FALEX 400 Fuel

Thermal Oxidation
Test Machine
Operation and Maintenance Manual

Falex Corporation    1020 Airpark Drive    Sugar Grove, IL 60554    630.556.3669 www.falex.com
VER 1.1 (1-6-12)

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1 Table 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 Specifications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 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 Configuration . . . . . . . . . . . . . . . . . . . . . . . . . . 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

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Table of Contents 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 File Transfer Message . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 47

Notes: (Blank page for customer notes) . . . . . . . . . . . . . . . . . . . . . . . . . 48

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3 Forward:  Instructions–How to Use This Manual

This manual provides information and procedures to Machine Safety Labels

safely install, operate, and maintain the Falex 400 Ther-
mal Oxidation Test Machine, in future refered to as Falex
and Manual Safety Callouts
400. For your own safety and protection from injury, care- The following are safety labels placed in areas on the
fully read, understand and observe the safety instruc- test machine that may be hazardous to the operator.
tions described in this manual. These same symbols may be used in the manual to bring
attention to safety concerns. Please take caution and
Keep this manual with the machine. If you lose this
understand what these labels indicate before operating
manual or need an additional copy, please contact
the test equipment.
Falex Corporation.

The information contained in this manual was based on CAUTION

machines in production at the time of publication. Falex
Hot Surface.
Corporation reserves the right to change any portion of   or
Do NOT touch.
this information without notice.
Allow to cool before
servicing.
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 HOT SURFACE HAZARD: This symbol indicates hot
stating so. surface areas on the test machine. Use caution when
working in these areas where components could be hot.

Safety Introduction WARNING

The following safety precautions are published for your ELECTRIC SHOCK
information. This manual does not purport to detail HAZARD.
  or
This equipment is to be
all of the safety concerns, if any, associated with the serviced by trained
equipment’s use. It is the responsibility of the user of this personnel only.
equipment to establish appropriate safety and health
practices and determine the applicability of regulatory ELECTRICAL SHOCK HAZARD: This symbol indicates
limitations prior to use. hazardous voltage is present when opening the
electrical cabinet. This unit is to be serviced by trained
This machine is built with user safety in mind; however,
personnel only.
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-

WEAR SAFETY GLOVES: This symbol indicates
nel trained by Falex or a Falex approved distributor.
chemicals that may be hazardous to handle. Wear
This operation manual contains HAZARD, WARNING, safety gloves.
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. 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.

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Forward:  Instructions–How to Use This Manual 4

WARNING

FLAMMABLE HAZARD: This symbol indicates the

products used are flammable.    

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
CAUTION OR WARNING SYMBOL: This symbol Sheet (MSDS), Hazardous Materials Identification Sys-
indicates a general warning or caution. A caution is tem (HMIS), ISO 9000, Lab Standard Operating Proce-
important for protecting the equipment and performance. dures (SOP), and related instructions. Failure to comply
A warning is important to protecting yourself, others, and may result in personnel injury or death.
the equipment.
WARNING
Falex 400 General Safety Warnings
WARNING
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
tube test area when running test to prevent contact with
Fuels and solvents are flammable and may cause irri- the test section. When the bus bar cover is removed,
tation to the eyes or skin. Wear protective goggles and always assume the heater tube test section is hot and
gloves; avoid contact with skin, eyes, and clothing. Use in use caution when operating around this area.
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.

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5 Section 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
• Certified thermocouples guarantee accuracy
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 sactioned equivalency program.

Falex Corporation does not guarantee any specific test

results or desired functionality of this equipment outside
of its intended usage.

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Section 1:  General Information 6

1.3  Packing List

1. The following items are included in the package:
• 1 Falex 400 Thermal Oxidation Stability Tester
• 1 Start-Up Kit
• 1 CD Manual

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

Heater tube holder

1 400-103-009
assembly

1 Aeration line assembly 400-105-002

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7 Section 1:  General Information

Start-Up Kit continued

Quantity Description Part Number Picture

Sample output line

1 400-105-028
assembly

Fuel heater tube holder

1 400-105-004
input line assembly

Fuel heater tube holder

1 400-105-005
output line assembly

1 Pre-Filter assembly 400-105-010

1 Sample input line assembly 400-105-020

Lead calibration holder with

1 400-108-004
melted lead

1 Falex 400 Manual CD 400-112-001

1 DP calibration bottle 400-200-005

Heater Tubes with DP filters

1 Package of 12 400-560-001
and O-rings

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Section 1:  General Information 8

Start-Up Kit continued

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

2 Beaker, 1000 ml 648-400-012

1 Funnel, large 648-400-003

1 Package of
Funnel filter papers 648-400-011
100

1 Package of 25 Pre-Filter filter papers 648-400-005

1 Cleaning brush 648-400-006

1 Hex wrench 648-400-007

Cleaning pan,
1 648-400-008
stainless steel

Ceramic insulator
1 648-400-009
removal tool

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9 Section 1:  General Information

Start-Up Kit continued

Quantity Description Part Number Picture

1 Tweezers 648-400-010

Thermocouple - fuel
1 650-009-055
sample

1 Thermocouple - heater tube 650-009-064

650-030-140 (120VAC)
1 Power cord
or 650-030-150 (220VAC)

1 Pump priming syringe 650-049-021B

1 Keyboard and Mouse 650-204-048

1 Stylus 650-204-065

1 Mouse Pad 657-100-019

Quality Control Certificate

Oxidation
Stability Apparatus

1
Tube Kit
p/n 400-560-003

of Inspection Material: 316 Stainless Steel

Form number: 400-111-006

Falex Corporation | 1020 Airpark Drive, Sugar Grove, IL 60554 USA | (630) 556-3669 | f: (630) 556-3679 | www.falex.com

CERTIFICATE OF INSPECTION
Tube Kit p/n 400-560-003
The enclosed test pieces have been inspected and meet
the following requirements:
Material: 316 Stainless Steel
Manufactured in conformance with:

QA Manager: ______________________________ Date: ___________

ISO 9001:2000

USA: (630) 556-3669 | [email protected] Europe: +32 (0)16 407 965 | [email protected]

F10617_PackagingInsert.indd 1 3/1/11 10:09 AM

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Section 1:  General Information 10

1.4  Getting To Know The Falex 400

Front USB
Slot
DP Calibration
High Alignment
Line

Desiccant
Chamber
Door

Fault Indicators
(Resettable Fuses)
Touch Screen
Interface On/Off Switch
Air Flow Meter

Ring Stand
Assembly

Coolant
Flow Meter

DP+
Calibration
Alignment
Sample Line
Container
Area
Sample
Test Area

Pump Priming
Door

Figure 1   Fuel Thermal Oxidation Tester–Front

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11 Section 1:  General Information

Fans — DO NOT BLOCK

Interface Panel
USB (2)
Ethernet (1)

Circuit Breaker

Power Plug
Receptical

Figure 2   Rear of the Falex 400 120V Unit

Fans — DO NOT BLOCK

Interface Panel
USB (2)
Ethernet (1)

Circuit Breaker

Power Plug
Receptical

Figure 3   Rear of the Falex 400 220V Unit

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Section 1:  General Information 12

Sample input Sample output

line assembly line assembly
400-105-020 400-105-028
Thermocouple Aeration line
- fuel sample assembly
650-009-055 400-105-002
Beaker, 1000 ml Beaker, 1000 ml
648-400-012 648-400-012

Figure 4   Sample Container Area

Aeration line
assembly
400-105-002

Sample output
line assembly
400-105-028
Sample input
line assembly
400-105-020

Figure 5  Sample Container Area Lines  Note that the

sample-in line is longer than the aeration line.

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13 Section 1:  General Information

Bus Bar Thermocouple

400-103-004

DP- Port (Out)

Thermocouple
- heater tube DP+ Calibration Line
650-009-057
DP+ Port (Out)
Upper Bus Bar
Heater Tube
Thermocouple
Retaining Clip
DP Filter Housing
(behind fuel out
line) Fuel heater tube holder
output line assembly
400-105-005
Fuel Bypass Line
Part of 400-103-009

Heater tube holder

assembly
Fuel heater tube holder 400-103-009
input line assembly
400-105-004
Pre-Filter assembly
400-105-010 Lower Bus Bar

Pre-Filter Bulkhead

Figure 6   Sample Test Area

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Section 1:  General Information 14

Heater Tube Holder

Assembly Hex Nut
977-438-001

Upper insulation bushing

400-018-003

O-ring Fuel heater tube holder

650-008-002 output line assembly
Lower insulation bushing 400-105-005
400-018-003
Bypass Line (part of
heater tube holder
Lower insulation bushing assembly)
400-018-003
DP Filter Housing
(part of heater tube
O-ring holder assembly)
650-008-002
Upper insulation bushing Heater tube holder
400-018-003 assembly
400-103-009
Heater Tube Holder
Assembly Hex Nut
977-438-001 Figure 7   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

Figure 8   Components For Assembly of Prefilter

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15 Section 2:  Setup

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, 50/60Hz) 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 filter 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
on usage. See section 7.1 for charcoal filter Aeration Line
replacement instructions.

2.2  Sample Area And Fuel Preparation Glass Beaker

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
Figure 9   Sample-In Beaker Area
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.

Figure 11a   Ring Stand Assembly

Figure 10   Thermocouple Storage
Filter Paper

Funnel

Ring Stand

Figure 12   Funnel/Filter Setup Figure 11b   Ring Stand Assembly

F10572_F400Manual.indd 15 2/3/12 9:12 AM

Section 2:  Setup 16

New O-ring Damaged O-ring

Figure 14a   O-ring Inspection

Beaker

Filter/Funnel

Figure 13   Filtering Fuel Figure 14b   O-ring Placement

funnel until all the fuel has been placed into the
WARNING 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
Fuels and solvents are flammable and may cause and sample-in lines. Place a clean small O-ring
irritation to the eyes or skin. Wear protective gog- (650-005-002) at the end of each line before
gles, gloves, and an apron; avoid contact with skin, securing the line in place [Figure 14a and 14b]. Inspect
eyes, and clothing. Use in well ventilated areas and the O-rings and replace if damaged or missing.
keep away from heat or flame. Follow all Material
6. Connect the sample-out line to the appropriate
Safety Data Sheet (MSDS), Hazardous Materials
fitting on the front panel [Figure 4].
Identification System (HMIS), ISO 9000, Lab Stan-
dard Operating Procedures (SOP), and related in- 7. Once the fuel has been filtered, remove the filter
structions. Failure to comply may result in person- and dispose of it according to local regulations.
nel injury or death.
8. Remove, clean, and store the funnel.
4. Using the graduations on the side of a clean
9. Rotate the ring stand assembly to the left and
beaker, pour appropriate amount of fuel into the
store into the ring stand housing of test machine
beaker per the method. A minimum of 500 ml
[Figure 11].
may be used. Slowly add the fuel into the filter/

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17 Section 2:  Setup

2.3  Instrument And Test Configuration

Note: Before instrument setup, all components must the riveted end down and the tube ID number
be clean. If the components are not clean, review the closest to the DP filter housing. Secure the heater
Component Cleaning section [see section 4.3]. A new tube to the top of the heater tube housing using
heater tube, DP test filter and three O-rings are required the lower insulator bushing with the flare facing
for each test. end of tube, O-ring (supplied in the heater tube
kit), upper insulator bushing, and hex nut [Figure 15].
1. Retrieve a new heater tube kit from the box of Finger tighten loosely.
specimens.
5. Position the heater tube inside the housing by
2. Carefully remove the new heater tube from the looking though the fuel discharge hole (DP filter
container. Wear gloves and handle the heater tube housing) and centering the heater tube shoulder
by the ends only. Do not touch the center section in the hole so that the shoulder is lined up with the
of the tube. center of the bypass line [Figure 16].
3. Inspect the center section of the tube for 6. Secure the heater tube to the bottom of the heater
scratches, unpolished areas, or other visual tube housing using the lower insulator bushing
defects. Ensure the tube is not bent by rolling it with flare facing the end of the tube, O-ring
on a flat surface. If the tube is bent or has other (supplied in heater tube kit), upper insulator
defects, discard that tube and retrieve another kit. bushing, and hex nut. Finger tighten loosely.
It is advisable to write the tube number down as
this number is a required entry value on the test 7. Finger tighten the hex nuts on both ends of the
configuration setup. heater 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

Upper Insulator Brushing

O-ring

Lower Insulator Housing

Heater Tube
Housing
Heater Tube
Shoulder

Figure 15   Heater Tube Installation Components Figure 16   Heater Tube Position

F10572_F400Manual.indd 17 2/3/12 9:13 AM

Section 2:  Setup 18

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 Figure 17a   DP Filter Installation
the left retaining screw of each bus bar cap
using the hex tool, so that the cap is free to pivot 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
O-ring

Figure 17b   DP O-ring Installation

Figure 18   Assembled Test Section

Figure 19  Removing Right Bus Bar Screw

and Loosening Left Screw

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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 Bus Bar Caps
number stamped on the inside of each
cap to the number stamped on the end of
the contact.
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 Heater Tube
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]. 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.

Figure 20   Inserting Test Section Installation

Fuel-Out
Line To
DP- Fitting

Fuel Bypass
Line To DP+
Fitting

Figure 21   Tube Aligned With Top of Figure 22   Fuel-Out and Fuel Bypass Lines
Bus Bar

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Section 2:  Setup 20

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
17. Place the pre-filter screen into the upper housing housing into the upper housings [Figure 23]. Finger
[Figure 23].
tighten the screws with the hexagon wrench.
18. Using clean tweezers, remove a new pre-filter filter 19. Inspect the O-ring on the end of the pre-filter
paper from the protective case and place onto the assembly. Replace the O-ring if missing or
pre-filter screen. damaged.
 Note: There are two blue paper spacers 20. Connect the pre-filter assembly to the pre-filter
between each pre-filter filter paper. Do not bulkhead fitting and finger tighten [Figure 24].
use blue spacer paper. Use only the white
pre-filter element. Use of the blue spacer
paper will cause the test to fail.

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

Figure 23   Pre-Filter Components   Attaching the Pre-Filter

Figure 24

Assembly

F10572_F400Manual.indd 20 2/3/12 9:13 AM

21 Section 2:  Setup

21. Attach the pre-filter assembly to the assembled Note: The 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.
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
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

  Fuel Input Line to Assembled

Figure 25

Test Section

Heater Tube
Thermocouple Insert Thermocouple Retaining Thermocouple
Retaining Clip into top of Tube Bus Bar Screws Clip in Place Installed

Figure 26a   Thermocouple Retaining Clip   Heater Tube Thermocouple and

Figure 26b

Retaining Clip

F10572_F400Manual.indd 21 2/3/12 9:13 AM

Section 3:  Software Operation 22

It is recommended that the user familarize themself with Lower right corner buttons: Usually there is a back-
the software by reading this section prior to using any ward arrow, forward arrow or both [Figure  29]. The back-
portion of it. 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
3.1  Falex 400 Software Program conditions are met on the current screen (such as; man-
General Notes: Various software screens have datory test information entered, a button pushed, a tem-
similar buttons which are discussed below. perature value reached).

Header: Each screen has a blue shaded header. Lower left corner buttons: Buttons in the lower left are
The center of the header has the screen title with the for user assistance [Figure  29]. Various screens during a
date and time displayed underneath. The time is shown running test have a “Status’ button which activates a Sta-
in standard or military format depending on the user tus screen. The Status screen shows live feedback of
preference. The headers right side may have an abort critical test data and where that data is taken from.
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].

Return to Main Screen (Figure 28)

Screen Title Date & Time Software build or
Operational Manual
Help (Figure 29)

Help Location
in Operation
Aborts test or Manual
procedure

Figure 27   Header Bars

Figure 28   Software Build

F10572_F400Manual.indd 22 2/3/12 9:13 AM

23 Section 3:  Software Operation

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.
Instructions
1. Accessing the Test Type screen: On the MAIN
Forward SCREEN press the 'Run Test' button [Figure 31]. If
screen this button is not visible there will be a temperature
and back bar in its place [Figure 32]. This bar shows the
screen current heater tube thermocouple temperature
buttons and will not allow an operator to start a new test
until the temperature drops below 40ºC, at which
time it is safe to remove the old heater tube and
Figure 29   Lower Left and Right Buttons set up for a new test.
 The heater tube test section is extremely
The ‘Instructions’ button pops up a window to help ex- hot and dangerous to handle during and
plain how the current procedure is run [Figure 30]. These after a test has completed or aborted. Keep
instructions are basic and the user should refer to other the thermocouple in the heater tube after
sections in this manual for a more detailed explanation any test has completed or aborted until its
on that particular procedure. Some instructions may temperature drops below 40ºC. Once the
have multiple pages and the arrow in the lower right cor- temperature is below 40ºC the unit is safe
ner takes you to additional instructions. Press the ‘Close’ to handle.
button to exit the instructions and return to the program.
Access
Test
Sleection
Screen

Additional
pages

  Main Screen In
Figure 31

Ready State
Figure 30  Additional Page Arrow
on Instruction Pages Temperature
Throughout various screens will be 'factory' buttons.
must be
‘Factory’ buttons are solely for the use of authorized
below 40ºC
factory personnel and access to this area is protected.
before ‘Run
Test’ button
appears
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. Figure 32  Main Screen Waiting For Heater
Tube Temperature to Lower

F10572_F400Manual.indd 23 2/3/12 9:13 AM

Section 3:  Software Operation 24

2. Test Type Screen: This screen has the possibility Note: Only tube rating entries of 0, <1, 1,
of eight different test types to choose from <2, 2, <3, 3, <4, and 4 are accepted for the
[Figure 33]. The D3241 ASTM test is always active breakpoint tube reading.
and the button cannot be deactivated. Single,
Breakpoint 1, Breakpoint 2, and the 4 Custom D. Breakpoint 2: Breakpoint 2 runs a matrix of
tests are activated from the ‘Preference’ screen. tests checking both the visual tube reading
value (numeric, abnormal and peacock) and
the maximum ΔP value. All tests run
150 minutes.
Active
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-
Inactive formation and the test parameters as a unique
test name. This information is retained with the
button selection until it is overwritten. Select-
ing a test type will advance to the respective
configuration screen
Figure 33   New Screen Shot 3. Configuration Screens: All test types require
configuration prior to starting. Data File Root
Name, Lab, Operator, Tube ID Fuel Type and
A. ASTM: A D3241 test commences following Fuel ID fields can be entered by the operator,
the mandatory test information entry. All tests however tube ID and the Fuel ID must be entered
are 150 minutes with a flow rate of 3ml/minute. before the configuration screen will display a
These values cannot be altered. The tem- forward arrow allowing program advancement
perature default to the value set under ‘Prefer- [Figure 34]. Some test configurations allow for entry
ences’ and can only be altered through the of test duration, flow rate and test temperature.
‘Preferences’ screen. All four custom configuration screens have
B. Single tests: This selection allows the opera- one additional entry field for the button name.
tor to set parameters for test duration, flow rate Information entered in the Configuration screens
and test temperature for one run. The param- is considered the header for the generated data
eters entered are not stored. files and will appear on both the printed report
and the electronic file. The back arrow at the
C. BreakPoint 1: Breakpoint 1 runs a series of bottom right returns to the ‘Test Type’ screen. The
automated tests, sequencing from the visual forward arrow on the bottom right will only appear
tube reading numeric value only. It does once the mandatory configuration information has
not consider the visual tube reader entry of been entered. The Instructions button on the lower
abnormal or peacock and does not consider left opens a window with generic instructions for
the differential pressure (ΔP). All tests run 150 setting up and running a test. Please refer to the
minutes. Configuration allows for the opera- method for specific instructions.
tor to choose the initial control temperature
(between 180–380ºC) 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 10ºC if the entered tube reading is
<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 5ºC below the previous run.
Figure 34   ASTM Configuration Screen
All results are compiled into a single data file.

F10572_F400Manual.indd 24 2/3/12 9:13 AM

25 Section 3:  Software Operation

A. Data File Root Name: The 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 Data
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.
B. Lab: A lab name may be entered up to
15 characters in length.
C. Operator: An operator name may be entered
Figure 35   Single Configuration 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
tube ID number can be found on the speci-
men tube.
E. Fuel Type: An fuel type may be entered up to
15 characters in length.
F. Fuel ID: A fuel ID entry is required. It may be
up to 15 characters in length.
G. Test Temperature, C: Enter a temperature.
The test will control the temperature of the
tube between 180–380˚C. Single, breakpoint
Figure 36   Breakpoint/Configuration 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. 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 fixed value for an
ASTM test.
Figure 37   Custom Configuration
4. Aeration Screens: Proceeding from the
configuration screen the aeration screen appears
[Figure 38]. The user has the choice to start aeration
or skip aeration.

Figure 38   Aeration Screen

F10572_F400Manual.indd 25 2/3/12 9:13 AM

Section 3:  Software Operation 26

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 Figure 40   Status Screen
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- 6. During the aeration, inspect all fittings in the
tion, the sample temperature should be held between sample test area for leaks.
15–32ºC and the aeration humidity to no greater than 7. If leaks are found, re-tighten using fingers only.
21%. Should the sample temperature or humidity be out-
side of this range the test will abort. The current values 8. Test Screens: These screens remain open the
for temperature and humidity appear in the center Data duration of a test. The Pressure box in the lower
box on the screen. The Digital Points then displays status right indicates the system pressure and the DP
within the system during aeration. The ‘Status’ button in value. Tests run at 3.45MPa+/- 10%. Once system
the lower left corner opens a pictorial screen of the F400 pressure is reached the heater will commence.
showing live values of critical measurements [Figure 40]. It is recommended that the operator watch for
leaks during this pressurization. When leaks
5. The test will automatically begin after the 6-minute are visible, abort the test, tighten all fittings and
fuel aeration. As the sample is being aerated, restart the test. Should the unit not reach required
the previous runs fuel is purged from all lines pressure within 180 seconds the system will
and valves. 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 is reached.
Likewise, if the temperature is not held within
two degrees of the set point a system abort will
Aeration be triggered. When the set point temperature is
Flow Meter reached (Indicated in the Temperature box on the
right) the test run timer starts.

Coolant 9. The bus bars are cooled once heating of the

Flow Meter 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].

Figure 39   Aeration Coolant Meters

F10572_F400Manual.indd 26 2/3/12 9:13 AM

27 Section 3:  Software Operation

Figure 41a   Test run time Figure 42  Test Completion Screen Waiting
For Tub Temperature To Cool

A. Tube Rating: Upon a successful test comple-

tion a tube rating screen appears 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
  System pressure and heater
Figure 41b supplied with the Tube Rater. The Falex 420
tube temperature Tube Rater is specifically designed to meet
ASTM D3241 for tube rating. Any characters
can be entered for a tube rating however if is
10. Test Completion: Tests either complete or recommended that the individual test method
they fail due to operator aborts, failure to meet for procedure and instructions on how to rate
or maintain operational requirements such as a tube be used.
pressure loss, failure to maintain temperature
or excessive bus bar temperature. Following
test completion or failure, a safety screen
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
Complete screen when the unit has reached a
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 40ºC. Once the Figure 43   Tube Rating Screen
temperature is below 40ºC the unit is safe
to handle. B. 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 termination and which alarms initiate
only a warning message.

F10572_F400Manual.indd 27 2/3/12 9:13 AM

Section 3:  Software Operation 28

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: If the Falex 400 has had a power cycle since the
last test, data transfer cannot be performed.

The name of the last test run is on the top line on this
screen. This is the file that the first three buttons refer to
[Figure 45]. The user can view the test data on the touch
screen, transfer the data from the PLC storage onto the
computer, print this report and/or copy files from the
touch screen to a USB device or Ethernet connection.
Complete data records of DP mmHg, heater tube 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 ‘Copy’ the file to an external folder. Data files
are saved in .csv format and can be viewed using ap-
Figure 46  Viewing Data
propriate software. Page 1 - Test Information

Access
the data

Figure 44  How To Access Figure 47  Viewing Data

Test Data Page 2 - DP Values

Name of
data file
that View,
Transfer
and Print
refer to

Figure 45   Data File Name

F10572_F400Manual.indd 28 2/3/12 9:13 AM

29 Section 3:  Software Operation

2. Transfer: After a test completion this button 4. Copy: ‘Copy’ opens Windows Explorer. Navigate
MUST be selected to move the test data to the to the “Data” folder under the root directory (400
computer. Upon transfer, data files reside in the (C:)). This folder contains all the data files that
“Data” folder under the root directory (F400 (C:)). have been transferred. Close Windows Explorer
An acknowledgement window appears upon when copying is complete. For copying to external
successful data transfer [Figure 48]. Do not proceed devices there are three USB ports and one
until this acknowledgement appears. Ethernet port located on the 400. Two USB ports
and the Ethernet port are on the convenience
 Note: The current test data will be lost at outlet on the back panel. One USB port is located
the start of the next test if this ‘Transfer’ on the front of the unit directly above and to the
button is not pressed or when the F400's right of the drierite window.
power is cycled. The computer has limited
hard drive space and it is recommended  Note: Do not delete or rename the Data
that the user regularly perform file folder or data transfer will not occur and test
maintenance on the “Data” folder . data information will be lost.

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 for use upon power up. Should
a different printer be used refer to the ‘Preference’
section of this manual to install a printer.

Figure 48  File Transfer Message

F10572_F400Manual.indd 29 2/3/12 9:13 AM

Section 4:  Disassembly and Component Cleaning 30

9. Remove the test section assembly.

WARNING
10. Remove the fuel-out line (J-line) from the heater
tube housing and place in the pan provided.
11. Remove the O-ring and the DP filter from the DP
      filter housing using the extraction tool provided.
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, bushings from both sides of the heater tube
eyes, and clothing. Use in well ventilated areas and housing and place them in the pan provided.
keep away from heat or flame. Follow all Material Remove and discard the O-rings.
Safety Data Sheet (MSDS), Hazardous Materials 13. Remove the lower insulator bushings from both
Identification System (HMIS), ISO 9000, Lab Stan- sides of the heater tube and the heater tube
dard Operating Procedures (SOP), and related in- housing and place them in the pan provided.
structions. Failure to comply may result in person-
nel injury or death. 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-
15. Rinse the heater tube with Iso-Octane and allow
peratures of 180 °C–380 °C during operation. Al-
the solvent to evaporate. Place the heater tube
ways place bus bar cover over the heater tube test
back in the original plastic container and cap until
area when running test to prevent contact with the
you are ready to rate the tube.
test section. When the bus bar cover is removed,
always assume the heater tube test section is hot 16. Rate the tube using an approved method and
and use caution when operating around this area. record value on screen.

4.1  Unit Disassembly

1. Position a waste solvent container as needed to
catch solvent during the component cleaning.
2. The 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
germicidal wipe. Upper And
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]. Figure 49   Removal of the Test Section

F10572_F400Manual.indd 30 2/3/12 9:13 AM

31 Section 4:  Disassembly and Component Cleaning

4.2  Continued Unit Disassembly 4.3  Component Cleaning

17. Use the hex wrench to remove the three screws in Notice: The heater tube housing is the only
the pre-filter assembly. component to be cleaned with Tri-Solvent.
18. Disassemble the pre-filter. Remove and discard 1. Brush the inside of the heater tube housing with
the white pre-filter element. Place the remaining the provided cleaning brush and Tri-Solvent.
components of the pre-filter assembly into the
provided pan. The prefilter O-ring is reusable afer 2. Inspect the inner surfaces of the heater tube
proper cleaning. housing for cleanliness and repeat step 1
if needed.
19. Open the cover from the sample container area.
3. Rinse with Iso-Octane and dry using
20. Remove the aeration line and the sample-in line compressed air.
and place them in the pan provided.
4. Use a wash bottle filled with Iso-Octane to flush/
21. Remove the fuel thermocouple from the beaker rinse all components in the pan and dry using
and wipe down. compressed air. Make certain all fuel has been
removed from all components.
22. Remove the sample-in and sample-out
glass beakers.
23. Dispose of fuel appropriately according to
local regulations.

F10572_F400Manual.indd 31 2/3/12 9:13 AM

Section 5:  Software Preferences 32

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. Figure 51   Preferences Screen

Access
Preferences A. 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
Figure 50  Accessing machine‘s power is cycled.
Preferences
‘Breakpoint1’ follows the breakpoint method
described inn ASTM D3241. It is based only
2. Preferences Screen: After the password is on the VTR (visual tube reader) integer value
entered, the Preference screen appears [Figure 51]. entered at the completion of each test section.
There are four areas to this screen. First there is
the 'Test Selection' section to the left-hand side of ‘Breakpoint2’ is a matrix method used to
the screen containing seven test types, a ‘Time’ determine the fuel’s breakpoint but takes into
section containing selections for the date/time consideration the VTR readings with the A
format, an ‘Install Printer’ button for access to (abnormal) and P (peacock) attributes and the
the Windows Control Panel for adding additional DP value. The only test parameter the user
printers, and a value box labeled ‘ASTM Temp, C:’ may enter is the starting temperature.
to set the stored ASTM test 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.
B. 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.

F10572_F400Manual.indd 32 2/3/12 9:13 AM

33 Section 5:  Software Preferences

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 & Time. Once you have set
the correct date and time, cycle the power by
turning the unit off and then on.
E. ASTM Temperature: This is where a default
test temperature can be stores for all ASTM
tests. For instance, some specifications
require 270ºC rather than the default value of
260ºC.

F10572_F400Manual.indd 33 2/3/12 9:13 AM

Section 6:  Maintenance 34

6.1  Charcoal Filter Replacement Desiccant Cover

 To prevent equipment 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.

Figure 53   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
apart from the cover.

   
Desiccant may cause irritation to the eyes 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.

Figure 54  Desiccant Cartridge Mounted In

Housing

F10572_F400Manual.indd 34 2/3/12 9:13 AM

35 Section 6:  Maintenance

4. Grasp the desiccant cartridge with one hand

and pull the desiccant cartridge straight out of
the machine. If rubber bushings are attached
to 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 Figure 56   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 installed. replace
desiccant cover and install six screws to secure.

Desiccant Housing

Retainer Clips
Desiccant Cartridge Inlet/Outlet Ports
Rubber Bushings

Figure 55   Desiccant Cartridge Housing

F10572_F400Manual.indd 35 2/3/12 9:13 AM

Section 6:  Maintenance 36

6.3  Pump Maintenance 6.3.1  Prime Pump

Select the Prime button on the maintenance screen 
WARNING [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
Fuels and solvents are flammable and may cause sequence. The appropriate valves are open and closed
irritation to the eyes or skin. Wear protective gog- as needed as can be seen by the lighted Digital Point
gles, gloves, and an apron; avoid contact with skin, (green=open, red=closed). The pump is adjusted to a
eyes, and clothing. Use in well ventilated areas and flow rate of 9 ml/minute during this prime. The Status bar
keep away from heat or flame. Follow all Material returns feedback during the prime sequence. There is no
Safety Data Sheet (MSDS), Hazardous Materials time limit to the prime sequence and the operator must
Identification System (HMIS), ISO 9000, Lab Stan- press the Stop button to end the pump priming.
dard Operating Procedures (SOP), and related in-
structions. Failure to comply may result in person- Watch the fuel flow into the outlet beaker. When a steady
nel injury or death. stream is reached (no air in the line) the priming is suc-
cessful. Should air pockets still be visible in the lines,
Air in the lines is indicated by visible air pockets in the proceed to the purge sequence. If the prime pump did
sample output line, the lack of fuel being expelled; or remove all air pockets, dispose of the fuel properly and
the lack of a steady stream of fuel expelled through the begin testing.
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 accessed from the
‘Main’ screen [Figure 57].

Figure 58  Maintenance Screen

Access
Maintenance
Screen

Figure 57  Accessing The

Maintenance Screen

Figure 59   Prime Pump Screen

F10572_F400Manual.indd 36 2/3/12 9:13 AM

37 Section 6:  Maintenance

6.3.2  Priming Pump On the maintenance screen, select PRIME.

4. Press the PRIME button.
6.3.2.1  Manual Method
5. Insert an empty, plastic 10 ml syringe into the
Although not the recommended method, the pump and pump priming port at the center of the black
lines may be primed manually. priming port knob [Figure 61]. Rotate black priming
port knob counterclockwise and suction fuel out
1. Open the sliding door in front of the pump by of the pump priming port by pulling in the syringe
gently pressing the black handle in and sliding the plunger. Allow 6–8 ml fuel to fill syringe. Close
door to the left [Figure 60]. the black priming port knob by turning clockwise.
2. Place a towel under the two pump heads. Remove the syringe from the black priming port
knob and dispose of fuel appropriately.
3. On the main screen, select the MAINTENANCE.

Black Handle

  Opening the Door

Figure 60

to Prime the Pump

Black Priming Port Knob

Plastic Syringe

Two Pump Heads

Figure 61   Priming the Pump

F10572_F400Manual.indd 37 2/3/12 9:13 AM

Section 6:  Maintenance 38

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
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 Figure 62   Purge Screen
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.

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 2/3/12 9:13 AM

39 Section 7:  Calibration

Calibrations should be preformed regularly on the 400 7.1.1  Thermal Calibration Lo Check
in accordance with the method. Refer to each method
for it is required calibration schedule. Calibrations should 1. Prepare a low temperature standard, from an ice
be performed on the heater tube thermocouple, the dif- bath of distilled water and crushed distilled water
ferential pressure transducer and the system pressure. ice (an insulated cup works best).

‘Thermocouple’ allows for a calibration of the temperature 2. Place the heater tube thermocouple in the
control system using ice and the eutectic temperature of ice bath.
lead to calibrate the heater tube thermocouple. The dif- 3. Stir the thermocouple in the bath watching the
ferential pressure is the measurement across the DP test tube temperature on the display [Figure 64].
filter. Excessive differential pressure (DP) is an indication
of poor fuel quality. ‘Diff Press’ provides a calibration of 4. Continue stirring until the tube temperature no
the differential pressure transducer. ‘Sys Press’ allows for longer drops and holds constant for 20–30
adjustment of the pressure measurement against a NIST seconds. Press the ‘Accept’ button. This will
certified reference pressure gage. store the observed low temperature and will
initiate the Thermocouple Hi Check display. The
Select thermocouple reading should be accepted if
Thermocouple 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.

Current
Thermocouple
Reading

Figure 63  

7.1  Thermocouple
The auto calibration performs a calibration of the heater Figure 64  Thermocouple Lo
tube thermocouple by a ‘low’ calibration check using an Check Screen
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 7.1.2  Thermocouple Calibration
the correct position during each step can cause the unit
to continue to apply heat to the bus bars or fail to heat the
Hi Check
bus bars. Should a step not complete as documented 1. Install the lead calibration check assembly in the
within seven minutes of initiation, shut the unit off upper/lower bus bars. Make sure the top of the
from the power switch on the front, allow the unit to assembly is flush with the top of the upper bus bar
cool for a minimum of 20 minutes before restoring and that the bus bar screws are tight.
power and re-initiating calibration.
 Manual insertion and removal of the
1. [Figure 63] Fromthe Main Menu, go to the thermocouple is required during the Hi
Maintenance > Calibrate > Thermocouple display Check. Care should be taken during all
and select ‘Auto Calib’ button. This will reset the steps as the bus bars are extremely hot
previous calibration factors to the default values and can carry high current. Only insert
(0 ºC factor = 0 and 327.5 ºC factor = 327.5). It and remove the thermocouple by the
will also call up the ‘Thermocouple Calibration Lo insulated leads.
Check’ display.
2. Insert the heater tube thermocouple through
the top bus bar into the assembly so that the
thermocouple is in contact with the lead.

F10572_F400Manual.indd 39 2/3/12 9:13 AM

Section 7:  Calibration 40

3. Push the ‘Start‘ button to begin the heat cycle 10. If the eutectic temperature capture was not
that will raise the lead assembly temperature successfully detected, a popup message
to 350 °C. Once pushed, the ‘Heat’ button will display a failure and abort the calibration
will disappear. procedure. It is suggested that the test be
repeated to confirm that the thermocouple is
4. The lead temperature will begin to rise. The
defective. Push the ‘OK’ button on the popup
thermocouple must maintain contact with the
display for a one minute heating cycle to begin to
lead. An occasional light pressure on the top of
allow for thermocouple removal. As described in
the thermocouple wires may be required. Once
steps 9 and 10 above. Remove the thermocouple
the temperature is above 327.5 °C, the lead will
and inspect it for damage. Allow the lead
melt down into the fixture cup. Make sure that the
calibration check assembly to cool. Repeat
thermocouple remains in contact with the lead
the calibration.
by pushing it down to the lowest position with the
tip centered in the cup (do not let thermocouple 11. If the thermocouple fails to capture a satisfactory
touch the sides of the lead cup). eutectic temperature detection again, it should
be replaced.
The Following steps are automated
Real-Time
5. Once the temperature is above 340 °C for 1 Temperature
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 Figure 67   Thermocouple Hi Check Screen
the eutectic temperature will be moved to the
thermocouple calibration factors until the next time
an auto calibration is initiated. 7.2  Differential Pressure
7. If the eutectic temperature was successfully 1. Falex 400 must be on for at least 30 minutes
detected, push the ‘OK’ button on the popup before following this procedure.
display. This will cause the popup to disappear.
The temperature will increase to melt the lead for 2. Fill the calibration bottle ¾ full with fuel.
thermocouple removal. A message is displayed
3. Be sure the sample out line is in place and
notifying the operator to remove the thermocouple
empties into a beaker. The aeration and sample in
from the lead once the temperature reaches
lines can remain in place or they can be closed by
>330 °C. A one minute timer is started to allow
attaching nuts to the bulkhead fittings.
thermocouple removal.
4. The heater tube and prefilter assemblies are not
8. Once the one minute timer has completed or
used for this calibration and need to be removed.
the thermocouple has been removed, heating
Place a nut over the bulkhead where the prefilter
is stopped. The operator must remove the
assembly attaches to the unit. Cap the DP+
thermocouple from the lead at this time and
bulkhead but leave the DP- port open.
clean the thermocouple with a cloth to remove
any residual lead on the thermocouple. Dispose 5. Get to the DP Calibration screen from the Main
of the cloth properly. Wear appropriate gloves screen by the following sequence of buttons:
when handling the hot thermocouple with possible Maintenance-Calibration-DP.
lead residue
6. Upon entering the DP Calibration screen press
9. A four minute timer is initiated to allow for the lead START.
cup assembly to cool. Once the four minutes has
been completed the cooling is stopped..

F10572_F400Manual.indd 40 2/3/12 9:13 AM

41 Section 7:  Calibration

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.
28. Return to the Main screen.
8. Close the System Vent by pushing the System
29. Attach nuts to the DP+ and DP- bulkheads or
Vent button on the screen until it appears red.
reattach the heater tube assembly. Leaving the
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
12. Wait until the DP value on the screen holds steady
Reading
(approximately 50 mls have run out of the bottle
and into the outlet beaker).
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.
15. Leave the bottle on top of the Falex 400.
16. Remove the nut from the DP+ port and set it aside.
17. Disconnect the bottle from the DP- port and attach
the bottle to the DP+ port. DO NOT CAP THE
DP- PORT. Figure 68   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 values 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 0 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 25mmHG
Figure 69   Calibration Factors Screen
+/- 2.5.
26. The fluid bottle may now be set down on the
bench top.

F10572_F400Manual.indd 41 2/3/12 9:13 AM

Section 8:  Service 42

8.1  Software Accessible Service 3. Close DP Pos: Pressing this button manually
operates the DP positive valve. This button is not
Obtaining manual access to machines functionalities is interlocked with the bypass valve and should be
done through the ‘Service’ screen accessed from the used only if the operator has an understanding
maintenance screen [Figure 70]. The user has access to of the system as not to damage the pressure
various controls so operation should only be undertaken transducer.
by someone with understanding of the system.
4. Factory: This is a protected area for the authorized
1. I/O & Vars: [Figure 71] Manual operation of different users only.
controls can be accessed by pressing the large
green or red buttons under Digital Points. The 8.2  Alarm Log
HPLC pump can manual be set to flow at either
3 or 9 ml/min for this service screen. And live Pressing the alarm log button displays the last
[Figure 72]
feedback is seen in the Data section of this screen. 25 warnings and abort alarms.

2. Close DP Neg: Pressing this button manually

operates the DP negative valve. This button 8.3  Fault Indicators
is not interlocked with the bypass valve and
On the front of the Falex 400 are 7 indicator lights. If
should be used only if the operator has an
a fuse trips an indicator light will be visible with the
understanding of the system as not to damage the
description of the problem area. Cycle the power on the
pressure transducer.
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.

Figure 70  Service Screen Reached From

The Maintneance Screen
Figure 72   Listing of most current alarms

Figure 71   I/O & Variable Screen

F10572_F400Manual.indd 42 2/3/12 9:13 AM

43

Description Alarm Abort Condition Lo Limit Hi Limit Alarm Message (HMI) Comments

Checked at beginning of test

F10572_F400Manual.indd 43
5 ºC in 10
after pressure achieved.
Heater Tube Tempera- sec af- Heater Tube Failed to
x Possible Cause: Thermocouple
ture Fail To Rise ter press Rise 5 C in 10 s
not installed properly, Thermo-
achieved
couple not in heater tube.
Checked at beginning of test
after pressure achieved. Tem-
90 sec perature must be within range
Section 8:  Service

Heater Tube Failed to Heater Tube Failed to

x after press < SP - 2 ºC > SP + 2 ºC within alotted time, otherwise test
Reach Temperature Reach Temp
achieved aborts.Possible Cause: Ther-
mocouple not installed properly,
heater failure.
8.4  Alarm and Warning Messages

Checked at beginning of Test.

Failure to Reach Pres- 3 min after Fail to Reach System
x 3.1 Mpa Possible Cause: filter paper,
sure test start Pressure in 3 min
pressure leak.
Checked during aeration. Tem-
perature must be 'outside' of
limits for 1 sec.
Sample Fuel Tempera- Aeration Sample Fuel Temp Out
x < 15 ºC > 32 ºC Possible Cause: Thermocouple
ture Out of Range active of Range
not installed properly, Thermo-
couple failure, fuel not at room
temperature.
Initiated from touchscreen to stop
any running devices or active
Operator Abort x Operator Initiated Abort test.
Possible Cause: Operator hit
abort button on display.
Pump communication failure
between controller and pump.
Pump Communication Pump Serial Comm Possible Cause: Network cable
x
Failure Failure disconnected, Network HUB
failure, HPLC pump powered off,
HPLC pump failure.

2/3/12 9:13 AM
Description Alarm Abort Condition Lo Limit Hi Limit Alarm Message (HMI) Comments

Checked after 30 seconds of

F10572_F400Manual.indd 44
Aeration aeration. Temperature must be at
High Humidity x time > 30 21% High Humidity high level for 1 sec.
sec Possible Cause: Air pump failure,
humidity sensor failure.
Abort after 1 second. Possible
Heater Tube Thermo- Cause: Excessive deposit on
Heater Tube 'High' Temp x 425 ºC
couple Hi Failure heater tube, Heater tube thermo-
couple failure.
Abort after 1 second.
Possible Cause: Cooling system
Bus Bar 'High' Temp x 80 ºC Bus Bar Temp > 80 C
failure, Thermocouple not in-
stalled properly.
Abort after 1 second.
Possible Cause: Cooling system
Bus Bar 'High' Temp x 60 ºC Cooling System Failure
failure, Thermocouple not in-
stalled properly.
Abort after 1 second.
System 'Low' Pressure x Test active 3.1 Mpa Low System Pressure Possible Cause: Pressure leak,
inlet valve failure.
Abort after 1 second.
System 'High' Pressure x Test active 3.8 Mpa High System Pressure Possible Cause: tubing blockage,
pressure sensor failure.
Temperature must be 'outside' of
≤ 2.5 ºC ≥ 2.5 ºC limits. Abort after 3 seconds.
Heater Tube Temp De- Heater Tube Temp Out
x Test active from set- from set- Possible Cause: Thermocouple
viation of Range
point point failure, excessive buildup on
heater tube.
Abort after 1 second.
Heater Tube Temp Ther- Heater Tube Thermo- Possible Cause: Thermocouple
x Test active -100 ºC
mocouple Failure couple Lo Failure failure, Thermocouple not con-
nected.
Section 8:  Service
44

2/3/12 9:13 AM
45

Description Alarm Abort Condition Lo Limit Hi Limit Alarm Message (HMI) Comments

Abort after 1 second.

F10572_F400Manual.indd 45
Bus Bar Temp Thermo- Bus Bar Thermocouple Possible Cause: Thermocouple
x Test active -100 ºC
couple Failure Failure failure, Thermocouple not con-
nected.
Abort after 1 second.
Sample Fuel Temp Ther- Sample Thermocouple Possible Cause: Thermocouple
x Test active -100 ºC
mocouple Failure Failure failure, Thermocouple not con-
nected.
Section 8:  Service

Warning only.
Safety Cover Missing x Test active Bus Bar Cover Missing Possible Cause: Cover removed
during test, photo eye failure.
Checked after data transfer but-
Data xfer ton selected.
FTP Comm Open Action
Data Transfer Failure x button Possible Cause: Data file not
Failure
selected created, data directory does not
exist, FTP application corrupt.

2/3/12 9:13 AM
Addendum A: Parts Listing 46

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
648-400-011 Funnel filter papers (100 filters/box)
648-400-012 Beaker, 1000 ml
650-009-055 Thermocouple - fuel sample
650-009-057 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)

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47 Addendum B: File Transfer Message

F10572_F400Manual.indd 47 2/3/12 9:13 AM

Notes 48

issue date: 1/6/2012

F10572_F400Manual.indd 48 2/3/12 9:13 AM