu asnez e qissog Duooes Jaye yoqy SJUAUIW01 INH aessa uuely jdnooow y seg sng yw TH yw 07 UOIJIPUO9
7. areas and keep away from heat or flame Follow all Material bushings from both sides of the heater tube housing and place them in the pan provided Remove and discard the O rings oafety Data Sheet MSDS Hazardous Materials 13 Identification System HMIS ISO 9000 Lab Stan dard Operating Procedures SOP and related in structions Failure to comply may result in person nel injury or death Remove the lower insulator bushings from both sides of the heater tube and the heater tube housing and place them in the pan provided 14 Carefully slide the heater tube out of the housing NOTE Lower insulator bushings may come out of the heater tube housing while removing the heater tube or they may stay in the heater tube housing Take care not to lose them The heater tube test section can reach high tem peratures of 180 C 380 C during operation Al ways 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 15 Rinse the heater tube with Iso Octane and allow the solvent to evaporate Place the heater tube back in the original plastic container and cap until you are ready to rate the tube 16 Rate the tube using an approved method and record value on screen 41 Unit Disassembly 1 Position a waste solvent container as needed to
8. during a running test have a Status button which activates a Sta tus screen The Status screen shows live feedback of critical test data and where that data is taken from Return to Main Screen Figure 28 Software build or Operational Manual Help Figure 29 Help Location in Operation Aborts test or Manual procedure Header Bars AE Poles FA Software Build F10572 F400Manual indd 22 2 3 12 9 13 AM Section 3 Software Operation ASTM Configuration ae Fait Data Fig Roi Massi Lez Operator Instructions Puis ih uu Forward seks screen nun ial and back screen buttons PILE LSS QUIE Lower Left and Right Buttons The Instructions button pops up a window to help ex plain how the current procedure is run Figure 30 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 cor ner takes you to additional instructions Press the Close button to exit the instructions and return to the program DP calibrat OP Calibration Instructions L Pl he cbion Gore RECETTES fl HEP MD ee ee on tar oe BILE TIE LES Pia es LPS J Gayo che CF cran scan Er Mie IL ER 4 Upon eniereg l G rer pres Par L Gran the lapsa vas by perahu che Dipsas vas on et Pe bibam N eee he Chora the tetera iy pu
9. is initiated T If the eutectic temperature was successfully detected push the OK button on the popup display This will cause the popup to disappear The temperature will increase to melt the lead for thermocouple removal A message is displayed notifying the operator to remove the thermocouple from the lead once the temperature reaches gt 330 C A one minute timer is started to allow thermocouple removal 8 Once the one minute timer has completed or the thermocouple has been removed heating is stopped The operator must remove the thermocouple from the lead at this time and clean the thermocouple with a cloth to remove any residual lead on the thermocouple Dispose of the cloth properly Wear appropriate gloves when handling the hot thermocouple with possible lead residue 9 A four minute timer is initiated to allow for the lead cup assembly to cool Once the four minutes has been completed the cooling is stopped F10572 F400Manual indd 40 Section 7 Calibration UU TT 10 If the eutectic temperature capture was not 11 gi Fat successfully detected a popup message will display a failure and abort the calibration procedure It is suggested that the test be repeated to confirm that the thermocouple is defective Push the OK button on the popup display for a one minute heating cycle to begin to allow for thermocouple removal As described in steps 9 and 10 above Remove the thermocouple and inspect it
10. refered to as Falex 400 For your own safety and protection from injury care fully read understand and observe the safety instruc tions described in this manual Keep this manual with the machine If you lose this manual or need an additional copy please contact Falex Corporation The information contained in this manual was based on machines in production at the time of publication Falex Corporation reserves the right to change any portion of this information without notice This operation manual is divided into sections and addenda as listed in the Table of Contents Sections not relevant to this machine will have a page inserted stating so oafety 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 equipment s 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 person nel trained by Falex or a Falex approved distributor This operation manual contains HAZARD WARNING
11. tube housing firmly 4 Assemble the test section Insert the heater NOTICE Overtightening will break the ceramic tube into the heater tube housing so that it is bushings and can cause leaks approximately in the center of the housing with Hex Nut Heater Tube O ring Qu Heater Tube Installation Components F10572 F400Manual indd 17 e Heater Tube Housing Heater Tube Shoulder Upper Insulator Brushing Lower Insulator Housing C QS Heater Tube Position 2 3 12 9 13 AM Section 2 Setup 8 Using clean tweezers install the DP filter supplied DP Filter DP Filter Housing 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 Figure 17a 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 Figure 17b 9 Attach the large end of the fuel out line to the DP filter housing Figure 18 Finger tighten 10 Inspect the O rings on the fuel out and bypass lines Replace if missing or damaged 11 Remove the right retaining screw of each bus bar cap using the hex wrench supplied Loosen SUUS DP Filter Installation the left retaining screw of each bus bar cap using the hex tool so that the cap is free to p
12. 057 Thermocouple heater tube 650 030 140 Power cord 120v 650 030 150 Power cord 220v 650 049 021B Pump priming syringe 657 400 001 Desiccant cartridge 698 400 006 Lead Samples bag of 10 F10572_F400Manual indd 46 2 3 12 9 13 AM Addendum B File Transfer Message datalog dat Falex Jet Fuel Thermal Oxidation Report Test Date Test Time Test Type Data File Name Lab Name Machine Number Tube ID Fuel Type Fuel ID Operator Termination Mode e 12 23 24 Single Data72 csv 4 123456789012345 400 1205 1205 123456789012345 123456789012345 123456789012345 123456789012345 normal Temperature Setpoint C Flow Rate ml min Aeration Duration min Tube Rating Scheduled Run Time min Actual Run Time min Pumped Fuel volume calculated ml Pumped Fuel volume Actual ml Thermocouple calibration Date System Pressure Calibration Date DP Calibration Date Sample Temperature 00 10 S Sample Temperature 05 50 DP Average mmHg DP Max mmHg Time to i mmHg min D mmHg 30 min DP mmHg at min D t im 90 min DP mmHg 120 min DP 31 150 min DP mmHg 180 min DP 210 min DP 240 min DP mmHg 270 min DP mmHg 300 min DP mmHg 330 min DP mmHg 360 min DP mmHg F10572 F400Manual indd 47 260 0 jap 10 30 90 0 12 15 10 12 17 10 12 16 10 D cc ot oc oo e Page 1 2 3
13. 13 AM Section 2 Setup 21 Attach the pre filter assembly to the assembled NOTE Ihe heater tube thermocouple can be stored in test section using the fuel input line Figure 25 the hole found on the top right of the beaker stand to Inspect the O rings on both ends of the sample the left of the bus bar area when not in use Figure 26b line union Replace if missing or damaged u 24 Check all of the fittings to ensure they are 22 Finger tighten the fittings until snug finger tight 23 Plug in the heater tube thermocouple Carefully 25 Close the acrylic cover to the sample test area insert the thermocouple tip into the hole on the top Leaving the cover open will cause an alarm while of the heater tube and lower until it stops Rotate a test is running the thermocouple retaining clip to the left to lock E m the thermocouple into place Figure 26a and 26b If this is the initial setup or if the F400 has not been oper ated for 15 days it is recommended that the automated Purge be run prior to any tests being performed on the unit Refer to section 6 3 2 Assembled Test Section Fuel Input Line Pre Filter Assembly Figure25 Fuel Input Line to Assembled Test Section Heater Tube Thermocouple Insert Thermocouple Retaining Thermocouple Retaining Clip into top of Tube Bus Bar Screws Clip in Place Installed TER Thermocouple Retaining Clip Heater Tube Thermocouple and Retaining Clip F10572 F400Manu
14. 9 Components For Assembly of Test Section Area Pre Filter Screws 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 Components For Assembly of Prefilter 2 3 12 9 12 AM Section 2 Setup A 2 1 Initial Setup NOTE The sample thermocouple can be stored in the hole at the left of the beaker area when not in use 1 Plug the Power Cord into the rear of the Falex 400 Figure 10 2 Plug the power cord 120V 60Hz 220V S0 60Hz 2 Grasp the ring stand assembly and pull from the into an appropriate outlet Electrical source housing Figure 11a After the ring stand assembly is must have a good ground or an isolated power fully extended from the housing rotate to the right with ground to lock into position Figure 11b 3 Connect a Printer to one of the USB or Ethernet 3 Place the funnel into the ring stand and place a port on the rear of the machine See page 31 for clean filter paper into the funnel Figure 12 instructions to load printer driver 4 Turn the unit on by the the rocker switch on the front of the unit and allow to warm up for 15 sample minutes prior to use Thermocouple 5 The Falex 400 is shipped with a charcoal filter located in the beaker stand Remove the shipping filter by sliding the filt
15. Copy the file to an external folder Data files 2L are saved in csv format and can be viewed using ap Viewing Data propriate software Page 1 Test Information bru Luis ee tg mir 1 ke F EL J aic mx Access ru the data b How To Access Viewing Data Test Data Page 2 DP Values Data Name of data file Dam Flu Mans that View Transfer and Print refer to Figure 45 Data File Name F10572 F400Manual indd 28 D 2 3 12 9 13 AM Section 3 Software Operation 2 Transfer After a test completion this button MUST be selected to move the test data to the computer Upon transfer data files reside in the Data folder under the root directory F400 C An acknowledgement window appears upon successful data transfer Figure 48 Do not proceed until this acknowledgement appears NOTE The current test data will be lost at the start of the next test if this Transfer button is not pressed or when the F400 s power is cycled he computer has limited hard drive space and it is recommended that the user regularly perform file maintenance on the Data folder 3 Print Pressing the print button sends the data file to the installed printer An internal message appears while the data transfer Is in process and will close automatically sample can be seen in printout See Addendum B Falex recommends using the printer sold by Falex as the drivers are installed and ready
16. Disassembly Cleaning 31 Component Cleaning 31 Software Preferences 32 Maintenance 34 Charcoal Filter Replacement 34 Desiccant Cartridge Replacement 34 Pump Maintenance Prime Purge 36 Calibration 39 Thermocouple 39 Differential Pressure 40 System Pressure 41 gcc IA AA aa we 41 2 3 12 9 12 AM Table of Contents _____ O_O TS Section 8 8 1 8 2 8 3 8 4 Addendum A Addendum B Notes F10572 F400Manual indd 2 NS a eee bees 42 Software Accessible Service 42 PGI ES a 454868 s Gun ee wees ASIA WA eos bade ee ma Ge 42 Fault Indicators 42 Alarm and Warning Messages 43 Parts Listing 46 File Transfer Message 47 Blank page for customer notes 48 2 3 12 9 12 AM Forward Instructions How to Use This Manual This manual provides information and procedures to Safely install operate and maintain the Falex 400 Ther mal Oxidation Test Machine in future
17. J Ie aun OOO PSE aD d 0 pojreJ egn 19129 e 09S eJeduie eqn 19129 pe eiuoe ainssaid 194e pele Sani H 2 G ant H Isa JO Huluuibeq je peyoeuy SJUAUIW01 INH aessa uuely yw TH yw 07 UOIJIPUO9 uonduasag 2 3 12 9 13 AM F10572_F400Manual indd 43 e ice Serv Section 8 pejoeu uoo jou ejdnooouuau ainjreJ ejdnooouua8u esnez e qissog Duooes Jaye 1oay eqn 19jeeu uo dnpjinq eAisseoxe AJINIIC ejdnooouuaeu esnez e qissog SPUO98S e JOWe VOY SiluJll JO 9pisino eq 1snuJ eunje1eduue gine 07 ejdnoo ouli9u egn Je1eeH oDuey jo INC due egn J91eeH juiod 9S WOJ Oo 9c lt Oo OOL juiod 9S WOJ Jes ud ONE ISO JANE ISO nje ejdnooouJ Jeu Gwe san 1ejeoH UOIJBIA 9q dus eqn 19 28H an iej Josues ainssaJd ebexoo q Hulgn esne ejqissog puooes JOUE LOGY oJnssaeJg uleis S UBIH BAN 8 OAI 9E ISO ainsseld YBIH W JS S aIn I amp 9A 6A oJul YBO QINSSAld SNE ejqissogd puooes Jeye 1Jogqy oJnssaJg W JS S MOT BAN L ONE ISO oJnSsaJg MOT W JS S Auedoud poj p s ul jou ejdnooouueu njej wajsAs DUIIOOD esne e gissog PUO98S 1 ye yoqy ounjre4 WeISAS BUI 009 Oo 09 due u iH jeg sng uedoud poj p s UI jou ejdnooouuoau njej ulaisAs DUIIOOD esne a gissod PUO98S
18. a File Root Name is Data This can be overwrit ten Every test run has a sequential number added to the root name Once any combina tion of 99 tests are run the sequential number resets to 01 d 5 E E 4 E Es AED E n B Lab A lab name may be entered up to 15 characters in length C Operator An operator name may be entered up to 15 characters in length D Tube ID A tube ID entry is a mandatory entry The value can not exceed 15 characters The AA tube ID number can be found on the speci ST La men tube parens m E Fuel Type An fuel type may be entered up to Kom 15 characters in length imd Tem Z F Fuel ID A fuel ID entry is required It may be up to 15 characters in length F Em Emm mum G Test Temperature C Enter a temperature The test will control the temperature of the tube between 180 380 C Single breakpoint and custom test configurations allow this to be an operator entry but on ASTM tests this is a fixed value H Duration min Enter a time for the test dura tion between 9 360 minutes The timer begins once the unit has reached the temperature set point Single and custom configurations allow this to be an operator entry but is a fixed value in both ASTM tests and breakpoint tests i l Flow Rate ml min Enter a pump flow rate between 2 9 ml minute Single breakdown and custom configurations allow this to be an operator entry but it is a fix
19. al indd 21 e 2 3 12 9 13 AM lt is recommended that the user familarize themself with the software by reading this section prior to using any portion of it 3 1 Falex 400 Software Program GENERAL NOTES Various software screens have similar buttons which are discussed below HEADER Each screen has a blue shaded header The center of the header has the screen title with the date and time displayed underneath The time is shown in standard or military format depending on the user preference The headers right side may have an abort button or a home button The home button returns to the Main screen while the abort button will end the current process The invokes the software version builds on the main screen Figure 28 The invokes a reference for help on all other screens Figure 27 Screen Title Date amp Time ASTM Configuration TI Lent EIE E F400 ASTM Test Section 3 Software Operation Lower right corner buttons Usually there is a back ward arrow forward arrow or both Figure 29 The back ward 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 man datory test information entered a button pushed a tem perature value reached Lower left corner buttons Buttons in the lower left are for user assistance Figure 29 Various screens
20. ars following the cool down Follow the heater tube disas sembly procedure Section 4 to prepare the tube for rating The operator can enter a value for the tube rating and pumped fuel volume or advance without entries Figure 43 All entries are stored with 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 if is recommended that the individual test method for procedure and instructions on how to rate a tube be used ASTM Tube Rating E Tabe iD LI Tuts Aer Ia Complete screen when the unit has reached a id safe temperature to proceed The heater tube test section is extremely hot and dangerous to handle after a test has completed or aborted Keep the thermocouple in the heater tube after any test has completed or aborted until its temperature drops below 40 C Once the Figure 43 Tube Rating Screen temperature is below 40 C the unit is safe to handle B F10572 F400Manual indd 27 D Aborted Tests A test is terminated by the op erator 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 immedi ate test
21. art Up Kit continued Quantity Description Part Number Picture Sample output line assembly Fuel heater tube holder input line assembly Fuel heater tube holder output line assembly 1 DP calibration bottle 400 200 005 Heater Tubes with DP filters 1 Package of 12 and O rings 400 560 001 F10572 F400Manual indd 7 e 2 3 12 9 12 AM Section 1 General Information Start Up Kit continued Quantity Part Number Picture 1 Package of 25 O ring tubing 620 005 002 1 Package of 5 O ring Pre Filter 620 210 001 2 Beaker 1000 ml 648 400 012 1 Funnel large 648 400 003 e a Funnel filter papers 648 400 011 1 Package of 25 Pre Filter filter papers 648 400 005 1 Cleaning brush 648 400 006 1 Hex wrench 648 400 007 A Se MAR 648 400 008 stainless steel 4 Ceramic insulator 648 400 009 removal tool F10572 F400Manual indd 8 e 2 3 12 9 12 AM Start Up Kit continued Section 1 General Information Tweezers 648 400 010 1 Thermocouple fuel 650 009 055 sample 1 Thermocouple heater tube 650 009 064 Power cord 650 030 140 120VAC or 650 030 150 220VAC Pump priming syringe 650 049 021B 1 Keyboard and Mouse 650 204 048 1 otylus 650 204 065 1 Mouse Pad 657 100 019 Quality Control Certificate of Inspection F10572_F400Manual
22. be 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 2 3 12 9 12 AM Section 1 General Information OO 11 Technical Specifications Machine Weight 150 pounds Machine Footprint 16 in wide x 20 in deep x 30 in high Hecommended Working Space It is recommended that 12in be left on both sides and 6in at the back of the machine This is to allow the Lexan cover to swing and access to the USB port Include area needed for cleaning pan Machine Power 120V e0Hz 220V 50 60Hz The F400 requires a dedicated service with a ground and a breaker sufficient to supply 10 amps to the 120V units and 5 amps for the 220V units 1 2 Brief Description Of Equipment The Falex 400 Fuel Thermal Oxidation Test Machine is designed to measure the high temperature stability of gas turbine fuels It subjects the test fuel to conditions that occur within gas turbine engine fuel systems It meets ASTM D3241 IP 323 and ISO 6249 standards It is robust reliable and compact 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 The Falex 400 has been designed for years of operatio
23. e Start button to begin the heat cycle that will raise the lead assembly temperature to 350 C Once pushed the Heat button will disappear 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 5 Once the temperature is above 340 C for 1 minute to allow the lead temperature to equalize the cooling sequence will be initiated so that the eutectic temperature can be detected 6 The system will attempt to automatically detect the eutectic temperature of the lead by lowering the temperature below 327 5 C to a value of 310 C When the temperature reaches 310 C a popup display will appear It will inform the operator if the eutectic temperature detection was successfully detected or if it failed If it was successful the temperature detected will be displayed and the date it was detected and stored will be displayed The stored low temperature point from step 5 and the eutectic temperature will be moved to the thermocouple calibration factors until the next time an auto calibration
24. eaker and wipe down Hemove the sample in and sample out glass beakers Dispose of fuel appropriately according to local regulations F10572 F400Manual indd 31 section 4 Disassembly and Component Cleaning 4 3 Component Cleaning NOTICE The heater tube housing is the only component to be cleaned with Tri Solvent 1 Brush the inside of the heater tube housing with the provided cleaning brush and Tri Solvent Inspect the inner surfaces of the heater tube housing for cleanliness and repeat step 1 if needed Rinse with Iso Octane and dry using compressed air Use a wash bottle filled with Iso Octane to flush rinse all components in the pan and dry using compressed air Make certain all fuel has been removed from all components 2 3 12 9 13 AM 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 1 Accessing the Preferences screen On the MAIN SCREEN press the Preferences button Figure 50 A pop up box will appear on the screen asking for a password Enter the password and press OK to continue Access Preferences hain E Figure 50 Accessing Preferences 2 Preferences Screen After the password is entered the Pr
25. ed from the Main screen Figure 57 Flair m Access A Ciats Maintenance Screen ja Pretorences i E Miniera Accessing The Maintenance Screen F10572_F400Manual indd 36 Section 6 Maintenance 6 3 1 Prime Pump Select the Prime button on the maintenance screen Figure 58 Before beginning the Prime Pump operation be sure the sample beaker has plenty of fluid 250 mls al lows for 15 minutes of priming Attach the sample in line properly placing the filter end into the beaker Attach the sample outline and be sure there is a beaker under the properly attached sample out metal line Figure 59 Press ing the Start button begins an automated prime pump sequence he appropriate valves are open and closed as needed as can be seen by the lighted Digital Point green open red closed The pump is adjusted to a flow rate of 9 ml minute during this prime The Status bar returns feedback during the prime sequence There is no time limit to the prime sequence and the operator must press the Stop button to end the pump priming Watch the fuel flow into the outlet beaker When a steady stream is reached no air in the line the priming is suc cessful Should air pockets still be visible in the lines proceed to the purge sequence If the prime pump did remove all air pockets dispose of the fuel properly and begin testing Maintenance Li a Prime Pump Screen 2 3 12 9 13 AM 37 6 3 2 Priming Pu
26. ed value for an ASTM test fi 4 Aeration Screens Proceeding from the ASTM Aeration configuration screen the aeration screen appears Figure 38 he user has the choice to start aeration barmin Teme AE G pie or skip aeration minin Tampi Terp jC F H l Humidity PA mE 4 z ETT E E zx Apin Dapat E Fanp Pump oh DE i P CF Fix mr me leni i ere Wa E LI Aeration Screen F10572 F400Manual indd 25 D 2 3 12 9 13 AM NOTE According to D3241 aeration most take place within 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 but ton An aeration timer begins counting the 6 minutes that the aeration pump is on Bubbles will appear in the sam ple beaker from the aeration line filter Aeration rate is at about 1 5 L minute when the ball is set in the middle of the green area on the aeration flow meter on the front of the unit Adjust the meter as required Figure 39 During aera tion the sample temperature should be held between 15 32 C and the aeration humidity to no greater than 2196 Should the sample temperature or humidity be out side of this range the test will abort The current values for temperature and humidity appear in the center Data box on the screen The Digita
27. eference screen appears Figure 51 There are four areas to this screen First there is the Test Selection section to the left hand side of the screen containing seven test types a Time section containing selections for the date time format an Install Printer button for access to the Windows Control Panel for adding additional printers and a value box labeled ASTM Temp C to set the stored ASTM test temperature F10572 F400Manual indd 32 Section 5 Software Preferences TM Preferences Single Birgakreot 1 Pesaka i wees Keria 1 inatal Primer Camions F Esa ore l Se PC Time Dartam 4 i Figure 51 Preferences Screen Test Selection This section is on the left hand side of the screen containing seven box es 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 A Single test allows the user to enter all the test header information and all the test param eters A single test runs one test with these parameters They are not saved when the machine s power is cycled Breakpoint1 follows the breakpoint method described inn ASTM D3241 It is based only on the VTR visual tube reader integer value entered at the completion of each test section Breakpoint2 is a ma
28. el injury or death Using the graduations on the side of a clean beaker pour appropriate amount of fuel into the beaker per the method A minimum of 500 ml may be used Slowly add the fuel into the filter F10572 F400Manual indd 16 section 2 Setup New O ring Damaged O ring Figure 14b O ring Placement funnel until all the fuel has been placed into the filter Figure 13 Place the now empty beaker in the sample out position at the right of the sample container area 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 Figure 14a and 14b Inspect the O rings and replace if damaged or missing Connect the sample out line to the appropriate fitting on the front panel Figure 4 Once the fuel has been filtered remove the filter and dispose of it according to local regulations Remove clean and store the funnel Hotate the ring stand assembly to the left and store into the ring stand housing of test machine Figure 11 2 3 12 9 12 AM WS 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 see section 4 3 A New heater tube DP test filter and three O rings are required for each test 1 Ret
29. ential 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 gage select Thermocouple ae Fao 7 1 Thermocouple 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 63 From the Main Menu go to the Maintenance Calibrate Thermocouple display and select Auto Calib button This will reset the previous calibration factors to the default values 0 C factor 9 and 327556 factor 327 5 Ii will also call up the Thermocouple Calibration Lo Check display F10572 F400Manual indd 39 D Fan 71 1 Thermal Calibration Lo Check Prepare a low temperature standard from an ice bath of distilled water and crushed dist
30. er Area Lines Note that the sample in line is longer than the aeration line sample output line assembly 400 105 028 Aeration line assembly 400 105 002 Beaker 1000 ml 648 400 012 2 3 12 9 12 AM Thermocouple heater tube 650 009 057 Upper Bus Bar DP Filter Housing behind fuel out line Fuel heater tube holder input line assembly 400 105 004 Pre Filter assembly 400 105 010 Pre Filter Bulkhead F10572_F400Manual indd 13 Section 1 General Information OO QUT Sample Test Area Bus Bar Thermocouple 400 103 004 DP Port Out DP Calibration Line DP Port Out Heater Tube Thermocouple Retaining Clip 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 Lower Bus Bar 2 3 12 9 12 AM Section 1 General Information lt _____________ A Heater Tube Holder Assembly Hex Nut 977 438 001 Upper insulation bushing 400 018 003 O ring 650 008 002 Lower insulation bushing 400 018 003 Lower insulation bushing 400 018 003 O ring 650 008 002 Upper insulation bushing 400 018 003 Heater Tube Holder Assembly Hex Nut 977 438 001 F10572_F400Manual indd 14 Fuel heater tube holder output line assembly 400 105 005 Bypass Line part of heater tube holder assembly DP Filter Housing part of heater tube holder assembly Heater tube holder assembly 400 103 00
31. er out of the opening on the Sample In Line 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 j H 1000 mL on usage See section 7 1 for charcoal filter Aeration Line X n ME replacement instructions 2 2 Sample Area And Fuel Preparation Place Dealer Setup will take approximately 20 min 1 Place aclean empty glass beaker in the sample in position at the left of the sample container area Connect the aeration line and the sample in line to the appropriate fittings on the front panel Figure 9 Fittings should be finger tight Place the aeration and sample in lines into the glass beaker letting end of sample in line rest on bottom of beaker Plug in the sample thermocouple and place the thermocouple into the glass beaker QT Thermocouple Storage Filter Paper t Figure 11b Ring Stand Assembly F10572 F400Manualindd 15 D 2 342 9 12 AM Beaker Filter Funnel Fuels and solvents are flammable and may cause irritation to the eyes or skin Wear protective gog gles gloves and an apron 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 Stan dard Operating Procedures SOP and related in structions Failure to comply may result in person n
32. es and date for 21 Bring the bottle down from the top of the machine the last calibration of the heater tube thermocouple dif and align the fluid level in the bottle with the center ferential pressure and system pressure Figure 69 of the DP port alignment line 22 Hold the DP calibration bottle steady so the fluid level is level Hold the bottle in this position for about 1 5 minutes until the DP value on the graph remains constant 23 Press the Zero button on the screen without moving the bottle The Zero offset value on the screen should now show O and show the today s date 24 Raise the fluid level in the bottle to the 400mm DP calibration high alignment line on the machine front near the top right of the Drierite cover 25 The DP reading on the graph should be 252mmHG Calibration Factors Screen 2 5 26 The fluid bottle may now be set down on the bench top F10572 F400Manual indd 41 D 2 342 9 13 AM 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 amp 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 manual be set to flow at either 3 or 9 ml
33. ferential pressure AP All tests run 150 minutes Configuration allows for the opera tor to choose the initial control temperature between 180 380 C for the series of tests The operator enters a tube rating value for each test in the series and the program auto matically sets up the parameters for the next test Each subsequent test will automatically increment 10 C if the entered tube reading is lt 3 There is one exception to the automated temperature increase and that is on the sec ond run The operator is given the chance to reenter his starting temperature to a higher value if he feels the initial temperature setting was too low Once a reading of 3 or greater is entered the final test in the series is initiated at a temperature of 5 C below the previous run All results are compiled into a single data file F10572 F400Manual indd 24 Section 3 Software Operation TU TS NOTE Only tube rating entries of O 1 1 2 2 lt 3 3 4 and 4 are accepted for the breakpoint tube reading D Breakpoint 2 Breakpoint 2 runs a matrix of tests checking both the visual tube reading value numeric abnormal and peacock and the maximum AP value All tests run 150 minutes NOTE At the time of this printing Breakpoint 2 is not included in the test series matrix E Custom buttons 1 4 Custom 1 4 buttons allow the user to store both the test header in formation and the test parameters as a unique test name Thi
34. for damage Allow the lead calibration check assembly to cool Repeat the calibration If the thermocouple fails to capture a satisfactory eutectic temperature detection again it should be replaced Real Time Temperature Thermocoupie Calibration Hi Check IE ritu G Lm Thermocouple Hi Check Screen 2 Differential Pressure T Falex 400 must be on for at least 30 minutes before following this procedure Fill the calibration bottle 94 full with fuel Be sure the sample out line is in place and empties into a beaker The aeration and sample in lines can remain in place or they can be closed by attaching nuts to the bulkhead fittings The heater tube and prefilter assemblies are not used for this calibration and need to be removed Place a nut over the bulkhead where the prefilter assembly attaches to the unit Cap the DP bulkhead but leave the DP port open Get to the DP Calibration screen from the Main screen by the following sequence of buttons Maintenance Calibration DP Upon entering the DP Calibration screen press START 2 3 12 9 13 AM Section 7 Calibration OO 7 Open the Bypass valve by pushing the Bypass 27 Press the Done button on the screen Valve button on the screen until it appears green SATE TEE NAA AIDA NA 29 Attach nuts to the DP and DP bulkheads or reattach the heater tube assembly Leaving the 8 Close the System Vent by pushing the System Vent button on the screen until i
35. for use upon power up Should a different printer be used refer to the Preference section of this manual to install a printer Advisory Lor tad LTD File Transfer Message F10572 F400Manualindd 29 D 4 Copy Copy opens Windows Explorer Navigate to the Data folder under the root directory 400 C This folder contains all the data files that have been transferred Close Windows Explorer when copying is complete For copying to external devices there are three USB ports and one Ethernet port located on the 400 Two USB ports and the Ethernet port are on the convenience outlet on the back panel One USB port is located on the front of the unit directly above and to the right of the drierite window NOTE Do not delete or rename the Data folder or data transfer will not occur and test data information will be lost 2 3 12 9 13 AM section 4 Disassembly and Component Cleaning 9 Remove the test section assembly 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 Discard the used O ring and the DP filter Fuels and solvents are flammable and may cause irritation to the eyes or skin Wear protective gog 12 Remove the hex nuts and the upper insulator gles gloves and an apron avoid contact with skin eyes and clothing Use in well ventilated
36. g QT Tube Aligned With Top of QUIE Fuel Out and Fuel Bypass Lines Bus Bar F10572 F400Manual indd 19 e 2 3 12 9 13 AM Section 2 Setup lt _ lt EEE II A 16 Begin assembling the pre filter by placing the Place the lower housing onto the upper housing pre filter O ring on the lower housing Figure 23 Line up the screw holes on the upper and lower housings and insert the screws through the lower housing into the upper housings Figure 23 Finger tighten the screws with the hexagon wrench 17 Place the pre filter screen into the upper housing Figure 23 18 Using clean tweezers remove a new pre filter filter 19 paper from the protective case and place onto the pre filter screen Inspect the O ring on the end of the pre filter assembly Replace the O ring if missing or damaged NOTE There are two blue paper spacers 20 between each pre filter filter paper Do not use blue spacer paper Use only the white pre filter element Use of the blue spacer paper will cause the test to fail Connect the pre filter assembly to the pre filter bulkhead fitting and finger tighten Figure 24 Pre Filter Screws Lower Pre Filter Housing Pre Filter O ring Pre Filter Bulkhead Fitting Pre Filter Assembly Pre Filter Paper Filter Pre Filter Metal Screen Upper Pre Filter Housing Fuel Input Line QT Pre Filter Components Gains Attaching the Pre Filter Assembly F10572 FA00Manual indd 20 e 2 3 12 9
37. illed water ice an insulated cup works best Place the heater tube thermocouple in the ice bath Stir the thermocouple in the bath watching the tube temperature on the display Figure 64 Continue stirring until the tube temperature no longer drops and holds constant for 20 30 seconds Press the Accept button This will store the observed low temperature and will initiate the Thermocouple Hi Check display The thermocouple reading should be accepted if the displayed value is 0 1 C 2 C Should the thermocouple not reach this value verify the ice bath is not contaminated If it still will not reach an acceptable value replace the thermocouple Thermocouple Calibration Lo Check Current Thermocouple Reading linecrected Tampar Bor Papa LEE a2 E Thermocouple Lo Check Screen 7 1 2 Thermocouple Calibration Hi Check Install the lead calibration check assembly in the upper lower bus bars Make sure the top of the assembly is flush with the top of the upper bus bar and that the bus bar screws are tight Manual insertion and removal of the thermocouple is required during the Hi Check Care should be taken during all Steps as the bus bars are extremely hot and can carry high current Only insert and remove the thermocouple by the insulated leads Insert the heater tube thermocouple through the top bus bar into the assembly so that the thermocouple is in contact with the lead 2 3 12 9 13 AM 3 Push th
38. indd 9 2 3 12 9 12 AM Section 1 General Information 1 4 Getting To Know The Falex 400 Front USB Slot DP Calibration High Alignment Line Desiccant Chamber Door RE ico LM Resettable Fuses i On Off Switch Touch Screen Interface ri M E Air Flow Meter L Ring Stand 5 Assembly te Coolant K Flow Meter 2 NE x Eu DP cdi Calibration Fal Alignment Sample Line Container Area iy sample ae Test Area Pump Priming Door FALEX 400 lt Figure1 Fuel Thermal Oxidation Tester Front F10572 F400Manualindd 10 D 2 3 12 9 12 AM Section 1 General Information me Fans DO NOT BLOCK Interface Panel USB 2 Ethernet 1 Circuit Breaker Power Plug Receptical GEES Rear of the Falex 400 120V Unit Fans DO NOT BLOCK Interface Panel USB 2 Ethernet 1 Circuit Breaker Power Plug Receptical Witte Rear of the Falex 400 220V Unit F10572 F400Manual indd 11 e 2 3 12 9 12 AM Section 1 General Information sample input line assembly 400 105 020 Thermocouple fuel sample 650 009 055 Beaker 1000 ml 648 400 012 Aeration line assembly 400 105 002 Sample output line assembly 400 105 028 sample input line assembly 400 105 020 F10572 F400Manual indd 12 1000 mL KIN Ax ONELE APPRCSIM TE VOLUMES E Sample Container Area M Figures Sample Contain
39. ions How to Use This Manual FLAMMABLE HAZARD This symbol indicates the products used are flammable CAUTION OR WARNING SYMBOL This symbol indicates a general warning or caution A caution is important for protecting the equipment and performance A warning is important to protecting yourself others and the equipment Falex 400 General Safety Warnings Fuels and solvents are flammable and may cause irri tation 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 Hazard ous Materials Identification System HMIS ISO 9000 Lab Standard Operating Procedures SOP and related instructions Failure to comply may result in personnel injury or death F10572 F400Manual indd 4 Desiccant 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 Sys tem HMIS ISO 9000 Lab Standard Operating Proce dures SOP and related instructions Failure to comply may result in personnel injury or death The heater tube test section can reach high temperatures of 180 C 380 C during a test based upon test configuration Always place bus bar cover over the heater tu
40. is reached Likewise if the temperature is not held within two degrees of the set point a system abort will be triggered When the set point temperature is reached Indicated in the Temperature box on the right the test run timer starts The bus bars are cooled once heating of the tube begins The coolant flow meter should be adjusted to 10 gal hr flow Figure 39 The bar at the bottom of the screen gives graphical feedback of the test run time Figure 41a The button on the top right will open a graph with the DP system pressure and heater tube temperature overlapping Figure 41b 2 3 12 9 13 AM Section 3 Software Operation ASTM Tesi ae Pade Lee Frais Hs Tite Together ii Sesi MPa OF eee ASTM Graph System pressure and heater tube temperature 10 Test Completion Tests either complete or they fail due to operator aborts failure to meet or maintain operational requirements such as pressure loss failure to maintain temperature or excessive bus bar temperature Following test completion or failure a safety screen a Fac appears halting program advancement until a safe handling temperature is reached at the heater tube thermocouple Figure 42 The Tube Temperature timer bar will disappear from the Test Test Completed Tabi Tap CHEO O F QUI Test Completion Screen Waiting For Tub Temperature To Cool Tube Rating Upon a successful test comple tion a tube rating screen appe
41. ivot O ring DP Filter Housing on the screw Figure 19 TO remove any fuel that may have seeped on to the bus bars clean the bus bar contacts and bus bar caps focusing on the portions that comes in contact with the heater tube Attach Fuel Out Line Onto Assembled DP Housing Fuel Out Line Assembled Test Section Removing Right Bus Bar Screw and Loosening Left Screw F10572 F400Manualindd 18 D 2 342 9 13 AM 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 Bus Bar Caps Bus Bar 12 Install the assembled test section into the Contacts sample test area Figure 20 Place the assembled test section in the groove between the bus bar contacts and bus bar caps serial number side up Insert both right hand retaining screws and loosely finger tighten Heater Tube 13 Align the top of the heater tube so that it is flush with the top of the bus bar contact Figure 21 Assembled 14 When the test section is properly aligned tighten Test Section the upper and lower bus bar screws with the hexagon wrench provided 15 Attach the fuel out line to the DP fitting and fuel bypass line to the DP fittings Figure 22 Finger tighten the fittings Fuel Out Line To DP Fitting Fuel Bypass Line To DP Fittin
42. l Points then displays status within the system during aeration The Status button in the lower left corner opens a pictorial screen of the F400 showing live values of critical measurements Figure 40 5 The test will automatically begin after the 6 minute fuel aeration As the sample is being aerated the previous runs fuel is purged from all lines and valves Aeration Flow Meter Coolant Flow Meter AERATION COOLANT Figure 39 Aeration Coolant Meters F10572 F400Manual indd 26 Section 3 Software Operation Bos Bar Tarp E Ce IL ZET EH Tube Terap PC Status Screen During the aeration inspect all fittings in the sample test area for leaks If leaks are found re tighten using fingers only Test Screens These screens remain open the duration of a test The Pressure box in the lower right indicates the system pressure and the DP value Tests run at 3 45MPa 10 Once system pressure is reached the heater will commence It is recommended that the operator watch for leaks during this pressurization When leaks are visible abort the test tighten all fittings and restart the test Should the unit not reach required pressure within 180 seconds the system will abort After the required pressure is reached the heater tube temperature will increase A system abort will automatically happen if the heater tube temperature set point is not reached within 90 seconds after the 3 45MPa pressure
43. lled replace desiccant cover and install six screws to secure Desiccant Housing Retainer Clips Desiccant Cartridge Inlet Outlet Ports Rubber Bushings Desiccant Cartridge Housing F10572 FA00Manual indd 35 e 2 3 12 9 13 AM 6 3 Pump Maintenance Fuels and solvents are flammable and may cause irritation to the eyes or skin Wear protective gog gles gloves and an apron 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 Stan dard Operating Procedures SOP and related in structions Failure to comply may result in person nel injury or death Air in the lines is indicated by visible air pockets in the sample output line the lack of fuel being expelled or the lack of a steady stream of fuel expelled through the sample out line while the pump is running assuming fluid is in the sample beaker and the supply in line is properly installed It is recommended the first attempt to free the system of air is to run the automated Prime If after running the Prime for 2 3 minutes and a steady fluid flow is not achieved the automated Purge should be used Should the Purge not produce a steady flow the manual prime pump method can be used Access the automated methods thru the maintenance software screen The Maintenance screen is access
44. min for this service screen And live feedback is seen 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 pressure transducer service a Faw Sere Tim FOR Vars Clase OF Meg Less LP Poa Service Screen Reached From The Maintneance Screen at n Service VO amp Variables SHE E fa rm M M I O amp Variable Screen F10572 F400Manual indd 42 4 Section 8 Service O 3 Close DP Pos Pressing this button manually operates the DP positive 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 pressure transducer 4 Factory his is a protected area for the authorized users only 8 2 Alarm Log Figure 72 Pressing the alarm log button displays the last 25 warnings and abort alarms 8 3 Fault Indicators On the front of the Falex 400 are 7 indicator lights If a fuse trips an indicator light will be visible with the description of the problem area Cycle the power on the unit and restart the procedure that caused the fault The fuse should have reset If the indicator light comes on again contact the Falex service department Alarm Log a Feta Listing of most current ala
45. mp 6 3 2 1 Manual Method Although not the recommended method the pump and lines may be primed manually 1 Open the sliding door in front of the pump by gently pressing the black handle in and sliding the door to the left Figure 60 2 Place a towel under the two pump heads 3 On the main screen select the MAINTENANCE F10572 F400Manual indd 37 Section 6 Maintenance A On the maintenance screen select PRIME 4 Press the PRIME button 5 Insert an empty plastic 10 ml syringe into the pump priming port at the center of the black priming port knob Figure 61 Rotate black priming port Knob counterclockwise and suction fuel out of the pump priming port by pulling in the syringe plunger Allow 6 8 ml fuel to fill syringe Close the black priming port knob by turning clockwise Remove the syringe from the black priming port Knob and dispose of fuel appropriately Black Handle QUT Opening the Door to Prime the Pump Black Priming Port Knob Plastic Syringe Two Pump Heads Y Figure 61 Priming the Pump 2 3 12 9 13 AM Section 6 Maintenance TM 6 3 3 Purge The Purge cycle should be performed the first time the Falex 400 is started whenever the unit has sat unused for 30 days or more or whenever there is air in the lines and the prime pump sequence failed to remove all the air select the Purge button from the maintenance screen Figure 58 Before beginning the Purge Pump operation be
46. n It provides traceability long maintenance intervals and reliable results Other features of the Falex 400 e Automatic aeration and fuel sequence during an ASTM D3241 test e Priming is simple with easy access and processor control e Certified thermocouples guarantee accuracy his machine utilizes Falex Heater Tube specimens Falex certifies these tubes meet all of the ASTM D3241 requirements for dimensions surface finish and material Falex has proven to meet the requirements of ASTM D3241 through participation and successful completion of an ASTM sactioned equivalency program Falex Corporation does not guarantee any specific test results or desired functionality of this equipment outside of its intended usage F10572 F400Manual indd 5 D 2 3 12 9 12 AM Section 1 General Information 1 3 Packing List 1 The following items are included in the package e Falex 400 Thermal Oxidation Stability Tester e 1 Start Up Kit e 1 CD Manual Table 1 Start Up Kit Contents Picture Quantity Description Part Number 1 Package of 2 Pack of insulation bushings 400 018 003 1 Bus Bar Drip Pan 400 021 006 1 Package of 5 Charcoal filter 400 025 002 1 Package of 2 Metal Pre Filter screen 400 027 003 4 Heater tube holder 400 103 009 assembly 1 Aeration line assembly 400 105 002 F10572 F400Manual indd 6 YA 2 3 12 9 12 AM Section 1 General Information St
47. nce the temperature is below 40 C the unit is safe to handle Mal Ti Access Test oleection Screen Figure 31 Main Screen In Ready State pe revo ll Temperature must be pd WA below 40 C ic uL LL te ied bi oe i before Run Test button appears Dinka Praterences AM Meniru naa GK Main Screen Waiting For Heater Tube Temperature to Lower 2 3 12 9 13 AM 2 Test Type Screen This screen has the possibility of eight different test types to choose from Figure 33 The D3241 ASTM test is always active and the button cannot be deactivated Single Breakpoint 1 Breakpoint 2 and the 4 Custom tests are activated from the Preference screen Test Type ae Fa Ca Active QUE New Screen Shot A ASTM A D3241 test commences following the mandatory test information entry All tests are 150 minutes with a flow rate of 3ml minute These values cannot be altered The tem perature default to the value set under Prefer ences and can only be altered through the Preferences screen B Single tests This selection allows the opera tor to set parameters for test duration flow rate and test temperature for one run The param eters entered are not stored C BreakPoint 1 Breakpoint 1 runs a series of automated tests sequencing from the visual tube reading numeric value only It does not consider the visual tube reader entry of abnormal or peacock and does not consider the dif
48. or skin Wear protective goggles gloves and an apron 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 Pro cedures SOP and related instructions Failure to comply may result in personnel injury or death QT Desiccant Cartridge Mounted In Housing F10572 F400Manual indd 34 D 2 342 9 13 AM Section 6 Maintenance PD mw aaaaaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAaAEN 4 Grasp the desiccant cartridge with one hand and pull the desiccant cartridge straight out of the machine If rubber bushings are attached to desicant filter remove and replace in machine Figure 55 Properly dispose of used desiccant cartridge 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 QUITE Desiccant Cartridge maintenance screen Push the aeration button Verify the humidity level is dropping If it is not the dessicant is not seated correctly in the rubber bushing Remove dessicant cartridge reposition rubber bushing and reinstall cartridge 8 Once the cartridge is properly insta
49. rieve a new heater tube kit from the box of specimens 5 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 6 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 f configuration setup the riveted end down and the tube ID number closest to the DP filter housing Secure the heater tube to the top of the heater tube housing using the lower insulator bushing with the flare facing end of tube O ring supplied in the heater tube kit upper insulator bushing and hex nut Figure 15 Finger tighten loosely Position the heater tube inside the housing by looking though the fuel discharge hole DP filter housing and centering the heater tube shoulder in the hole so that the shoulder is lined up with the center of the bypass line Figure 16 oecure the heater tube to the bottom of the heater tube housing using the lower insulator bushing with flare facing the end of the tube O ring supplied in heater tube kit upper insulator bushing and hex nut Finger tighten loosely Finger tighten the hex nuts on both ends of the heater
50. rms 2 3 12 9 13 AM e ice Serv Section 8 8 4 Alarm and Warning Messages ane dund 574 Yo paiamod dund 214H ainyiey INH YOMIEN peijoeuuoosip 9 9829 XIOMION Gsne a gissodg duund pue Je oJjuoo U98M 9Q anje uoneoiunuJuJoo duung oJnjIe UJUJO jeas duung ones uoneoiunuJuJo 2 duung Aeldsip uo Yong uoge IY 10 218d0 esne e gissogd 139 SAI Oe 10 seoi ep Buluuni Aue dois 0 ueaJosuono WO pereiiu 1oqy peieniu 101219dO 1J0qy 101219d0O OInjelodweg WOOL Je JOU Jon Sinje ejdnoo ouuau A nodod pej pejsul JOU ejdno20uua8u esne 9 qISSO sees e lt gt us SOLE Jo icy eun 41 De INC duel jenJ ejduueg Jo CE Jo St uoneJov eJoduJe enJ ajdwes O9S JO SHIWI JO 9DISINO 99 snw nd Uul9 uoneJjee Buunp pexo99u2 yea ainssaid UIU e Ul eunssaJg Wels 150 ains AN ee Cd WalsAS U9 9H OI Ie BAN LE Jaye UIW S914 U9 9H OI ANJE 1501 Jo Duiuui amp eq 1e payoeuD ISAS UO9EO9H OI IE He ulu d U9 9H O 8eJn re onje 191284 uedoud pejjejsul jou ejdnooouu JOY ene 9 gISSOJ SUOdE due yoeeu POA8IU9E eimjeJedue uses 1S8 esiMJeujo OUI POHOP UIUIIM o1 pere eani apoy 0 dS lt De dS gt sseJd Joye 01 poire eani Jejeori oDueiJ UIUIM eq snu eunjyejed Pel 99S 06 i Ul9 pe aluoe mnss Id 194e Isa JO Huluuibeq ye peyoeuy eqni 49 e2au ui jou ejdnoo peAeluae ouuau Ayeodoid pejjejsul jou S OL Ul 2 GBSIH ssoeJd 19 9SIH O
51. s information is retained with the button selection until it is overwritten Select ing a test type will advance to the respective configuration screen Configuration Screens All test types require configuration prior to starting Data File Root Name Lab Operator Tube ID Fuel Type and Fuel ID fields can be entered by the operator however tube ID and the Fuel ID must be entered before the configuration screen will display a forward arrow allowing program advancement Figure 34 Some test configurations allow for entry of test duration flow rate and test temperature All four custom configuration screens have one additional entry field for the button name Information entered in the Configuration screens is considered the header for the generated data files and will appear on both the printed report and the electronic file The back arrow at the bottom right returns to the Test Type screen The forward arrow on the bottom right will only appear once the mandatory configuration information has been entered The Instructions button on the lower left opens a window with generic instructions for setting up and running a test Please refer to the method for specific instructions AT IM Serigar alter TER ASTM Configuration Screen 2 3 12 9 13 AM A Data File Root Name Ihe Data File Root Name can be entered maximum of 6 charac ters or left with the default value Every time any configuration screen is entered the Dat
52. sure the sample beaker has at least 400 mls 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 metal 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 expell 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 aire Purge Screen Following a successful purge all air should be removed from the lines Dispose of used fuel properly and be gin tests F10572 F400Manual indd 38 D 2 342 9 13 AM 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 dif ferential 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 dif ferential pressure is the measurement across the DP test filter Excessive differ
53. t appears red 9 Attach the calibration bottle to the DP port on the bulkhead fitting open to atmosphere will cause Falex 400 fuel to drain from the unit which may cause pump damage if the unit is run without proper priming 10 Set and leave the bottle on the top of the machine and purging 11 Open the DP Vent on the screen by pressing the DP button until it turns green Live DP Reading 12 Wait until the DP value on the screen holds steady approximately 50 mls have run out of the bottle and into the outlet beaker DP Calibration JL IE E 13 Close the Bypass Valve on the screen by pressing the Bypass Valve button until it turns red 14 Close the DP vent on the screen by pressing the DP button until it turns red fern tte i rrHE az 15 Leave the bottle on top of the Falex 400 E E Eero Dana 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 DO NOT CAP THE DP PORT DP Calibration Screen 18 Open the DP vent on the screen by pressing the DP button turning it green 7 3 System Pressure 19 Wait until the DP value on the screen holds steady approximately 50 mls have run out of the bottle This calibration is to be factory trained personnel only and into the outlet beaker Figure 68 20 Close the DP vent by pushing the button on the 7 4 Factors screen turning it red Factors displays the most recent valu
54. termination and which alarms initiate only a warning message 2 3 12 9 13 AM Section 3 Software Operation a 3 3 Data 1 View This initiates a display of the printout information from the last run test There are two Data The Data screen is accessed from the Main screens The first View Data General screen screen Figure 44 or it will automatically appear at the displays test information on the test Figure 46 completion of a successful test The Data menu allows Press the forward arrow to advance to the View the user to retrieve the data file from the last test whether Data Pressure screen to see the DP readings successfully completed or not taken every 30 minutes during the test Figure 47 NOTE lf the Falex 400 has had a power cycle since the last test data transfer cannot be performed Ke Dala General Flers re pri tomen Ia 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 Figure 45 he 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 tem perature 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
55. tir ee ur lE dine en he acre vel A epee re Additional pages P Ae he gaian t i he CE PEINE E thee Fle ERE a Figure 30 Additional Page Arrow on Instruction Pages Throughout various screens will be factory buttons Factory buttons are solely for the use of authorized factory personnel and access to this area is protected 3 2 Run Test If this is the inital setup or if the unit has not been operated for 15 days it is recommended that the automated Purge be run prior to any tests being performed on the unit Refer to section 6 3 2 F10572 F400Manual indd 23 The RUN TEST menu allows users to choose various test types and record the visual tube reading The test data can be viewed printed and or stored after a suc cessful test completion 1 Accessing the Test Type screen On the MAIN SCREEN press the Run Test button Figure 31 If this button is not visible there will be a temperature bar in its place Figure 32 This bar shows the current heater tube thermocouple temperature and will not allow an operator to start a new test until the temperature drops below 40 C at which time it is safe to remove the old heater tube and set up for a new test The heater tube test section is extremely hot and dangerous to handle during and after a test has completed or aborted Keep the thermocouple in the heater tube after any test has completed or aborted until its temperature drops below 40 C O
56. trix method used to determine the fuel s breakpoint but takes into consideration the VIR readings with the A abnormal and P peacock attributes and the DP value The only test parameter the user may enter is the starting temperature There are four custom tests the user can choose Each Custom test allows the user to enter all the test header information and the test parameters Once they are entered they are stored in the unit even through power cycles Time On the right hand side of the Prefer ences 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 2 3 12 9 13 AM Section 5 Software Preferences TS C Install Printer Pressing the Install Printer button will initiate the Windows Control Panel Select the Printers and Faxes icon in the Window s Control Panel and then select Add Printer Users can also install a printer driver from a flash drive Printer drivers 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 amp Time Once you have set the correct date and time cycle the power by turning the unit off and then on E ASTM Temperature his is where a default test temperat
57. ure can be stores for all ASTM tests For instance some specifications require 270 C rather than the default value of 260 C F10572 F400Manual indd 33 D 2 342 9 13 AM Section 6 Maintenance lt q 6 1 Charcoal Filter Replacement Desiccant Cover To prevent equioment contamination the charcoal filter must be changed monthly 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 left side of the beaker stand Figure 52 4 Properly dispose of the charcoal filter 5 Slide a new charcoal filter into the slot on the left side of the beaker stand QI Desiccant Cartridge Location DO NOT use the ethernet port in the desiccant chamber It is for use by Falex technicians only 1 Change the desiccant cartridge when 75 90 most of the desiccant granules turn from blue to pink 2 Be sure the Falex 400 is powered off Locate the desiccant cover on the front of the Falex 400 Figure 52 Charcoal Filter Figure 53 3 While holding the desiccant cover in place use a flat tipped screwdriver to loosen six flathead 6 2 Desiccant Cartridge Replacement screws until the cover can be removed Figure 54 These screws are captivated and will not come pum apart from the cover Desiccant may cause irritation to the eyes

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