Fuel Conditioning Module

Service Instructions
Printed

Aug 2008

Book No.

1810722-02 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 .............................................................................................. 1

1.1
1.2
1.3
1.4
1.5
1.6
1.7

Periodic Maintenance ....................................................................................... 1

Maintenance Schedule ..................................................................................... 2
Spare Parts........................................................................................................... 2
On-site Service.................................................................................................... 2
Depressurizing the System ............................................................................. 3
Change of Circuit Board................................................................................... 4
Replacement of Viscosity Sensor ................................................................ 8

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FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS

1 COMPONENT SERVICE

1 Component Service
1.1 Periodic Maintenance
The 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 regasketing 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.

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FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS

1.2 Maintenance Schedule

Maintenance Guidelines
Component

Action

Time Interval

Complete Module

Operate the module with pure MDO for approx. 3

hours.

5000 hours

Pumps

Clear suction strainers

3000 hours (100 hours after

first start-up)

Inspection of mechanical seal and ball bearings.

8000 hours

Heaters

Inspection of flanged connections and temperature

performance. Check pressure drop.

6 months

Automatic filter

Clean the filter elements.

4 months

Change ball bearings.

12 months

Inspection of sensor and cleaning if necessary

12 months

Viscosity sensor

1.3 Spare Parts

Regional 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 Service

For 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.

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1 COMPONENT SERVICE

1.5 Depressurizing the

System

ON
CAUTI

Pressure Risk

X0 23 29 5A

Before starting maintenance work on the filters,

pumps, or viscosity block, release the pressure in
them.

Release the pressure as follows.

Open the by-pass line or standby system.

Turn off the flow to and from the component.

Remove the threaded ventilation nipple.

Screw in the supplied ventilation tube, holding

the other end of the tube over a recepticle.

When fuel has stopped draining from the

ventilation tube, open the drain plug to remove
the remaining fuel in the component.

Ventilation nipple

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.

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FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS

1.6 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.

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1 COMPONENT SERVICE

OP-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.

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FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS

Viscosity Circuit Board

Open the door of the EPC50V control unit.

Turn off the power with the main switch

(located on the right side of the cabinet).

Locate the Viscosity circuit board in the upper

left corner of the cabinet.

Unplug terminal J1, J6 and the contact for

voltage supply on the old board.

Dismount the four screws holding the board.

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.

Mount the four screws.

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.

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FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS

1 COMPONENT SERVICE

Screws
Cooling
flange
Terminal J6
Screws

Terminal J1
4-20 mA signal

Contact for voltage supply

Terminal X5

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FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS

1.7 Replacement of Viscosity Sensor

Stop the viscosity system by pressing the
stopbutton.

Turn off the power with the main switch

located on the inside of the cabinet.

Open the by-pass valves

Close valves in order to isolate the sensor.

Cool down the housing and sensor.

Depressurise the housing and sensor.

Remove the old sensor. Do not remove the

square flange.

X 02 25 43 A

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.

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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FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS

1 COMPONENT SERVICE

Mount the new sensor carefully.

NOTE

X0 23 96 2 A

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.

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FUEL CONDITIONING MODULE SERVICE INSTRUCTIONS

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