PML²/User Guide
Contents
1. Bottle Sampling A triple test with results average and quicker than the Dynamic Test 24ml sample volume comprised of three individual 8 ml samples tested consecutively For Bottle Sampling refer to separate User Guide Continuous For detailed instructions refer to Continuous Sampling page 19 Short Single Test 8 ml 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 6 as the accuracy 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 communications and familiarisation with the software especially when an oil supply is not available When a simulated test is performed the particle counter will generate test results without being connected to a hydraulic system Format Choose the preferred display format ISO 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 PMIZ2 This is recorded in each test re sult 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 PML2 Results will be disp2. PML User Guide RAPFEILT el www mpfiltri co uk 200 052 EN COVERS MODEL NUMBERS All PML2 Models SAFETY WARNING Hydraulic systems contain dangerous fluids at high pressures and tempera tures Installation servicing and adjustment is only to be performed by qual ified personnel Do not tamper with this device INTERNAL CLEANING DO NOT clean the PML or Bottle Sampler with Acetone or similar solvents that are not compatible with the seals The recommended cleaning fluid for internal flushing is listed in the Fault Finding section page 60 The use of a 500um coarse screen filter screwed onto the HP connector is recommended for heavily contaminated systems Refer to page 59 for details DOCUMENT REVISION 8 1 Contents 10 11 12 13 Introduction Scope of Supply Connecting the PML Methods of Operation PC Operation Using the Computer Serial Port Determining the COM Port USB Port Log Settings Normal Test Without Moisture Sensor e With Moisture Sensor Continuous Sampling Continuous Test Basic Operation eWith Moisture Sensor Moisture Sensor Alarms External Circuit Relays Remote Display Optional Equipment Using the Pushbuttons Downloading the Results Bottle Sampling Drain Reservoir and System Pressures Flush Valve Opening Times 10 Operation 17 19 25 26 28 30 34 35 36 14 Warranty 37 Recalibr
3. drink or smoke around critical systems processes Don t leave tools objects clothing or other materials etc on surfaces or tanks of critical systems Don t use open tanks on critical systems Don t take samples or perform on line analysis from the top of a reservoir tank Don t design use tanks which contain crevices internal corners etc Don t assume that if a sample looks clean that it is You wont be able to see the contaminants Don t perform off line analysis in an un controlled environment E g workshop Don t rely on a single test for a capable representation of your system Don t start using your system process until it has gone through a commissioning period whereby contamination levels are relatively stable Don t mix fluids into the same system They can emulsify and eliminate any chance of a reliable particle count Don t use unsuitable containers to take a fluid sample CLEAN WORKING PRACTISES APPENDIX I Specification As a policy of continual improvement MP Filtri UK reserve the right to alter the spec ification without prior notice Technology Laser Package Sensitivity Accuracy repeatability Calibration Analysis Range PML Sample volume Operation Viscosity range Operating temperature Electrical Requirement Moisture amp Temp Meas Fluid compatibility SPECIFICATION Automatic Optical Particle Analyser Twin Laser and Twin Optical Diode Detectors gt 4 6 14 21 25 38
4. 000 155 698 27 608 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 3 392 512 12 3 200 000 1 245 584 221 584 39 184 6 784 1 024 Table Il AS4059E Table 2 Cleanliness Classes for Cumulative Particle Counts SAE AS4059 REV E CLEANLINESS CLASSIFICATION For 45 VIII APPENDIX E Recommendations Unit Type ISO 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 Com ponent Cleanliness ISO 4406 1999 VI Most component manufacturers know the proportionate effect that increased dirt level has on the performance of their components and issue maximum permissi ble contamination levels They state that operating components on fluids which are cleaner than those stated will increase life However the diversity of hydraulic systems in terms of pressure duty cycles environments lubrication required con taminant types etc makes it almost impossible to predict the components service life over and above that which can be reasonably expected Furthermore without the benef
5. 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 ISO11171 1999 on equipment cer tified by LET S 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 24V DC 1 amp max current Included on PML W model Mineral oil amp petroleum based fluids consult MP Filtri UK for other fluids 57 APPENDIX I Typical test time Data storage Computer interface Hose connections Dimensions IP Rating Operation Result in 2 5 mins normal test 600 tests RS 232 communication port Minimess fittings Microbore hose 1 5 metres long Waste fluid hose Height 120mm Length 277mm Width 280mm Weight 5 9 kilos IP66 Model A Design Reference 30 Minimum oil inlet pressure 2 bar Maximum oil inlet pressure 400 bar Drain Reservoir System atmospheric zero back pressure Model B Design Reference 31 Minimum oil inlet pressure 10 bar Maximum oil inlet pressure 400 bar Drain Reservoir System Back pressure not exceeding 1 bar Analyser Upper Contamination Limmit The analyser upper operating
6. 7 095 205 9410 Email mpfiltrirussiag 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 4 91 9945599899 Email s mishra mpfiltri com Website www mpfiltri com
7. PML will stop testing when the specified clean alarm level is achieved A status of COMPLETED is shown when the specified clean alarm level is achieved For other Alarm Modes refer to page 27 Cleanliness Target options Continuous Sampling Follow the instructions on page 15 for inputting settings select Continuous Test Type Input Test Interval input the time in minutes that is required between the end of a test and the begining of a new test Clean Alarm Level ISO Input desired Clean Alarm Level in the code format Number Number Number any code number combination can be input from code 5 to 24 example 10 9 5 21 22 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 15 Testing will automatically continue until each of the three numbers in the Code have been achieved or cleaner LIC MM Test Reference CERTIFIED Format EC Test Type Continuous x r Clean Alarm Level Test Number fe 150 23 21 19 AS4059E 2 04 08 0C 0D 0E 0F Current Time 2009 03 12 11 17 21 Set NAS1638 4S4059E 1 po Identification n 27 v0 63 r Dirty Alarm Level Measure Water Content 150 0 Simulate Test Results AS4059E 2 04 08 0C 0D 0E 0F NAS1638 4S 4059E 1 fo r Continuous Test Alarm Mode fi IV Log all test results v Confirm Target Level Cancel Test Interval Minutes 20 Figur
8. 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 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 labo ratory servo systems 17 15 11 6 3 6 Robotic and servo sys tems 18 16 13 7 10 12 Very sensitive high reliability systems 20 18 14 9 12 15 Sensitive reliable sys tems 21 19 16 10 15 25 General equipment of limited reliability 23 21 18 12 25 40 Low pressure equip ment not in continuous service 48 HYDRAULIC SYSTEM TARGET CLEANLINESS LEVELS APPENDIX F The table above is a guide to the recommended filtration level for various hydraulic components together with typical target system cleanliness levels HYDRAULIC SYSTEM TARGET CLEANLINESS LEVELS 49 APPENDIX G New ISO Medium Test Dust and its effect on ISO Contamination Control Standards When General Motors gave advance warning to the International Standards Organiza tion 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 Au tomatic Particle Counters APCs and
9. nector The system to be monitored must not exceed 400 bar or be less than 2 bar Installing LPA View Software refer to the LPA View User Manual and follow the CD Installation instructions Connect Multi core cable into the PC and the other end into the small connector on the PML If the PC has only USB ports use the USB to serial converter and follow the instructions on page 12 500 um Coarse Screen Filter Optional Equipment Screw this filter directly onto the PML minimess connector and then connect the minimess hose to the other end This filter is recommended for heavily contaminated systems Methods of Operation Users may operate the PML in two ways PC Operation 2 Remote Display optional equipment see page 30 Connecting the PML 9 4 PC Operation 4 1 PC control of the PMI is performed using the Remote Device Dialogue 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 parameters 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 PML opertates as a stand alone item performing tes
10. on the printed results Temperature measurement provides a reference temperature for the RH reading 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 The PML can be configured to do a test with or without the moisture sensor se lected If the moisture sensor has been selected the flush valve will open automat ically 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 zi Test Reference CERTIFIED Format fis Test Type Continuous x r Clean Alarm Level Test Number fe I0 pans 7 AS4059E 2 04 08 0C 0D 0E 0F Current Time 2203 03 211 20 24 Set NA S1638 A54059E 1 0 Identification 127 v0 63 Dirty Alarm Level IV Measure Water Content 150 0 Simulate Test Results AS4059E 2 oa 0B 0C 0D 0E 0F N451638 454059E 1 CE Continuous Test Alarm Mode NN v Log all test results v Confirm Target Level Cancel Test Interval Minutes 2g Figure 1 Measure Water Content Enabled To switch the moisture sensor on select the Settings option in the Remote Device dialogue as described on page 15 The Measure Water Content box should be ticked Moisture Sensor 25 8 3 Alarms Access the Remote Device dialogue as desc
11. screen shot e g RDU V0 6 1 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 L Low Pressure refer to page 60 30 Remote Display Optional Equipment 2 3 10 1 W Waiting Continuous testing only C Test Completed Continuous testing only Pushbuttons e F Black Toggles the flush valve open and closed e OGreen Starts a test e O Red Aborts a test Cleanliness Codes ISO 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 high est recorded in all of the sizes e g NAS 8 AS4059E 2 A single number is displayed which is the highest record for all of the sizes e g AS 7 Using the Pushbuttons All new PMIZ 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 10 When running a Normal test the user will first make the oil and power supply con nections as described on page 8 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 PML2 so that any fluid from the previous test is flushed out of the connecting pipe to eliminate the possibility of cross contami
12. 0 Close This closes the Remote Device Dialogue box Log The PML 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 com puter connected after the test has been initiated although most users will find this more convenient This fact is especially useful for the continuous test mode when a test sequence might be programmed to take several hours In this case pressing the Transfer Log button describe below will transfer the complete result log of the PML into the test database Transfer Log As explained immediately above if the PML has been oper ated as a stand alone item then connecting the computer to the PML and pressing the Transfer button will transfer all the test results into the test database The PML has a memory capacity if approximately 600 tests When this memory is full the earliest of the test records will be over written by the new tests 14 PC Operation Erase Log This erases all the test results that are stored in the PML mem Ory Settings Opens the Settings dialogue described in the next section 4 6 Settings DTCITTIOOXx Test Reference CERTIFIED O Format iso Test Type Normal x m Clean Alarm Level Test Number Fo 150 0 AS4
13. 007 07 20 12 15 46 CERTIFIED 21 20 16 12 12A 12B 11C 11D 10E 10F 3546 005021 3 0 2007 07 20 12 09 57 CERTIFIED 21 20 16 12 12A 12B 11C 11D 10E 10F 3545 005021 2 0 2007 07 20 12 04 06 CERTIFIED 21 20 16 12 124 12B 10C 11D 10E 10F 3544 005021 1 3 2007 07 20 11 57 11 CERTIFIED 21 20 16 12 124 128 11C 11D 10E 9F 3543 005021 9 0 2007 07 17 16 47 29 CALIBRATION 22 21 17 15 154 15B 11C 12D 11E 10F 3542 005021 8 0 2007 07 17 16 41 37 CALIBRATION 22 21 17 15 15A 15B 11C 12D 10E 10F 3541 005021 7 0 2007 07 17 16 35 50 CALIBRATION 22 21 17 15 154 15B 11C 12D 11E 10F 3540 005021 1 3 2007 07 17 09 17 50 CALIBRATION 16 14 12 8 6A 6B 7C 8D 6E 0F zl For Help press F1 IE 7 Figure 1 LPA View ATEN USB to Serial Bridge COM1 z Figure 2 COM Port selection 2 Press the OK button and when the correct port is chosen the Remote Device dia logue will show the remote device values The LPA View program will remember this selection the next time it is used 4 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 PC Operation 11 Jiz Test Reference CERTIFIED Settings Next Test Number 1 Transfer Log Test Type Normal Ready Erase Log Result Laje Fh Figure 3 Remote Device dialogue Right click on My Computer icon and then left click on Properties Click on the Hardware tab and the
14. 059E 2 04 08 0C 0D 0E 0F Current Time 2203 03 116 41 46 Set NAS1638 A54058E 1 n Identification n 27 v0 63 Dirty Alarm Level Measure Water Content 150 0 Simulate Test Results AS4059E 2 04 08 0C 0D 0E 0F N451638 454059E 1 fo Continuous Test SS Alarm Mode Fo FN Log all test results Confirm Target Level Cancel Test Interval Minutes p o Figure 5 Remote Device Settings dialogue Use this dialogue box to examine the current settings stored in the PMI2 and change the settings After making any changes pressing the OK button will update the PML 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 PML be usually operated in either the Normal test mode or the Continuous test mode until the user is fully familiar with the features The PML test menu is harmonised with that of MP Filtri UK s other particle analysers and so can also perform Short Triple and Dynamic tests Normal Single Test 15ml sample volume PC Operation 15 Dynamic A comprehensive triple test with results average 30 ml sample volume comprised of three 10ml sampling and emptying cycles Allows the effect of system fluctuations to be measured over a longer period of time The system Triple
15. 3 2117 15 154 15B 12C 12D 11E 11F 3533 005158 10 0 2008 11 03 15 04 55 CALIBRATION 22 2117 15 154 15B 12C 12D 11E 11F 3532 Mao 4 3 2008 11 03 09 40 32 CALIBRATION 19 18 13 10 94 9B 7C 9D 6E OF 353 005158 3 2 27 14 CALIBRATION 24 5 15A 15B 15C 15D 15E 12F 0 0 3530 005158 2 2 2008 10 27 14 22 56 CALIBRATION 24 22 20 15 154 15B 15C 15D 15E 12F 0 0 3529 005158 1 2 2008 10 27 14 22 44 CALIBRATION 24 22 20 15 154 15B 15C 15D 15E 12F 3559 005099 6 0 2008 02 26 16 58 26 CERTIFIED 23 21 17 15 154 15B 12C 12D 10E 9F 20 57 35 98 3558 005099 5 0 2008 02 26 16 48 21 CERTIFIED 23 21 17 15 15A 15B 12C 12D 10E 10F 3557 005099 4 0 2008 02 26 16 39 44 CERTIFIED 23 21 17 15 154 15B 12C 12D 11E 8F 3556 005099 3 0 2008 02 26 16 33 57 CERTIFIED 23 2117 15 154 15B 12C 12D 10E 9F 3555 005099 2 0 2008 02 26 16 27 58 CERTIFIED 23 2117 15 154 15B 12C 12D 11E 10F 3554 005099 1 3 2008 02 26 16 22 03 CERTIFIED 23 2117 15 154 15B 12C 12D 11E 9F 3553 005099 11 0 2008 02 26 14 07 05 CALIBRATION 22 2117 15 154 15B 11C 12D 11E 10F 3552 005099 10 0 2008 02 26 13 57 43 CALIBRATION 23 2117 15 154 15B 11C 12D 10E 9F 3551 005099 9 0 2008 02 26 11 30 09 CALIBRATION 22 21 17 15 15A 15B 11C 12D 11E 10F 3550 005099 8 2008 02 26 11 23 23 CALIBRATION 22 21 17 15 154 15B 11C 12D 10E 9F 3549 005099 7 0 2008 02 26 11 17 42 CALIBRATION 22 21 17 15 15A 15B 11C 12D 11E 10F 3548 005021 5 0 2007 07 20 12 25 35 CERTIFIED 22 20 16 12 124 12B 11C 11D 10E 10F 0 30 59 3547 005021 4 0 2
16. Log Test Type Normal Ready Erase Log Result 150 23 21 18 O Start Stop Flush Close Figure 2 A Completed Test 5 2 With Moisture Sensor For the PML W the procedure is similar to that detailed for the PML without moisture 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 accurated reading Measure Water Content box in the Remote Device Setting dialogue has to be ticked to obtain a result Temperature is displayed in C and moisture is expressed in RH Relative Hu midity 18 Normal Test 6 Continuous Sampling The Analyser can be selected for continuous testing at set time intervals Once continuous sampling has started the PML s flush valve automatically opens and closes before each test This allows representative fluid to reach the sensing arrangement before the 15ml sampling test commences The flush valve automati cally opens at the end of the sampling cycle and remains open whilst the analyser is emptying to waste the sample fluid from the previous test Additionally depending on the time set for Minutes Between Tests the Flush valve operates as follows Time set to 0 At the end of the analyser s emptying cycle the flush valve auto matically closes and the next sampling test immediately starts Time set to between 1 and 5 After the analyser s emp
17. ampling Unit in conjunction with a suitable solvent Refer to the website for more information on flushing fluids www mpfiltri co uk DO NOT USE ACETONE Low Pressure The PML must always be connected to an inlet oil supply when carrying out a test as operating the unit dry could cause internal damage to the pump etc To prevent this happening a switch is incorporated inside the PML which detects low pressure and stops the test If this occurs the status on the Remote Device dialogue will be shown as Low Pressure and L will also be displayed on the Remote Display is being used with the unit 60 FAULT FINDING APPENDIX K However to allow the user to become familiar with the software a Simulate Test facility has been provided refer to page 15 for details If the unit is being operated in the Continuous Test mode when low pressure is detected the following will occur automatically e The sampling cycle will stop e The flush valve will open and the internal PML syringe pump will empty e Flush valve closes e PML waits for oil inlet pressure to be restored at which point the PML will automatically resume testing Note If the PML had been set to carry out a relative humidity test when the low pressure event occurred the first RH result after pressure has been restored will be invaid and should be discounted FAULT FINDING 61 APPENDIX K 62 FAULT FINDING Produced by MP Filtri UK Revis
18. ation A Measuring Water in Hydraulic and Lubricating Fluids 39 B 1S04406 1999 Cleanliness Code System 41 C NAS1638 Cleanliness Code System 43 D SAE AS4059 REV E Cleanliness Classification For Hydraulic Fluids 44 E Recommendations 46 F Hydraulic System Target Cleanliness Levels 48 G New ISO Medium Test Dust and its effect on ISO Contamination Control Standards 50 Calibration New Test Dust Benefits Effect on Industry Correlation Other Standards H Clean working practises 55 Specification 57 J Spare Product Part Numbers 59 K Fault Finding 60 ow Pressure 1 Introduction The PML Contamination Analyser is designed to measure and quantify the num bers of solid contaminants in Hydraulic Lubrication and Transmission applica tions The PML is designed to be an accurate instrument suitable for permanently installed applications utilising mineral oil as the operating 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 PML2 W has the additional feature to allow the measurement of saturation of water in oil RH and temperature C Temperature measurement provides a reference temperature for the Relative Hu midity reading RH Due to the t
19. c O 00 IQ UA 4 UD 10 RSS ODAINNUE RONN TODO 19 Ut RE DRE LE RUE poor ON O2 U U D D D N 2 2 N D D D D ND B2 e mememe et et nt pt et pt pt pt pt OO 00 I I AU LA R 43 SW NO NNO ANONN DODNAUNODONAN ON ADNO EU ON Although the ISO 4406 1999 standard is being used extensively within the hydraulics industry other standards are occasionally required and a comparison may be requested The following table gives a very general comparison but often no direct comparison is New ISO Mepium TEST DUST AND ITS EFFECT ON ISO 53 APPENDIX G possible due to the different classes and sizes involved 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 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 2000F 19 17 14 8 5 20 18 12 2 000 20 18 13 4 400F 20 18 15 9 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 XI Al section headings indicated with are reproduced by kind permission of British Fluid Power Asso ciation from BFPA P5 1999 issue 3 Appendix 44 54 New ISO MEpiuM TEST DUST AND ITS EFFECT ON ISO 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 e
20. e 2 Setting ISO Target Cleanliness Level Clean Alarm Level NAS1638 AS4059E 1 Input desired Clean Alarm Level as a single Class number in the range 2 to 12 inclusive For continuous testing until the NAS1638 AS4059E 1 Class is achieved select NAS Format or AS4059E Table 1 as described on page 15 Testing will automatically continue until the Class number has been achieved at each of the five micron size ranges covered by NAS 1638 amp AS4059E Table 1 Note AS4059E 1 denotes Table 1 of the AS4059E standard Clean Alarm Level AS4059E 2 Input desired Clean Alarm Level in the for mat 1 A 2B 3C 4D SE 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 Continuous Sampling Example 4A 4B 5C 6D 6E 7F For continuous testing until the ASA059E Table 2 size codes are achieved select AS4059E TABLE 2 FORMAT as described on page 15 Testing will automatically continue until the Class number has been achieved at each of the six Size Codes Also the PML will handle deviations from the above format intelligently The size code can be out of order 7F 4A 5C 4AB 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 con tinue until th
21. e 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 2Log all test results box A tick in this box will log every test that is carried out on the continuous test mode into the memory of the PML If the box is not ticked then the PML will only store the results of the test when the Target Cleanliness Level is achieved this saves on memory space The PML has a memory capacity of approximately 600 tests When this mem ory is full the earliest of the test records will be over written by the newest tests Inserting a tick in the Confirm Target Level box instructs the PML to repeat the sampling cycle until the target cleanliness level has been achieved in two consecutive samples before the Complete status is displyed Leaving the Confirm Target Level box blank permits the target cleanliness level to be achieved only one time before the Complete status is displayed Press OK button to save settings and return to Remote Device dialogue 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 Refer to page 36 for more information about flushing times Press Stop button to close flush valve Press Start button the PML will now commence the samp
22. emperature 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 consist 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 particulate contaminants and these are ever present in all hydraulic systems There is a revised standard ISO cleanliness code ISO 4406 1999 which classifies the numbers of particles that can be tolerated within the system and it is these levels of contaminants that the particle counter is designed to measure ISO Cleanliness Code The international standard for reporting solid contaminants is ISO4406 1999 this standard has been revised to incorporate the change to ISO Medium Test Dust as the calibration standard Introduction 5 REMOTE DISPLAY OPTIONAL COMPUTER 24 V DC POWER SUPPLY REMOTE DISPLAY OPTIONAL CONNECTOR DETAILS CLEARANCE HOLE FOR M6 SCREW 250 FIXING CENTRES 181 FIXING CENTRES Particle Counter OIL OUTLET OIL INLET MINIMESS CONNECTOR M16 x 2 Figure 1 6 Introduction 2 Scope of Supply N Each standard PML supplied consists of the follow
23. en core is not used and can be cut off 3 pin plug Relay 1 pe d IO NRA DE 1 ja Relay 2 2e 4 gt Socket case wall supplied loose Figure 1 Example 1 Bulb illuminates when target cleanliness level is achieved Completed status and is off during sampling 28 External Circuit Relays Relay 1 CR EL lose D gt Socket supplied loose case wall Figure 2 Example 2 Bulb illuminates during sam pling and extinguishes when target cleanliness level is achieved Completed status Relay 1 is also switched during Normal Dynamic and Triple test types Relay will open at test end or when stop but ton is pressed External Circuit Relays 29 10 Remote Display Optional Equipment The PMI can be operated from the Remote Display unit with or without being permanently connected to a computer Setting the types of test downloading test results etc are implemented using a PC running LPA View software refer to page 10 for details o o RH41S 35C e 00 Or 71 9 0 Figure 1 The LCD screen displays two lines of eight alpha numeric characters The top line is used to display the test code the bottom line showing RH Relative Humidity and Temperature C only appears on the PML 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 by a software version number on the second
24. for the testing of components APCs are used for testing oil filters and also for contaminant sensitivity testing of hy draulic 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 clean liness 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 microscope This particle size distribution subsequently formed the basis of ISO 4402 the method for calibrat ing 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 sys tems There was also an absence of formal controls over the distribution of the test dust and batch to batch variability was much greater than is acceptable nowadays 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 stan dard traceable refe
25. gue 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 Refer to page 36 for more information flushing times Press Stop button to close flush valve Press Start button The PML will now commence the sampling cycle The completion progress bar indicates the status of the test Results will be auto matically 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 20 Continuous Sampling 11 Press the Stop button at any time in the cycle to end the continuous sampling The test status will show as Idle 6 1 1 Continuous Sampling with Clean Alarm Levels Alarm Mode 1 Remote Device Settings Test Reference CERTIFIED Test Type Continuous E Current Time 2009 03 12 11 16 11 Identification 127 v0 63 Measure Water Content Simulate Test Results Test Number Alarm Mode Do Cancel Set x Format fiso X r Clean Alarm Level Iso eooo AS4053E 2 04 08 0C 00 0E OF NAS1638 AS4059E 1 o Dirty Alarm Level Iso ec AS4059E 2 04 08 0C 00 0E OF NAS1638 AS4059E 1 o m Continuous Test IV Log all test results Confirm Target Level Test Interval Minutes 20 Figure 1 Continuous Test Settings This operating mode is similar to the Basic Operation but in this mode the
26. he effects of free also emulsi Saturation point fied water is more harmful than those coss NEN 10096 of dissolved water water levels should Emulsified remain well below the saturation point However even water in solution can cause damage and therefore every reasonable effort should be made to keep satura 50 tion levels as low as possible There Free water 7596 RM Water is no such thing as too little water As 258 E a guideline we recommend maintain ing saturation levels below 50 in all A equipment 0 a MEASURING WATER CONTENT 39 APPENDIX A Typical Water Saturation Levels For New Oils 600 z i S 400 9 My gt E i X 1 Oo i Q i V T 200 E i gt sure tt 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 40 MEASURING WATER CONTENT APPENDIX B 1S04406 1999 Cleanliness Code System The International Standards Orga nization standard ISO 4406 1999 is the preferred method of quoting the number of solid contaminant particles in a sample The code is constructed from the combination of three scale num bers selected from the following ta ble 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 repre
27. ing 1 x PML particle counter 1 x Minimess hose x 1 5m long 1 x Waste hose x 1 5m long 1 x 24V DC power supply x Calibration certificate 1 x PML User guide 1 x LPA View CD Rom software package 1 x LPA View test analysis software manual x USB to serial converter used when computer has only USB ports x PC download cable e 1x Multi core cable x 2 5m long Optional Equipment e Remote display unit including cable and connector 500 um coarse screen filter Part number SK0040 This is a dedicated unit for the PML and should not be used with other MP Filtri UK products especially the 12V Bottle Sampler Units Scope of Supply 7 3 Connecting the PML Refer to key drawing on page 6 1 Fix the PML in place by bolting through the feet 2 Power supply and external circuits These are two alternative arrangements possi ble depending on whether or not the external circuit relays are intended to be used The alternatives are a External circuit relays are not being used In this case plug the cable supplied with the power supply into the respective PML connector push in gently with the groove at the top then turn the blue sheath clockwise to lock it in place b External circuit relays are intended to be used see page 28 for further details of external circuits In this case x Cut off and discard the connector supplied with the 24 V DC power supply Identify which is the positive and zero vo
28. ion 8 1 As a policy of continual improvement MP Filtri UK reserve the right to alter specifications 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 mechanical 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 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
29. its of significant research material and the existence of standard contami nant sensitivity tests manufacturers 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 comparing cleanliness levels recommended from different sources It should be noted that the recommendations made in this table should be viewed as starting levels and may have to be modified in light of operational experiences or user requirements 46 RECOMMENDATIONS APPENDIX E The table gives a selection of maximum contamination levels that are typically 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 temperature or high failure risk RECOMMENDATIONS 47 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 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 sensitive components are added to the system The demand for greater reliability may also necessitate an
30. layed upon completion of three tests including emptying cycle 16 PC Operation 5 1 Normal Test Without Moisture Sensor Input settings as described on page 15 for the following Test Reference Test Type select Normal Test Number Format Press OK button to return to Remote Device dialogue Press Flush button to open flush valve flush indicator turns yellow colour to indi cate valve is open Leave valve open until at least 200ml has passed to waste Refer to page 36 for more information about flushing times Press Stop button to close flush valve Press Start button The PMI will now commence the sampling cycle The completion bar indicates progress of the test and the status is shown as Sam pling alo Test Reference CERTIFIED Settings Next Test Number d Transfer Log Test Type Normal Sampling el Result Stop Flu Coss Figure 1 A Test in Progress Normal Test 17 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 automatically trans ferred to the test database Following the sampling results the PML discharges the sample fluid to waste Test status is shown as Emptying When emptying cycle is finished the status is shown as Ready and another test can then be started BIET Test Reference CERTIFIED Next Test Number 4 Transfer
31. lays Relay 1 Dirty NAS AS4059E 1 single number result gt set limit result lt set limit ISO AS4059E 2 multi part any result gt corresponding set limit all results lt corresponding set limit Relay 2 Clean NAS AS4059E 1 single number result lt set limit result gt set limit ISO AS4059E 2 multi part all results lt corresponding set limit any result gt corresponding set limit Alarm Modes 3 and 4 These are reserved for future development Alarms 27 9 External Circuit Relays Page 8 item b explains actions to be taken if it is intended to use the external circuit relays that are built into the PML2 There are two solid state relays for external circuit use The function of these re lays is illustrated in the following simple wiring diagram using a battery and bulb circuit for illustrative purposes Each relay is designed for a maximum current of 1 amp at 24 volt nominal AC or DC absolute maximum 60 volt peak Operation above these limits will cause irreparable damage to the relays If the User requires to switch voltages currents in excess of the above maximum limits then separate higher rated interposing relays will need to be incorporated into the final electrical scheme designed by the User In the multi core cable that is supplied with the PMI there are three cores that are used to connect with the relays These cores are colour coded black white and yellow see diagrams below The gre
32. limit is set at 24 22 20 Tests that result in particle counts exceeding any scale number in the three part ISO upper limit has the scale number replaced by asterisk on the remote Display optional equipment example Sim ilarly for NAS1638 AS4059E 1 and AS4059E 2 the Display will show and re spectively 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 ASA059E 1 and AS4059E 2 58 SPECIFICATION APPENDIX J Spare Product Part Numbers For spares and part numbers please see the website www mpfiltri co uk SPARE PRODUCT PART NUMBERS 59 APPENDIX K Fault Finding FAULT CHECK Unexpected results Check that the minimess hose has been fully connected at obtained from sample both the system and the PML ends Confirm that there is a free flow of fluid to the PML2 by operating the flush valve and observing fluid passing to waste High water aeration levels Test stops after If low pressure status is shown on the Remote Device dia sampling has logue check that the fluid supply to the PML is connected commenced and pressurised Remote Device dialogue Check that correct COM port has been selected in the Re not responding to mote Device dialogue buttons being pressed Disconnect power supply to PML and then reconnect it a If excessive system contamination is suspected flush out the Analyser using a Bottle S
33. ling cycle Continuous Sampling 23 e The Completion progress bar indicates the status of the test Results will be automatically displayed on the Remote Device dialogue 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 continuous sampling Thes test status will show as Idle 6 2 With Moisture Sensor Continuous Test Basic Operation and Continuous Test with Target Cleanliness Level The procedure is similar to that detailed for the PML without moisture sensor previous section except when the Start button is pressed the flush valve will open automatically for a period of at least 3 minutes 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 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 moisuture is expressed in 9o RH Relative Humidity 24 Continuous Sampling 7 Moisture Sensor The PML 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
34. lly 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 Downloading the Results After using Pushbutton Operation the test results can be downloaded The PML 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 new tests Connect the PML to a PC running LPA View and follow the instructions given to Transfer Log on page 14 It is important to set the Test Reference refer to page 15 before transferring the test results as all results transferred to the databasewill be given the same Test Reference that is active at the time in the Settings dialogue box 32 Remote Display Optional Equipment 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 fol lowed 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 Remote Display Optional Equipment 33 11 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 34 Bottle Sampling 12 Drain Re
35. lt cores in the two core cable using a voltmeter x Connect the 24 V DC positive core to the red core in the multi core cable supplied with the PML2 x Connect the 24 V DC zero volt core to the blue core in the multi core cable x Connect the black white and yellow cores in accordance with the external circuit details shown on page 28 x Connect the outer screen of the multi core cable to ground The above connections should all be made in a separate junction box or to a terminal block inside a panel etc 3 Remote Display optional equipment Plug the cable supplied with the remote display into the respective connector on the PML The smll arrow marked on the connector must be placed at the top when pushing the connector into place To disconect pull the connector outwards 8 Connecting the PML 3 1 Important Do not connect Waste Fluid Hose to a pressurised system as this will cause the Analyser to malfunction and could cause internal leakage The Waste Fluid Hose must be discharged into a waste disposal bottle or into a tank vessel vented to atmosphere if running a Continuous test due to the large quantity of oil discharged during a test x p Connect WASTE FLUID HOSE to Analyser waste connector Push back quick coupling outer ring before connecting disconnecting hose end Connect FLUID SAMPLING HOSE to Analyser HP connector Connect FLUID SAMPLING HOSE to the system by means of the minimess con
36. n click on the Device Manager Button Click on the plus sign next to Ports COM amp LPT Windows 7 View the installed devices using Start Button Devices and Printers You should see an icon representing the port Communications port if using the Serial lead Aten USB to Serial Cable 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 4 3 USB Port When a built in computer serial port is not available the USB to serial converter can be used 12 Connect PML to the computer using the Serial lead and the USB to Serial Converter Install the Prolific driver from the file PL2303 Prolific DriverInstaller v110 exe on the provided CD You will need to accept any warnings about making changes to your computer PC Operation 4 4 e Follow the installer Wizard accepting the defaults e When the Installer has completed plug in the USB to Serial Adaptor e Amessage should pop up indicating successful hardware instillation Note any COM port number indicated in the message e Connect the PMI to the computer using the Serial lead and the USB to Serial Converter e If necessary determin the COM port allocated by the computer for this device using the proceedure above Operation The following describes the function of the buttons on the Remote Device dialogue x Tes
37. nation between tests The time for which the flush valve is left open depends on the distance of the PML from the system being sampled As Remote Display Optional Equipment 31 10 2 a guide a 200ml flush volume is recommended when using the 1 5m long minimess hose Refer to page 36 for more information about flushing times After the flush volume has been discharged to waste the flush valve may be manu ally closed by again pressing pushbutton F Alternatively the flush valve will close automatically when pushbutton Start I is pressed Note For version PMI2 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 form 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 PMI2 W version the moisture and temperature function can be switched off refer to page 18 for details 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 PML will come to rest and the test results will be displayed on the LCD screen Stop Pushbutton O This optiona
38. ning Times 14 14 1 Warranty The PML is guaranteed for 12 months upon receipt of the Analyser 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 PML if the unit is recalibrated every 12 months Please ensure that the test results in the Log are downloaded to LPA View before the PML is despatched in case action taken by MP Filtri UK during the service recalibration causes the Log to be cleared It is requested that only the PML2 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 PML is packed appropriately for transportation Warranty 37 38 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 Mineral oil usually has a water content of 50 300 ppm which it can support without adverse consequences Once the water content exceeds about 500ppm the oil starts to 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 t
39. ods of reporting data relating to the contamination levels Tables 1 and 2 below provide the Maximum Contamination Limits Particles 100ml of differential and cumulative particle counts respectively for counts obtained by an automatic particle counter e g PML2 Size range um c 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 T 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 Differen tial Particle Counts VII 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 44 SAE AS4059 REV E CLEANLINESS CLASSIFICATION FOR APPENDIX D Size um c gt 4 gt 6 gt 14 gt 21 gt 38 gt 70 Size Code A B C D E F Classes 000 195 76 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
40. or the contamination contained within aircraft components The application of this standard was extended to industrial hydraulic systems simply because nothing else existed at the time The coding system defines the maximum numbers permitted of 100ml volume at various size intervals differential counts rather than using cumulative counts as in ISO 4406 1999 Although 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 PML 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 1 2 3 6 11 22 45 90 180 360 720 1440 2880 5760 Over 100 O0 0 1 1 2 4 8 16 32 64 128 256 512 1024 Figure 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 differential basis in a given size bracket NAS1638 CLEANLINESS CODE SYSTEM 43 APPENDIX D SAE AS4059 REV E Cleanliness Classification For Hydraulic Fluids This SAE Aerospace Standard AS defines cleanliness levels for particulate cont amination of hydraulic fluids and includes meth
41. quid automatic particle counters ISO 4406 1987 Hydraulic fluid power Code for defining the level of contamination by solid particles ISO 4572 1981 Hydraulic fluid power Filters Multi pass method for evaluating filtration performance of a filter element New ISO Mepium TEST DUST AND ITS EFFECT ON ISO 51 APPENDIX G In order that users are not confused by the changes to these standards particularly 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 particles 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 neces sity to change any system cleanliness specifications It is proposed that the cleanliness codes for APCs will be formed from threel particle counts at 4 6 and 14 um with 6 and 14 um corresponding very 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 To clarify matters still further ISO standards written around the new test dus
42. rence material The new dust s particle size distribution has been accurately determined with the aid of modern scanning electron microscope and image analysis techniques 50 New ISO MEpiuM TEST DUST AND ITS EFFECT ON ISO APPENDIX G 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 be cause 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 pro cedures 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 variation in par ticle 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 Improved levels of particle count reproducibility with different equipment More accurate and consistent filter test results Effect on Industry The introduction of ISO MTD has necessitated changes to certain ISO standards The standards affected include ISO 4402 1991 Hydraulic fluid power Calibration of li
43. ribed on page 15 The Alarm Options will be displayed 1 Alarm Mode 1 2 Dirty Alarm Level ISO 0 3 Dirty Alarm Level NAS1638 AS4059E 1 0 4 Dirty Alarm Level AS4059E 2 1A 2B 3C AD SE 6F The PML includes two solid state relays for connections to an external circuit These can be arranged to function as follows Alarm Mode O Selecting option 0 switches relays 1 and 2 always off Alarm Mode 1 Selecting option 1 will configure relays 1 and 2 as described on page 28 refer to the examples given on the simple wiring diagrams Clean alarm levels are set in accordance with the instructions starting on page 21 Alarm mode 1 is used in conjunction with the Continuous Sampling test type enabling the Analyser to operate continuously until the specified clean alarm level is achieved Alarm Mode 2 Selecting option 2 arranges the relays to operate when the Clean and Dirty alarm levels are reached exceeded Alarm mode 2 will normally be used in conjunction with the Continuous test type refer to page 20 but can be used with all other test types as well Set the Clean and Dirty alarm levels by inputting the desired levels in to the Remote Device dialogue on page 15 also setting the appropriate result format to ISO NAS or AS4059 as described on page 21 26 Alarms Both relays are initially off and remain off until an alarm level has been reached ex ceeded The following illustrates the switching logic of the Re
44. sents 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 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 0 01 O ISO4406 1999 CLEANLINESS CODE SYSTEM 4 APPENDIX B Microscope counting examines the 1 6 107 24 particles differently to APCs and 8 the code is given with two scale 23 numbers only These are at 5 um 22 and 15 um equivalent to the 6 um c 2 x code and 14 pm c of the APCs 10 22 19 14 20 5 19 25 18 5 1 3 6 4 16 3 2 15 1 6 10 14 8 13 4 12 2 11 10 10 g 5 8 2 2 5 E 8 E 213 5 107 7 2 6 4 8 6 a 42 5 5 ei 1 6 F 2 wn E 10 3 5 38 E E S 2 8 oO 2 lt E 19 21 4 6 14 NewISO 4406 standard um c 5 15 Old standard 42 ISO4406 1999 CLEANLINESS CODE SYSTEM APPENDIX C NAS1638 Cleanliness Code System The NAS system was originally developed in 1964 to define contamination classes f
45. servoir and System Pressures The PML is produced in two standard models as detailed below e Model A Design Reference 30 Minimum oil inlet pressure 2 bar Maximum oil inlet pressure 400 bar Drain Reservoir System Atmospheric pressure zero back pressure e Model B Design Reference 31 Minimum oil inlet pressure 10 bar Maximum oil inlet pressure 400 bar Drain Reservoir System Back pressure not exceeding 1 bar The PML model suffix letter is stamped on the serial number plate after the num ber Drain Reservoir and System Pressures 35 13 Flush Valve Opening Times The table below shows the flush valve opening times that are required to achieve a 200ml flush volume for different conditions Model Oil Inlet Drain Pressure Approximate Time Type Pressure for 200ml Flush Volume Model A X 2bar Atmospheric pressure zero back pressure 2 minutes 30 seconds Model B 10 bar Back pressure not exceeding 0 5 bar minute 20 seconds Model B 10 bar Back pressure not exceeding 1 0 bar 2 minutes The above flush times assume that the oil inlet hose from the sampling point to the PML does not exceed 1 5m in length Longer lengths of hose should be avoided as they can become a source of cross contamination between tests However if a hose length greater than 1 5m is used the flushing time should be increased pro rata refer to previous section 6 ISO 32 oil grade at 35 C 36 Flush Valve Ope
46. t Reference CERTIFIED Settings Next Test Number 1 Transfer Log Test Type Normal Ready Erase Log Result C Fush Figure 4 Remote Device dialogue Start Starts sampling and emptying cycle Stop Stops test at any point in the sampling emptying 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 PML 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 the flush valve is left open depends on the distance of the PML from the system being sampled and the conditions existing in the drain reservoir refer to page 36 for guidance However for version PML W PC Operation 13 4 5 moisture and temperature indication every test is automati cally preceded by a 3 minute flush period to allow the moisture sensor to stabilise and give an accurate reading Therefore a separate flush period is unnecessary unless a Continuous Test flush period greater than 3 minutes is required For the PMI2 W version the moisture and temperature function can be switched off refer to Measure Water Content on page 25 for details Press the Flush button to open the flush valve and press the Stop button to close it The Flush indicator turns a yellow colour when flushing is in progress Connect Refer to Remote Control section page 1
47. t 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 PML 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 1 5 15 25 30 50 75 100 ISO MTD 4 6 14 21 25 38 50 70 The option of quoting just two counts of 6um and 14um for APCs remains Not verified by NIST XI acftd 52 New ISO MEpiuM TEST DUST AND ITS EFFECT ON ISO Correlation The table shows the correla tion between Particle Sizes Ob tained using ACFTD ISO 4402 1991 and NIST ISO 11171 Cali bration Methods This table is only a guide line The exact relationship between ACFTD sizes and the NIST sizes may vary from in strument to instrument depend ing on the characteristics of the particle counter and orig inal ACFTD calibration Other Standards APPENDIX G Particle Size Obtained Using ACFTD ISO NIST ISO 4402 matt MTD ISO 11171 um
48. ts as defined for the Continuous Test Occasionally the operator connects 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 cable supplied with the PML2 If the computer has only USB to serial ports use the USB to serial converter and follow the instructions on page 12 Apply power to the PMI2 make the PC connection and then start LPA View run ning To access the Remote Device facility 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 10 PC Operation Machine T AS4059E 2 005158 6 0 LITE 13 58 29 CERTIFIED 22 2117 15 154 15B 11C 12D 10E 10F 21 68 3538 005158 5 0 2008 11 04 13 02 28 CERTIFIED 22 2117 15 154 15B 12C 12D 11E 10F 3537 005158 4 0 2008 11 04 12 54 08 CERTIFIED 22 2147 15 15A 15B 11C 12D 10E 11F 3536 005158 3 0 2008 11 04 12 48 51 CERTIFIED 22 21 17 15 154 158 11C 120 11E 10F 3535 005158 2 0 2008 11 04 12 43 39 CERTIFIED 22 21 17 15 154 158 11C 120 11E 10F 3534 005158 1 3 2008 11 04 12 37 48 CERTIFIED 2
49. tying cycle has finished the flush valve remains open for the time set then automatically closes before the next sampling test Time set to between 6 and 30000 Flush valve automatically closes after the emp tying cycle has finished and remains closed un til 5 minutes before the next sample test is pro grammed to start The servo motor operating the Flush valve exhibits a slight ticking noise both when it is open and closed This is normal Continuous Sampling 19 6 1 10 Continuous Test Basic Operation Follow the instructions on page 15 for inputting settings select Continuous Test Type Input Test Interval input the time in minutes that is required between 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 F after pressing OK 0 zero ISO Dirty Alarm Target O0 zero NAS 1638 AS4059E 1 Dirty Alarm Target 0 zero ASA059E 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 PML If the box is not ticked none of the test results will be stored in the memory of the PML Press OK button to save settings and return to Remote Device dialo
50. yesight 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 products are at the forefront of this challenge and will help you to manage the quality and productivity of your systems Do s e Do use filter breathers on tank tops e Do use tank designs which are self draining sloped or conical e Do use tanks which can be sealed off from the surrounding environment e Do exercise care and use funnels when filling tanks with fluid e Do utilize stainless steel and methods such as electro polishing in the design of system components upstream of your first filter set e Do perform off line analysis in a controlled environment such as a laboratory which should contain fewer airborne contaminants that where the sample was taken from e Do use suitable glass bottles ideally certified clean to take samples along with a hand pump to reduce contamination ingress e Do filter your system thoroughly before using it in your production process 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 CLEAN WORKING PRACTISES 55 APPENDIX H 56 Don t eat
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