FALEX 400 User manual

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

1Table of Contents
Page
Forward Instructions–How to Use This Manual ......................3
Safety, Safety Label Descriptions and Hazardous Areas
of Test Machine .........................................3
Section 1 General Information ....................................5
1.1 Technical Specications ..................................5
1.2 Brief Description of Equipment .............................5
1.3 Packing List ............................................6
1.4 Getting To Know The Falex 400 ............................10
Section 2 Setup ................................................15
2.1 Initial Setup ...........................................15
2.2 Sample Area and Fuel Preparation .........................15
2.3 Instrument and Test Conguration ..........................17
Section 3 Software Operation ....................................22
3.1 Falex 400 Software Program ..............................22
3.2 Run Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23
3.3 Data .................................................28
Section 4 Disassembly and Component Cleaning ...................30
4.1 Heater Tube Disassembly ................................30
4.2 Continued Unit Disassembly Cleaning ......................31
4.3 Component Cleaning ....................................31
Section 5 Software Preferences ..................................32
Section 6 Maintenance ..........................................34
6.1 Charcoal Filter Replacement ..............................34
6.2 Desiccant Cartridge Replacement ..........................34
6.3 Pump Maintenance (Prime, Purge) .........................36
Section 7 Calibration ...........................................39
7.1 Thermocouple ....................................39
7.2 Differential Pressure ...............................40
7.3 System Pressure ..................................41
7.4 Factors .........................................41

2
Section 8 Service ..............................................42
8.1 Software Accessible Service ..............................42
8.2 Alarm Log ............................................42
8.3 Fault Indicators ........................................42
8.4 Alarm and Warning Messages ............................43
Addendum A Parts Listing ..........................................46
Addendum B Printed Report Example ................................47
Notes: (Blank page for customer notes) .........................48
Table of Contents

3Forward: 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 referred 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.
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
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,
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.
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.
CAUTION
or
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.
WARNING
ELECTRIC SHOCK
HAZARD.
This equipment is to be
serviced by trained
personnel only.
or
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.

4
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
WARNING
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.
WARNING
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.
WARNING
The heater tube test section can reach high
temperatures of 180– 380 °C during a test based upon
test configuration. 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.
Forward: Instructions–How to Use This Manual

5Section 1: General Information
1.1 Technical Specifications
Machine Weight: 150 pounds
Machine Footprint: 16¾ in wide x 20¼ in deep x 30 in high
Recommended 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/60Hz 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 operation,
it provides traceability, long maintenance intervals, and
reliable results.
Other features of the Falex 400:
• Automatic aeration and fuel sequence during
an ASTM D3241 test
• Priming is simple with easy access and
processor control
This 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 sanctioned equivalency program.
Falex Corporation does not guarantee any specic test
results or desired functionality of this equipment outside
of its intended usage.

6
Section 1: General Information
1.3 Packing List
1. The following items are included in the package:
• 1 Falex 400 Thermal Oxidation Stability Tester
• 1 Start-Up Kit
Table 1: Start-Up Kit Contents
Quantity Description Part Number Picture
1 Package of 2 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
1Heater tube holder
assembly 400-103-009
1Aeration line assembly 400-105-002

7
Quantity Description Part Number Picture
1Sample output line
assembly 400-105-028
1Fuel heater tube holder
input line assembly 400-105-004
1Fuel heater tube holder
output line assembly 400-105-005
1Pre-Filter assembly 400-105-010
1 Sample input line assembly 400-105-020
1Lead calibration holder with
melted lead 400-108-004
1 Falex 400 Manual CD 400-112-001
1DP calibration bottle 400-200-005
1 Package of 12 Heater Tubes with DP filters
and O-rings 400-560-001
Section 1: General Information
Start-Up Kit continued

8
Quantity Description Part Number Picture
1 Package of 25 O-ring tubing 620-005-002
1 Package of 5 O-ring Pre-Filter 620-210-001
2Beaker, 1000 ml 648-400-012
1Funnel, large 648-400-003
1 Package of
100 Funnel filter papers 648-400-004
1 Package of 25 Pre-Filter filter papers 648-400-005
1Cleaning brush 648-400-006
1Hex wrench 648-400-007
1Cleaning pan,
stainlesssteel 648-400-008
1Ceramic insulator
removaltool 648-400-009
Section 1: General Information
Start-Up Kit continued

9
Quantity Description Part Number Picture
1Tweezers 648-400-010
1Thermocouple - fuel
sample 650-009-055
1Thermocouple - heater tube 650-009-064
1Power cord 650-030-140 (120VAC)
or 650-030-150 (220VAC)
1 Pump priming syringe 650-049-021B
1 Keyboard with Touchpad 650-204-048
1Stylus 650-204-065
1Quality Control Certificate
of Inspection FalexCorporation |1020Airpark Drive, Sugar Grove, IL 60554 USA |[phone] |f: [phone] |www.falex.com
Material: 316Stainless Steel
Form number: 400 - 111- 0 0 6
CERTIFICATE OF INSPECTION
Tube Kit p/n400-560-003
The enclosed test pieces haveb een inspected and meet
the following requirements:
Material: 316Stain less Steel
QA Manager: ______________________________ Date: ___________
Manufacturedin conformance with:
ISO 9001:2000
USA: (630) 556 -3669 |sales@ falex.com Europe:[phone] |[e-mail]
Oxidation
Stability Apparatus
Tub e Ki t
p/n400-560-003
F10617_PackagingInsert.indd 1 3/1/11 10:09 AM
Start-Up Kit continued
Section 1: General Information

10
Section 1: General Information
Touch Screen
Interface
Sample
Container
Area
Ring Stand
Assembly
Pump Priming
Door
Air Flow Meter
Coolant
Flow Meter
Desiccant
Chamber
Door
Front USB
Slot
Sample
Test Area
DP+
Calibration
Alignment
Line
Figure 1 Fuel Thermal Oxidation Tester–Front
1.4 Getting To Know The Falex 400
DP Calibration
High Alignment
Line
On/Off Switch
Fault Indicators
(Resettable Fuses)

11 Section 1: General Information
Figure 2 Rear of the Falex 400 120V Unit
Figure 3 Rear of the Falex 400 220V Unit
Interface Panel
USB (2)
Ethernet (1)
Circuit Breaker
Circuit Breaker
Power Plug
Receptacle
Power Plug
Receptacle
Interface Panel
USB (2)
Ethernet (1)
Fans — DO NOT BLOCK
Fans — DO NOT BLOCK

12
Section 1: General Information
Figure 4 Sample Container Area
Figure 5 Sample Container Area Lines Note that the
sample-in line is longer than the aeration line.
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
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

13 Section 1: General Information
Figure 6 Sample Test Area
Thermocouple
- heater tube
650-009-064
Fuel heater tube holder
input line assembly
400-105-004
Upper Bus Bar
Pre-Filter assembly
400-105-010
DP Filter Housing
(behind fuel out
line)
Pre-Filter Bulkhead
Bus Bar Thermocouple
400-103-004
Fuel heater tube holder
output line assembly
400-105-005
DP- Port (Out)
Fuel Bypass Line
Part of 400-103-009
Heater Tube
Thermocouple
Retaining Clip
Heater tube holder
assembly
400-103-009
DP+ Port (Out)
DP+ Calibration Line
Lower Bus Bar

14
Section 1: General Information
Fuel heater tube holder
output line assembly
400-105-005
Bypass Line (part of
heater tube holder
assembly)
Upper insulation bushing
400-018-003
Heater Tube Holder
Assembly Hex Nut
977-438-001
Lower insulation bushing
400-018-003 DP Filter Housing
(part of heater tube
holder assembly)
Heater tube holder
assembly
400-103-009
Lower insulation bushing
400-018-003
Upper insulation bushing
400-018-003
O-ring
650-008-002
O-ring
650-008-002
Heater Tube Holder
Assembly Hex Nut
977-438-001
Figure 8 Components For Assembly of Prelter
Figure 7 Components For Assembly of Test Section Area
Lower Pre-Filter Cover Assembly
400-105-014
Upper Pre-Filter Cover Assembly
400-105-021
O-ring Pre-Filter
620-210-001
Fuel heater tube holder
input line assembly
400-105-004
Pre-Filter filter paper
648-400-005
Pre-Filter Screws
870-190-063
Metal Pre-Filter screen
400-027-003

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 withground.
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.
2.2 Sample Area And Fuel Preparation
Setup will take approximately 20 min.
1. Place a clean, 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.
NOTE: The sample thermocouple can be stored in the hole
at the left of the beaker area when not inuse [Figure10].
2. Grasp the ring stand assembly and pull from the
housing [Figure11a]. After the ring stand assembly is
fully extended from the housing, rotate to the right to
lock into position [Figure11b].
3. Place the funnel into the ring stand and place a
clean filter paper into the funnel [Figure12].
Glass Beaker
Aeration Line
Sample-In Line
Sample
Thermocouple
Figure 11a Ring Stand Assembly
Figure 11b Ring Stand Assembly
Figure 10 Thermocouple Storage
Funnel
Filter Paper
Ring Stand
Figure 9 Sample-In Beaker Area
Figure 12 Funnel/Filter Setup

16
Section 2: Setup
WARNING
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.
4. 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/
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.
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 [Figure14a 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 [Figure4].
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
[Figure11a].
Beaker
Filter/Funnel
Figure 13 Filtering Fuel
Figure 14a O-ring Inspection
Figure 14b O-ring Placement
New O-ring Damaged O-ring

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
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.
5. 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].
6. Secure 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.
7. Finger tighten the hex nuts on both ends of the
heater tube housing firmly.
NOTICE: Overtightening will break the ceramic
bushings and can cause leaks.
Figure 15 Heater Tube Installation Components Figure 16 Heater Tube Position
Heater Tube
Housing
Heater Tube
Lower Insulator Housing
O-ring
Upper Insulator Brushing
Hex Nut
Heater Tube
Shoulder

18
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 [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
the left retaining screw of each bus bar cap
using the hex tool, so that the cap is free to pivot
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.
Figure 19 Removing Right Bus Bar Screw
and Loosening Left Screw
Figure 17b DP O-ring Installation
Figure 17a DP Filter Installation
Figure 18 Assembled Test Section
DP Filter Housing
DP Filter Housing
O-ring
DP Filter
Fuel-Out Line
Attach Fuel-Out Line Onto
Assembled DP Housing
O-ring

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.
12. Install the assembled test section into the
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.
13. Align the top of the heater tube so that it is flush
with the top of the bus bar contact [Figure21].
14. When the test section is properly aligned, tighten
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+
Fitting
Figure 22 Fuel-Out and Fuel Bypass Lines Figure 21 Tube Aligned With Top of
BusBar
Figure 20 Inserting Test Section Installation
Bus Bar
Contacts
Bus Bar Caps
Heater Tube
Assembled
Test Section