HIAC PODS GLYCOUNT - Particle Counters
Contents
1. Clean the instrument A Fire hazard Do not use flammable agents to clean the instrument NOTICE Make sure not to bend the pick up tube or scratch the lower end where the seal connection is made Damage causes leakage or misalignment with the online adapter 1 Clean the instrument with a cleaning brush and a clean glycol base solution 2 Flush the instrument Change the filter To remove the filter refer to Figure 5 16 English Figure 5 Filter removal Charge the battery Power the instrument with an internal rechargeable battery an external power supply The instrument operates on a fully charged internal battery for a minimum of 100 samples before the battery needs to be charged The external power supply is also used to charge the internal battery The instrument can be used while the internal battery charges Items to collect External power supply Power cord 1 Connect the power cord to the external power supply 2 Connect the other end of the power cord to an electrical outlet 3 Connect the external power supply jack to the instrument at the power port location located below the pressure gauge 4 Listen for a click sound Make sure that the Battery Charging Status light located on the keypad is turned on This light shows one of three charging status modes Indicator Status Steady green Charging Flashing green Maintenance mode2. Precautionary labels Read all labels and tags attached to the instrument Personal injury or damage to the instrument could occur if not observed A symbol if noted on the instrument will be included with a danger or caution statement in the manual A This symbol if noted on the instrument references the instruction manual for operation and or safety information Electrical equipment marked with this symbol may not be disposed of in European public disposal systems after 12 August of 2005 In conformity with European local and national regulations EU Directive 2002 96 EC European electrical equipment users must now return old or end of life equipment to the Producer for disposal at no charge to the user Note For return for recycling please contact the equipment producer or supplier for instructions on how to return end of life equipment producer supplied electrical accessories and all auxiliary items for proper disposal This symbol indicates the need for protective eye wear e Class 1 laser product This instrument is classified as a Class 1 laser product This product complies with IEC EN 60825 1 2007 and 21 CFR 1040 10 except for deviations pursuant to Laser Notice No 50 dated June 24 2007 US FDA Accession number 9912262 006 This product contains a 810 852 nm 50 mW class 3B laser that is not user serviceable 4 English Certification Canadian Radio Interference Causing Equipmen
3. notice or obligation Revised editions are found on the manufacturer s website Safety information NOTICE The manufacturer is not responsible for any damages due to misapplication or misuse of this product including without limitation direct incidental and consequential damages and disclaims such damages to the full extent permitted under applicable law The user is solely responsible to identify critical application risks and install appropriate mechanisms to protect processes during a possible equipment malfunction Please read this entire manual before unpacking setting up or operating this equipment Pay attention to all danger and caution statements Failure to do so could result in serious injury to the operator or damage to the equipment Make sure that the protection provided by this equipment is not impaired Do not use or install this equipment in any manner other than that specified in this manual Use of hazard information ADANGER Indicates a potentially or imminently hazardous situation which if not avoided will result in death or serious injury Indicates a potentially or imminently hazardous situation which if not avoided could result in death or serious injury Indicates a potentially hazardous situation that may result in minor or moderate injury Indicates a situation which if not avoided may cause damage to the instrument Information that requires special emphasis
4. the instrument automatically turns off PURGE VOL The volume of fluid that flows through the after 15 minutes of no activity Idle state ENBL Enabled or DSBL hydraulic hose and unit to purge any contamination before Disabled samples are taken The longer the hydraulic hose the greater the purge volume must be 15 999 ml STD Controls the standard format to show the sample results ISO C ISO NAS C NAS NAV C NAV SAE C SAE MIL P 10 ml or PM ml English 11 Table 4 Screen SIZ Programmable size menu When MODE is set to P 1 ml or P 10 ml the PG2 menu becomes available for any of the eight size channels to be programmed The minimum and maximum size program limit is 4 0 to 68 0 um The size must be programmed in an ascending order from the smallest size on channel 1 to the largest size on channel 8 Note If needed use F2 DEFAULT to reset all sizes to factory default settings Table 5 Screen I O Variable Description UNIT_ID Sets a unique device address that is used in the serial communication of the instrument MODBUS protocol 01 99 CNTRL Set to LOCAL when the instrument is manually operated Set to REMOTE when a computer program operates and controls the instrument sampling Set to DOWNLOAD when a computer program retrieves the records from the sample buffer only The setting of this variable can also be changed automatically through the seria
5. 5 Pressure gauge 2 Handle 6 Power input port 3 Shoulder strap D ring 7 RS232 port 4 Clean out port 8 Shop air port Product components Make sure that all components have been received Refer to Figure 3 If any items are missing or damaged contact the manufacturer or a sales representative immediately 6 English Figure 3 Instrument components 1 Instrument 4 Power cord 7 Printer paper 2x 2 AC power adapter 5 Sample bottle 10x 8 Cleaning brush 2x 3 CO bottle empty 6 Allen wrench 9 Software disc 2x Installation described in this section of the document A Multiple hazards Only qualified personnel must conduct the tasks Connect external pressure Connect the supplied CO bottle or shop air to the instrument to supply external pressure Connect the CO bottle ADANGER Multiple hazards Only qualified personnel must conduct the tasks described in this section of the document ADANGER Explosion hazard For the safe use of the instrument obey the precautions and the instructions as specifically described Personal injury hazard Enclosed systems contain high pressure gt Qualified personnel must remove pressure from the system before the instrument can be installed or removed Fire hazard Do not use flammable agents to clean the instrument The CO bottle is a compressed gas bottle under high pressure Do not alte
6. F3 for a period Push F4 to accept the new setting or push CANCEL to return to the Setup menu and keep the previous selection To see the test results in a different Standard Viscosity or Temperature set the variables and see or print the test results from the buffer Refer to Test results on page 15 10 English Table 2 Setup menu Table 2 Setup menu continued Variable Description Variable Description SAMPLE Shows a second menu Sample Text menu Under this menu VOL Volume of fluid that runs 3 times during a sample LABEL set the following items Volume RUN The BOTTLE mode sampling is limited 5 10 or SAMPLE LABEL SAMPLE NAME The user input name for 20 ml per RUN samples The sample labels limit is 10 characters For each FLOW The flow rate is fixed at 50 mL min sample label there is an auto counter extension that increments up to 500 This extension is reset to one every time a new PRINT Enables or disables the printer so that it does not automatically sample label is programmed re entered or exceeds a count of print at the end of a sample The SETUP option prints the 500 current instrument setup ENBL DSBL or SETUP REMARKS User input remarks for any additional sample ae q labeling as necessary These optional remarks become part of CONTRAST Use the navigation keys to control the display contrast the record of any completed samples Records ret
7. Steady red Battery charging failure Add printer paper 1 Open the printer door 2 Put the printer paper in the instrument so that the paper comes from the bottom of the roll 3 While the instrument power is set to on insert the paper into the printer and push LINE FEED The paper feeds through the printer English 17 4 Fold up the slack in the paper roll and push it into the paper holder Lift the free end of the paper and close the printer door 6 Remove the excess paper Note In the case of paper misalignment lift the lever on the left side of the printer to raise the printer carriage Pull the paper straight and align it Lower the carriage before the printer is operated am Remove the flow sensor blockages A Chemical exposure hazard Obey laboratory safety procedures and wear all of the personal protective equipment appropriate to the chemicals that are handled Refer to the current safety data sheets MSDS SDS for safety protocols NOTICE Excessive force can result in brush and possible cell damage If the brush does not go into the cell pull the brush out and examine the cleaning tip for damage Use all precautionary steps to prevent damage to the instrument and personal injury Items to collect Absorbent cloth Allen wrench Cleaning brush 1 Putan absorbent cloth under the instrument to catch any liquid that drains from the clean out port Refer to Figure 6 2 Putth
8. get hot near their end of charge cycle If ambient conditions are too hot then a battery over temperature condition can result and the red indicator illuminates Decrease the ambient or fluid temperature conditions Put the unit in a cool area until it cools off If it fails again replace the battery The battery is faulty Replace the battery 20 English Replacement parts and accessories Personal injury hazard Use of non approved parts may cause personal injury damage to the instrument or equipment malfunction The replacement parts in this section are approved by the manufacturer Note Product and Article numbers may vary for some selling regions Contact the appropriate distributor or refer to the company website for contact information Standard accessories Description Quantity Item no Reusable shipping container 1 SA 000197 01 Foam insert for shipping container 1 MP000172 01 02 Online adapter 1 SA000008 01 Shoulder strap 1 VP753400 AC DC power supply 1 VP624002 U S power cord 1 VP6235001 DOT rated CO bottles 1 VP760000 100 ml glass sample bottles 1 570 396 9217 Sensor brushes 2 SA000066 01 Printer paper 1 460 511 High pressure hose 1 VP350000 Ultrasonic Benchtop PC 3 1 690 500 1172 pe E E Optional accessories Description Item no Control software software utility for data collection 2087044 RS232 serial interface cable EP096010
9. particle count Maximum particles 100 mL in specified size range um Maximum contamination limits particles 100 mL Class 5 15 15 25 25 50 50 100 gt 100 Size gt 1 um gt 5 um gt 15um gt 25um gt 50um gt 100 um range 00 125 22 4 1 0 1 0 6 Sep 44 8 2 0 Size gt 4 um c gt 6um c gt gt gt gt 1 500 89 16 3 1 range 14 um c 21 um c 38 um c 70 um c 2 1000 178 32 6 1 Size A B C D E F 3 2000 356 63 11 2 code 4 4000 712 126 22 4 o 195 16 14 3 1 0 5 8000 1425 253 45 8 Class 390 152 27 5 1 0 6 16 000 2850 506 90 16 00 7 32 000 5700 1012 180 32 o 780 304 54 10 2 0 8 64 000 11 400 2025 360 64 Class 1560 609 109 20 4 1 9 128 000 22 800 4050 720 128 1 10 256 000 45 600 8100 1440 256 Class 3120 1220 217 39 7 1 2 11 512 000 91 200 16 200 2880 512 Class 6250 2430 432 76 13 2 12 1 024 000 182 400 32 400 5760 1024 3 mM Class 12 500 4860 864 152 26 4 Table 11 Equivalent APC sizes that relate to calibration method 4 Code and size Particle sizes Class 25 000 9730 1730 306 53 8 5 ISO 11171 Size um c 24 26 gt 14 gt 21 gt 38 gt 70 Class 50 000 19 500 3460 612 106 16 ISO 4402 Size um gt 1 gt 5 gt 15 gt 25 gt 50 gt 100 6 Class 100 000 38 900 6920 1220 212 32 7 Class 200 000 77 900 13 900 2450 424 64 8 English 23 Table 12
10. tested 4 From the main menu push F4 to go to the flush menu 5 Push START The fluid goes out of the drain port and the amount of fluid is shown on the display 6 When the fluid is flushed push CANCEL to stop the flush process and return to the main menu Note If the power is set to off while the system is flushed it causes the internal flow controller to stay open and allows fluid to continue to flow Always cancel the flushing process and allow five seconds to pass before the instrument power is set to off Note The system stays pressurized after the pressure source is removed To remove the system pressure remove the pressure source and push START or select SOL ON and then SOL OFF until the pressure gauge reads O psi Fluid compatibility The instrument is compatible with most petroleum and phosphate ester based fluids within the specified viscosity and temperature ranges If the compatibility of a fluid is in question compare the compatibility to the wetted material list included in the Specifications on page 3 If the compatibility cannot be found submit a request to a local manufacturer representative for a recommendation on the fluid use within the instrument The internal components of this instrument are not compatible with water Water causes instrument malfunction and damage The instrument is only compatible with fluids that contain lubricating properties Take a sample in the bottle mode Put a s
11. the current mode of operation for the charging CHARGING STATUS light system For more information refer to Charge the battery on page 17 Alphanumeric keys Adds letters and numbers into the program For more information refer to Set the operation variables on page 10 Function keys 6 POWER 2 LINE FEED 7 BATTERY CHARGING STATUS light 3 CANCEL 8 Alphanumeric keys 4 START 9 Navigation keys Display Feature Description Function keys Push the function key to activate an attribute on the screen LINE FEED Moves the printer paper Navigation keys Selects operating variables and moves the cursor left and right English 9 See the system status menu parameters Push F3 SYS in the main menu to get the system status menu Table 1 shows various system parameters that the instrument measures These system parameters show convenient information and diagnostic troubleshooting Table 1 System parameters Parameter Power supply Description Shows whether the instrument is connected to the external power supply or it is operated from the internal battery When an external power supply is used the battery icon shows that the internal battery is controlled by the external power supply When the internal battery is used the battery icon shows the remaining relative battery supply voltage capacity The useful battery voltage range for the instrument is 11
12. to four internal standard settings Table 9 Table 12 Select the applicable standard during setup The selected standard is printed and kept in memory At the time of printing no cleanliness standard except ISO 4406 1999 specifies a specific calibration method Usually users work with ACFTD calibrations since ACFTD is no longer considered valid calibration material particle counter manufacturers must change to ISO MTD calibrations The other standards also have to use the ISO MTD sizes if the cleanliness codes remain the same Table 9 ISO 4406 1987 E Table 9 ISO 4406 1987 E continued Number of particles per milliliters counts mL Scale number Number of particles per milliliters counts mL Scale number More than Up to and includes 640 1300 17 320 640 16 160 320 15 80 160 14 40 80 13 20 40 12 10 20 11 5 10 10 2 5 5 9 1 3 2 5 8 0 64 1 3 7 0 32 0 64 6 0 16 0 32 5 0 08 0 16 4 0 04 0 08 3 0 02 0 04 2 0 01 0 02 1 0 0 01 1 More than Up to and includes 2 500 000 gt 28 1 300 000 2 500 000 28 640 000 1 300 000 27 320 000 640 000 26 160 000 320 000 25 80 000 160 000 24 40 000 80 000 23 20 000 40 000 22 10 000 20 000 21 5000 10 000 20 2500 5000 19 1300 2500 18 22 English Table 10 NAS 1638 Contamination Classification System Table 12 SAE AS4059 cleanliness levels by
13. vessel used for sample delivery through the instrument It is critical that it is installed in the locked position before sampling The bottle adapter must be aligned on the instrument and in the locked position Item to collect Clean lubricant for ease of use and to prevent damage to the O ring 1 Examine the threads and the O ring on the bottle for damage Turn the bottle clockwise into the CO port As the bottle turns into the CO port the bottle valve opens and pressure is applied to the instrument When this occurs the bottle becomes difficult to turn Turn the bottle another turn until the bottle stops If CO is released around the bottle threads when this pressurization occurs remove the CO bottle and examine the O ring for damage m D Connect the shop air source Qualified personnel must remove pressure from the system before the instrument can be installed or removed Personal injury hazard Enclosed systems contain high pressure The compressed air source must be clean dry and between 620 to 758 kPa 90 to 100 psi 6 2 to 7 6 bar 1 If the shop air nipple is the wrong type install a new nipple A g inch male NPT connection is required 2 Make sure that the port threads are clean 3 Connect the shop air to the instrument and tighten Connect the communications cables The instrument has an RS232 communications port installed Use this port to communicate with a comput
14. 5 to 13 8 volts The amount of battery life that stays below this range is minimal so charge the battery before operation is continued Internal temperature Shows only the temperature inside the instrument enclosure This measurement tells if the temperature is too hot or cold to do a sample test Printer status Shows the different status conditions or errors of the internal printer If the printer is good a condition of NORMAL shows An error message shows if a problem exists For an explanation of these error codes refer to Troubleshooting on page 19 Set the operation variables The operation variables are located under the Setup menu Refer to Table 2 Table 6 To set an operation variable 1 Push F1 SETUP to get the Setup menu 2 Push the numeric number on the keypad that corresponds to the number on the left side of the variable to program 3 Push F1 PRG and use the navigation keys to select the proper setting or use the keypad to input numbers letters or symbols To add letters a Push the numeric key that contains the letter to use in succession b Push once for the number twice for the first letter three times for the second letter etc The time between the key pushes tells if the current character is selected or if the next character is selected To add symbols a Push the function key that shows the symbol to be used b Push F1 for a space F2 for a forward slash and
15. DOC026 53 80184 6 HIAC PODS GLYCOUNT COULTER 10 2013 Edition 3 User Manual Table of Contents SDeCIIICatlOlls Ed ce sae de dad copia Latin a a 3 General Information an a NA e GS uo Lae eds 4 oatety InfOrmiatlOr te Mate Are A te ange de DO aa 4 Use of hazard information ii ic 4 A A A 4 Class 1 laser producir A AA e a a eva 4 Certification 2552 iei er A A AA eene 5 Product Overview rene entire ent he dm need ia 5 Product components 2 ne trente a Ine de aaa 6 n Ep NOE ROTE ETT 7 Gonnect exterrial pressure cotidiana eee Dern stg i ec Vase ERE Ze ce gu deen ERR n Ee Ede Rene Goad Ene PAR cate Seas 7 Connect the COZ Bottle viii a onto 7 Connect the shop air source as ant 8 Connect the communications cables e at MR iei ie Nan pa derit e eda ete ntm ete a 8 Connect the external power supply 4 ee ed a e eve A ten gea 8 SIJFIUD cuore bu itte e dba dc dto Ee ete t e tro RER ER den tb TER SERRE TE I EEE 8 Power up and self test verification oes nee ire idee det ile lere ban ida redire dne de Lande idee de dne ye dress 8 User interface and navigation nt digo ete ue dt 9 Keypad descriplioni z 55 5 erbe teh Era e HORE etr D inte ORE Teu RE OH ORA Re diei ema 9 See the system status menu parameters ummm teca 10 Set the Tee Ir ee aciei m 10 STEN ON PST D PM 12 Procedure to lake a Sample ista e reet toe xe este ter tdeo ciae am
16. Prepare for shipping Note The instrument must be sent back with a decontamination certificate To get a certificate contact the manufacturer If residual oil stays in the flow path of the counter the optical switches that operate the flow controller may be contaminated with oil during transportation Potential issues are a Flow Controller Failure error message or the keypad may not operate Do the steps that follow before transportation 1 Remove any sample bottles from the sample bottle adapter 2 Attach the sample bottle adapter to the instrument 3 Do a flush procedure without any fluid in the adapter From the main menu push F4 to go to the Flush menu Push START 4 Push F1 CO ON 5 Flush the air until the flow meter switches on and the fluid in the System moves into the waste container 6 Push F2 CO OFF to stop the purge process 7 Remove the waste container and remove the contents from the container Let the container drip dry 8 Attach the waste container to the instrument 9 Attach the protective cap to the sample inlet probe 10 Complete the decontamination certificate Appendix Particle count and other codes The instrument is equipped to handle four cleanliness standards English 21 ISO 4406 1999 for NIST ISO 11171 um c internally named ISO C ISO 4406 1999 for ACFTD ISO 4402 sizes um internally named ISOACF NAS 1638 1992 SAE AS4059 The cleanliness standards correlate
17. SAE AS4059 cleanliness levels by particle count continued 1 APC Calibrated per ISO 4402 1991 2 APC Calibrated per ISO 11171 or Electron Microscope based on projected area equivalent diameter Maximum contamination limits particles 100 mL 400 000 156 000 27 700 4900 848 128 is 800 000 311 000 55 400 9800 1700 256 um 1 600 000 623 000 111 000 19 600 3390 512 ne 3 200 000 1 250 000 222 000 39 200 6780 1020 Optical microscope based on longest dimension as measured per ARP598 or 24 English I Beckman Coulter Inc Beckman Coulter do Brasil Com e Imp de Prod de Lab Ltda 250 S Kraemer Blvd Estr dos Romeiros 220 Galpao G3 Km 38 5 Brea CA 92821 U S A 06501 001 Sao Paulo SP Brasil www particle com CNPJ 42 160 812 0001 44 Sus N 7 v 02 y eb meras SEWA EM KR WLRKAW ETA SETS Brea ili S Kraemer Xf 250 5 Ilii 92821 TOC HU zx F 7 Hie 001 714 993 5321 Beckman Coulter Inc 2011 2013 All rights reserved Printed in U S A
18. ample fluid in the bottle adapter Connect the adapter to the instrument From the main menu push F1 SETUP to go to the setup menu Set the sampling mode to BOTTLE and make sure that the other operation variables are programmed as needed For more information refer to Specifications on page 3 Boo m 5 Make sure that a CO bottle or shop air is connected to the instrument 6 Make sure that there is 90 to 110 psi 6 2 to 7 6 bar shown on the pressure gauge Due to regulation variances the pressure shown on the pressure gauge moves up to 120 psi 8 3 bar during no flow conditions The pressure drops when a sample is started 7 Turn the bottle adapter counterclockwise to disconnect it from the instrument 8 Fill a sample bottle with the fluid to be tested 9 Putthe sample bottle into the bottle adapter 10 Connect the sample adapter to the instrument 11 Make sure that the waste bottle holds the fluid 12 Push START The sampling process begins When this process is complete the test results are put in the buffer shown on the display and or printed Take a sample in the online mode In the online mode a sample moves directly from a hydraulic system The CO or shop air external pressure sources are not used in this mode but they remain connected during the sampling process 1 From the main menu push F1 SETUP to go to the setup menu 2 Set the sampling mode to ONLINE and set the program to the number of runs
19. d ende redde ced nde a dai ete qe deese ds 18 e ero A A N 18 Troubleshooling oce eiie lues titu et bem tendi dd dite segetes 19 Replacement parts and accessories tette tnt 21 Prepare Tor shipping oreet eem e CORTE RR e TRIER itr AGR NAT a eim 21 ADH RER A q etr orn 21 Particle co nt and oth r codes rre E e rie Ee etu Ver pere A ene a 21 Specifications Specifications are subject to change without notice Specification Details Altitude 2000 m 6561 7 feet Specification Details Certifications CE Dimensions D x W x H Weight 18 5 x 33 0 x 40 0 om 7 3 x 12 5 x 15 7 in 9 3 kg 20 5 Ib Bottle operation Number of channels 8 Sample volume 3 runs averaged of 5 10 or 20 ml run programmable Size channels ISO MTD 4 4 6 6 9 8 14 21 2 38 68 um ACFTD 1 2 5 10 25 50 100 um Purge volume 15 to 30 ml programmable Pressure cartridge CO replaceable rechargeable Flow rate 50 ml min Operating time 60 samples 120 ml sample bottle Light source Class 3B laser 810 852 nm 50 mW maximum Shop air 620 to 758 kPa 90 to 110 psi 6 2 to 7 6 bar Calibration PSL spheres in water ISO MTD in glycol Online operation Counting efficiency JIS B9925 1997 Sample volume 3 runs averaged of 5 10 20 50 or 100 ml run programmable Concentra
20. ded in a fluid sample the sample contains concentrations beyond the saturation limits of the instrument The average person only sees particles greater than 40 um in size Use the fluid sampling vacuum pump to take sample fluid from reservoirs 1 Cuta length of clean tube that extends from the fluid in the reservoir to a point accessible from outside the reservoir 2 Connect a clean sample bottle to the fluid sampling vacuum pump VP633001 Install one end of the tube to the pump so that it extends into the sample bottle and tighten the knob 3 Install the other end of the tube into the reservoir Do not contaminate the end of the tube 4 Use the pump to fill the sample bottle to the applicable level 5 Disconnect the sample bottle from the pump 6 Install the cap until the sample is ready to test Prepare to take an online measurement Suitable places for an online measurement include Upstream of the high pressure filter condition after pump Upstream of the return filter condition after system Upstream of the bypass filter tank condition 1 Disconnect the hydraulic hose that connects the instrument to the System to be tested 2 Remove the previously tested fluid 3 Set the purge volume to two times the internal volume of the hydraulic hose 4 Speak to an application specialist before the port installation Note Do not install any additional fluid control devices on the hydraulic sample hose or the syste
21. e brush into the clean out port until there is resistance 3 Gently push the brush into the sensor flow cell with a twisting motion 4 Operate the instrument with clean sample fluid To purge any trapped air in the clean out line a Put an absorbent cloth over the wrench and slightly loosen the clean out cap while the sample run is in progress Fluid and air come out quickly when the cap is loosened b Continue the process until no more air comes from the port 5 Tighten the clean out port cap snugly To avoid damage to the threads do not over tighten the cap Figure 6 Sensor blockage removal Calibration Return the instrument annually for calibration The calibration date is shown on the calibration sticker that is located on the serial plate inside the left side door behind the waste container Each instrument is calibrated at the factory 18 English Troubleshooting For help with potential problems refer to Table 7 and Table 8 If the program malfunctions and the instrument needs to be reset to the default settings push and hold F4 while the power is cycled Note This erases all buffer contents and all of the operation variables to their factory settings A default message and the firmware part number are shown as the instrument initializes its systems again Table 7 Critical errors Table 7 Critical errors continued Error Possible cause Solution Error Possible cause Solut
22. eporting the run volume gives the lowest level of the contamination code For a run volume of 5 ml the lowest reported ISO code level is 03 03 03 Fora run volume of 10 ml the lowest reported ISO code level is 02 02 02 Fora run volume of 20 ml the lowest reported ISO code level is 01 01 01 For additional information on this subject refer to ISO 4406 Hydraulic fluid power Fluids Code to calculate the level of contamination by solid particles The temperature shown is the temperature at the end of the hydraulic circuit inside the flow controller It is not a measurement of the incoming fluid temperature The hydraulic circuit has thermal masses that influence the temperature of the fluid Ifthe instrument is colder than the fluid there is a temperature drop of the fluid while the fluid is sampled Ifthe instrument is hotter there is a temperature increase while the fluid is sampled Interpretation of results Compare the reported results to the corresponding target ranges for the system that is tested Fluid treatment or replacement can then be given Buffer operation See the contents 1 Use the buffer menu to see the contents of the buffer LAST SAMPLE shows the results of the last sample LIST BUFFER shows the eight most recent sample names for further review SEARCH BUFFER searches for a particular sample name Enter the entire or partial name of the sample 2 Once a samp
23. er for data acquisition analysis and remote operation Baudrate 9600 Data bits 8 Parity None Stop bits 2 If the computer or terminal has a 9 pin serial port with a male connector use a standard serial cable that has a male end and a female end The instrument is already configured as Data Communication Equipment DCE A null modem cable is not necessary Connect the external power supply If an external power supply is used obey the instructions in Charge the battery on page 17 Startup Power up and self test verification Push POWER and the startup screen shows then the initialization Screen shows the serial number and firmware revision level of the instrument At this point the instrument examines its internal systems for any problems If a problem is found the instrument shows an error message Refer to Troubleshooting on page 19 8 English User interface and navigation Keypad description Figure 4 shows the features included on the keypad Figure 4 Keyboard features 4 DDD E N O BATTERY CHARGING STATUS SOC Feature Description CANCEL Cancels a sample test or cancel a programming function and maintain the previous selection START Starts a sample test Display Shows the information on the counting process error codes sample test results and the status of the operating variables POWER Sets the power on and off BATTERY Shows
24. ernal air source is stable and set near 100 psi Decrease the flow rate especially with high viscosity fluids Make sure that there are no leaks on the sample cup O ring SNSR FLOW CELL ERROR There is a blockage in the sensor cell within the view area and the detector does not see the laser light Do the cell cleaning procedure as described in Remove the flow sensor blockages on page 18 The amount of sample fluid is not sufficient The sensor is out of calibration This results in a low signal Add more sample fluid Return the unit to the factory for calibration or repair The sample is contaminated with water or high particle contamination Remove the water or try another sample If the sample is highly contaminated dilute the sample The laser or sensor electronics failed GlyCount only Return the unit to the factory for calibration or repair The sample fluid viscosity is too high PODS only Decrease the flow rate or dilute the sample with a suitable clean filtered and miscible fluid that will decrease the sampling viscosity to within the range of the counter 10 424 cSt There is an internal hydraulic regulator failure or adjustment setting that is out of tolerance Contact technical support The unit could have been put in a high temperature location Attempts to charge battery in a higher than normal ambient temperature condition Batteries
25. ge in the viscosity of the sample fluid Purge the instrument The sample fluid viscosity is too high PODS only Decrease the flow rate or dilute the sample with a suitable clean filtered and miscible fluid that will decrease the sampling viscosity to within the range of the counter 10 424 cSt The pick up tube cap was not removed Remove the cap English 19 Table 7 Critical errors continued Table 8 Non critical errors Error Possible cause Solution Error Possible cause Solution Hydraulic pressure for online sampling is not sufficient The hydraulic pressure source is not sufficient Make sure that the fluid pressure is more than 40 psi for all of the sample period Make sure that there are no leaks on the online adapter O ring High pressure found An internal hydraulic regulator failure occurred or the adjustment setting is out of tolerance Contact technical support Low pressure The external pressure source is not sufficient Make sure that the external air source is stable and set near 100 psi Decrease the flow rate especially with high viscosity fluids Make sure that there are no leaks on the sample cup O ring The pick up tube cap is installed Remove the pick up tube cap Pressure dropped to a level that is not sufficient The external pressure was decreased during the sample test Make sure that the ext
26. he user will be required to correct the interference at their expense The following techniques can be used to reduce interference problems 1 Disconnect the equipment from its power source to verify that it is or is not the source of the interference 2 If the equipment is connected to the same outlet as the device experiencing interference connect the equipment to a different outlet 3 Move the equipment away from the device receiving the interference 4 Reposition the receiving antenna for the device receiving the interference 5 Try combinations of the above Product overview The Portable Glycol Analysis System GlyCount is used to measure keep and report glycol contamination data that is important for reliable filter system operation The instrument takes an analysis of pressurized fluids and lubricants in online or bottle sampling modes without disruption of machine operations The instrument is compatible with glycol hydraulic fluids The instrument comes with refillable CO bottles for use in the field and a shop air port fitting for in house operation For different views of the instrument refer to Figure 1 and Figure 2 Note Due to U S shipping restrictions the instrument is shipped with empty CO bottles English 5 Figure 1 Product overview Figure 2 Side view 1 Printer door 4 CO bottle 2 Display 3 Keypad 5 Sample bottle adapter 1 Waste bottle
27. hold time and purge volume The purge volume should be approximately twice the internal volume of the hydraulic tube that connects the instrument to the system 3 Make sure that the other operation variables are programmed as needed For more information refer to 4 To connect the online adapter to the instrument move the pick up tube into the hole in the center of the adapter and turn the tube clockwise until the adapter is locked 5 Connect a hydraulic hose with a Minimesse1 test hose thread to the online adapter 6 Connect the other end of the hydraulic hose to the system to be tested 7 Push START The sampling process begins 14 English When this process is complete the test results are put in the buffer shown on the display and or printed Note If the power is set to off while the instrument is flushed it causes the internal flow controller to remain open and allows fluid to move Always cancel the flushing process and allow five seconds to pass before the instrument power is set to off Test results The count data shows the number of counts per individual run and the average of the three runs A test report shows Sample type Serial number of the unit that took the sample Date and time the sample was taken Volume per sample run Flow rate Measured viscosity Measured fluid temperature Concentration units Measured cleanliness format Count data per micron size For ISO Standard r
28. ion Flow controller failure The unit is unable to find the HOME switch on the flow controller during System initialization or at the end of a sample test Start the instrument again There is a flow controller malfunction Contact technical support Flow regulation failure The external pressure was decreased during the sample test Make sure that the external air Source is stable and set near 100 psi Make sure that there are no leaks on the sample cup O ring The instrument was not purged before a change in The viscosity of the sample fluid occurred Purge the instrument The amount of sample fluid is not sufficient Add more sample fluid There was an attempt to flush the system GlyCount only Flush the instrument Make sure that sample fluid stays in the flow path There is trapped air in the internal hydraulic tubing PODS only Remove the air from the internal hydraulic tubing including the clean out port with a clean fluid The instrument was not purged before a change in the viscosity of the sample fluid occurred PODS only Clean the system with a new fluid Low flow rate possible high viscosity External pressure was decreased during sample test Make sure that the external air Source is stable and set near 100 psi Make sure that there are no leaks on the sample cup O ring The instrument was not purged before a chan
29. l MODBUS protocol LOCAL REMOTE or DOWNLOAD Table 6 Screen CLK Variable Description TIME Current time in 24 hour format Hours Minutes Seconds DATE Current date Month Day Year Operation A Chemical exposure hazard Obey laboratory safety procedures and wear all of the personal protective equipment appropriate to the chemicals that are handled Refer to the current safety data sheets MSDS SDS for safety protocols Chemical exposure hazard Dispose of chemicals and wastes in accordance with local regional and national regulations Procedure to take a sample Use proper techniques to take a sample It is important to get a representative sample of the contamination level of the system under test Take the sample from a source with moving fluid Note If the sample is taken from a slow moving stream a non representative sample can result Let the system run for at least 30 minutes before a sample is taken Note The Filter mode is no longer active Use one of the other modes to take a sample When a series of tests is complete there is still some sample inside the instrument This instrument must be flushed with a fluid that does not contaminate the next sample To flush the instrument 1 Use the same fluid type as intended for the next sample Do not mix fluid types If other fluid types are used fluid incompatibility causes sampling errors 2 If an online operation is used the instrument is flushed
30. le selection has been made push the corresponding function keys to see the next sample or the previous sample The buffer contents are shown in the currently programmed configuration 3 To show the results in a different configuration change the operation variables to another configuration and look at the buffer contents again Delete or print data Use the buffer menu to delete or print the buffer contents 1 Push F2 DEL BUF to delete the entire buffer contents The instrument shows a confirmation message and asks for the operation to be accepted or cancelled 2 Push F3 PRT BUF to print the entire buffer contents The instrument shows a confirmation message and asks for the operation to be accepted or cancelled 3 Push F1 DEL SMP or F2 PRT SMP while in the average count AVG CNT menu to delete or print an individual sample test result English 15 When a sample selection is shown the average count menu is available See the sample data When a sample selection is made the instrument shows the sample statistics for that particular sample Push the average count AVG CNT function key to see the remainder of the sample data Maintenance ADANGER Multiple hazards Only qualified personnel must conduct the tasks described in this section of the document is a laser based instrument and the user risks injury if exposed to the Personal injury hazard Never remove covers from the instrument This laser
31. m test port These devices make bubbles and create particle traps that cause sample inaccuracies Flush the instrument in bottle mode Note If the flushed volume exceeds the amount of fluid in the bottle adapter pneumatic pressure is flushed through the instrument and out of the drain port This creates air pockets in the hydraulic system and leads to sampling errors 1 Make sure that a CO bottle or shop air is connected to the instrument and that the pressure gauge shows 90 to 110 psi 6 2 to 7 6 bar 2 Turn the bottle adapter counterclockwise to disconnect the adapter from the instrument 3 Fill a sample bottle with the fluid to be flushed 4 Putthe sample bottle into the bottle adapter and connect it to the instrument 5 From the main menu push F4 to go to the flush menu 6 Push START 7 Push F1 SOL ON The bottle adapter pressurizes and fluid begins to exit the drain port The amount of fluid that is flushed is shown on the display 8 When the fluid has been flushed push CANCEL to stop the fluid and return to the main menu Flush the instrument in the online mode 1 Connect the online adapter to the instrument Move the pick up tube into the hole in the center of the adapter and turn the adapter clockwise until the pick up tube is locked 2 Connect a hydraulic hose with a Minimess test hose thread to the online adapter English 13 3 Connect the other end of the hydraulic hose to the system to be
32. r this bottle in any way Use only CO bottles that are supplied by the manufacturer Use the bottle only as directed in this manual For storage and disposal of the bottle refer to the text on the bottle Do not expose the pressurized bottle to temperatures in excess of 177 C 350 F Bottles exposed to a fire or heated to temperatures in excess of 177 C 350 F should be discarded Let the temperature of the bottle cool before it is discarded Keep the protective cap on the CO bottles that are not in use Valves must be installed or removed only by trained personnel Use only a mild detergent and water to clean the cylinder Use of caustic cleaners may corrode pressure fittings or tank walls and cause an uncontrolled pressure release or rupture English 7 Make sure that the bottle adapter is installed properly when pressurization begins If the bottle adapter is not installed properly it comes off the instrument and personal injury and or damage to the instrument occurs Due to multiple shipping rules and regulations the CO bottles supplied in the shipping container are empty Make sure that the bottles are filled by a certified CO supplier NOTICE Do not remove or cover the label on the bottle NOTICE This bottle must only be filled and transported by properly trained personnel in accordance with compressed gas bottle filling regulations of the local jurisdiction NOTICE The bottle adapter is a pressure
33. rieved from the sample buffer can have their remarks reviewed and re Table 3 Screen PG 2 edited as necessary The sample remarks limit is 10 characters on any of 3 lines Any existing remarks show on printed sample Variable Description reports LANG Shows the language used in the operation and control of the MODE Sampling method BOTTLE or ONLINE or FILTER instrument English French German Span and Ital If BOTTLE mode is selected or re entered a second screen is ar x shown and it allows the following variable to be set TEMP Shows the temperature units C or F PURGE VOL Volume of fluid that flows through the PRESS Shows the pressure units BAR or PSI instrument to purge any contamination before samples are taken 15 30 ml DISPL Controls the brightness of the background light background Normal If ONLINE mode is selected or re entered a second screen is or dark background Reversed NORM or REV shown and it allows the following variable to be set BKLT Controls the back light on the LCD display If AUTO is selected the NUM SAMPLES Numbers of samples that run during the back light turns off after 5 minutes of inactivity ON OFF or AUTO sampling period 1 500 HOLD TIME Time delay from the end of a sample to the start BEEP EE audio feedback of the beeper when a key is pushed KEY or of the next sample If set for 00 00 a minimum 5 second hold time is set hh mm BSAVE Battery save feature If enabled
34. t Mee ena d eee tef pese Rak 12 Prepare to take a sample with a bottle issues 12 Prepare to take an online measurement siennes 13 Flush the instrument in bottle mode e Lei edt nt tante Mean ode Dig dee dtque doe denses 13 Flush the instrument iri the online mode 2 ain nee pese eae eto Ergo d een ne een ee nee net 13 Fluid compatibility s2aes2222san02e 14 Take a sample in the bottle mode ects cen anae cee tnnt test tt tetett EEES sinere ness t siet nntes isset nana acena sess nnetns sais rne rein nes ense ns 14 Table of Contents Take a sample in the online mode siennes 14 Test results iowa we eo a ne ie en ea eee se 15 Buffer operation iia 15 See lh contents ss assess E 15 Delete or print data Ars x a eats ad Sick a DSO do dom teet Dada MA ac a d en Eu ias 15 See the sample dat cies RE iin eel al ad 16 cl A o 16 Clean the instrumento doc Aids 16 Ghange the Mieres ct Eth tiene be Ec hd eta ab teeta e Behe ente he Zach teh e tert Id A ac ee eee aa 16 Gharge the battery fs ra RU hy E A ages ae nine Ead eo Dep rui Dro et ane lea ee bit og al tunity tad bach sa malice 17 Add printer paper uidere eer e eR A sun MEDI RI DU ae 17 Remove the flow sensor blockages 2 eite ester tcc iden then a eeepc d nde seed nee reuse pe doe ice
35. t Regulation IECS 003 Class A Supporting test records reside with the manufacturer This Class A digital apparatus meets all requirements of the Canadian Interference Causing Equipment Regulations Cet appareil num rique de classe A r pond a toutes les exigences de la r glementation canadienne sur les quipements provoquant des interf rences FCC Part 15 Class A Limits Supporting test records reside with the manufacturer The device complies with Part 15 of the FCC Rules Operation is subject to the following conditions 1 The equipment may not cause harmful interference 2 The equipment must accept any interference received including interference that may cause undesired operation Changes or modifications to this equipment not expressly approved by the party responsible for compliance could void the user s authority to operate the equipment This equipment has been tested and found to comply with the limits for a Class A digital device pursuant to Part 15 of the FCC rules These limits are designed to provide reasonable protection against harmful interference when the equipment is operated in a commercial environment This equipment generates uses and can radiate radio frequency energy and if not installed and used in accordance with the instruction manual may cause harmful interference to radio communications Operation of this equipment in a residential area is likely to cause harmful interference in which case t
36. tion limit 20 000 particles per ml 5 coincidence loss per ISO 11171 30 000 particles ml 10 coincidence Purge volume 25 to 999 ml programmable Fluid pressure 690 to 20684 kPa 100 to 3000 psi 7 to 207 bar Fluid temperature range 0 to 65 C at 25 C ambient 32 to 150 F at 77 F Measured fluid temperature 0 to 65 C 0 5 C 32 to 150 F 0 9 F Power DC input 24 VDC 2 Amaximum AC adapter Universal 100 240 VAC 50 60 Hz 60 W Viscosity range 2 to 50 cSt Rechargable battery Nickel metal hydride Wetted materials Brass stainless steel sapphire PTFE and Aflas Operating time 100 samples or 4 hours continuous Recharge time 2 5 hours Cleanliness classification ISO 4406 1991 ISO 4406 1999 NAS 1638 SAE AS 4059 Data storage 500 sample records Environment Operating environment 0 to 50 C 32 to 122 F 20 to 85 relative humidity non condensing Input output serial communication RS232 Storage 40 to 70 C 40 to 158 F up to 98 relative humidity non condensing English 3 General information In no event will the manufacturer be liable for direct indirect special incidental or consequential damages resulting from any defect or omission in this manual The manufacturer reserves the right to make changes in this manual and the products it describes at any time without
37. with the fluid to be tested For proper flush of the instrument the flush volume must be approximately twice that of the internal volume of the hydraulic hose that connects the instrument to the system to be tested 3 Do a maximum flush before a sample is taken to make sure that an accurate sample measurement To flush the instrument refer to Flush the instrument in bottle mode on page 13 or Flush the instrument in the online mode on page 13 Note An excessive amount of flushes causes prematurely clogged filters Prepare to take a sample with a bottle Common sources of contamination inadvertently added to fluid samples come from the bottles pick up tube and airborne particles Use only clean sample bottles and keep them covered at all times 12 English Sample inaccuracies result from excessive air bubbles and water contamination Both are counted as particles To remove the air bubbles apply a vacuum to the sample in a vacuum chamber or put the sample in an ultrasonic bath for several seconds Particles settle to the bottom of a sample bottle within minutes so a sample should be shaken to re suspend the particles and degassed to remove bubbles Highly contaminated samples soak the sensor and make the particle count data invalid The instrument limit is 20 000 particles per ml at 5 coincidence loss per 15011171 and 30 000 particles per ml at 10 coincidence loss of fluid for a specific size If contamination is seen suspen
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