Fuel Conditioning Module

Service InstructionsPrintedBook No.

Aug 20081810722-02 V 4

Alfa Laval reserves the right to make changes at any time without prior notice.

Any comments regarding possible errors and omissions or suggestions for improvement of this publication would be gratefully appreciated.

Copies of this publication can be ordered from your local Alfa Laval company.

Published by: Alfa Laval Tumba AB Marine & Diesel Equipment SE - 147 80 Tumba Sweden

Copyright Alfa Laval Tumba AB 2008.

Contents

1 Component Service ..............................................................................................11.1 Periodic Maintenance ....................................................................................... 11.2 Maintenance Schedule ..................................................................................... 21.3 Spare Parts........................................................................................................... 21.4 On-site Service.................................................................................................... 21.5 Depressurizing the System ............................................................................. 31.6 Change of Circuit Board................................................................................... 41.7 Replacement of Viscosity Sensor ................................................................ 81810722-02

1810722-02

FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS 1 COMPONENT SERVICE

ce1 Component Servi

1.1 Periodic MaintenanceThe following general guideline gives a brief description of parts to be cleaned, checked, or renewed, at different maintenance intervals.

It is primarily the components with moving parts, i.e. pumps and automatic filter, that require regular replacement of worn parts. Other components require regular inspection and, if necessary, cleaning, e.g. heaters and viscosimeter. PHE type heaters will need re-gasketing after a number of years, depending on temperature.

For maintenance actions in connection with first start-up, see the Installation System Reference booklet.

For further information concerning component maintenance, see the individual component descriptions.

Before any maintenance is done, it is essential to carefully study the instruction manuals for each of the main components. These instructions are included in this complete instruction binder.

For an overview of recommended regular maintenance, see the section below.1810722-02 1

1 COMPONENT SERVICE FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS

Time Interval

DO for approx. 3 5000 hours

3000 hours (100 hours after first start-up)

d ball bearings. 8000 hourss and temperature op.

6 months

4 months12 months

g if necessary 12 months1.2 Maintenance Schedule

Maintenance Guidelines

1.3 Spare PartsRegional Distribution Centres in Sweden, North America, and Singapore linked with Alfa Laval offices worldwide ensure that the spare parts you order are delivered to the port of your choice within 24 48 hours.

For recommended stock of spare parts and service kits, see the Overhaul Kit table in the Spare Parts Catalogue.

NOTE

Always use Alfa Laval genuine parts as otherwise the warranty may become invalid.Alfa Laval takes no responsibility for the safe operation of the equipment if non-genuine spare parts are used.

1.4 On-site ServiceFor on-site service by an Alfa Laval service engineer, please contact your local Alfa Laval office. See www.alfalaval.com. for contact information.

The Alfa Laval office can also assist in upgrading the module to, for example, a higher level of automation.

Component Action

Complete Module Operate the module with pure Mhours.

Pumps Clear suction strainers

Inspection of mechanical seal anHeaters Inspection of flanged connection

performance. Check pressure drAutomatic filter Clean the filter elements.

Change ball bearings.Viscosity sensor Inspection of sensor and cleanin2 1810722-02

FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS 1 COMPONENT SERVICE

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5A

Ventilation nipple1.5 Depressurizing the System

CAUTION

!

Pressure RiskBefore starting maintenance work on the filters, pumps, or viscosity block, release the pressure in them.

Release the pressure as follows.

1 Open the by-pass line or standby system.

2 Turn off the flow to and from the component.

3 Remove the threaded ventilation nipple.

4 Screw in the supplied ventilation tube, holding the other end of the tube over a recepticle.

5 When fuel has stopped draining from the ventilation tube, open the drain plug to remove the remaining fuel in the component.

When maintenance work is finished, replace the drain plug. Replace the ventilation nipple, open the flow line to and from the component, and close the by-pass line or standby system. Clean the ventilation tube using compressed air.1810722-02 3

1 COMPONENT SERVICE FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS1.6 Change of Circuit Board

Maintenance of the EPC 50B Controller

Maintenance is not required unless a fault occurs in the boards.

If a persistant fault in the boards occurs, this must not be repaired. The board must be replaced with a spare board.

If a circuit board has to be changed, proceed as follows:

Note down the fuel consumption and running hours as shown under Process Info.

Change the board according to the instructions below.

Go to parameters Fa 45 58, and insert the information.4 1810722-02

FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS 1 COMPONENT SERVICEOP-Board

Switch power off.

Disconnect the two cable plugs (do not remove the cables from the plugs).

Disconnect the flatcable connector at the top.

Unscrew the five hexagon nuts.

Mount the new board, and connect in reverse order.

I/O-Board

Switch power off.

Disconnect the cable plug(s) on the expansion and other optional boards (do not remove the cables from the plug(s)).

Disconnect the flatcable connector at the top.

Unscrew the three hexagon nuts.

Note the position of the board and remove the board.

Disconnect all the cable plugs on the large board (do not remove the cables from the plugs).

Unscrew the hexagon nuts. Take care to note where the special nuts for optional board(s) are located.

Mount the new board in the same position as the old, and connect in reverse order. 1810722-02 5

1 COMPONENT SERVICE FUEL CONDITIONING MODULE SERVICE INSTRUCTIONSViscosity Circuit Board

1 Open the door of the EPC50V control unit.

2 Turn off the power with the main switch (located on the right side of the cabinet).

3 Locate the Viscosity circuit board in the upper left corner of the cabinet.

4 Unplug terminal J1, J6 and the contact for voltage supply on the old board.

5 Dismount the four screws holding the board.

6 Replace the old board with the new one and mount it in the same way (see picture) as at delivery.

a The Viscosity circuit board shall be placed on the 35 mm spacers (enclosed and mounted at first delivery), according to picture.

b The Cooling flange shall be turned to the left (means numbers on terminals turned up side down), according to picture.

7 Mount the four screws.

8 Re plug terminal J1, J6 and the contact for voltage supply - see picture and interconnection diagram.

a Terminal J1; X5:2 to J1:2 and X5:5 to J1:1 - check with interconnection diagram. (Viscosity signals 4-20 mA from the Viscosity circuit board to the EPC50V control unit).

b Terminal J6: See interconnection diagram. (Signal from Viscosity sensor to Viscosity circuit board).

c Contact for voltage supply, see picture.6 1810722-02

FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS 1 COMPONENT SERVICE

Terminal J6Screws

voltage supplyTerminal X5

Contact for

Terminal J14-20 mA signal

ScrewsCooling flange1810722-02 7

1 COMPONENT SERVICE FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS1.7 Replacement of Viscosity Sensor

1 Stop the viscosity system by pressing the stopbutton.

2 Turn off the power with the main switch located on the inside of the cabinet.

3 Open the by-pass valves

4 Close valves in order to isolate the sensor.

5 Cool down the housing and sensor.

6 Depressurise the housing and sensor.

7 Remove the old sensor. Do not remove the square flange.

NOTE

Be very careful when handling the viscosity sensor. Never use abrasive materials to clean the flow tube as this will damage the Teflon coating. Clean the space between the tube and the pendulum with diesel oil.

8 Disconnect teminal J6 on the viscosity circuit board and disconnect the cables from the terminal.

NOTE

Make sure that the housing is firmly mounted and supported before mounting of the sensor.

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3A8 1810722-02

FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS 1 COMPONENT SERVICE

X0

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2A9 Mount the new sensor carefully.

NOTE

The hole in the viscosity sensor tube must face upwards! Be sure that the nut is tightened with the pin in the top position.

10 Connect the cables to terminal J6 according to the interconnection diagram. Connect the teminal on the viscosity circuit board.1810722-02 9

1 COMPONENT SERVICE FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS10 1810722-02

Fuel Conditioning ModuleService Instructions1 Component Service 11.1 Periodic Maintenance 11.2 Maintenance Schedule 21.3 Spare Parts 21.4 On-site Service 2

1 Component Service1.1 Periodic Maintenance1.2 Maintenance ScheduleMaintenance Guidelines

1.3 Spare Parts1.4 On-site Service1.5 Depressurizing the System1 Open the by-pass line or standby system.2 Turn off the flow to and from the component.3 Remove the threaded ventilation nipple.4 Screw in the supplied ventilation tube, holding the other end of the tube over a recepticle.5 When fuel has stopped draining from the ventilation tube, open the drain plug to remove the remaining fuel in the component.

1.6 Change of Circuit BoardMaintenance of the EPC 50B ControllerOP-BoardSwitch power off.Disconnect the two cable plugs (do not remove the cables from the plugs).Disconnect the flatcable connector at the top.Unscrew the five hexagon nuts.Mount the new board, and connect in reverse order.I/O-Board

Switch power off.Disconnect the cable plug(s) on the expansion and other optional boards (do not remove the cables from the plug(s)).Disconnect the flatcable connector at the top.Unscrew the three hexagon nuts.Note the position of the board and remove the board.Disconnect all the cable plugs on the large board (do not remove the cables from the plugs).Unscrew the hexagon nuts. Take care to note where the special nuts for optional board(s) are located.Mount the new board in the same position as the old, and connect in reverse order.Viscosity Circuit Board1 Open the door of the EPC50V control unit.2 Turn off the power with the main switch (located on the right side of the cabinet).3 Locate the Viscosity circuit board in the upper left corner of the cabinet.4 Unplug terminal J1, J6 and the contact for voltage supply on the old board.5 Dismount the four screws holding the board.6 Replace the old board with the new one and mount it in the same way (see picture) as at delivery.a The Viscosity circuit board shall be placed on the 35 mm spacers (enclosed and mounted at first delivery), according to picture.b The Cooling flange shall be turned to the left (means numbers on terminals turned up side down), according to picture.7 Mount the four screws.8 Re plug terminal J1, J6 and the contact for voltage supply - see picture and interconnection diagram.

a Terminal J1; X5:2 to J1:2 and X5:5 to J1:1 - check with interconnection diagram. (Viscosity signals 4-20 mA from the Viscosity circuit board to the EPC50V control unit).b Terminal J6: See interconnection diagram. (Signal from Viscosity sensor to Viscosity circuit board).c Contact for voltage supply, see picture.

1.7 Replacement of Viscosity Sensor1 Stop the viscosity system by pressing the stopbutton.2 Turn off the power with the main switch located on the inside of the cabinet.3 Open the by-pass valves4 Close valves in order to isolate the sensor.5 Cool down the housing and sensor.6 Depressurise the housing and sensor.7 Remove the old sensor. Do not remove the square flange.8 Disconnect teminal J6 on the viscosity circuit board and disconnect the cables from the terminal.9 Mount the new sensor carefully.10 Connect the cables to terminal J6 according to the interconnection diagram. Connect the teminal on the viscosity circuit board.

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