ACMU/User Guide
Contents
1. All section headings indicated with are reproduced by kind permission of British Fluid Power Association from BFPA P5 1999 issue 3 Appendix 44 40 New ISO Medium Test Dust its effect on 150 APPENDIX G ISO 4406 1999 DEFSTD 05 422 7 V 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 09 400 16 14 11 5 2 17 15 09 400 17 15 10 800 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 I New ISO Medium Test Dust and its effect on 150 41 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 42 Do use filter breathers on tank tops Do use tank designs which are self draining sloped or conical Do use tanks which can be sealed off from the surrounding enviro2. ACMU User Guide Mec el O www mpfiltri co uk 200 189 EN SAFETY WARNING Hydraulic systems contain dangerous fluids at high pressures and temperatures Installation servicing and adjustment is only to be performed by qualified personnel To secure optimum efficiency from your ACMU we recommend that you read and follow the instructions set out in this manual Do not tamper with this device Should you have any questions please contact MP Filtri UK Document REVISION 1 1 Contents 1 Introduction 5 2 Variants 7 Product Map C Version Installation dimensions C version Product P Version _ Installation dimensions P version 3 Materials of Construction 12 4 Operating Procedures 13 Mounting Fixing Hydraulics Motor Wiring Communication wiring C version Communication wiring P version 5 Safety precautions 20 6 FaultFinding 21 A Measuring Water in Hydraulic and Lubricating Fluids 23 B 1504406 1999 Cleanliness Code System 25 C NAS1638 Cleanliness Code System 27 D SAE AS4059 REV E Cleanliness Classification For Hydraulic Fluids 28 E Recommendations 31 Hydraulic System Target Cleanliness Levels 33 New ISO Medium Test Dust and its effect on ISO Contamination Control Standards 35 Calibration New Test Dust Benefits Effect on Industry Correlation Other Standards Clean working practises 42 1 Introduction MP Filtri UK s ACMU combines te
3. i V NLET G1 4 BSP DelailB Figure 4 Dimensions for P version Variants 11 3 Materials of Construction Wetted parts for both C and P units Brass Stainless Steel Aluminium C version case Polyvinyl paint Steel Polyester 12 Materials of Construction 4 Operating Procedures 4 1 Mounting Fixing Ensure that installation servicing and adjustment is only per formed by qualified personnel Install with the ICM in the vertical position Mount the ACMU using the mounting lugs provided Make sure the pressure gauge is visible at all times Enable access to all monitoring points Protect the ACMU against corrosion or aggressive environ ments if necessary 4 2 Hydraulics The inlet of the ACMU is the suction side of the pump it is a 1 4 BSP inlet also supplied with 1 4BSP to 7 16th adaptor Connect the suction side of the pump to the reservoir by means of a hydraulic hose use the correct internal diame tere g 1 4 Keep the suction hose as short as possible make sure the pressure never drops below atmospheric Operating Procedures 13 Connect the suction line to the lowest point of the reservoir e g the drain If this is not possible find a suitable location or use a down pipe through the filter lid The point of suction must be below the fluid level Use correct hydraulic fittings and hydraulic hoses for the in stallation D
4. C 200ppm 100 saturation Hydraulic oil 65 C 500ppm 100 saturation 24 Measuring Water Content 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 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 1504406 1999 Cleanliness Code System APPENDIX B 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 T 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 25 APPENDIX B Microscope counting examines the T 10 particle
5. 400 VAC 1 03 A 0 60 A 1345 Nominal Current 0 29kW 230 400 VAC 1 65 A 0 95 A 1320 Nominal Current 0 37kW 230 400 VAC 1 90 1 10 A 1350 Nominal Current 0 37kW 200 346 VAC 2 10 A 1 19 A 1350 Nominal Current 0 60kW 230 400 VAC 2 75 A 1 60 A 1350 Nominal Current 16 Operating Procedures 3 phase 60Hz Description Voltage A Nominal Current RPM Setting mot protection 0 21kW 265 460 VAC 1 04 A 0 60 A 1650 Nominal Current 0 18kW 200 340 VAC 1 06 A 0 62 A 1575 Nominal Current 0 33kW 265 460 VAC 1 65 A 0 95 A 1585 Nominal Current 0 37kW 200 346 VAC 1 85 A 1 08 A 1630 Nominal Current 0 43kW 265 460 VAC 1 85 1 10 A 1655 Nominal Current 0 69kW 265 460 VAC 2 63 1 52 1655 Nominal Current 1 phase 50Hz Description Voltage Nominal Current RPM Setting mot protection 0 18kW 110 VAC 3 30A 1415 Nominal Current 0 18kW 230 VAC 1 30 1415 Nominal Current 0 37kW 110 VAC 6 10 A 1400 Nominal Current 0 37kW 230 VAC 2 90 A 1400 Nominal Current 1 phase 60Hz Description Voltage Nominal Current RPM Setting mot protection 0 18kW 110 VAC 2 70A 1710 Nominal Current 0 18kW 230 VAC 1 30 A 1710 Nominal Current 0 37kW 110 VAC 520A 1700 Nominal Current 0 37kW 230 VAC 2 50 A 1700 Nominal Current Operating Procedures 17 4 4 Communication wiring C version Figure 1 Wiring diagram for C version For further information on communications and wiring please refer to the supplied
6. 4050 8100 16200 32400 50 100 ER 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 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 27 APPENDIX D SAE AS4059 REV E Cleanliness Classification For Hydraulic Fluids This SAE Aerospace Standard AS defines cleanliness levels for particulate contamination of hydraulic fluids and includes methods of reporting data re lating to the contamination levels Tables 1 and 2 below provide the Max imum Contamination Limits Particles 100ml of differential and cumula tive particle counts respectively for counts obtained by an automatic particle counter e g ACMU 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 28 SAE AS4059 REV E Cleanliness Classification For Hydraulic APPENDIX D Size range 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 1
7. CD containing relevant user guides 18 Operating Procedures 4 5 Communication wiring P version Electrical supply 9V to 36V 24V typical Flug tho control cablo from your USBI into the ICM power connection port For harcwired or PLO controlled aapiications to the full user manual for instruction A permanent DC supoly may also ba 10 COMMON A Caution Ensure that power is connected to the RED wire only to avoid damaging product Figure 2 Wiring diagram for P version Operating Procedures 5 Safety precautions 1 Dangers The ACMU is designed to comply with the latest technological and safety standards Nevertheless its incorrect usage can present danger to the user or third party The ACMU must only be used inline with guidance from MP Filtri UK when in perfect working order with regard to safety regulations Faults which could affect safety must be rectified immediately In addition to the installation manual the general and local regulations concerning ac cident prevention and environment and conservation respectively must be observed and followed All safety installations must be in place and fully functional before starting up the system Check from time to time if there are exterior damages and if the ACMU works correctly Do not carry out any alterations conversions or additions to the ACMU with out the written co
8. size distribution was determined using an optical micro scope This particle size distribution subsequently formed the basis of ISO 4402 the method for calibrating APCs Due to the limitations of that method of measurement the particle size distribution was questioned below about Sum It was also not traceable to any national standard of measurement critical requirement for today s quality management systems 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 New ISO Medium Test Dust and its effect on ISO 35 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 5um 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 combine
9. 1 400 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 Hydraulic 29 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 64 400 000 155 698 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 AS4059E Table 2 Cleanliness Classes for Cumulative Particle Counts 30 SAE 54059 REV E Cleanliness Classification For Hydraulic 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 Car
10. 6 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 491 9945599899 Email s mishra mpfiltri com Website www mpfiltri com RUSSIAN FEDERATION MP FILTRI RUSSIA INC Phone mobile 7 095 502 5411 Fax 7 095 205 9410 Email mpfiltrirussia yahoo com Website www mpfiltri ru USA MP FILTRI USA Inc Tel 1 215 529 1300 Fax 1 215 529 1902 Email sales mpfiltriusa com Website www mpfiltriusa com UAE MP FILTRI UEA Tel 91 9945599899 Email s mishra mpfiltri com Website www mpfiltri com
11. CULAR PURPOSE MP Filtri UK LTD SHALL NOT BELIABLE FOR ANY SPECIAL INDIRECT INCIDENTAL OR CONSEQUENTIAL DAMAGES OR LOSSES INCLUD ING LOSS OF DATA WE SPECIFICALLY DISCLAIM ANY AND ALL WARRANTIES TO CUSTOMERS OF THE CUSTOMER THE CUSTOMER S SOLE REMEDY FOR ANY BREACH OF WARRANTY IS THE REPAIR OR REPLACEMENT AT MP FILTRI DISCRETION OF THE FAILED PRODUCT MP Filtri UK maintains a policy of product improvement and reserves the right to modify the specifications without prior notice 47 48 Produced by MP Filtri UK Revision 1 1 As a policy of continual improvement MP Filtri UK reserve the right to alter specifi cations without prior notice Except as permitted by such licence no part of this publication may be reproduced stored in retrieval system or transmitted in any form or any means electronic me chanical recording or otherwise without prior written permission of MP Filtri UK MP FILTRI UK Limited Bourton Industrial Park Bourton on the Water GL54 2HQ U K Tel 44 1451 822522 Fax 44 1451 822282 Email sales mpfiltri co uk Website www mpfiltri co uk ITALY HEADQUARTERS MP FILTRI S p A Tel 39 02 95703 1 Fax 39 02 95741497 95740188 Email sales mpfiltri com Website www mpfiltri com CANADA MP FILTRI CANADA INC Tel 1 905 303 1369 Fax 1 905 303 7256 Email mail mpfiltricanada com Website www mpfiltricanada com CHINA MP FILTRI Shanghai Co Ltd Tel 86 21 5891991
12. D and the new ISO MTD The ACMU 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 ISOMTD 4 6 14 21 25 38 50 70 Not verified by NIST acftd 38 New ISO Medium Test Dust and its effect on 150 APPENDIX G 5 Particle Size Obtained Using Correlation ACFTD _ ISO NIST oe ISO 11171 4402 1991 The table shows the correla an um c tion between Particle Sizes Obtained using ACFTD ISO 4402 1991 and NIST ISO 11171 Calibration Methods O O0 JDN UN 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 N N WWWNNNNNNNNNNNNDND OO AA DNA A A Leu New ISO Medium Test Dust and its effect on 150 39 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
13. L Pressure Pressure Pressure Relief Adjustment Control Pump Valve Valve Manifold Lifting Eyes p Ww O QR Code 5 i ACMU gt Y d Webpage and Literature L Window Side Overlay Overlay QR Code ICM Webpage and Literature Hydraulic Outlet Nameplate Communication 8 Cable Gland 07 t Hydraulic Motor Power m Gland Figure 1 Product map C version Variants 2 2 Installation dimensions C version 4x 030 jf 7 7 OUTLET G 1 BSP INLET G 1 4 BSP_ Figure 2 Dimensions for C version 2 3 Product Map P Version Similar to the cabinet product the P version does not benefit from the same level of protection interaction and USBi functionality It is however e Lighter weighing only 13kg e More compact e Supplied with a 3 metre 8 core shielded cable and instructions for ICM communications and power Variants 9 Lifting Shackles Pressure Hydraulic Relief Outlet Pressure Valve Adjustment Valve Pressure Gauge Point Pressure ICM Control Contamination Manifold Monitor Pump Nameplate Mounting Holes Inlet Hydraulic Diagram HYDRAULIC TANK DIL Figure 3 Product map for P version 10 Variants 2 4 Installation dimensions P version CUTLET G 14 BSP eg 410 370 Je i
14. ay conflicts with the MP Filtri UK product 4 Eligibility This warranty extends to the original purchaser only or to the end user client of a MP Filtri UK authorised affiliate 5 How to obtain service To obtain service under the terms of this warranty the customer is required to notify MP Filtri UK before the expiration of the warranty period and to return 45 the item in accordance with MP Filtri UK product return policy Any prod uct returned for warranty repair must be accompanied by a full fault report specifying the symptoms and the conditions under which the fault occurs Should MP Filtri UK incur additional cost as a result of a failure to complete the appropriate paperwork an administrative charge may be levied Exclusions This warranty shall not apply to any defect failure or damage caused by im proper use or improper or inadequate care MP Filtri UK shall not be oblig ated to provide service under this warranty if Damage has been caused by a failure to make a full and proper inspec tion of the product as described by the documentation enclosed with the product at the time of shipment on initial receipt of the product following shipment Damage has been caused by the attempts of individuals other than MP Filtri UK staff to repair or service the product Damage has been caused by the improper use or a connection with in compatible equipment or product including software applications Charges Un
15. chnology to enable sampling on low pressure hydraulic and lubrication systems where aeration can be an issue The ACMU suppresses the air bubbles so they are no longer counted as particles The ACMU can be installed in most low pressure hydraulic and lu brication systems ranging from zero bar pressure to a maximum of 50 bar D version pump A further option B version pump can be installed on systems with a maximum of 6 bar on the inlet of ACMU pump and a maximum of 3 bar on system return These two options give the user the versatility to install the ACMU in a variety of different system applications Utilising the best contamination monitor product in its class as stan dard the ACMU delivers the simplicity practicality and accuracy for the most demanding of applications Proven optical technology and algorithms ensure consistent monitoring of your system pro viding peace of mind for your operators investors Both variants of ACMU come with an ICM as standard complete with RS485 232 MODBUS and CANBUS J1939 typical proto cols for remote control ICM communication and motor power needs to be completed by the customer during installation Cable for motor is not supplied Designed with you in mind The ACMU is configured deliberately to provide customers the ver satility they require for existing systems or those in development All pressures are stated as gauge pressures in bar Introduction 5 The in built motor pump a
16. d with a revised ISO APC calibration method give 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 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 equip ment More accurate and consistent filter test results Effect on Industry The introduction of ISO MTD has necessitated changes to certain ISO stan dards 36 New ISO Medium Test Dust and its effect on 150 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 part
17. der cover of this warranty MP Filtri UK will pay the carriage and insur ance charges for the shipment of defective product back to MP Filtri UK and for its return to the client s original site of despatch except when MP Filtri UK product return policy has not been followed 46 Product failure is caused by any of the exclusions described above when the customer will be liable for the full cost of the repair parts and labour plus all carriage and insurance costs to and from MP Filtri UK premises The product is damaged in transit and a contributory cause is inadequate packaging It is the customer s responsibility to ensure that the packaging used to return equipment to MP Filtri UK is the same or has equivalent protective qualities to that used to ship the product to the customer in the first instance Any damage resulting from the use of inadequate pack aging will nullify MP Filtri UK obligations under this warranty Should the customer s product be damaged in transit following a repair at MP Filtri UK site a full photographic record of the damage must be obtained packaging and the product to support any claim for recompense Fail ure to present this evidence may limit MP Filtri UK obligations under this warranty THIS WARRANTY IS GIVEN BY MP Filtri UK IN LIEU OF ANY OTHER WARRANTIES EXPRESS OR IMPLIED INCLUDING BUT NOT LIM ITED TO ANY IMPLIED WARRANTY OF MERCHANTABILITY NON INFRINGEMENT OR FITNESS FOR A PARTI
18. e Attach the pressure gauge 22 Fault Finding 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 danger of free water accumulating in the system in areas of low flow This can lead to corrosion and accelerated wear Similarly fire resistant fluids have a natural water content which may be different to mineral oils Saturation Levels Since the effects of free also emul Saturation point E g sified water is more harmful than 100 those of dissolved water water lev els should remain well below the sat ee 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 23 APPENDIX A Typical Water Saturation Levels For New Oils 600 5 400 Q 5 t 200 T 0 20 30 40 50 60 70 Temperature C Figure Examples Hydraulic oil 30
19. elate 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 32 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 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 the contamination sensitivity of the components the operational conditions of the system the required reliability and life expectancy Hydraulic System Target Cleanliness Levels 33 APPENDIX F Contamination Corresponding Recommended Typical Codes Codes Filtration Applications ISO 4406 1999 NAS 1638 Degree 4 6 14 Bx200 pm c pm c gm 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 equip
20. i 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 Y particle counts at 4 6 and 14 um with 6 and 14 um correspond ing 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 The option of guoting just two counts of 6um and 14um for APCs remains New ISO Medium Test Dust and its effect on 150 37 APPENDIX G To clarify matters still further ISO standards written around the new test dust will utilize a new identifier 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 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 ACFT
21. ment 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 34 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 Organization ISO that it was intending to stop the production of AC Fine Test Dust ACFTD work commenced immediately on finding an improved replacement dust ACFTD was used extensively within the fluid power and automotive industries for calibrating Automatic Particle Counters APCs and for the testing of components APCs are used for testing oil filters and also for contaminant sensitivity test ing of hydraulic components For 25 years APCs have been the main stay in the measurement of solid particles in hydraulic fluids The growth in demand for measuring fluid cleanliness in a variety of industrial processes including fluid power has resulted in APCs moving from the laboratory environment out into the factory In fact they are now a critical part of many production processes It is therefore essential that the data they provide is both accurate and consistent Calibration ACFTD has been used as an artificial contaminant since the 1960s and its original particle
22. nment Do exercise care and use funnels when filling tanks with fluid Do utilize stainless steel and methods such as electro polishing in the design of system components upstream of your first filter set Do perform off line analysis in a controlled environment such as a labo ratory which should contain fewer airborne contaminants that where the sample was taken from Do use suitable glass bottles ideally certified clean to take samples along with a hand pump to reduce contamination ingress Do filter your system thoroughly before using it in your production process Clean working practises APPENDIX H Do perform a statistically large enough sample of particle analysis results 25 to arrive at a base cleanliness level for your system Do make sure that filters are correctly sized for your applications and cleanliness you are trying to achieve Don ts Don t eat 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 reser voir 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 an un controlled enviro
23. nment 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 com missioning 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 43 APPENDIX H 44 Clean working practises 1 Warranty amp Servicing MP Filtri UK warrants that the products that it manufactures and sells will be free from defects in material workmanship amp performance for a period of 12 months from the date of shipment 2 Hardware Firmware Should the hardware prove defective during the warranty period MP Filtri UK at its discretion will either repair the defective product or replace it with an equivalent product in exchange for the defective unit without charge for parts labour carriage and insurance 3 Software MP Filtri UK warrants that software will operate substantially in accordance with its functional specification for 12 months from date of shipment pro vided that the integrity of the operating environment has not been compro mised through misuse inappropriate handling abnormal operating condi tions neglect or damage unintentional or otherwise or the introduction of third party product software or hardware that in any w
24. nsent of MP Filtri UK Defective parts have to be replaced immediately by original spare parts If other parts are used there is no guarantee they are suitable for the use and built to applicable safety standards We recommend to run the ACMU with mineral oil in accordance with DIN 51524 51525 Do not operate with other fluids without the consent of MP Filtri UK 2 Dangers by electricity All work on the electrical equipment of the ACMU must be carried out by a qualified electrician Check the electrical equipment of the ACMU regularly Rectify any faults immediately 20 Safety precautions 6 Fault Finding FAULT No oil flow Electric motor keeps tripping Fault Finding CHECK Check rotation of electric motor ifincorrect change the electrical connection Pump is not drawing fluid pre fill the suction hose with oil and start again Check local grid with motor identification plate Check motor protection switch for setting and ad just according to electric motor identification la bel Adjust to normal Amperage 10 21 Airlock at start up Vent the system Open the measuring point or the valve shown in the figure below Make sure the suction hose is filled with oil be fore start up The return line must be connected to the applica tion reservoir pressure less To set the system pressure provide the manifold with a pressure gauge and adjust the valve shown in the figure below Adjust the valv
25. o not use Teflon tape or liquid sealants Do not fit ball valve or any other obstructions in the return line of the filter unit the return line must be free to flow back to tank Keep the return line as short as possible and use hydraulic hose of the correct internal diameter e g 1 4 Make sure the point of return on the reservoir is as far away as possible from suction point 4 3 Motor Wiring 14 Ensure that a qualified electrician carry out the electric installa tion of the ACMU Before installation ensure that the electrical data of the elec tric motor corresponds with the data of the local electrical supply Connection 3 phase 1 phase Ensure that the electric motor rotates in accordance with the arrow on the electric motor Operating Procedures Wiring Diagram for Electric Motor Description Visual 3 Phase motor 2 2 v2 11 12 13 Not connected w2 u2 v2 wm 1 12 13 Y star W2 2 v2 u dv lw 1 12 13 triangle Operating Procedures 15 Description Visual 1 Phase motor 2 22 ul e L1 n Not connected u2 72 ul e 9 CA CA 71 Left rotation 2 22 ul L1 ca CA zi Right rotation Technical Details E motors 3 phase 50Hz Description Voltage A Nominal Current RPM Setting mot protection 0 18kW 230 400 VAC 1 03 A 0 60 A 1345 Nominal Current 0 18kW 200
26. s differently to APCs and 8 ae 23 the code is given with two scale 4 numbers only These are at 5 um 1 code 21 and 15 um equivalent to the 6 um c 156 22 19 14 and 14 um c of the APCs 20 19 2 5 18 5 1 3 10 6 4 16 3 2 15 1 6 104 14 8 13 4 12 2 11 103 10 g 5 2 5 3 8 213 8 10 7 z 6 4 P 6 2 32 5 5 1 6 3 4 5 2 5 2 3 m o E 2 1 9 21 4 6 14 NewISO 4406 standard um c 5 15 Od standard 26 1504406 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 A 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 ACMU 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
27. ssembly and automatic monitoring prod uct ICM can be wired directly allowing control through a wide range of communication protocol and logic controllers A small footprint and lifting eyes make it the ideal solution for safe instal lation on new or retrofit applications A wide range of operating voltages allow us to support a global market and emerging tech nologies 6 Introduction 2 2 1 Variants The ACMU comes ready assembled It consists of a hydraulic gear pump fitted to an electric motor by means of a flexible coupling and bell housing The pump motor is bolted to a frame assembly in one of the two variants described Product Map C Version The C version represents the functionality required in the more challenging of applications The steel cabinet with integral lifting eyes provides protection and practicality during installation e Multi language instructions and smart phone interaction via prod uct markings make installation simple for operators especially in remote locations e In built USBi communication box means that diagnostic and ICM set up can be achieved via a laptop e Supplied with a 5 metre 8 core shielded cable and instructions for ICM communications and power Variants 7 Motor e Contamination Monitor Hydraulic Diagram USBi Communications Box Pressure Gauge Point Mounting Holes HYDRAULIC TANK CI
28. tridge valve 20 18 15 Proportional 18 16 13 Servo valve 16 14 11 ACTUATOR 20 18 15 Table 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 Tt 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 Recommendations 31 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 r
Download Pdf Manuals
Related Search