CML2/User Guide
Contents
1. 3 4 5 1 Pushbuttons e F Black Toggles the flush valve open and closed e I Green Starts a test O Red Aborts a test Cleanliness Codes 1504406 Code The test result is displayed as a three part code e g 22 19 16 NAS1638 AS4059E 1 Class A single number is displayed which is the highest recorded in all of the sizes e g NAS 8 AS4059E 2 single number is displayed which is the highest recorded for all of the sizes e g AS 7 Using the Pushbuttons All new CML2 s are factory set to perform a normal test which consists of one test sampling 15ml of fluid Other test types can be selected using a PC running LPA View refer to page 19 When running a Normal test the user will first make the oil and power supply connections as described on page 12 Follow the actions below to perform a Normal test Press Flush Pushbutton F This will open the flush valve to allow fluid to pass through the CML2 so that any fluid from the previous test is flushed out of the 16 Pushbutton Operation connecting pipe to eliminate the possibility of cross contamination between tests The time for which the flush valve is left open de pends on the distance of the CML2 from the system being sampled As a guide a 200ml flush volume is recommended when using the 1 5m long test hose After the 200ml flush volume has been discharged to waste the flush valve may be manually closed by again pressing pushbutton F2. CML2 User Guide MPFILT EI O www mpfiltri co uk 200 051 EN Covers Model Numbers CML2 SAFETY WARNING Hydraulic systems contain dangerous fluids at high pressures and temperatures Installation servicing and adjustment is only to be performed by qualified personnel Do not tamper with this device DocuMENT REVISION 4 1 Contents 1 Precautions 5 Internal Cleaning Battery 2 Introduction 6 3 Scope of Supply 11 4 Connection 12 Methods of Operation 5 Pushbutton Operation 14 Using the Pushbuttons Downloading the Results 6 PC Operation 19 Using the Computer Serial Port Determining the COM Port USB Port Operating the CML2 Log Settings 7 Normal Test 28 CML2 without Moisture Sensor CML2 W with Moisture Sensor 8 Continuous Sampling 30 Continuous Test Basic Operation With Moisture Sensor 9 Moisture Sensor 38 10 Bottle Sampling 40 11 Battery Charging series 41 only 41 12 Warranty Recalibration A Measuring Water in Hydraulic and Lubricating Fluids B 1S04406 1999 Cleanliness Code System C NAS1638 Cleanliness Code System D SAE AS4059 REV E Cleanliness Classification For Hydraulic Fluids E Recommendations F Hydraulic System Target Cleanliness Levels G New ISO Medium Test Dust and its effect on ISO Contamination Control Standards Calibration New Test Dust Benefits Effect on Industry Other Standards H Clean working practises Specification J Spare Pro
3. MP FILTRI FRANCE Tel 33 1 40 86 47 00 Fax 33 1 40 86 47 09 Email contact mpfiltrifrance com Website www mpfiltri com INDIA MP FILTRI INDIA Tel 91 9945599899 Email s mishra mpfiltri com Website www mpfiltri com RUSSIAN FEDERATION MP FILTRI RUSSIA INC Phone mobile 7 095 502 5411 Fax 7 095 205 9410 Email mpfiltrirussia yahoo com Website www mpfiltri ru USA MP FILTRI USA Inc Tel 1 215 529 1300 Fax 1 215 529 1902 Email sales mpfiltriusa com Website www mpfiltriusa com UAE MP FILTRI UEA Tel 91 9945599899 Email s mishra mpfiltri com Website www mpfiltri com
4. e Improved levels of particle count reproducibility with different equip ment e More accurate and consistent filter test results Effect on Industry The introduction of ISO MTD has necessitated changes to certain ISO stan dards 56 New ISO MEDIUM TEST DUST AND ITS EFFECT ON ISO APPENDIX G The standards affected include ISO 4402 1991 Hydraulic fluid power Calibration of liquid automatic particle counters ISO 4406 1987 Hydraulic fluid power Code for defining the level of contamination by solid par ticles ISO 4572 1981 Hydraulic fluid power Filters Multi pass method for evaluating filtration performance of a filter element In order that users are not confused by the changes to these standards par ticularly by reference to them in technical literature ISO is updating 4402 to ISO 11171 and 4572 to ISO 16889 Two standards which concern our industry are the ISO 4406 coding system and the new ISO 16889 Multi pass test As APCs will henceforth count parti cles more accurately there will now be a change in the way sizes are labelled In the new ISO 4406 1999 new calibration sizes are used to give the same cleanliness codes as the old calibration sizes of 5 and 15 um In this way there will be no necessity to change any system cleanliness specifications It is proposed that the cleanliness codes for APCs will be formed from three VIT particle counts at 4 6 and 14 um with 6 and 14 um correspond ing ve
5. 0 r Dirty Alarm Level Iso eooo AS4059E 2 04 0B 0C 0D 0E 0F NAS1638 AS4059E 1 0 r Continuous Test IV Log all test results I Confirm Target Level Test Interval Minutes 29 Figure 1 Continuous Test Settings Press Stop button to close flush valve Press Start button The CML2 will now commence the sampling cycle The completion progress bar indicates the status of the test Results will be automatically displayed on the Remote Device dialogue after each test The status is shown as Waiting between the ending of one test and the starting of the next test Press the Stop button at any time in the cycle to end the continuous sampling The test status will show as Idle 32 Continuous Sampling 8 1 1 Continuous Sampling with Clean Alarm Levels Alarm Mode 1 This operating mode is similar to the Basic Operation but in this mode the CML2 will stop testing when the specified clean alarm level is achieved A status of C is shown on the LCD when the specified clean alarm level is achieved meaning completed Follow the instructions on page 25 for inputting settings select Continuous Test Type Alarm mode should be set to the default of 1 Input Test Interval input the time in minutes that is required between the end of a test and the begining of a new test Cleanliness Target options Clean Alarm Level ISO Input desired Clean Alarm Level in the code format Number Number Num
6. Al ternatively the flush valve will close automatically when pushbutton Start I is pressed Note For version CML2 W moisture and temperature indication every test is automatically preceded by a 3 minute flush period to allow the moisture sensor to stabilise and give an accurate reading The 3 minute period starts from the time the Start pushbutton I is pressed Therefore a separate flush period is unnecessary unless a flush period greater than 3 minutes is required For the CML2 W version the moisture and temperature function can be switched off refer to page 29 for details e Press Start Pushbutton This will initiate the commencement of a test Each test comprises a sampling cycle that sizes and counts the particles in a 15ml volume of test fluid followed by an emptying cycle during which the 15ml of fluid is discharged to waste At the end of the emptying cycle the CML2 will come to rest and the test results will be displayed on the LCD screen e Stop Pushbutton O This optionally aborts the test at any point in the sampling emptying cycle Please note The next test will start with an emptying cycle before the test commences Pushbutton Operation 17 5 2 Downloading the Results After using Pushbutton Operation the test results can be downloaded The CML2 has a memory capacity of approximately 600 tests When this memory is full the earliest of the test records will be over writ ten by the new tests Conne
7. normal test 600 tests RS 232 communication port Minimess fittings Microbore hose 1 5 metres long Waste fluid hose Height 152mm Length 340mm Width 295mm Weight 5 9 kilos CML2 Upper Contamination Limit The CML2 upper operating limit is set at 24 22 20 Tests that result in parti cle counts exceeding any scale number in the three part ISO upper limit has the scale number replaced by asterisk on the remote Display optional equip ment example Similarly for NAS1638 AS4059E 1 and AS4059E 2 the Display will show and respectively Within LPA View exceeding the upper contamination level is denoted by the use of code 25 in the case of ISO and Class 15 for NAS1638 AS4059E 1 and AS4059E 2 SPECIFICATION 65 APPENDIX J Spare Product Part Numbers For spares and part numbers please see the website www mpfiltri co uk 66 SPARE PRODUCT PART NUMBERS FAULT Unexpected results obtained from sample Remote Device dialogue not responding to buttons being pressed APPENDIX K Fault Finding CHECK Check that the test hose has been fully connected at both the system and the CML2 ends Confirm that there is a free flow of fluid to the CML2 by operating the flush valve and observ ing fluid passing to waste High water aeration levels Check that correct COM port has been selected in the Remote Device dialogue Disconnect power supply to CML2 and then re connect it If excessive sys
8. 21 17 15 15A 15B 12C 12D 10E 10F 3557 005099 0 2008 02 26 16 39 44 CERTIFIED 23j21 17 15 15A 15B 12C 12D 1 LE BF 3556 00509 3 0 2008 02 26 16 33 57 CERTIFIED 23 21 17 15 154 158 12C 12D 10E 9F 3555 005099 2 0 2008 02 26 16 27 58 CERTIFIED 232117 15 154 158 12C 12D 11E 10F 3554 005099 1 3 2008 02 26 16 22 03 CERTIFIED 23 21 17 15 154 158 12C 12D 11E 9F 3553 005099 11 0 2008 02 26 1 CALIBRATION 22j21 17 15 15A 15B 11C 12D 11E 10F 3552 005099 10 o 2008 02 26 1 CALIBRATION 23 21 17 15 154 158 11C 12D 10E 9F 3551 005099 9 0 2008 02 26 1 CALIBRATION 22j21 17 15 15A 15B 11C 12D 11E 10F 3550 005099 8 0 2008 02 26 1 CALIBRATION 22 21 17 15 15A 15B 11C 12D 10E 9F 3549 005099 7 0 CALIBRATION 22j21 17 15 15A 15B 11C 12D 11E 10F 3548 005021 5 o CERTIFIED 22 20 16 12 124 128 11C 11D 10E 10F 0 30 59 3547 005021 4 0 CERTIFIED 2ij2o i6 12 12A 12B 11C 11D 10E 10F 3546 005021 3 0 CERTIFIED 21 20 16 12 124 128 11C 11D 10E 10F 3545 005021 2 0 CERTIFIED 21 20 16 12 12A12B 10C 11D 10E 10F 3544 005021 1 3 2007 07 20 11 57 11 CERTIFIED 21 20 16 12 12A 12B 11C 11D 10E 9F 3543 005021 9 0 2007 07 17 16 47 29 CALIBRATION z2j2i i7 15 15A 15B 11C 12D 11E 10F 3542 005021 8 0 2007 07 17 16 41 37 CALIBRATION 22 21 17 15 154 158 11C 120 10E 10F 3541 005021 7 0 2007 07 17 16 35 50 CALIBRATION 22j21 17 15 15A 15B 11C 120 11E 10F 3540 005021 1 3 2007 07 17 09 17 50 CALIBRATION 16 14 12 8 6A 6B 7C BDIGE OF z For Help press F1 S 2 Figure 1 LPA View To access the Remote Device facility
9. 6 as the ac curacy of the result might be compromised by the small sample volume Test Number Input desired number e g 123 Test number will automatically increment for each successive test Simulate Test Results This is useful for checking device commu nications and familiarisation with the soft ware especially when an oil supply is not available When a simulated test is per formed the particle counter will generate test results without being connected to a hy draulic system Format Choose the preferred display format ISO4406 1999 NAS1638 AS4059E 1 AS4059E 2 This also sets which of the cleanliness targets is used for the continuous test mode Serial Number The serial number of the CML2 This is recorded in each test result The serial number together with the test timestamp uniquely identify the test record These two parameters are used to avoid duplication of test records Software Revision This identifies the program running on the CML2 PC Operation 27 7 Normal Test 7 1 CML2 without Moisture Sensor 1 Input settings as described on page 25 for the following Test Reference Test Type select Normal Test Number Format 2 Press OK button to return to Remote Device dialogue 3 Press Flush button to open flush valve flush indicator turns yel low colour to indicate valve is open Leave valve open until at least 200ml has passed to waste 4 Press Stop button to c
10. AS4059E standard Clean Alarm Level AS4059E 2 Input desired Clean Alarm Level in the format 1 A 2B 3C 4D 5E 6F in the following range Size Code A 000 to 12 Size Code B 00 to 12 Size Code C 00 to 12 Size Code D 2 to 12 Size Code E 4 to 12 Size Code F 7 to 12 Example 4A 4B 5C 6D 6E 7F For continuous testing until the AS4059E Table 2 size codes are achieved select AS4059E TABLE 2 FORMAT as described on Continuous Sampling page 25 Testing will automatically continue until the Class number has been achieved at each of the six Size Codes Also the CML2 will handle deviations from the above format intelligently The size code can be out of order 7F 4A 5C 4B 6E 6D If any sizes are missing they will be assigned the value The effect of this is a don t care value when used as the cleanliness target For example 6B 6C 7D is translated as A 6B 6C 7D E F In this case testing will continue until the B C and D Classes are less than or equal to 6 6 7 respectively The A E and F Classes are effectively ignored since they cannot ever be worse than a Class Note AS4059E 2 denotes Table 2 of the AS4059E standard e Log all test results box A tick in this box will log every test that is carried out in the continuous test mode into the memory of the CML2 If the box is not ticked then the CML2 will only store the results of the test when the Target Cleanliness Level is achieve
11. Temperature is displayed in C and moisture is expressed in RH Relative Humidity Normal Test 29 8 Continuous Sampling The CML2 can be selected for continuous testing at set time inter vals Once continuous sampling has started the CML2 s flush valve auto matically opens and closes before each test This allows representa tive fluid to reach the sensing arrangement before the 15ml sampling test commences The flush valve automatically opens at the end of the sampling cycle and remains open whilst the CML2 is emptying to waste the sample fluid from the previous test Additionally de pending on the time set for Minutes Between Tests the Flush valve operates as follows Time set to 0 Atthe end of the CML2 s emptying cycle the flush valve automatically closes and the next sampling test immediately starts Time set to between 1 and 5 After the CML2 s emptying cycle has finished the flush valve remains open for the time set then automati cally closes before the next sampling test Time set to between 6 and 30000 Flush valve automatically closes after the emptying cycle has fin ished and remains closed until 5 minutes before the next sample test is programmed to start 4 The servo motor operating the Flush valve may exhibit a slight ticking noise both when it is open and closed This is normal 30 Continuous Sampling 8 1 Continuous Test Basic Operation Follow the instructions on page 2
12. as defined for the Continuous Test Occasionally the operator con nects a PC and uses LPA View to download the accumulated test data Using the Computer Serial Port This connection is made using the standard computer connecting ca ble supplied with the CML2 If the computer has only USB to serial ports use the USB to serial converter and follow the instructions on page 22 Apply power to the CML2 make the PC connection and then start LPA View running PC Operation 19 aA A A aI _ a a Sa a Er 2 T T Reference AS4059E 2 RH i 3539 005158 6 0 2008 11 04 13 58 29 CERTIFIED 22 21 17 15 15A 15B 11C 12D 10E 10F 21 68 32 59 3538 005158 5 0 2008 11 04 13 02 28 CERTIFIED 22 21 17 15 154 158 12C 120 11E 10F 3537 005158 4 0 2008 11 04 12 54 08 CERTIFIED 22 2117 15 154 158 11C 120 10 11F 3536 005158 3 0 2008 11 04 12 48 51 CERTIFIED 22j21 17 15 154 158 11C 120 11E 10F 3535 005158 2 0 39 CERTIFIED 22j21 17 15 154 158 11C 120 11E 10F 3534 005158 1 3 48 CERTIFIED 23 21 17 15 154 158 12C 120 11E 11F 3533 005158 10 0 CALIBRATION 22 21 17 154 158 12C 120 11E 11F 3532 005158 4 3 9A 9B 7C 9D 6E 0F 3531 8 3 2 Ci ATION 24 0 5 154 15B 15C 15D 15E 12F 0 0 3530 005158 2 2 CALIBRATION 24 22 20 15 ISA ISB ISC ISD ISE 12F 0 0 3529 005158 1 2 CALIBRATION 24 22 20 15 ISA ISB ISC ISD 15E 12F 0 0 3559 005099 6 0 CERTIFIED 232117 15 154 158 12C 120 10E 9F 2057 35 98 3558 005099 5 o CERTIFIED 23
13. in LPA View press the Remote Control button on the toolbar The first time that this is done the correct communications port COM port on the computer has to be selected as detailed below The program scans the computer for available ports and puts them in a list to choose from this list appears in the box Click on the right hand side of this box and choose the connection on your computer Refer to Section below Determining COM Port ATEN USB to Serial Bridge COM1 El Figure 2 COM Port selection 20 PC Operation 2 Press the OK button when the correct port is chosen the Remote Device dialogue will show the remote device values ax Test Reference CERTIFIED Settings Next Test Number 1 Transfer Log Test Type Normal Ready Erase Log Result Start Stop Flush Figure 3 Remote Device dialogue The LPA View program will remember this selection the next time it is used 6 2 Determining the COM Port To check the COM port number allocated by the computer for the Serial lead or the USB to Serial Connector e Windows 2000 Windows XP Windows Vista Rightclick on My Computer icon and then left click on Prop erties Click on the Hardware tab and then click on the Device Man ager Button Click on the plus sign next to Ports COM amp LPT e Windows 7 PC Operation 21 View the installed devices using Start Button Devices and Printers You should see an icon repres
14. pressing the OK button will update the CML2 with the new settings Or press Cancel to leave the settings as they were Test Reference Type in this box the description you wish to use for the test e g Vehicle 012 Up to 14 characters may be used Test Type Used to select one of the five available test types It is recommended that the CML2 be usually operated in ei ther the Normal test mode or the Continuous test mode until the user is fully familiar with the features The CML2 test menu is harmonised with that of MP Filtri UK s other CMP and so can also perform Short Triple Bot tle and Dynamic tests Normal Single Test 15ml sample volume Dynamic A comprehensive triple test with results averaged 30ml sample volume comprised of three 10ml sampling and emptying cycles Allows the effect of system fluctua tions to be measured over a longer period of time Triple Bottle Sampling A triple test with results average and quicker than the Dynamic Test 24ml sample vol ume comprised of three individual 8ml samples tested consecutively For Bottle Sampling refer to separate User Guide Results will be displayed upon completion of three tests including emptying cycle 26 PC Operation Continuous For detailed instructions refer to Continuous Sam pling page 30 Short Single Test 8ml sample volume This provides results in less time than the Normal Test It is not recommended for oil samples cleaner than ISO 17 15 12 NAS
15. 402 1991 The table shows the correla um um c tion between Particle Sizes Obtained using ACFTD ISO 4402 1991 and NIST ISO 11171 Calibration Methods NO DIU ECS DA This table is only a guideline 11 The exact relationship between 13 ACFTD sizes and the NIST sizes 14 may vary from instrument to in 16 strument depending on the char 18 acteristics of the particle counter 20 and original ACFTD calibration 21 OOO RAASAKEOND Sova NUN BLESSE K L Ron N N WWWNNNNNNNNNNNNDND mm mn ee DO OO I I ON 071 CA RH SRUWON NOR BION WNON ION NION BACH van New ISO MEDIUM TEST DUST AND ITS EFFECT ON ISO 59 APPENDIX G Other Standards Although the ISO 4406 1999 standard is being used extensively within the hydraulics industry other standards are occasionally required and a compar ison may be requested The following table gives a very general comparison but often no direct comparison is possible due to the different classes and sizes involved X All section headings indicated with are reproduced by kind permission of British Fluid Power Association from BFPA P5 1999 issue 3 Appendix 44 60 New ISO MEDIUM TEST DUST AND ITS EFFECT ON ISO APPENDIX G ISO 4406 1999 DEF STD 05 42 7 NAS 1638 5 SAE 749 8 Table A TableB ISO 11218 6 13 11 08 2 14 12 09 3 0 15 13 10 4 1 16 14 09 400F 16 14 11 5 2 17 15 09 400 17 15 10 800F 17 15 12 6 3 18 16 10 800 18 16 11 1 300F 18 16 13 7 4 19 17 11 1 300 2000
16. 5 for inputting settings select Con tinuous Test Type Input Test Interval input the time in minutes that is required be tween the end of a test and the begining of a new test Input 0 zero ISO Cleanliness Target 0 zero NAS1638 AS4059E 1 Cleanliness Target 0 zero AS4059E 2 Cleanliness target displayed as A B C D E P after pressing OK 0 zero ISO Dirty Alarm Target 0 zero NAS1638 AS4059E 1 Dirty Alarm Target 0 zero AS4059E 2 Dirty Alarm Target displayed as A B C D E F after pressing OK Insert a tick in the Log all test results box This will log every test that is carried out in the continuous test mode into the memory of the CML2 If the box is not ticked none of the test results will be stored in the memory of the CML2 Press OK button to save settings and return to Remote Device dial logue Press Flush button to open flush valve flush indicator turns yellow to indicate valve is open Leave valve open until at least 200ml has passed to waste Continuous Sampling 31 10 11 Remote Device Settings 4 i ks Test Reference CERTIFIED Continuous bs Current Time 2203 03 211 16 11 Identification fin 27 v0 63 J Measure Water Content T Simulate Test Results Test Type Test Number Alarm Mode 1 Cancel Set Format fiso r r Clean Alarm Level Iso e 7 AS4059E 2 04 08 0C 0D 0E 0F NAS1638 AS4059E 1
17. 6 14 3 1 0 00 390 152 27 5 1 0 0 780 304 54 10 2 0 1 1 560 609 109 20 4 1 2 3 120 1 217 217 39 7 1 3 6 250 2 432 432 76 13 2 4 12 500 4 864 864 152 26 4 5 25 000 9 731 1 731 306 53 8 6 50 000 19 462 3 462 612 106 16 7 100 000 38 924 6 924 1 224 212 32 8 200 000 77 849 13 849 2 449 424 64 9 400 000 155 698 27 698 4 898 848 128 10 800 000 311 396 55 396 9 796 1 696 256 11 1 600 000 622 792 110 792 19 592 3 392 312 12 3 200 000 1 245 584 221 584 39 184 6 784 1 024 Table II AS4059E Table 2 Cleanliness Classes for Cumulative Particle Counts 50 SAE AS4059 REV E CLEANLINESS CLASSIFICATION FOR APPENDIX E Recommendations Unit Type TSO 4406 1999 Code PUMP Piston slow speed in line 22 20 16 Piston high speed variable 17 15 13 Gear 19 17 15 Vane 18 16 14 MOTOR Axial piston 18 16 13 Radial piston 19 17 13 Gear 20 18 15 Vane 19 17 14 VALVE Directional solenoid 20 18 15 Pressure control modulating 19 17 14 Flow control 19 17 14 Check valve 20 18 15 Cartridge valve 20 18 15 Proportional 18 16 13 Servo valve 16 14 11 ACTUATOR 20 18 15 Table I Typical Manufacturers Recommendations for Component Clean liness ISO 4406 1999 Most component manufacturers know the proportionate effect that increased dirt level has on the performance of their components and issue maximum permissible contamination levels They state that operating components on VI Tt should be noted that the recomm
18. 9 21 46 14 New ISO 4406 standard um c 5 15 Od standard 46 1S04406 1999 CLEANLINESS CODE SYSTEM APPENDIX C NAS1638 Cleanliness Code System The NAS system was originally developed in 1964 to define contamination classes for the contamination contained within aircraft components The ap plication of this standard was extended to industrial hydraulic systems simply because nothing else existed at the time The coding system defines the max imum numbers permitted of 100ml volume at various size intervals differ ential counts rather than using cumulative counts as in ISO 4406 1999 Al though there is no guidance given in the standard on how to quote the levels most industrial users quote a single code which is the highest recorded in all sizes and this convention is used on the CML2 software 00 0 1 2 3 4 5 6 7 8 9 10 11 12 5 15 125 250 500 1000 2000 4000 8000 16000 32000 64000 128000 256000 512000 1024000 15 25 22 44 89 178 356 712 1425 2850 5700 11400 22800 45600 91200 182400 25 50 4 8 16 32 63 126 253 506 1012 2025 4050 8100 16200 32400 50 100 a 2 3 6 11 22 45 90 180 360 720 1440 2880 5760 Over 100 O 0 1 1 2 4 8 16 32 64 128 256 512 1024 Figure I CONTAMINATION LEVEL CLASSES according to NAS1638 January 1964 The contamination classes are defined by a number from 00 to 12 which indicates the maximum number of particles per 100 ml counted on a differ ential basis in a given size bracket NAS1638 C
19. F 19 17 14 8 5 20 18 12 2 000 20 18 13 4 400F 20 18 15 2 6 21 19 13 4 400 6 300F 21 19 16 10 22 20 13 6 300 22 20 17 11 23 12 14 15 000 23 21 18 12 24 22 15 21 000 25 23 17 100 000 Table New ISO MEDIUM TEST DUST AND ITS EFFECT ON ISO 61 APPENDIX H Clean working practises The majority of hydraulic systems require cleanliness which controls below around a 40 micron threshold beyond the limit of human eyesight When analysing particles down to levels of 4um 6um amp 14um you are talking about objects of a cellular bacterial size This creates various challenges and is starting to drive better and cleaner working practices in industry Our prod ucts are at the forefront of this challenge and will help you to manage the quality and productivity of your systems Do s 62 Do use filter breathers on tank tops Do use tank designs which are self draining sloped or conical Do use tanks which can be sealed off from the surrounding environment Do exercise care and use funnels when filling tanks with fluid Do utilize stainless steel and methods such as electro polishing in the design of system components upstream of your first filter set Do perform off line analysis in a controlled environment such as a labo ratory which should contain fewer airborne contaminants that where the sample was taken from Do use suitable glass bottles ideally certified clean to take samples along with a hand pump to reduce contam
20. LEANLINESS CODE SYSTEM 47 APPENDIX D SAE AS4059 REV E Cleanliness Classification For Hydraulic Fluids This SAE Aerospace Standard AS defines cleanliness levels for particulate contamination of hydraulic fluids and includes methods of reporting data re lating to the contamination levels Tables 1 and 2 below provide the Max imum Contamination Limits Particles 100m1 of differential and cumula tive particle counts respectively for counts obtained by an automatic particle counter e g CML2 V The information reproduced on this and the previous page is a brief extract from SAE AS4059 Rev E revised in May 2005 For further details and explanations refer to the full Standard 48 SAE AS4059 REV E CLEANLINESS CLASSIFICATION FOR APPENDIX D Size range um e 6 14 14 21 21 38 38 70 gt 70 Class 00 125 22 4 1 0 0 250 44 8 2 0 1 500 89 16 3 1 2 1 000 178 32 6 1 3 2 000 356 63 11 2 4 4 000 712 126 22 4 5 8 000 1 425 253 45 8 6 16 000 2 850 506 90 16 7 32 000 5 700 1 012 180 32 8 64 000 11 400 2 025 360 64 9 128 000 22 800 4 050 720 128 10 256 000 45 600 8 100 1 440 256 11 512 000 91 200 16 200 2 880 512 12 1 024 000 182 400 32 400 5 760 1 024 Table AS4059E Table 1 Cleanliness Classes for Differential Parti cle Counts SAE AS4059 REV E CLEANLINESS CLASSIFICATION FOR 49 APPENDIX D Size LM C gt 4 gt 6 gt 14 gt 21 gt 38 gt 70 Size Code A B C D E F Classes 000 195 7
21. appear hazy Above this level there is a danger of free water accumulating in the system in areas of low flow This can lead to corrosion and accelerated wear Similarly fire resistant fluids have a natural water content which may be different to mineral oils Saturation Levels Since the effects of free also emul Saturation point g sified water is more harmful than 100 those of dissolved water water lev els should remain well below the sat IANA 75 uration point However even water in solution can cause damage and therefore every reasonable effort should be made to keep saturation levels as low as possible There is no such thing as too little water As a guide line we recommend maintaining sat a A uration levels below 50 in all eguip ment Emulsified 50 25 Dissolved Water MEASURING WATER CONTENT 43 APPENDIX A Typical Water Saturation Levels For New Oils 600 S 400 S u o Q u 200 G a 0 20 30 40 50 60 70 Temperature C Figure I Examples Hydraulic oil 30 C 200ppm 100 saturation Hydraulic oil 65 C 500ppm 100 saturation 44 MEASURING WATER CONTENT APPENDIX B IS04406 1999 Cleanliness Code System The International Standards Orga nization standard ISO 4406 1999 is the preferred method of quoting the number of solid contaminant par ticles in a sample The code is constructed from the combination of three scale numbers selected from
22. be verified Thus if no failures have occurred the average level measured may well be one which could be made a bench mark However such a level may have to be modified if the conditions change or if specific contaminant sen sitive components are added to the system The demand for greater reliability may also necessitate an improved cleanliness level The level of acceptability depends on three features e the contamination sensitivity of the components e the operational conditions of the system e the required reliability and life expectancy HYDRAULIC SYSTEM TARGET CLEANLINESS LEVELS 53 APPENDIX F Contamination Corresponding Recommended Typical Codes Codes Filtration Applications ISO 4406 1999 NAS 1638 Degree 4 6 14 Bx200 um c pm c pm c 14 12 9 3 3 High precision and laboratory servo sys tems 17 15 11 6 3 6 Robotic and servo systems 18 16 13 7 10 12 Very sensitive high reliability systems 20 18 14 9 12 15 Sensitive reliable systems 21 19 16 10 15 25 General equipment of limited reliability 23 21 18 12 25 40 Low pressure equip ment not in continu ous service The table above is a guide to the recommended filtration level for various hydraulic components together with typical target system cleanliness levels 54 HYDRAULIC SYSTEM TARGET CLEANLINESS LEVELS APPENDIX G New ISO Medium Test Dust and its effect on ISO Contamination Control Standards When General Motors gave advance warning
23. ber any code number combination can be input from code 5 to 24 example 10 9 5 For continuous testing until the ISO Code is achieved select ISO Format in the Remote Device Settings dialogue as described under the previous section on page 25 Testing will automatically continue until each of the three num bers in the Code have been achieved or cleaner Clean Alarm Level NAS 1638 AS4059E 1 Input desired Clean Alarm Level as a single Class number in the range 2 to 12 in clusive For continuous testing until the NAS 1638 AS4059E 1 Class is achieved select NAS Format or AS4059E Table 1 as described Continuous Sampling 33 34 Remote Device Settings E ks Test Reference CERTIFIED Format fiso Test Type Continuous X r Clean Alarm Level Test Number CE 150 23 21 19 AS4059E 2 04 08 0C 0D 0E 0F Current Time 2003 031 211 17 21 Set NAS1638 A54059E 1 fo Identification j 27 v0 63 Dirty Alarm Level FP Measure Water Content ISO 0 J Simulate Test Results AS4059E 2 04 08 0C 0D 0E 0F NAS1638 AS4059E 1 g r Continuous Test Alarm Mode fi IV Log all test results IV Confirm Target Level Cancel Test Interval Minutes 20 Figure 2 Setting ISO Target Cleanliness Level on page 25 Testing will automatically continue until the Class number has been achieved at each of the five size ranges covered by NAS1638 amp AS4059E Table 1 Note AS4059E 1 denotes Table 1 of the
24. ct the CML2 to a PC running LPA View and follow the in structions given to Transfer Log on page 24 It is important to set the Test Reference refer to page 25 before transferring the test results as all results transferred to the data basewill be given the same Test Reference that is active at the time in the Settings dialogue box If the User is carrying out tests at different locations and wishes to give the tests different references it is necessary to download the tests after each location followed by changing the Test Reference for the next location Alternatively the Test Reference may be edited at a later date by accessing the individual test record using LPA View refer to the separate LPA View test analysis software manual 18 Pushbutton Operation 6 6 1 PC Operation PC control of the CML2 is performed using the Remote Device Di alogue included in the LPA View software package refer to the separate LPA View user manual for details of software installation Users may typically wish to operate the Remote Device Dialogue facility in one of two ways e Direct Online Operation The particle counter is permanently connected to a computer whilst tests are carried out The operator can set the test pa rameters initiate the test monitor the progress of each test and download each test as it is completed e Disconnected Operation using Continuous Test Type The CML2 operates as a stand alone item performing tests
25. d this saves on memory space The CML2 has a memory capacity of approximately 600 tests When this memory is full the earliest of the test records will be over written by the newest tests e Inserting a tick in the Confirm Target Level box instructs the CML2 to repeat the sampling cycle until the target cleanliness level has been achieved in two consecutive samples before the Complete status is displayed Leaving the Confirm Target Level box blank permits the target cleanliness level to be achieved only one time before the Com plete status is displayed Continuous Sampling 35 8 2 e Press OK button to save settings and return to Remote Device dialogue e Press Flush button to open flush valve flush indicator turns yel low to indicate valve is open Leave valve open until at least 200ml has passed to waste e Press Stop button to close flush valve e Press Start button the CML2 will now commence the sampling cycle e The Completion progress bar indicates the status of the test Re sults will be automatically displayed on the Remote Device dia logue after each test e The status is shown as Waiting between the ending of one test and the starting of the next test e Press the Stop button at any time in the cycle to end the contin uous sampling The test status will show as Idle With Moisture Sensor Continuous Test Basic Operation and Continuous Test with Target Cleanliness Level The procedure is sim
26. duct Part Numbers K Fault Finding 42 43 45 47 48 51 53 55 Correlation 62 64 66 67 1 1 1 1 2 Precautions Internal Cleaning Do NOT clean the CML2 or Bottle Sampler with Acetone or similar solvents that are not compatible with the seal For flushing fluids please see the website www mpfiltri co uk The use of a 500m coarse screen filter screwed onto the HP con nector is recommended for heavily contaminated system Please see the website above for part numbers Battery Series 41 only It is recommended that the unit is charged for a minimum of 24 hours prior to first use to fully charge the internal battery Precautions 5 2 Introduction The CML2 is designed to measure and quantify the numbers of solid contaminants in Hydraulic Lubrication and Transmission applica tions The CML2 is a portable accurate instrument suitable for laboratory or on site applications utilising mineral oil as the op erating fluid The instrument uses the light extinction principle whereby 2 laser light systems shine through the fluid and land on photodiodes When a particle passes through the beam it reduces the amount of light received by the diode and from this change in condition the size of the particle can be deduced The CML2 W has the additional feature to allow the measurement of saturation of water in oil RH and temperature C The temper ature measurement provides a refere
27. endations made in this table should be viewed as starting levels and may have to be modified in light of operational experiences or user reguirements RECOMMENDATIONS 51 APPENDIX E fluids which are cleaner than those stated will increase life However the di versity of hydraulic systems in terms of pressure duty cycles environments lubrication required contaminant types etc makes it almost impossible to predict the components service life over and above that which can be rea sonably expected Furthermore without the benefits of significant research material and the existence of standard contaminant sensitivity tests manufac turers who publish recommendations that are cleaner than competitors may be viewed as having a more sensitive product Hence there may be a possible source of conflicting information when com paring cleanliness levels recommended from different sources The table gives a selection of maximum contamination levels that are typ ically issued by component manufacturers These relate to the use of the correct viscosity mineral fluid An even cleaner level may be needed if the operation is severe such as high frequency fluctuations in loading high tem perature or high failure risk 52 RECOMMENDATIONS APPENDIX F Hydraulic System Target Cleanliness Levels Where a hydraulic system user has been able to check cleanliness levels over a considerable period the acceptability or otherwise of those levels can
28. enting the port Communications port if using the Serial lead ATEN USB to Serial Bridge or Prolific USB to Serial Comm Port if using an adaptor cable Either of these will have a COM number after it This is the number you should use when selecting the Com Port 6 3 USB Port When a built in computer serial port is not available the USB to serial converter can be used 22 Connect CML2 to the computer using the Serial Cable and the USB to Serial Converter Install the Prolific driver from the file PL2303 Prolific Dri verInstaller_v110 exe on the provided CD You will need to accept any warnings about making changes to your computer Follow the installer Wizard accepting the defaults When the Installer has completed plug in the USB to Serial Adaptor A message should pop up indicating successful hardware instal lation Note any COM port number indicated in the message PC Operation e Connect the CML2 to the computer using the Serial Cable and the USB to Serial Converter e If necessary determine the COM port allocated by the computer for this device using the procedure above 6 4 Operating the CML2 The following describes the function of the buttons on the Remote Device dialogue PER Test Reference CERTIFIED Settings Next Test Number 1 Transfer Log Test Type Normal Ready Erase Log Result Start Stop Flush Figure 4 Remote Device dialogue Start Starts sampling and e
29. er Log button describe below will transfer the complete result log of the CML2 into the test database Transfer Log As explained immediately above if the CML2 has been operated as a stand alone item then connecting the computer to the CML2 and press ing the Transfer Log button will transfer all the 24 PC Operation test results into the test database that have oc curred since the last time the transfer was car ried out The CML2 has a memory capacity of approxi mately 600 tests When this memory is full the earliest of the test records will be over written by the new tests Erase Log This erases all the test results that are stored in the CML2 memory Settings Opens the Settings dialogue described in the next section 6 6 Settings zi Test Reference CERTIFIED Format iso X Test Type Koma x m Clean Alarm Level Test Number Fo 150 fo AS4059E 2 04 0B 0C 0D 0E 0F Current Time 2203 03 116 41 46 Set NAS1638 454059E 1 Io Identification j 27 v0 63 r Dirty Alarm Level I Measure Water Content 150 0 T Simulate Test Results AS4059E 2 04 08 0C 0D 0E OF NAS1638 454053E 1 g r Continuous Test Alarm Mode fi IV Log all test results I Confirm Target Level Cancel Test Interval Minutes o Figure 5 Remote Device Settings dialogue PC Operation 25 va Use this dialogue box to examine the current settings stored in the CML2 and change the settings After making any changes
30. f formal controls over the distribution of the test dust and batch to batch variability was much greater than is acceptable nowadays New ISO MEDIUM TEST DUST AND ITS EFFECT ON ISO 55 APPENDIX G ISO therefore defined the requirements for the replacement for ACFTD and asked the National Institute of Standards and Technology NIST in the USA to produce a standard traceable reference material The new dust s parti cle size distribution has been accurately determined with the aid of modern scanning electron microscope and image analysis techniques New Test Dust Benefits The new ISO Medium Test Dust ISO MTD consists of similar materials to the old ACFTD but to minimize particle counting errors it is of a slightly coarser grade because ACFTD included too many particles smaller than Sum which gave problems during testing ISO MTD is produced to a standard distribution and stringent quality control procedures thereby ensuring excellent batch to batch repeatability These procedures combined with a revised ISO APC calibration method give e A traceable and controlled reference test dust with greatly reduced vari ation in particle size distribution This gives the trace ability required by ISO 9000 QS9000 and similar quality management systems e A procedure for determining the performance of APCs so that minimum acceptable levels can be set by the user Improved calibration techniques and procedures More accurate calibration
31. ilar to that detailed for the CML2 without mois ture sensor previous section except when the Start button is pressed the flush valve will open automatically for a period of at least 3 min utes before the test commences this is to allow the moisture sensor to stabilise and give an accurate reading Measure Water Content box in the Remote Device Setting dialogue has to be ticked to obtain a result 36 Continuous Sampling For example if zero minutes is input in the Test Interval box the effective time between one test finishing and the next starting will be 3 minutes Temperature is displayed in C and moisture is expressed in RH Relative Humidity Continuous Sampling 37 9 Moisture Sensor The CML2 version fitted with the optional moisture sensor module allows both measurement of saturation of water in oil Relative Humidity and temperature These are displayed as RH and C on the main test progress screen and on the downloaded results Temperature measurement provides a reference temperature for the RH reading g D Due to the temperature gradient existing between the system tapping point and the RH temperature module the tempera ture reading can be 5 C to 10 C less than the actual system temperature depending on operating conditions lt d The CML2 can be configured to do a test with or without the mois ture sensor selected If the moisture sensor has been selected the flush valve wil
32. imess Type Power on LED Waste Connector Quick Coupling Figure 2 Series 40 Key Diagram Introduction Flush Start Stop RS232 Connector DC Power Input Socket HP Connector Minimess Type Waste Connector Quick Coupling Figure 3 Series 41 Key Diagram 10 Introduction 3 Scope of Supply N Each standard CML2 supplied consists of the following 1 x CML2 1 x CML2 particle counter accessories bag containing 1 x Test hose x 1 5m long 1 x Waste hose x 2 0m long 1 x Waste bottle 1 x 15V DC power supply series 35 40 or 12V series 41 1 x Calibration certificate 1 x CML2 User guide 1 x LPA View CD Rom software package 1 x LPA View test analysis software manual 1 x USB to serial converter used when computer has only USB ports 1 x Serial cable Optional Equipment 500 um coarse screen filter External Battery Pack See page 66 for more details This is a dedicated unit for the CML2 and should not be used with other MP Filtri UK products especially the 12V Bottle Sampler Units Scope of Supply 11 4 Connection 1 Refer to key drawing on page 8 Insert waste fluid hose in to the waste disposal bottle provided Important Do not connect waste fluid hose to a pressurised system as this will cause the unit to malfunction and could cause internal leakage The waste fluid hose must be discharged into the waste disposal bottle provided or into a tank vessel ve
33. ination ingress Do filter your system thoroughly before using it in your production process CLEAN WORKING PRACTISES APPENDIX H e Do perform a statistically large enough sample of particle analysis results 25 to arrive at a base cleanliness level for your system e Do make sure that filters are correctly sized for your applications and cleanliness you are trying to achieve Don ts e Don t eat drink or smoke around critical systems processes e Don t leave tools objects clothing or other materials etc on surfaces or tanks of critical systems e Don t use open tanks on critical systems e Don t take samples or perform on line analysis from the top of a reser voir tank e Don t design use tanks which contain crevices internal corners etc e Don t assume that if a sample looks clean that it is You wont be able to see the contaminants e Don t perform off line analysis in an un controlled environment E g workshop e Don t rely on a single test for a capable representation of your system e Don t start using your system process until it has gone through a com missioning period whereby contamination levels are relatively stable e Don t mix fluids into the same system They can emulsify and eliminate any chance of a reliable particle count e Don t use unsuitable containers to take a fluid sample CLEAN WORKING PRACTISES 63 APPENDIX I Specification As a policy of contin
34. inutes charge time prior to commencing a test The CML2 must remain connected to the power adaptor during subsequent tests until the battery has had time to recharge Total discharge will shorten the battery lifetime so should be avoided where possible Battery Charging series 41 only 41 12 12 1 Warranty The CML2 is guaranteed for 12 months upon receipt of the CML2 subject to it being used for the purpose intended and operated in accordance with this User Guide Recalibration MP Filtri UK will only verify the accuracy of the CML2 if the unit is recalibrated every 12 months Please ensure that the test results in the Log are downloaded to LPA View before the CML2 is despatched in case action taken by MP Filtri UK during the service recalibration causes the Log to be cleared lt 4 It is requested that only the CML2 not the support case or any other ancilliaries be returned for recalibration MP Filtri UK will not be held responsible for any items returned as such Ensure that the CML2 is packed appropriately for transportation 42 Warranty APPENDIX A Measuring Water in Hydraulic and Lubricating Fluids From North Notts Fluid Power Centre In mineral oils and non aqueous fire resistant fluids water is undesirable Min eral oil usually has a water content of 50 300 ppm which it can support with out adverse consequences Once the water content exceeds about 500ppm the oil starts to
35. l open automatically for a period of 3 minutes before the particle count test commences This is to allow the moisture sensor to stabilise and give an accurate reading To switch the moisture sensor on select the Settings option in the Remote Device dialogue as described on page 25 The Measure Water Content box should be ticked 38 Moisture Sensor Remote Device Settings CERTIFIED Coins 04 08 0C 0D 0E 0F 04 08 0C 0D 0E 0F Figure 1 Measure Water Content Enabled Moisture Sensor 39 10 Bottle Sampling An alternative to operating on line is to use MP Filtri UK s Bottle Sampling Unit to test oil contained in bottles Refer to the separate User Guide for details 40 Bottle Sampling 11 Battery Charging series 41 only The CML2 is equipped with an internal rechargeable battery capa ble of sustaining 50 continuous tests following a 24 hour charging period When the low battery level LED is illuminated the CML2 requires recharging as soon as possible Before commencing recharging always turn off the CML2 To recharge connect lead from power adaptor to the DC power in put socket on the CML2 Observe that the battery charge indicator illuminates on the CML2 Battery power may be conserved by e Operating CML2 whilst connected to power adaptor e Switching CML2 off between samples Should the battery become completely discharged it is advisable to allow a minimum of 15 m
36. lose flush valve 5 Press Start button The CML2 will now commence the sampling cycle 6 The completion bar indicates progress of the test and the status is shown as Sampling PER Test Reference CERTIFIED Settings Next Test Number 3 Transter Log Test Type Normal Sampling Result ES Stop Flush Oese Figure 1 A Test in Progress 28 Normal Test 7 At the end of the sampling cycle the test result will be displayed in the Remote Device dialogue box If the Remote Device dialogue is open the test results will be auto matically transferred to the test database Following the sampling results the CML2 discharges the sample fluid to waste Test status is shown an Emptying When emptying cycle is finished the status is shown as Ready and another test can then be started PER Test Reference CERTIFIED Next Test Number 4 Transfer Log Test Type Normal Ready Erase Log Result 150 23 21 19 2 Start Stop Flush Close Figure 2 A Completed Test 7 2 CML2 W with Moisture Sensor The procedure is similar to that detailed for the CML2 without mois ture sensor previous section except when the Start button is pressed the flush valve will open automatically for a period of 3 minutes to allow the moisture sensor to stabilise and give an accurate reading Measure Water Content box in the Remote Device Settings win dow has to be ticked to obtain a result
37. mptying cycle Stop Stops test at any point in the sampling empty ing cycle Next test will start with an emptying cycle before the test commences Flush The flush valve must be opened to allow fluid to pass through the CML2 so that any fluid from the previous test is flushed out of the connecting pipe to eliminate the possibility of cross con tamination between tests The time for which PC Operation 23 the flush valve is left open depends on the dis tance of the CML2 from the system being sam pled As a guide a 200ml flush volume is rec ommended when using the 1 5m long test hose Press the Flush button to open the flush valve and press the Stop button to close it The Flush indicator turns yellow in colour when flushing is in progress Connect Refer to Remote Control section page 19 Close This closes the Remote Device dialogue box Log The CML2 can be operated permanently connected to a computer with the Remote Device dialogue open This allows the user to set up a continuously updated trend graph and list view As each test is completed the trend graph and list view are updated However it is not necessary to keep the Remote Device dialogue open and computer connected after the test has been initiated al though most users will find this more convenient This fact is es pecially useful for the continuous test mode when a test sequence might be programmed to take several hours In this case pressing the Transf
38. nce temperature for the Relative Humidity reading RH Due to the temperature gradient existing between the system tapping point and the RH temperature module the temperature reading can be 5 C to 10 C less than the actual system temperature depending on operating conditions Hydraulic and Lubricating Systems consists of sets of continuously moving metal parts which use hydraulic fluid as the power medium Hydraulic fluid is also used to create a lubrication film to keep the precision parts separated and it is also used as a cooling medium The very nature of a hydraulic system is that it produces solid par ticulate contaminants and these are ever present in all hydraulic sys tems There is a revised standard ISO cleanliness code ISO 4406 1999 which classifies the numbers of particles that can be tolerated 6 Introduction within the system and it is these levels of contaminants that the par ticle counter is designed to measure ISO Cleanliness Code The international standard for reporting solid contami nants is ISO4406 1999 this standard has been revised to incorporate the change to ISO Medium Test Dust as the calibration standard Introduction 7 RS232 Connector DC Power Input Socket HP Connector Minimess Type Power on LED Waste Connector Quick Coupling Figure 1 Series 35 Key Diagram 8 Introduction Flush Start Stop RS232 Connector DC Power Input Socket HP Connector Min
39. nted to atmosphere if running a continuous test due to the large quantity of oil discharged during a test lt 4 Connect waste fluid hose to CML2 waste connector Push back quick coupling outer ring before connecting disconnecting hose end Connect fluid sampling hose to CML2 HP connector Connect fluid sampling hose to the system by means of the test con nector The system to be monitored must not exceed 400 bar or be less than 2 bar Connect the power supply to the connector The power on LED will illuminate and the LCD screen will turn on For series 41 the charging light will turn on and the On button should be pressed 12 Connection 6 Installing LPA View software refer to the LPA View User Manual and follow the CD Installation instructions 7 Connect serial cable into the CML2 RS232 connector and the other end into a PC If the PC has only USB ports use the USB to serial converter and follow the instructions on page 22 4 1 Methods of Operation Users may operate the CML2 in two ways 1 Pushbutton Operation 2 PC Operation These are described in the following chapters Please note that the series 35 units do not have the pushbutton operation and must be controlled by PC Operation Connection 13 5 Pushbutton Operation This mode of operation is the most straightforward way to use the CML2 as the three principal operations of opening closing the flush valve starting a tes
40. ry closely to the previous 5 and 15 um measurements This will ensure consistency in data reporting As the counts derived by microscope counting methods are not affected the particle sizes used for microscopy will remain unchanged i e at 5 and 15 um VI The option of quoting just two counts of 6um and 14um for APCs remains New ISO MEDIUM TEST DUST AND ITS EFFECT ON ISO 57 APPENDIX G To clarify matters still further ISO standards written around the new test dust will utilize a new identifier c Hence um sizes according to the new ISO 11171 will be expresses as um c and Beta ratios according to ISO 16889 will be expressed as Bx c e g B5 c However it must be stressed that the only real effect users will experience will be the improved accuracy in particle counts there will be no change in the performance of filters nor in the ISO cleanliness levels that they will achieve The following charts shows the correlation between the old ACFTD and the new ISO MTD The CML2 is calibrated with ISO Medium Test Dust to ISO 11171 The correlation between particle sizes and the ACFTD old standard to the ISO MTD new standard is as follows ACFTD lt 1 5 15 25 30 50 75 100 ISOMTD 4 6 14 21 25 38 50YE 70 VIT Not verified by NIST x acftd 58 New ISO MEDIUM TEST DUST AND ITS EFFECT ON ISO APPENDIX G Particle Size Obtained Using Correlation ACFTD ISO NIST 22 ISO 11171 4
41. t and stopping a test can be readily performed using the pushbuttons Setting the types of test downloading test results etc are imple mented using a PC running LPA View software refer to page 19 for details 22 19 15 RH41S 35C OOO RR Eh OFF SO Be og ee Series 40 Series 41 Figure 1 The LCD screen displays two lines of eight alpha numeric charac ters The top line is used to display the test code the bottom line showing RH Relative Humidity and Temperature C only appears on the CML2 W version When first switched on the display unit will show the letters MP Filtri UK Remote Display Unit on the first screen shot followed 14 Pushbutton Operation by a software version number on the second screen shot e g RDU V0 6 Power ON OFF buttons Series 41 only GREEN Switches the CML2 unit on Note the in built LED is used to display a low battery warning this will illuminate red if the battery has insufficient power RED Switches CML2 unit off Note the in built LED is used to display a unit charging warning this will illuminate red if the mains supply is connected Status Letters During a test a status letter flashes in the centre of the bottom line The letters denote the following System ready or user stop S Sampling E Emptying F Flushing W Waiting Continuous testing only C Test Completed Continuous testing only Pushbutton Operation 15
42. tem contamination is suspected flush out the CML2 us ing a Bottle Sampling Unit in conjunction with a suitable solvent Please see website for flushing fluid information www mpfiltri co uk DO NOT USE ACETONE FAULT FINDING 67 APPENDIX K 68 FAULT FINDING Produced by MP Filtri UK Revision 4 1 As a policy of continual improvement MP Filtri UK reserve the right to alter specifi cations without prior notice Except as permitted by such licence no part of this publication may be reproduced stored in retrieval system or transmitted in any form or any means electronic me chanical recording or otherwise without prior written permission of MP Filtri UK MP FILTRI UK Limited Bourton Industrial Park Bourton on the Water GL54 2HQ U K Tel 44 1451 822522 Fax 44 1451 822282 Email sales mpfiltri co uk Website www mpfiltri co uk ITALY HEADQUARTERS MP FILTRI S p A Tel 39 02 95703 1 Fax 39 02 95741497 95740188 Email sales mpfiltri com Website www mpfiltri com CANADA MP FILTRI CANADA INC Tel 1 905 303 1369 Fax 1 905 303 7256 Email mail mpfiltricanada com Website www mpfiltricanada com CHINA MP FILTRI Shanghai Co Ltd Tel 86 21 58919916 Fax 86 21 58919667 Email sales mpfiltrishanghai com Website www mpfiltrichina com GERMANY MP FILTRI D GmbH Tel 49 6894 95652 0 Fax 49 6894 95652 20 Email service mpfiltri de Website www mpfiltri de FRANCE
43. the following table The first scale number represents the number of particles in a mil lilitre sample of the fluid that are larger than 4 um c The second number represents the number of particles larger than 6 um c The third represents the number of particles that are larger than 14 um c Number of Particles per mL Scale No More Up to and than including 2 5M gt 28 1 3M 2 5M 28 640k 1 3M 27 320k 640k 26 160k 320k 25 80k 160k 24 40k 80k 23 20k 40k 22 10k 20k 21 5000 10k 20 2500 5000 19 1300 2500 18 640 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 0 9 1 53 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 0 01 0 45 ISO4406 1999 CLEANLINESS CODE SYSTEM APPENDIX B Microscope counting examines the 32 T i 10 particles differently to APCs and 8 A A 23 the code is given with two scale 4 numbers only These are at 5 um 5 a i code 21 and 15 um equivalent to the 6 um c 6 22 19 14 and 14 um c of the APCs E 20 19 2 5 18 5 1 3 10 6 4 16 3 2 15 1 6 10 14 8 13 4 12 2 11 10 10 g 5 8 3 2 5 8 213 5 10 7 z 6 4 6 z 3 2 Ss 5 1 6 3 4 e 3 2 5 f 2 3 O 2 2 s E 1
44. to the International Standards Organization ISO that it was intending to stop the production of AC Fine Test Dust ACFTD work commenced immediately on finding an improved replacement dust ACFTD was used extensively within the fluid power and automotive industries for calibrating Automatic Particle Counters APCs and for the testing of components APCs are used for testing oil filters and also for contaminant sensitivity test ing of hydraulic components For 25 years APCs have been the main stay in the measurement of solid particles in hydraulic fluids The growth in demand for measuring fluid cleanliness in a variety of industrial processes including fluid power has resulted in APCs moving from the laboratory environment out into the factory In fact they are now a critical part of many production processes It is therefore essential that the data they provide is both accurate and consistent Calibration ACFTD has been used as an artificial contaminant since the 1960s and its original particle size distribution was determined using an optical micro scope This particle size distribution subsequently formed the basis of ISO 4402 the method for calibrating APCs Due to the limitations of that method of measurement the particle size distribution was questioned below about Sum It was also not traceable to any national standard of measurement a critical requirement for today s quality management systems There was also an absence o
45. ual improvement MP Filtri UK reserve the right to alter the specification without prior notice Optical Package Sensitivity Accuracy repeatability Calibration Analysis Range CML2 Sample volume Operation Viscosity range Operating temperature 64 Twin Laser and Twin Optical Diode Detectors gt 4 6 14 21 25 38 50 70 um c sizes to revised ISO 4406 1999 Standard Better than 3 typical Each unit is individually calibrated with ISO Medium Test Dust MTD based on ISO 11171 1999 on equipment certified by LETS ISO 8 to ISO 24 to ISO 4406 1999 NAS 1638 2 to 12 AS4059E Table 1 2 to 12 AS4059E Table 2 Size Codes A 000 to 12 B 00 to 12 C 00 to 12 D 2 to 12 E 4 to 12 F 7 to 12 15 ml normal 30 ml dynamic 24 ml bottle sampler 15 ml continuous 8ml short Max system working pressure 400 bar Min working pressure 2 bar to 400 centistokes 5 to 80 C SPECIFICATION Electrical Requirement Battery Life Series 41 only Moisture amp Temp Meas Fluid compatibility Typical test time Data storage Computer interface Hose connections Dimensions APPENDIX I 12 to 24V DC 1 amp max 15V supplied with series 35 40 12V supplied with series 41 Internal battery pack performs approx 60 tests prior to recharge requirement Included on CML2 W model Mineral oil amp petroleum based fluids consult MP Filtri UK for other fluids Result in lt 2 5 mins
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