BSS 2

Bottle Sampling System

Instruction manual
Version 1.8

Serial-No.: ..................
Version-/Rev.-Date : 12.06.2012
Contents

1. General ................................................................................................................ 3

2. Safety Instructions ............................................................................................. 4

3. Extent of Delivery ............................................................................................... 5

4. Switch Panel ....................................................................................................... 6

5. Bottle Sampling .................................................................................................. 7

5.1. Reservoir ........................................................................................................ 7
5.2. Sampling......................................................................................................... 7
6. Commissioning................................................................................................... 8
6.1. Power supply .................................................................................................. 8
6.2. Compressed Air Supply .................................................................................. 9
6.2.1. Operation with the Compressor from INTERNORMEN-electronics ........ 10
6.2.2. Operation with Existing Compressed Air Supply..................................... 11
6.3. Connection to CCS 1 / CCS 2 ...................................................................... 12
7. Before the Analysis .......................................................................................... 13
7.1. Conditioning of the Sample ........................................................................... 14
8. Analysis of sample ........................................................................................... 14
8.1. Degassing ..................................................................................................... 14
8.2. Sample Feed ................................................................................................ 17
9. Cleaning and Maintenance .............................................................................. 19

10. Technical Data .................................................................................................. 20

10.1. Connections .................................................................................................. 20
10.1.1. Electrical ................................................................................................. 20
10.1.2. Pneumatic ............................................................................................... 20

2
1. General

Dear Customer

We congratulate you on buying the INTERNORMEN-electronics Bottle Sampling

System BSS 2. Before commissioning please read this manual carefully to prevent
damages to the BSS 2.

You have purchased a product which is technically up-to-date and which enables you
to perform a particle count in lab quality, at any points of your plant where an online-
analysis is not possible.
The sampling and the output of results only take a few minutes.

In general an online-measurement is to be preferred rather than a bottle sample

analysis. The process from sampling to particle counting involves many possibilities
of mistakes. Therefore this kind of analysis should be carried out only by trained per-
sonal.

3
2. Safety Instructions

 To prevent accidents it is important to keep strictly to the manual during the oper-
ation of the BSS 2.

 Never try to open the pressure chamber, when the system pressure varies from
the ambient air pressure.

 Never try to pressurise the chamber before being sure that it is tightly closed (see
the lighting diode!)

 Never use damaged or defective components (threaded joints, hoses, connect-

ors etc.)!

 A damaged pressure vessel (scratches in the glass, bent housing etc.) must not
be used.

 Never open the BSS 2 housing !

 In case of any irregularities concerning the function of the BSS 2 please

immediately contact your nearest INTERNORMEN Technology GmbH in
Altlußheim representative.

4
3. Components of BSS 2

The BSS 2 includes :

- Case [1]
- Instrument base with integrated service unit [2]
- Pressure vessel [3]
- Power supply unit [4]
- Connector for pneumatics [5]
- High pressure hose with mini-measuring connection M 16x2 [6]
- Compressor [7] (optional)
- Spiral hose [8] (optional)

4
2
5
8
7
3

Illustration 1

5
4. Switch Panel

B6
B1
B3
B5

B7

B4
B2

Illustration 2

B1 – Vacuum + pressure gauge

B2 – Regulator (pressure + vacuum)
B3 – Switch VENT / WORK
B4 – Switch PRESSURE / VACUUM
B5 – Switch OPEN / CLOSE
B6 – Green light emitting diode OPEN
B7 – Yellow light emitting diode CLOSE

6
5. Bottle Sampling

5.1. Reservoir

Before sampling make sure that the reservoir to be used can be put into the
pressure chamber of the BSS 2.

To guarantee reliable results of measurement you should only use reservoirs whose
cleanliness according to ISO 3722 is proved. You can buy them directly from
INTERNORMEN Technology GmbH (two sample bottle set, Best. Nr. 313427). These
glasses should be used only once.

5.2. Sampling

The bottle sampling requires a very careful handling. First flush the sampling point for
a few seconds. Open the sample reservoir just directly before taking the sample, and
close it immediately afterwards. Only this way the ambient influences do not impact
your measuring results.

Label your samples carefully. Note:

Sampling point
Date and time of sampling
Sampler (name, first name)
Special notes, if applicable

This is important for samplings at different plants, respectively different points of the
plant to help prevent any unclearness.

7
6. Commissioning

6.1. Power supply

For the operation of the BSS 2 you should only use the plug-in power supply supplied
by INTERNORMEN-electronics, which is included in the system. Make sure that this
power supply unit is set to the required output voltage of 12 V DC. (Illustration 3).

Illustration 3

Put the plug of the power supply unit into the current outlet (230 V~ 50 Hz) and the
connection cable into the socket of the BSS 2 (Illustration 4) on the backside of the
device. The actual unit might vary depending on the respective country's voltage.

8
 Illustration 4

When correctly connected, one of the light emitting

diodes OPEN respectively CLOSE should light up
after a few seconds.
Turn the switch VENT / WORK to the direction
VENT, if it is in WORK.

6.2. Compressed Air Supply

In addition to the electric connection, the BSS 2 of INTERNORMEN-electronics also

requires an external compressed air supply. This is provided either by an existing
compressed air piping or the compressor optionally available.

9
 6.2.1. Operation with the Compressor from INTERNORMEN-electronics

Instructions for the handling of the compressor are given in the enclosed manual.

Connect the BSS 2 with the com-

pressor. For this use the spiral hose
(Pos. 8, Illustration 1) which is op-
tionally available. Put the hose plug
into the coupler of the compressor.
(Illustration 5).

Illustration 5

Now put the other end (coupler) into the quick con-
nect plug at the backside of the BSS 2 (Illustration
6). The coupler is locked, when you hear a clicking
noise while putting into one another.

To release the plug connectors, pull back the lock-

ing ring of the closing coupler.
Before releasing make sure that the system is not
under pressure.
Illustration 6

10
Integrated service unit
The serialize inserted service unit prevents the entry
of dirt and humidity into the BSS 2.

To empty the container over knurled screw during

accumulation of liquid.

6.2.2. Operating with Existing Compressed Air Supply

 Note:
Take care that the parameters required concerning the air volume flow as well
as the pressure are strictly kept! Any divergences might cause malfunctions or
damages of the BSS 2. The filter regulator reducer which is optionally available
should be used.

Connect the BSS 2 to the pressure air supply. For this please use the optional
attached plug-in connection to be connected with the device. This plug-in connection
has an internal screw thread G 1/4 for the hose. Please make sure a firm seat and
sealing between the hose and connector.

Now slip the connection cap over the plug at the

backside of the BSS 2 (Illustration 7).

To release the plug connectors, pull back the

locking ring of the closing coupler.

Before releasing make sure that the system is

not under pressure.

Illustration 7

11
Integrated service unit
The serialize inserted service unit prevents the entry
of dirt and humidity into the BSS 2.

To empty the container over knurled screw during

accumulation of liquid.

6.3. Connection to CCS 1 / CCS 2

Connect the BSS 2 to the contamination control system by means of the pressure
hose (6, Illustration 1) included in the BSS 2. First remove the screw cap of the mini-
measuring connection at the top of the pressure vessel (Illustration 8). Now you can
mount the hose. The same way of connection applies to the CCS 1 as well as the
CCS 2.

Illustration 8

 Note:
Make sure a firm (hand-tight) fixing of the screw couplings to the high pressure
hose. A proper sealing is needed for correct results of the analysis!

12
7. Before the Analysis

After following the instructions you are ready to operate the BSS 2. Make sure that
you have sufficient air supply and pressure (max. 10 bar).

Turn the compressor on (if operated by compressor), respectively open the

feeding main to the BSS 2 (existing compressed air supply). Set the pressure control
valve to a rate between 6,0 and 6,5 bar. A different pressure rate might cause
malfunctions or damages to the BSS 2.

Turn the switch OPEN / CLOSE to the position OPEN. When the diode
OPEN (green) lights up, the pressure chamber lock is released. Now you
can remove the pressure vessel.

Make sure that an O-ring (90x2,5) is inside the locking device (Illustration 9).

Illustration 9

13
 7.1. Conditioning of the Sample

Before putting the bottle into the BSS 2 for examination, homogenize thoroughly
and ½ - 1 minute in the ultrasonic bath place. For exact measuring results an
equal distribution of the particles is important. The following shakingprocedure should
take about two minutes, dependent on the fluid viscosity, contamination and time
interval between sampling and analysis.
The vibration time depends directly on the fluid viscosity.
< ISO-VG-32 2 min
ISO-VG-46 ... 100 3 ... 4 min
> ISO-VG-100 5 ... 10 min (additional warming-up is indicated)

8. Analysis of sample

Instructions for the operation of the CCS1, respectively the CCS2 can be taken from
their manuals.

Immediately after termination of the sample conditioning the analysis should be done.

8.1. Degassing

Place the sample on the cover plate of the pressure chamber at the topside of the
device. Please make sure once again that the O-ring is in proper position. Place the
pressure vessel over the sample. Be aware of the correct position, i.e. it has to have
slipped completely downwards. Now you can turn the switch OPEN / CLOSE to the
position CLOSE (Illustration 12, 1). Wait until after a few seconds the diode CLOSE
(yellow) lightens. Close the ball valve at the topside of the pressure vessel (Illustra-
tion 10).

14
 open

close

Illustration 10

Turn the switch VENT / WORK to the position

WORK (Illustration 11, 2). Turn the switch
PRESSURE / VACUUM to the position
VACUUM (Illustration 11, 3). 1

2 3

Illustration 11

Pull out the handle of the

pressure regulator.

Illustration 12

15
Now turn the handle clockwise (Illustration 13) until – 1,0 bar. This will produce a
vacuum in the pressure chamber. The more you turn, the lower the pressure in the
chamber. You can observe this on the vacuum / pressure gauge (Illustration 13).

Illustration 13

 Note :
Observe the sample carefully during the degassing (Illustration 14). Reduce the
pressure in the chamber slowly and constantly. This will stop the sample from
bubbling over. This is important, since oil spills might damage the system.

Keep the vacuum in the chamber until there are no gas bub-
bles in the fluid anymore.

Illustration 14

16
 Turn the handle (illustration
15) anticlockwise until 0,0.

Illustration 15

8.2. Sample Feed

Turn the switch PRESSURE / VACUUM to the position PRESSURE (Illustration 16,
1).
Now turn the handle (Illustration 16, 2) slowly clockwise. This will increase the pres-
sure in the chamber. Continue turning until the gauge (Illustration 16) indicates a
pressure of about approximate 3,0 bar. When you hear a hissing noise, the pressure
in the chamber is too high. In this case turn the handle anticlockwise until this noise
stops.

Illustration 16

17
Open the ball valve at the top of the pressure vessel (Illustration 15).
Turn the switch PRESSURE / VACUUM to the position PRESSURE
(Illustration 16, 1).

open

close

Illustration 15

Now you can start the measurement at your particle counter. Please observe the in-
structions for „Bottle Sampling“ in the manual of your contamination controller.

 Note :
Due to the system design it is unavoidable that at the beginning of the sam-
pling analysis there is air in the supply tube of the contamination controller. If
there are only small differences between the individual ranges of particle size,
this might point to air bubbles in the measuring system. Therefore repeat the
measurement as long as the counting results are stable. Finish the analysis
before the whole sample is used up. The ascending tube of the pressure vessel
should sufficiently enter the fluid (Illustration 17).

Illustration 17

18
After finishing the measurements turn the switch VENT / WORK to the position
VENT. You will then hear a hissing noise produced by the air escaping from the
pressure chamber. Wait until this is ended, and then turn the switch OPEN / CLOSE
to the position OPEN. When the green diode OPEN lights up, the vessel is unlocked
and you can remove it by lifting upwards. Remove the sample glass.

9. Cleaning and Maintenance

Please keep the device and the feeding tubes absolutely clean. After every use the
device has to be flushed. For the flushing please use fine filtered low viscosity oil
(e.g. ISOVG22 / ISOVG32). Before operating the BSS2 after a long time of not using
it (about 2 weeks), the particle counting device should be flushed properly.

 For the cleaning of the pressure dome and the device housing please use a soft,
fuzz-free cloth.

 Take care that the ascending tube is not bent while cleaning the pressure cham-
ber. A contamination especially of this component would have negative affects on
correct counting results, as it is in direct contact with the sample.

 Wipe the oil remains away from the plate of the pressure chamber lock and from
the sealing area. For the cleaning do not use any aggressive chemical or rubbing
agents.

19
10. Technical Data

Dimensions: 220 x 240 x 390

Weight: 6,5 kg
Initial pressure: 0...4 bar
Vacuum: 0...-0,95 bar

10.1. Connections

10.1.1. Electrical

Power supply / mains: 230V ~ 50 Hz or 110 V ~ 60 Hz

Power supply / device: 12 V DC

10.1.2. Pneumatic

Pressure range: 5...7 bar

Flow rate: min. 40 l/min air
Connections: Rapid action coupling NW 7,2 with internal thread G ¼
Mini-measuring connection with screw coupling M16 x 2

Subject to technical alterations!

20
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