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ICM/User Guide

1. e Do filter your system thoroughly before using it in your production process 80 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 81 APPENDIX H 82 CLEAN WORKING PRACTISES Produced by
2. in the case of a fault is indicated using special result values as previously described User has set a non zero test interval User has not set tests to occur automatically Or fluid is totally clean no particle counts Flow alarm can be turned off by user if this is a problem for example cleaning rigs 56 Fault Finding 16 3 Other Faults Unexpected results Check that the Mini mess hose has been fully obtained from connected at both the system and ICM ends sample Confirm that the flow through the ICM is within the range of the unit High water aeration levels Remote Device Check that correct COM port has been se dialogue not lected in the Remote Device dialogue responding to Disconnect power supply to ICM and then re buttons being connect it pressed If the ICM has been subjected to excessive contamination and a blockage is suspected a flush with a suitable solvent may clear the blockage The standard ICM is fitted with Viton seals so Petroleum Ether may be used for this purpose in conjunction with the MP Filtri UK Bottle Sampling Unit DO NOT USE ACETONE Fault Finding 57 17 Cycle Time and Flow Rate Considerations The set Test Duration is the amount of time for which particle counts are accumulated before the test result is updated The default of 120 seconds is likely to be suitable for most applications However it is possible to set other values A shorter time enables the unit to resp
3. 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 100ml of differential and cumula tive particle counts respectively for counts obtained by an automatic particle counter e g ICM XX 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 66 SAE AS4059 REV E CLEANLINESS CLASSIFICATION FOR APPENDIX D 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 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 67 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
4. The ICM has one switched input and two switched outputs These can be used instead of or in addition to the RS485 interface for command and control The RS485 interface is more flexible but requires more software work if LPA View is not used e g control from a PLC An alternative is to control the ICM via these switched signals either from a PLC or using a manual switch and indicators In order to reduce wiring the input and outputs all connect together on one side see Figure 5 However they are optically isolated from the rest of the system so can be used to switch unrelated signals Start Signal The start signal is an opto isolated input that can be used to start a test This could be from a push button or a PLC output The input accepts AC or DC signals typically derived from the DC supply voltage The exact function of this input is determined by the Test Mode setting 12 6 46 Electrical Interface CONTAMINATION MONITOR er 8 gt 4 POWER SUPPLY F i oo I 1 b 4S IGNAL z RSL85 TRANCE IVER 4S IGNAL EE nse E ee ag ee es gee or ee ot i i ATOR TRTE I WHITE OUTPUT t h i O OUTPUT 1 i INDICATOR A 1 BROWN OUTPUT 2 BL er UT i PINK START 2 i 24 V START 1 4 ET a ay I GREY 1 0 COMMON 5 Y i i CONTROL PANEL OR PLC Figure 5 Switched I O Signals Item Minimum Maximum Voltage 9V DC 36V DC Impedance 10k
5. e Itis worth reinforcing that the primary function of the product is to produce a measurement of cleanliness and not act as a flow meter If the unit produces a contamination measurement then the flow rate is high enough for it to do so e The ICM needs particles to pass through the flow cell to calcu late flow the dirtier the system is the more statistically accurate the flow output becomes e Conversely when placed on a very clean system it can have diffi culty in working out the flow due to the very low number of 32 Settings particles passing through the flow cell This will not effect the contamination measurement but it is worth noting that a lower confidence or no indication at all on a clean sysem If this is the case the tick box is avaiable to allow a contamination reading e It may be necessary that the low flow indicator is turned off if filtration is below 10um 12 6 Continuous Testing In the Continuous Testing area are settings which control how the ICM decides when to perform and log a test Selecting Test Con tinuously makes the ICM automatically repeat the test according to the specified Test Interval Setting an interval longer than the test duration results in the test being repeated upon each expiry of that interval For example setting a Test Duration of I minute and a Test Interval of 10 minutes results in a 1 minute test performed every 10 minutes Setting the interval to a value less than the Test D
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7. RH is temperature dependent so the temperature is measured at the same time This enables results to be compared meaningfully The water sensor output is affected by pressure so the accuracy will be proportionally degraded above 100 bar operating pressure The temperature measured is that of the fluid passing through the unit Note this may differ from that of the hydraulic system depending on flow rate pipe length and ambient temperature It is not intended to be an accurate indication of system temperature but to provide a reference for the RH measurement Nevertheless experience has shown the temperature measured is within a few degrees of that of the hydraulic system in most applications 20 Water Sensor 120 100 80 60 Indicated RH 40 20 0 20 40 60 80 100 Actual RH Figure 1 Water Sensor Response variation with Absolute Pressure Water Sensor 21 7 Data Logger File Record Graph Wiew Window Tools Help Debacle lg EA x kr 12 gt lt v v x v K lt v V m 7 ID Machine Tet T Time Reference 150 Code NASJAS1 AS4059E 2 RH Temp C 309 20081234 5 2008 07 03 08 34 18 Example 20 19 16 12 104 10B 10C 11D 11E 12F 40 54 27 65 308 20081234 2 5 2008 07 03 08 33 48 Example 20 19 17 15 10A 11B 11C 15D 15E 15F 40 6 27 63 307 20081234 1 5 2008 07 03 08 33 18 Example 20 19 17 15 11A 11B 12C 15D 15E 15F 40 67 27 62 306 20081234 12 5 2008 06 29 20 48 00 Ex
8. i e the user has not connected them to anything Settings 37 limits are exceeded Output 2 is the Alarm output behaving sim ilarly for the upper limit Alarm Mode 1 Clean Dirty Output I Output 2 Turns on When lt Lower gt Upper Intended Function Clean Dirty This could be used in a cleaning system that attempts to maintain a cleanliness level by switching a pump on and off Output I is the Clean output coming on when the result is less than or equal to the lower Clean limit This could be used to stop a cleaning pump Output 2 is the Dirty output coming on when the result is greater than the upper Dirty limit This could be used to start the clean ing pump Alarm Mode 2 Green Amber Red Output I Output 2 Turns on When lt Upper gt Lower Intended Function Green Red This mode encodes the result in such a way that the internal alarm relays can be used to drive an external remote 3 colour LED indi cator This is a special type of LED containing both red and green emitters which could be mounted in a control panel This external LED will then turn green amber red according to the test result in a similar way to the built in one Output I Green is turned 38 Settings on when the result is less that the upper limit Output 2 Red is turned on when the result is greater than the lower limit If the result is in between both outputs are
9. 1 1 1E100 FRAME FANEN aata 1 1EAHEBIACHANHNEIOE For Help press F1 p 4a Figure 1 LPA View To access the Remote Device facility in LPA View press the Remote Control button on the toolbar The Connect dialogue will then appear ATEN USB to Serial Bridge COM1 E Figure 2 The Connect dialogue The first time that this is done the correct communications port COM port on the computer has to be selected as detailed below e The program scans the computer for available ports and puts them in a list to choose from this list is in the box above the Connect Button Press the arrow on the right hand side of this box and choose the connection on your computer e All working communication ports of the computer are available for selection Select the one used to connect the ICM then press OK If you are unsure which port is correct the device name should be next to the COM port number When communication 26 Remote Control has been established successfully the remote control dialogue will appear After a successful connection the COM port will be remembered for next time and will appear preselected in the dialogue Remote Control 27 11 OG PC Software Operation The Remote Control dialogue allows an operator to manually con trol the ICM from a PC using the LPA View software It can also be used to download test results that have accumulated during au tonomous disconnected operation Test Refer
10. 5 15 Od standard 64 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 ICM 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 Ek 2 3 6 11 22 45 90 180 360 720 1440 2880 5760 Over 100 0 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 CLEANLINESS CODE SYSTEM 65 APPENDIX D
11. 550 gt 70 RH Cc uf fe ff ff fe fe ee oe Leave Empty for Dont Care Water Content Figure 2 1504406 1999 Alarm Levels Alarms can be set on combinations of cleanliness codes water con tent and temperature The available codes and their interpretation vary according to the set test Format For example it is possible to set a threshold of NAS 11 or ISO 18 16 15 or AS4059E 8B F etc 34 Settings In general there are upper and lower limits that can be set for the cleanliness level also for water content and temperature if applica ble An alarm if enabled will become active if any of the associated upper lower limits are exceeded However if a field is left empty blank this is interpreted as a don t care setting In the example Figure 2 the Upper Alarm is exceeded if the 4um count is greater than ISO code 23 or the 6um greater than ISO code 22 or the 14um count greater than code 18 or the water content is greater than 80 RH or the temperature is greater than 65 C The lower alarm is never triggered since all the settings are empty 1504406 1999 Alarm Levels IS04406 1999 represents cleanliness using codes for the number of particles greater than 4 6 and 14 um These codes can be used as limits for the alarms by selecting the IS04406 1999 test Format and then entering values as required As an extension to IS04406 1999 it is also possible to specify codes for the other measured siz
12. AS4059E Table 1 18011218 Alarm Levels Contamination Code T arget Alarm Levels Basic pm 5 15 15 25 25 5050 10 gt 100 H20 Temperature Class pm C 6 14 14 21 21 38 38 70 gt 70 AH Cc we PITT EE EH Sees OE Leave Empty for Dont Care Water Content These two standards are similar except for terminology and report ing format The actual numeric sizes and class thresholds are the same 36 Settings 12 7 3 Alarm Mode Output 1 Output 1 lt Lower gt Upper 0 Warning Alarm Fassa 11 Clean Dirty 50 10C gt 100 38 70 gt 70 5 Tested Clean Upper 7 6 Testing ICI Figure 3 Alarm Modes The Alarm Mode sets the precise function of the two switched alarm outputs of the ICM This allows the ICM to be used in a variety of situations Note that the conditions under which the outputs are turned on are also displayed above the Alarm Mode selector for each setting Alarm Mode 0 Warning Alarm Output I Output 2 Turns on When gt Lower gt Upper Intended Function Warning Alarm This allows the ICM to switch external warning lights or alarms Output I is the Warning output switching on if any of the Lower 11 Note that these outputs are distinct from the front panel LED and that the set alarm mode does not affect the LED The set alarm mode determines the function of the two switched outputs only This setting and this entire section can be ignored if these outputs are unused
13. Ohms Other ways to start a test are e Via LPA View or PLC Modbus command e Periodic automatic testing according to a programmed test mode 14 5 Alarm Outputs These are opto isolated switches that can be used to signal external indicators PLC inputs or other equipment e g pump on off con trol Electrical Interface 47 The exact function of these outputs is determined by the Alarm Mode setting see 12 7 3 The outputs are voltage free contacts that can switch AC or DC signals up to 36V nominal 60V absolute maximum peak voltage Item Minimum Maximum Voltage 36V DC Current 0 5A 48 Electrical Interface 15 Hydraulic Connection 1 High or Low Pressure Parallel Connection Y 18 16 7 Y 18 16 7 Y 18 16 7 b gt gt Q FK S v y v Figure 1 ICM working pressure generated by hydraulic component 2 Low Pressure Off Line Operation 18 16 7 pst por Figure 2 ICM working pressure gen erated by hydraulic component 3 Very Low Flow Systems 18 16 7 gt gt gt Figure 3 Entire system flow rate is within the range of the ICM Hydraulic Connection 49 15 1 15 1 1 15 1 2 Flow Rate Summary For the majority of systems a differential pressure of a few Bar will generate an in range flow for an ICM connected using two 1 5 meter lengths of Mini mess hose The required
14. example from a pump in the feed to the ICM are then translated into pulsations in flow rate sometimes leading to flow reversals in time with the pulsations If the flow is very low this can sweep the same particle backwards and forwards through the sensing volume multiple times confusing the results 42 Installation 14 Electrical Interface Note The separate ICM USBi product is available for those wishing to simply plug the ICM into a computer This section is for those wishing to do their own wiring to the product RSL85 MASTER PLC OR PC WITH RSL85 ADAPTOR RS485 RS485 RSL85 V CONTAMINATION MONITOR 12 24 VDV RED POWER V 8 POWER SUPPLY v BLUE POWER V Fi Lo 7 N i i i I i 1 i l YELLOW DATA 1 STENA 3 RSUBS TRANCE IVER i l GREEN DATA SIGNAL este 55 NG INDICATOR WHITE OUTPUT 4 OUTPUT 1 I i INDICATOR BROWN OUTPUT 2 61 i OUTPUT 2 1 i i H I I I I PINK START 2o START i 424V START T i hibam I I v GREY 1 0 COMMON 54 i I I i 1 CONTROL PANEL OR PLC RSLB85 BUS Figure 1 External Wiring Example In Figure an example installation is shown Electrical Interface 43 14 1 14 2 DC Power DC power is connected to pins 7 and 8 of the ICM circular connector Red and Blue if using the pre wired cable All the other signals are optional Item Mini
15. of the test dust and batch to batch variability was much greater than is acceptable nowadays New ISO Meprum Test Dust AND ITS EFFECT ON ISO 73 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 e Improved levels of particle count
16. perform a measurement of saturation of Wa ter in oil RH and fluid temperature C Operating Principle The instrument uses a light extinction principle whereby a specially collimated precision LED light source shines through the fluid and lands on a photodiode 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 Introduction 7 2 How to Order ICM Ne Example ICM w M Kx JER JG Example ICM 0 BIG M J 0 pi 0 J G3 Common Features All versions can be controlled by a PC PLC or the ICM RDU Remote Display Unit Included is time stamped data logging for around 4000 tests an integral status LED to in dicate fault conditions RS485 communications and measurement in multiple international standard formats All units include 3m pre wired control cable and LPA View test analysis software For more details see the product brochure and the Specification 3 The base unit for remotely controlled embedded applications and comes without key pad and LCD Adds Water and Temperature Sensing See section 6 0 if not required Mineral Oil Fluid Compatibility Also N Offshore and selected water based fluids S Phosphate ester and aggressive fluids Keypad Adds graphical LCD and a key pad See section 5 0 if not required Adds settable upper and lower l
17. the Result Codes Measuring Water in Hydraulic and Lubricating Fluids 61 1S04406 1999 Cleanliness Code System 63 NAS1638 Cleanliness Code System 65 SAE AS4059 REV E Cleanliness Classification For Hydraulic Fluids 66 Recommendations 69 Hydraulic System Target Cleanliness Levels 71 New ISO Medium Test Dust and its effect on ISO Contamination Control Standards 73 Calibration New Test Dust Benefits Effect on Industry Correlation Other Standards Clean working practises 80 1 1 1 Introduction The ICM measures and quantifies the numbers of solid contaminants in Hydraulic Lubrication and Transmission applications The ICM is designed to be an accurate instrument for permanently installed applications utilising mineral oil as the operating fluid The unit can operate using any of the international standard formats ISO 4406 1999 NAS 1638 AS 4059E and ISO 11218 The ICM incorporates a serial data connection for comprehensive remote control and monitoring The integrated data logger records up to 4000 test results internally for use where a computer cannot be permanently connected Simple switched inputs and alarm outputs are provided as alterna tive means of controlling the testing and signalling the results The full colour front panel led provides a basic indication of the clean liness level The graphical LCD and keypad allow direct local display of the re sults in any selected format ICM W models also
18. 1 pen 18 marag ICM User Guide MPEFITEr O www mpfiltri co uk 200 000 EN Covers All ICM Models except AZ2 ATEX 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 0 26 Contents 1 10 11 Introduction Operating Principle How to Order Related Products Specification Performance Hydraulic Environmental Physical Warranty and Recalibration Status LED Front Panel Operation Result Display Diagnostics Display Water Sensor Data Logger Remote Display Unit Option USBi Optional Computer USB Interface Remote Control Computer Connection PC Software Operation 11 Electrical 14 16 20 22 23 24 25 28 12 13 14 15 16 17 18 Settings 30 General Test Number Test Duration Test Format Flow Indication Continuous Testing Alarms Installation 41 Installation Procedure Electrical Interface 43 DC Power Serial Interface Switched Input and Output Signals Start Signal Alarm Outputs Hydraulic Connection 49 Flow Rate Manual Flow Control Active Flow Control Fault Finding 55 LED Flashing Fault Codes Test Status Other Faults Cycle Time and Flow Rate Considerations 58 Modbus Programming 60 Reading
19. 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 New ISO Meprum Test Dust AND ITS EFFECT ON ISO 79 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 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 labo ratory 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
20. 3 4 Status LED All ICM versions have a multicolour indicator on the front panel which is used to indicate the status or alarm state The alarm thresh olds can be set from LPA View via the serial interface Je Or ic a MKATO ICM ICM K ICM Figure 1 Front Panel Versions amp Green indicates that the test result passed i e none of the alarm thresholds were exceeded Yellow indicates that the lower cleanliness limit was exceeded but not the upper one Red indicates that the upper cleanliness limit was exceeded Blue indicates that the upper water content limit was exceeded OG Red Blue Alternating indicates both cleanliness and water content upper limits exceeded we If all these codes seem confusing please note that a given colour will only ever be seen if the corresponding limit has been specifically set by the user So for example if a maximum temperature limit has not been set the violet indication will never be seen If all that is wanted is a green or red light that can be arranged by simply setting only the cleanliness threshold maximum limit 14 Status LED Violet indicates that the upper temperature limit was exceeded 0 0 The LED can also indicate various fault codes by turning red and flashing white a number of times see section 16 1 4 This alarm if set takes priority over the Contamination and Water alarms In the event of an over temperature condition the LED will turn vi
21. 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 3 392 512 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 68 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 XXI Tt should be noted that the recommendations made in this table should be
22. Disconnected Operation Here the ICM operates as a stand alone item performing tests on a schedule or under external command from a control system If a permanent record of the results is needed an operator can occasionally connect a computer and use LPA View to download the accumulated test data Computer Connection The connection is made using an RS485 adaptor connected to the PC Either a USB RS485 or a RS232 RS485 converter can be used depending on the the interface available on the computer The ICM USBi is separately available as a pre wired solution for USB all modern laptops and PCs Make the connection start LPA View running and then apply power to the ICM Remote Control 25 Bile Record Graph View Window Tool Help Haix Da Ms ie SB Be x he E E E aN TN v v v v v v v v v v xl zil mi zil Hl a Type Time Reference 150 Code NASJAS1 AS4059E 2 RH A 5 2008 06 10 21 37 32 Example 18 17 13 9 9A 9B 8C 8D 7E 7F 34 6 5 2008 06 10 21 35 43 Example 18 17 13 9 9A 9B 8C 8D 7E 7F 34 6 5 2008 06 10 21 33 06 Example 18 17 13 9 9A 9B 8C 8D 7E 7F 34 6 5 2008 06 10 21 31 40 Example 20 0 0 0 104 0008 000C 000D 00E 0F 34 79 2 2000 05 05 10 18 00 PG KH GT3 24 22 17 15 15A 15B 12C 12D 10E 9F 2 2000 05 05 09 37 00 PG KH GT2 24 22 17 15 154 15B 11C 12D 10E 7F 2 2000 05 05 09 02 00 PG KH GT1 24 22117 15 15A 15B 11C 12D 10E 7F 1 2000 05 02 16 37 00 CRANE 7000 5 24 2218 15 15A 15B 12C 12D 10E 8F 1 Ann NE
23. FC1 Flow Control Valve ICM USBi USB adaptor with pre wired ICM cable Installation Procedure e Decide on tapping points in hydraulic circuit e Locate the unit mechanically and bolt to desired location using fixing holes provided The ICM must be in a vertical orientation with the oil flowing upwards through it e Wire back to junction box e Check flow in acceptable range There needs to be a differen tial pressure placed across the ICM such that a flow of fluid is generated within the range of the unit Installation 41 e If there is no suitable differential pressure available then a flow controller will be needed One solution is the ICM FC1 which will accept a pressure from 4 400 bar emitting a constant flow within the range of the ICM This should be fitted to the drain side of the ICM the top fitting e Fix mechanically e Connect hoses There must be no extra restriction placed in the drain hose Do not have a pipe going to a restrictor to control flow Any such restrictor must be mounted directly to the ICM drain fitting Fluid flow must be from the bottom fitting to the top follow ing the direction of flow arrow on the product labelling Le the bottom fitting is the inlet and the top fitting is the outlet e Fit electrical connector wire back to a junction box 12 This is because any length of pipe between the ICM and a downstream restrictor can act as an accumulator Any pressure pulsations for
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25. Pa Ta Ta Ta Ta Ta Ta Ta ee He k LET ad LT de md ek LL UW ru ru PLA ru LA ru LLI LLI LLI LLI a SERIAL COMMS AN Interface Diagnostics Baud Rate Ed e Count Bi Established Internal Comms Errors 2 281 RH KEYMAP O00 PCE REU K External Comms Errors 1 290 STATUS TESTING General Modbus Figure 8 Diagnostic Screens The STATUS line shows the current state of the unit Any errors such as LOW FLOW will also appear here The second screen shows diagnostics relating to Modbus serial com munications traffic External Comms Errors are those between a connected PC and the ICM Internal Comms Errors are internal to the unit showing communications between the ICM keyboard dis play circuit board and the sensor itself The third screen shows diagnostics related to CAN bus communica tions For more details refer to the separate ICM CAN bus manual These correspond to the front panel LED fault codes Front Panel Operation 19 6 I Water Sensor ICM W models measure water content using a capacitive RH rela tive humidity sensor The result is expressed as percentage satura tion 100 RH corresponds to the point at which free water exists in the fluid i e the fluid is no longer able to hold the water in a dissolved solution This is also normally the point at which damage occurs in a hydraulic system so is an ideal measurement scale that is independent of the fluid characteristics The water saturation point 100
26. ample 19 18 14 10 10A 10B 9C 9D BE 8F 34 79 27 83 305 20081234 12 5 2008 06 29 14 59 17 Example 19 18 14 10 104 10B 9C 9D BE B8F 34 79 27 83 E 4 gt For Help press F1 PG The ICM includes a built in data logger which adds the facility to log and timestamp test results locally within an internal memory even when not connected to a computer e Tests that are logged and when are determined by the log set tings see section 12 6 e Each log entry is time stamped and contains the ICM serial num ber so that it can be identified later e The ICM memory has space for around 4000 log entries When full the oldest log entry is overwritten See chapter 11 for details of how to download the test log 22 Data Logger 8 Remote Display Unit Option The optional ICM RDU is a separate box that just contains the key pad and display The sensor itself is mounted remotely in another box This allows the operator full control of the ICM even when the sensor itself is not easily accessible The ICM RDU connects in between the incoming supply serial connections and the ICM sensor It is transparent to the serial communications This means that a PLC or LPA View can operate in the usual way to control the ICM change settings or download results without having to unplug the RDU The same components are used for the RDU as for the normal ICM K option so the same instructions apply for operation See chap ter 5 for more detail
27. ation 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 5um 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 of formal controls over the distribution
28. customer wiring to external devices An external DC adapter can be used to power the complete system or if the computer is always connected during use power can be taken directly from the USB cable Full usage instructions are provided in the separate product user guide 10 How to Order 3 Specification 3 1 Performance Technology Particle Sizing Analysis Range Reporting Formats Accuracy Calibration Test Time Moisture amp Temperature Measurement Specification Precision LED Based Light Extinction Automatic Op tical Particle Counter gt 4 6 14 21 25 38 50 70 um c to ISO 4406 1999 Standard ISO 4406 1999 Code 0 to 25 NAS1638 Class 00 to 12 AS4059 Rev E Table 2 Sizes A F 000 to 12 Lower Limits are Test Time dependent If system above 22 21 18 or approx NAS 12 a coarse screen filter should be fitted to prevent blockage This is available from MP Filtri UK Part SK0040 ISO 4406 1999 NAS 1638 AS4059E Table 2 AS4059E Table 1 ISO 11218 14 ISO code for 4 6 14um c 1 code for 21 25 38 50 70 um c Each unit individually calibrated with Iso Medium Test Dust MTD based on Iso 11171 1999 on equip ment certified by IFTS Adjustable 10 3600 seconds factory set to 120s saturation RH and fluid temperature C Min eral Oil Only See section 6 11 3 2 3 3 Data Storage Keypad amp LCD Hydraulic Fluid Compatibility Flow Rate Viscosity Range Fluid Temperat
29. differential pressure can be obtained by taking advantage of an existing pressure drop within the system Alternatively one can be created by e g inserting a check valve The ICM can then be connected across this differential pressure source Detailed Calculations In general the flow rate of fluid through the ICM needs to be kept within the range of the unit see hydraulic specification 3 2 The ICM measures the flow during operation so this can be used to check that the flow is correct A flow that is out of range will be indicated by a fault code see 16 1 Results taken with out of range flows are not logged The flow is entirely generated by the differential pressure between the ends of the pipes used to connect the ICM The pressure needed to generate an in range flow can be estimated by assuming a target flow and determining the resulting pressure drop across the ICM and connection piping Use the graph 4 to lookup the ICM pressure drop and manufacturers data to lookup the piping pressure drop at the desired flow The sum of these two pressures is the pressure needed 50 Hydraulic Connection The user connects the ICM between two points in the hydraulic cir cuit that have this pressure difference In order to use the graph e Determine the working viscosity of the fluid e g 30 cSt e Decide on a desired flow rate 200ml minute is normally used since this is in the middle of the ICM flow range But 100m1 minute is al
30. ela an um c tion between Particle Sizes Obtained using ACFTD ISO 4402 1991 and NIST ISO 11171 Calibration Methods VOINGBRN 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 AA SSGSPIIQAKKVDD S OOGINAUNKVNN OS 39 ma RUE RON N N WWWNNNNNNNNNNNNDND re ee ee ee OO ONANAN Daanan RH SRUWON NOR BION WNON ION NION BACH WOD New ISO Meprum Test Dust AND ITS EFFECT ON ISO 77 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 XXV Al section headings indicated with are reproduced by kind permission of British Fluid Power Association from BFPA P5 1999 issue 3 Appendix 44 78 New ISO Meprum Test Dust AND ITS EFFECT ON ISO APPENDIX G ISO 4406 1999 DEF STD 05 42 7 XV 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 2000F 19 17 14 8 5 20 18
31. ence Example Apply Test Number 12 H Status Ready Stop Settings M Result ISO 19 18 14 Download New RH 34 79 Temperature 27 83 C enes Erase Log Figure 1 The Remote Control dialogue To perform a test first optionally edit the Test Reference and press Apply to set the new value This is a descriptive label which can be used to identify or group the test later along with the test number and test time date An example would be a machine number or customer name The Test Reference can be up to 15 characters in length When connected the ICM status should show Ready The oper ator can then press the Start button to begin the test The progress bar shows how much of the test has been completed The test can Some items may be missing depending on the options fitted to the ICM 28 PC Software Operation be abandoned at any time by pressing the Stop button If the Start button is pressed during a test then the current test is abandoned and a new one started When the test has finished the Result area will display the contam ination level in the set format and water content and temperature if W option After a test the Test Number is automatically incremented and the status of the test is displayed If the status is Ready then the operator can press the Start button again to begin a new test It is also possible to configure the ICM to automatically begin another test after an
32. es the flow by measuring the transi tion time of the particles The Low Flow warning indicates that the flow rate is below the minimum recommended level 3 High Flow The flow rate is above the maximum recommended level This will degrade the accuracy of the particle counts 4 Logging Fault with data logging memory 5 Water Sensor Fault with the water sensor Test Status The status is shown on the ICM screen This contains a number indicating the current state of the ICM according to Table 1 This The unit will still work but may be more susceptible to errors caused by pressure fluctuations This warning can also come on when there are no particles whatso ever detected i e the fluid is totally clean In this case the correct result e g 0 0 0 is still generated Fault Finding 55 allows a system to remotely monitor the ICM operation if desired allowing more specific diagnostics Value Function Comment 0 NOT READY Unit is powering up or there is some problem READY Ready to start a test TESTING Test in progress 3 WAITING Waiting between tests 128 FAULT OPTICAL LED failure sensor blocked filled with air 129 FAULT FLOW Flow too low for reliable test LOW 130 FAULT FLOW HIGH 131 FAULT LOGGING Fault with data logging 132 FAULT WATER Water sensor failure SENSOR Table 1 The TEST STATUS Register However the fault conditions are also indicated on the front panel LED while No Result
33. es too If this is not needed then the entries can be left blank NAS1638 Alarm Levels Contamination Code Target Alarm Levels Basic H20 Temperature Class pm 5 15 15 25 25 50 50 10 100 ZRH C O M TITT FF Em EENEN EE fT Leave Empty for Don t Care Water Content NAS1638 can be used by selecting this as the test Format The headings and boxes for the available settings change appropriately NAS1638 represents the overall cleanliness level as a single code Settings 35 this being the highest of the individual codes generated for each de fined particle size Hence we have the option of setting a limit on this overall contamination class the Basic Class or we can set individ ual limits on any combination of the classes for the defined particle size ranges AS4059E Table 2 Alarm Levels Contamination Code T arget Alarm Levels Basic H2 Class A B G D E F ZRH we e e e EH TTE oe Leave Empty for Dont Care Water Content Temperature Cc AS4059E Table 2 uses letters instead of numbers to indicate the particle size range so the settings are labelled appropriately The standard specifies ways to represent a cleanliness level using only a subset of the available particle sizes for example B F The user can achieve this by only entering settings for the sizes desired leaving the others empty So a limit of AS4059 7B F could be represented simply by entering a value of 7 for B C D E and F
34. estrictor or even a piece of piping if it has a suitable pressure drop across it e If none of these options is feasible then an active flow controller will likely be needed see 15 3 e Otherwise connect the ICM across the points identified taking care to maintain an upward flow of oil through the unit this re duces trapped air Of course in a real system the pressure and viscosity will vary with temperature and operating conditions But since the work ing flow range of the ICM is very wide this should not be a prob lem provided it remains within range On the graph the area be tween upper and lower lines represents the usable operating re gion for the ICM with the middle line being ideal The differen tial pressure and the viscosity can vary from the ideal provided the system stays within the upper and lower lines This ensures the flow stays within the working range of 20 400 ml min It can be seen that the unit will accommodate a 20 1 variation in either viscosity or differential pressure during operation 13 Tn fact the ICM will work perfectly well at a lower flow for example 100m1 minute in which case a 2 Bar check valve could be used 52 Hydraulic Connection 15 2 p 5 100 ES men Sree Sass Shoe ae ee SS Ene P E Oml minute max a 200ml minute ideal flow po VE NNN 1 mer L 5 n 0 1 L A L wo 001 L g 0 001 Viscosity cSt Figure 4 Differential Pressure vs Fluid V
35. gt TERMINATION TEE A Ara TERMINATION DATA DATA X 7 RSL85 MASTER Figure 3 Multi Drop Network Example Figure 3 shows how to connect two or more ICM devices to a multi drop RS485 network Any termination resistors should be fitted to the network cable ends only Spurs off the main RS485 bus should be kept as short as possible e g below 2m Normally the pre wired 3m cable available for the ICM would be used with a junction box to connect to the RS485 trunk Either individual DC supplies can be used to power each ICM or a single supply run through the trunk cable Figure 4 shows how to connect the ICM RDU Remote Display Unit The RDU is used when the ICM location is not convenient for an op erator It can control and monitor a remote ICM as well as allowing an external controller to be connected to it for data download for example Electrical Interface 45 14 3 14 4 CONTAMINATION MONITOR RDU IN OUT Imre ath we ee od Lost 1 I lt lt lt lt lt lt tee HE EE See Sly Se ele i A See ae Se GO BA B008 0 3 se br Ad 2 4 6 5 7 1 3 8 u Zz r DC POKER PINK ES gt ei mA A Igan TERMINATION lt m o lp 0 TERMINATION SET gt DATA Va DATA XX RSL 85 MASTER Figure 4 Remote Display Unit Including PC Controller Example Switched Input and Output Signals
36. imits for the test results with two programmable Alarm relay outputs The full colour front panel LED indicator also reflects the test results indicating if any set limits have been exceeded See section 12 7 0 if not required For high frequency pressure pulse applications contact MP Filtri UK Ltd This option together with K is also required in order to display detailed particle counts on the LCD The option also provides a switched start signal input 8 How to Order M16x2 Mini mess connections ICM Standard Also G3 1 4 2 1 2 1 1 2 1 2 2 1 3 G4 7 16th UNF Related Products ICM RDU The ICM RDU is a separate product that is used to KO remotely monitor or control an ICM It is used when SS the ICM is in a location unsuitable for a display la such as an engine compartment 3m cable length as standard not Atex approved See section 8 Figure 1 RDU MARE ICM 3m cable length as standard not Atex approved ICM FC1 A pressure compensated flow control valve suitable for the ICM This may be needed if the application produces an oil flow that varies outside the upper flow range of the unit ICM USBi USB interface adaptor for the ICM ow This is a ready made solution for easily connecting a computer to the ICM Figure 2 USBi It comprises a USB RS485 interface with a terminal block pre wired with the ICM cable An extra terminal block is provided for any How to Order 9
37. iscosity for various flow rates Manual Flow Control Another possibility is to fit a simple manual flow control flow re strictor to the outlet of the ICM e This should only be done where the available pressure is less than twice the maximum value calculated This is because the small orifice size needed to control the flow from a pressure larger than this has a risk of blockage e The flow controller must be fitted to the outlet only If fitted to the inlet it will have a filtering effect e The flow controller must be fitted directly to the ICM outlet port Hydraulic Connection 53 15 3 Active Flow Control This is only needed for High Pressure Off Line Operation 18 16 7 Figure 5 ICM flow actively regulated A pressure compensated flow control valve is fitted to the ICM drain outlet This maintains a constant flow rate even with a varying inlet pressure provided this pressure stays above a minimum working value A suitable valve is the ICM FC1 see 2 1 2 but other ones can be used too 54 Hydraulic Connection 16 16 1 16 2 Fault Finding LED Flashing Fault Codes The ICM front panel led indicates a fault by a number of white flashes with a red background The number of flashes indicates the fault code 1 Optical An optical fault could indicate LED failure or blockage of the optical path Try flushing with Petroleum Ether or return to MP Filtri UK 2 Low Flow The ICM estimat
38. 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 XXU The option of quoting just two counts of 64m and 14um for APCs remains New ISO Meprum Test Dusrt AND ITS EFFECT ON ISO 75 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 ICM 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 50XXII 70XXIV XXI Not verified by NIST XXIV acftd 76 New ISO Mepium Test Dust AND ITS EFFECT ON ISO APPENDIX G Particle Size Obtained Using Correlation ACFTD ISO NIST oe ISO 11171 4402 1991 The table shows the corr
39. mum Maximum Voltage 9V DC 36V DC Current 200mA Serial Interface An RS485 interface can optionally be connected to pins 1 and 3 yel low and green This can be a PLC running customer software or a PC with a RS485 adaptor running the supplied LPA View soft ware To provide a reference the RS485 OV connection should also be linked to the ICM OV as shown on the drawing The standard ICM control protocol is Modbus RTU Modbus is a freely available open standard for industrial control Adapters are available to interface to other industrial control buses The stan dard LPA View software from MP Filtri UK itself uses Modbus to communicate with the ICM but it is also possible for customers to implement their own controllers see chapter 18 TERMINATION TERMINATION CONTAMINATION MONITOR DATA DATA USB P C USB to RSL8S DATA DATA ADAPTOR ov Nov V av POWER SUPPLY 24V_DC Figure 2 PC Control Example 44 Electrical Interface Figure 2 shows a single ICM linked to a PC using a USB RS485 adaptor 100 Ohm termination resistors should be fitted as shown for long cables for example over 10m Twisted pair wiring should be used for any length over 2m Contamination Monitors L L lt lt lt lt EE EE lt lt gt lt lt
40. 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 71 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 72 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 to the International Standards Organiz
41. olet only whether or not there is also a contamination or water alarm condition The rationale is that an over temperature condition could be immediately catastrophic for the hydraulic system Status LED 15 5 5 1 Nn Front Panel Operation Result Display ICM K models have a 6 button keypad anda small OG graphical LCD This allows the display of the test result current cleanliness level with water content and temperature if applicable MABE ICM Figure 1 The graphical format allows a full display of all codes of the stan dards supported The unit powers up in Display Mode This displays the test result in the selected format Figures 2 onward show those available The screenshots on the right are the detailed version of the display additionally showing the particle counts and flow rate The parti cle sizes and count representation are automatically matched to the selected format There is also a History screen which shows the last 10 results The operator can switch between these screens using the A and V keys The horizontal line is the progress bar it grows from left to right as the test progresses When it reaches the right hand side a new result is generated The selected format is typically set during installation using LPA View The rationale is that each industry or company will have its preferred format it is not something that an operator should be changing 16 Fron
42. ond more quickly to variations in cleanliness This may be desired in order to reduce the product test time in a production line situation A longer test time enables the unit to average out variations in clean liness and produce a more stable result This is especially true for the larger particle sizes In clean systems there are very few of these so a large amount of fluid needs to be sampled in order to count a statistically significant number Another factor is the flow rate This can be traded off with cycle time since a higher flow allows the same amount of fluid to be sam pled in a shorter time Very Clean Systems Longer test times higher flows needed Normal or Dirty Systems Shorter test times or lower flows are acceptable This relationship is shown in Figure 1 This means gt 20 particles counted as per ISO 4406 1999 58 Cycle Time and Flow Rate Considerations 1000 rogn FOTO len T T T T I 400ml minute max flow 3 200mIAninute ideal flow a 100 bama Test Time seconds for 20 counts 10 0 1 2 3 4 5 6 7 ISO Code Figure 1 Test Time needed for Reliable Indication by ISO code Cycle Time and Flow Rate Considerations 59 18 18 1 Modbus Programming The ICM can be controlled via commands on its serial RS485 in terface using the Modbus RTU protocol It is possible to control every aspect and setting of the ICM as is done by the MP Fil
43. opping M Ignore Initial 0 Tests Figure 1 Remote Device Settings dialogue 12 2 Test Number 12 3 The Test Number can be used to help identify a test within a se quence However it is automatically reset when the ICM is powered up so instead relying on the timestamp date and time of test and test reference is preferred Test Duration The length of the test is controlled by the Test Duration The factory set value of 2 minutes is suitable for most applications but the user is free to set a different value Shorter times will make Settings 31 12 4 12 5 the ICM more responsive to short term fluctuations in contamina tion level It will also result in less consistent results for the large particle sizes and clean systems due to statistical fluctuations in the number of particles counted Longer tests will allow more even results in very clean systems and for the larger particle sizes since there will be a larger total number of particles counted during the test This means that any fluctuations have less of an effect on the test result Test Format Use the selector to choose the preferred display Format ISO NAS etc This selection is not just cosmetic since it also determines how the cleanliness alarm targets are to be interpreted if these are used Flow Indication e The ICM uses the width of the pulse to derive flow its flow out put is only an indication intended for installation guidance
44. optional delay In this case the status will be Testing or Waiting The ICM incorporates a data logger so previous test results can be downloaded into the test database using the Download New and Download All buttons The difference between these is that Down load New only transfers results that have never been downloaded before Download All transfers all results that are stored in the ICM Erase Log deletes the test results from the memory of the ICM When the user has finished operating the ICM the dialogue can be dismissed using the close control the X at the top right corner of the dialogue or by pressing the Esc key Pressing the Settings button brings up the Remote Device Settings dialogue PC Software Operation 29 12 Settings 12 1 O The ICM can be reconfigured using the Remote Device Settings dialogue This is normally done as part of the installation or com missioning process After making any changes pressing the OK button will update the ICM with the new settings Or press Cancel to leave the settings as they were General Some general information about the connected ICM unitis available The Identification shows the ICM serial number and software ver sion The serial number together with the test timestamp uniquely identify the test record These two parameters are the ones used to avoid duplication of test records Current Time shows the time set on the ICM It is important that this is correc
45. r 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 Q 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 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 0 uration levels below 50 in all equip ment Emulsified 50 25 Dissolved water MEASURING WATER CONTENT 61 APPENDIX A Typical Water Saturation Levels For New Oils 600 S 400 S paa o Q i 200 kv a 0 20 30 40 50 60 70 Temperature C Figure I Examples Hydraulic oil amp 30 C 200ppm 100 saturation Hydraulic oil 65 C 500ppm 100 saturation 62 MEASURING WATER CONTENT APPENDIX B 1504406 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 the following table The first scale number
46. 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 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 0 63 IS04406 1999 CLEANLINESS CODE SYSTEM APPENDIX B Microscope counting examines the qo T i 10 particles differently to APCs and 8 ae i 23 the code is given with two scale 4 numbers only These are at 5 um 3 ee i code 21 and 15 um equivalent to the 6 um c 196 22 19 14 and 14 um c of the APCs 5 20 19 2 5 18 513 10 6 4 16 3 2 15 1 6 104 14 8 13 4 12 2 11 10 10 g 5 g 3 2 5 8 8 E 213 E 10 7 6 4 3 6 z 3 2 5 5 z 1 6 3 4 e 3 2 f 218 Oo 2 lt E 1 9 21 4 6 14 New ISO 4406 standard um c
47. 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 74 New ISO Meprum 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 particle counts at 4 6 and 14 um with 6 and 14 um corresponding very closely to the previous 5 and 15 um
48. s The RDU wiring details are shown in figure 4 Remote Display Unit Option 23 9 USBi Optional Computer USB Interface Figure 1 ICM USBi A USB Interface Unit for the ICM This is a ready made solution for easily connecting a computer to the ICM It comprises a USB RS485 interface with a terminal block pre wired with the ICM cable An extra terminal block is provided for any customer wiring to external devices An external DC adapter can be used to power the complete system or if the computer is always connected during use power can be taken directly from the USB cable Note Computer should have mains power applied at all times Detailed installation and usage instructions are provided in the sep arate product user guide 24 USBi Optional Computer USB Interface 10 10 1 Remote Control The ICM can be controlled using the remote control facility included in the LPA View software package installed on a PC Alternatively customers can use their own software running on a PC or PLC Since the ICM includes a built in datalogging memory operators can make use of the remote control facility in one of two ways e Direct Online Operation The ICM is permanently connected to a computer while tests are carried out The operator can set parameters type a label and initiate the test They can then monitor the progress of each test Each test result is displayed and downloaded into the test database as it is completed e
49. so suitable and uses less oil e Use the graph 4 to look up the pressure drop across the ICM ports at this flow rate and viscosity E g at 30cSt and 200ml minute this is 0 4 Bar The maximum and minimum allowed differen tial pressures can also be determined using the 400m1 min and 20ml min lines respectively e Determine the additional pressure drop caused by the piping used to connect the ICM This may be negligible for 1 4 inch piping and over but is very important for Mini mess hoses This information can be found in the manufacturers catalogues In the case of Mini mess hoses at 30 cSt these have a pressure drop of around 10 Bar per meter per lpm of flow So a 2m total hose length would add a pressure drop of 2 x 10 x 0 2 4 Bar So in this case the pressure flow relationship is mainly depen dent on hose resistance e Add the ICM pressure drop to that of the hoses e g 4 0 4 4 4 Bar When the required pressure drop has been found Hydraulic Connection 51 e See the figures at the start of this section for examples of where the ICM could be connected e Ifthere is a pair of connections in the hydraulic circuit that oper ates with a differential pressure near to that calculated then the ICM can be connected there e Alternatively create the pressure drop by modifying the hydraulic system For example insert a check valve in the circuit with a 4 bar spring The component could also be a filter a r
50. t Panel Operation unter em 24 20 17 151533 15886 243 Al Min 39 RH m 28 C LNW oooWn ocmo RH 39 28 C Simple Detailed Figure 2 1504406 1999 15 15 25 25 50 50 100 100 f 6 1001 243 ml min 615641 fia 394 RH RH 39 28 C W 28 C Simple Detailed Figure 3 NAS1638 243 almin 394 RH RH 39 28 C 28 C Simple Detailed Figure 4 AS4059E Table 2 Front Panel Operation 17 gt 10 f 6 243 Almin RH 39 28 C oe Simple Figure 5 AS4059E Table 1 gt 10 ISO 12 121 7 6 iti ee 39 RH RH 39 28 C es ee CEG Simple Detailed Figure 6 15011218 Draft 5 2 Diagnostics Display Press lt to show the diagnostics displays used when diagnosing problems Then switch between the diagnostics screens using the A and F buttons Completion shows a number from 0 to 1000 indicating the test progress FLOW ml min provides an approximate indication of flow rate up dated after each test This can be helpful when installing the unit or checking operation to ensure that the flow rate is within the limits of the unit The other items are mainly of use to assist in support when reporting problems 18 Front Panel Operation RH Yee 230 RH 422 230 RH 4er O m m Ca aan Joa ek dk ml ke de nw Ge I PLA LT EI LE de de de de md ale made de me me E LL PULU E LN ET LN PL LLI Pan Then Tein Ten Tan Ha Tan a a a do le de mn de me le md me ke UO uw Em Mm
51. t since this is used to timestamp the tests Pressing the Set button automatically synchronises the ICM time to that on the computer The calibration area displays the date last Calibrated and the next Calibration Due date The ICM has been designed to be a very flexible product so has a wide range of settings and operating modes However the shipped defaults are suitable for most applications and many users can skip this section Actual operation is straightfor ward even when advanced settings are used during initial configuration 10 Some items may be missing depending on the options fitted to the ICM 30 Settings Remote Device Settings x Test Number fy Identification fiPcHsoos2e v0 33 Test Durati og Current Ti 04 19 10 18 ene 00 02 00 STEN ane 2011 0419 10 18 03 Set Format i504406 1999 z Caibiated_ 2011 01 2014 3537 Simulated Test Calibration Due jo 2 01 20 14 35 37 Low Flow Alarm Disabled Clean Systems I Output 1 Output 2 gt Lower gt Upper _Cancel_ Alarm Mode fo Warning Alarm gt Communications r Contamination Code T arget Alarm Levels H20 Temperature um C gt 4 gt 6 gt 14 gt 21 gt 25 538 gt 50 gt 70 ZRH C wp eet TT F ma TPT epee ME EE Leave Empty for Don t Care Water Content r Continuous Testing Test Continously I Interval 99 01 00 Log Continuous F Interval foc0000 Start Testing Automatically I Stop Testing When Clean I Gontinn heraet WevelBefore St
52. tri UK LPA View control software All results and counts are available in all supported formats One scenario is to use LPA View to initially configure the ICM then the customer written software only has to read the test results This could be used to integrate the ICM mea surements with a general machine control vehicle control or factory monitoring system Customers wishing to implement their own modbus controller soft ware will need to refer to the full ICM Modbus Programming Man ual however a simple example is given here Reading the Result Codes The simplest arrangement is to configure the ICM to test continu ously with a set interval between tests For example a Test Duration of 2 minutes and a Test Interval of 10 minutes The Start Testing Automatically selection can be used so that the unit does not require a Start signal Then the most recent test results can be read from the appropriate Modbus Registers Register Function 56 4um C Result Code 57 6um C Result Code 58 14um C Result Code 60 Modbus Programming 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 appear hazy Above this level there is a dange
53. turned on and the LED colour will be amber i e a mixture of red and green light Alarm Mode 3 Particles Water Output 1 Output 2 Turns on When Cleanliness gt Upper Water gt Upper Intended Function Cleanliness Alarm Water Alarm This is used when separate alarm outputs are needed for particles cleanliness and water content Alarm Mode 4 Continue Clean Output 1 Output 2 Turns on When gt Lower lt Lower Intended Function Continue Testing Stop Testing Clean This is used for a cleaning application where a signal is needed to stop testing for example to stop a pump or signal an external controller Alarm Mode 5 Tested Clean Output 1 Output 2 Turns on When Test Complete lt Lower Intended Function Test Complete Signal Pass Signal Settings 39 This is used when controlling tests from a PLC using switched out puts The PLC gives a start signal then monitors the Test Com plete output If the test has passed it can detect this with the Pass signal Alarm Mode 6 Customer Requested Modes Other alarm modes will be defined as and when customers request them 40 Settings 13 13 1 Installation Each ICM supplied consists of the following ICM Calibration certificate LPA View CD ROM software package Pre wired cable Optional Equipment Circular connector pre wired with 3m cable ICM RDU Remote display unit 500 um coarse screen filter ICM
54. uration for example zero results in a new test being started immediately a test finishes Start Testing Automatically sets the ICM to begin a test soon after it is powered up This is ideal for unattended systems Stop Testing When Clean is a feature intended for cleaning rigs or filter trolley type applications The ICM continues testing until the fluid is clean at which point an alarm is signalled and testing stops Confirm Target Level Before Stopping This helps to ensure that a test sequence is not terminated too soon when there are still a few large particles in the system When selected two successive clean results are needed before testing halts Settings 33 12 7 12 7 1 12 7 2 Alarms The ICM has two switched alarm outputs that can be used to sig nal external equipment in various ways according to the test results and the alarm settings There is also a multi colour front panel light which indicates how the result compares to the set alarm thresholds The alarm settings are comprehensive and flexible allowing the ICM to be used in many different scenarios Alarm LED The front panel LED also indicates these alarm states to the operator see section 4 Alarm Levels The various alarm thresholds are set in the Contamination Code Tar get Alarm Levels area of the dialogue Contamination Code T arget Alarm Levels H20 Temperature um C gt 4 gt 6 gt 14 gt 21 gt 25 gt 38
55. ure Maximum Pressure Differential Inlet Outlet Pressure Seal Material Environmental Ambient Temperature IP Rating Vibration 12 Approximately 4000 timestamped tests in the integral ICM memory 6 keys 128x64 pixels back lit graphical display Standard unit Mineral oil amp petroleum based fluids Consult MP Filtri UK for other fluids 20 400 ml minute lt 1000 cSt 25 to 85 C 400 bar static For high frequency pressure pulse ap plications contact MP Filtri UK Typically 0 5 bar but see section 15 1 Viton Contact MP Filtri UK for any fluids that are incompatible with Viton seals 25 to 80 C for non K version 25 to 55 C for K version IP 65 67 Versatile TBD Specification 3 4 Physical 3 5 3 6 Dimensions 117mm H x142mm W x65mm D Fixing Holes Centers 126mm apart Diameter 6 9mm for M6 Weight 1 15kg Electrical Supply Voltage 9 36V DC Supply Current 12V 24V 36V 150mA 80mA 60mAfor K version 70mA 40mA 30mAfor non K version Power Consumption 2 2W Switched Inputs amp see section 14 3 for details Outputs Warranty and Recalibration Warranty Re calibration The ICM is guaranteed for 12 months from date of receipt The ICM is recommended to be recalibrated every 12 months Return to MP Filtri UK for recalibration As a policy of continual improvement MP Filtri UK reserve the right to alter the specification without prior notice Specification 1
56. viewed as starting levels and may have to be modified in light of operational experiences or user requirements RECOMMENDATIONS 69 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 70 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 be verified Thus if no failures have

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