HIAC POD System User Manual-DOC0265380331
HIAC POD System User Manual-DOC0265380331
80331
HIAC PODS
08/2013, Edition 1
User Manual
Table of Contents
Specifications ..................................................................................................................................................................................3
General information .....................................................................................................................................................................4
Safety information ..............................................................................................................................................................................4
Use of hazard information ..................................................................................................................................................................4
Precautionary labels ..........................................................................................................................................................................4
Class 1 laser product .........................................................................................................................................................................4
Certification ........................................................................................................................................................................................5
Product overview ...............................................................................................................................................................................5
Product components ..........................................................................................................................................................................6
Installation .........................................................................................................................................................................................7
Connect external pressure .................................................................................................................................................................7
Connect the CO2 bottle ..............................................................................................................................................................7
Connect the shop air source .......................................................................................................................................................8
Connect the communications cables .................................................................................................................................................8
Connect the external power supply ....................................................................................................................................................8
Startup .................................................................................................................................................................................................8
Power up and self-test verification .....................................................................................................................................................8
User interface and navigation ...............................................................................................................................................9
Keypad description ............................................................................................................................................................................9
See the system status menu parameters ........................................................................................................................................10
Set the operation variables ..............................................................................................................................................................10
Operation ..........................................................................................................................................................................................12
Procedure to take a sample .............................................................................................................................................................12
Prepare to take a sample with a bottle .....................................................................................................................................12
Prepare to take an online measurement ...................................................................................................................................13
Flush the instrument in bottle mode ..........................................................................................................................................13
Flush the instrument in the online mode ...................................................................................................................................13
Fluid compatibility .....................................................................................................................................................................14
Take a sample in the bottle mode .............................................................................................................................................14
1
Table of Contents
Take a sample in the online mode ............................................................................................................................................14
Test results ......................................................................................................................................................................................15
Buffer operation ...............................................................................................................................................................................15
See the contents .......................................................................................................................................................................15
Delete or print data ...................................................................................................................................................................16
See the sample data .................................................................................................................................................................16
Maintenance ...................................................................................................................................................................................16
Clean the instrument ........................................................................................................................................................................16
Change the filter ...............................................................................................................................................................................16
Charge the battery ...........................................................................................................................................................................17
Add printer paper .............................................................................................................................................................................17
Remove the flow sensor blockages .................................................................................................................................................18
Calibration ........................................................................................................................................................................................18
Troubleshooting ..........................................................................................................................................................................19
Replacement parts and accessories ...............................................................................................................................21
Prepare for shipping .................................................................................................................................................................22
Appendix ..........................................................................................................................................................................................22
Particle counts and other codes .......................................................................................................................................................22
2
Specifications Specification Details
Specifications are subject to change without notice. Data storage 500 sample records
English 3
General information NOTICE
In no event will the manufacturer be liable for direct, indirect, special, Indicates a situation which, if not avoided, may cause damage to the instrument.
Information that requires special emphasis.
incidental or consequential damages resulting from any defect or
omission in this manual. The manufacturer reserves the right to make
changes in this manual and the products it describes at any time, without Precautionary labels
notice or obligation. Revised editions are found on the manufacturer’s
website. Read all labels and tags attached to the instrument. Personal injury or
damage to the instrument could occur if not observed. A symbol, if noted
on the instrument, will be included with a danger or caution statement in
Safety information the manual.
NOTICE This symbol, if noted on the instrument, references the instruction
The manufacturer is not responsible for any damages due to misapplication or manual for operation and/or safety information.
misuse of this product including, without limitation, direct, incidental and
consequential damages, and disclaims such damages to the full extent permitted
under applicable law. The user is solely responsible to identify critical application Electrical equipment marked with this symbol may not be disposed of
risks and install appropriate mechanisms to protect processes during a possible in European public disposal systems after 12 August of 2005. In
equipment malfunction. conformity with European local and national regulations (EU Directive
2002/96/EC), European electrical equipment users must now return
Please read this entire manual before unpacking, setting up or operating
old or end-of-life equipment to the Producer for disposal at no charge
this equipment. Pay attention to all danger and caution statements. to the user.
Failure to do so could result in serious injury to the operator or damage Note: For return for recycling, please contact the equipment producer or supplier
to the equipment. for instructions on how to return end-of-life equipment, producer-supplied
electrical accessories, and all auxiliary items for proper disposal.
Make sure that the protection provided by this equipment is not impaired.
Do not use or install this equipment in any manner other than that This symbol indicates the need for protective eye wear.
specified in this manual.
4 English
Certification 4. Reposition the receiving antenna for the device receiving the
interference.
Canadian Radio Interference-Causing Equipment Regulation, 5. Try combinations of the above.
IECS-003, Class A:
Supporting test records reside with the manufacturer. Product overview
This Class A digital apparatus meets all requirements of the Canadian
The Portable Oil Diagnostic System (PODS) is used to measure, keep
Interference-Causing Equipment Regulations.
and report oil contamination that is important for reliable hydraulic
Cet appareil numérique de classe A répond à toutes les exigences de la system operation. The instrument takes an analysis of pressurized fluids
réglementation canadienne sur les équipements provoquant des and lubricants in online or bottle sampling modes without disruption of
interférences. machine operations.
FCC Part 15, Class "A" Limits The instrument is compatible with petroleum and phospate ester-based
®
Supporting test records reside with the manufacturer. The device hydraulic fluids (includes MIL-H-5606 and Skydrol ). The instrument
complies with Part 15 of the FCC Rules. Operation is subject to the comes with refillable CO2 bottles for use in the field and a shop-air port
following conditions: fitting for in-house operation. For different views of the instrument, refer
to Figure 1 and Figure 2.
1. The equipment may not cause harmful interference. Note: Due to U.S. shipping restrictions, the instrument is shipped with empty CO2
2. The equipment must accept any interference received, including bottles.
interference that may cause undesired operation.
English 5
Figure 1 Product overview Figure 2 Side view
Product components
Make sure that all components have been received. Refer to Figure 3. If
any items are missing or damaged, contact the manufacturer or a sales
representative immediately.
6 English
Figure 3 Instrument components Connect the CO2 bottle
DANGER
Multiple hazards. Only qualified personnel must conduct the tasks
described in this section of the document.
DANGER
Explosion hazard. For the safe use of the instrument, obey the
precautions and the instructions as specifically described.
WARNING
Personal injury hazard. Enclosed systems contain high pressure.
Qualified personnel must remove pressure from the system before the
instrument can be installed or removed.
CAUTION
1 Instrument 4 Power cord 7 Printer paper (2x) Fire hazard. Do not use flammable agents to clean the instrument.
2 AC power adapter 5 Sample bottle (10x) 8 Cleaning brush (2x)
3 CO2 bottle, empty 6 Allen wrench 9 Software disc The CO2 bottle is a compressed gas bottle under high pressure. Do not
(2x) alter this bottle in any way. Use only CO2 bottles that are supplied by the
manufacturer. Use the bottle only as directed in this manual. For storage
and disposal of the bottle, refer to the text on the bottle.
Installation
Do not expose the pressurized bottle to temperatures in excess of
WARNING 177 °C (350 °F). Bottles exposed to a fire or heated to temperatures in
excess of 177 °C (350 °F) should be discarded. Let the temperature of
Multiple hazards. Only qualified personnel must conduct the tasks the bottle cool before it is discarded.
described in this section of the document.
Keep the protective cap on the CO2 bottles that are not in use.
Valves must be installed or removed only by trained personnel.
Connect external pressure Use only a mild detergent and water to clean the cylinder. Use of caustic
cleaners may corrode pressure fittings or tank walls and cause an
Connect the supplied CO2 bottle or shop air to the instrument to supply uncontrolled pressure release or rupture.
external pressure.
English 7
Make sure that the bottle adapter is installed properly when The compressed air source must be clean, dry and between 620 to
pressurization begins. If the bottle adapter is not installed properly, it 758 kPa (90 to 100 psi; 6.2 to 7.6 bar).
comes off the instrument and personal injury and/or damage to the
instrument occurs. 1. If the shop air nipple is the wrong type, install a new nipple. A 1/8-inch
Due to multiple shipping rules and regulations, the CO2 bottles supplied male NPT connection is required.
in the shipping container are empty. Make sure that the bottles are filled 2. Make sure that the port threads are clean.
by a certified CO2 supplier. 3. Connect the shop air to the instrument and tighten.
NOTICE
Do not remove or cover the label on the bottle.
Connect the communications cables
The instrument has an RS232 communications port installed. Use this
NOTICE port to communicate with a computer for data acquisition, analysis and
This bottle must only be filled and transported by properly trained personnel in remote operation.
accordance with compressed gas bottle filling regulations of the local jurisdiction.
• Baud rate: 9600
NOTICE • Data bits: 8
The bottle adapter is a pressure vessel used for sample delivery through the • Parity: None
instrument. It is critical that it is installed in the locked position before sampling. • Stop bits: 2
The bottle adapter must be aligned on the instrument and in the locked position.
If the computer or terminal has a 9-pin serial port with a male connector,
Item to collect: use a standard serial cable that has a male end and a female end. The
• Clean lubricant (for ease of use and to prevent damage to the O-ring) instrument is already configured as Data Communication Equipment
(DCE). A null-modem cable is not necessary.
1. Examine the threads and the O-ring on the bottle for damage.
2. Turn the bottle clockwise into the CO2 port. As the bottle turns into
Connect the external power supply
the CO2 port, the bottle valve opens and pressure is applied to the If an external power supply is used, obey the instructions in Charge the
instrument. When this occurs, the bottle becomes difficult to turn. battery on page 17.
3. Turn the bottle another ¼ turn until the bottle stops. If CO2 is
released around the bottle threads when this pressurization occurs, Startup
remove the CO2 bottle and examine the O-ring for damage.
Power up and self-test verification
Connect the shop air source
Push POWER and the startup screen shows, then the initialization
WARNING screen shows the serial number and firmware revision level of the
Personal injury hazard. Enclosed systems contain high pressure. instrument. At this point, the instrument examines its internal systems for
Qualified personnel must remove pressure from the system before the any problems. If a problem is found, the instrument shows an error
instrument can be installed or removed. message. Refer to Troubleshooting on page 19.
8 English
User interface and navigation Feature Description
Alphanumeric keys Adds letters and numbers into the program. For more
information, refer to Set the operation variables
on page 10.
Navigation keys Selects operating variables and moves the cursor left
and right.
Feature Description
English 9
See the system status menu parameters To add letters:
Push F3 (SYS) in the main menu to get the system status menu. Table 1 a. Push the numeric key that contains the letter to use in
shows various system parameters that the instrument measures. These succession.
system parameters show convenient information and diagnostic b. Push once for the number, twice for the first letter, three times for
troubleshooting. the second letter, etc. The time between the key pushes tells if
the current character is selected or if the next character is
Table 1 System parameters
selected.
Parameter Description
To add symbols:
Power supply Shows whether the instrument is connected to the external
power supply or it is operated from the internal battery. When a. Push the function key that shows the symbol to be used.
an external power supply is used, the battery icon shows that b. Push F1 for a space, F2 for a forward slash and F3 for a period.
the internal battery is controlled by the external power supply.
When the internal battery is used, the battery icon shows the 4. Push F4 to accept the new setting or push CANCEL to return to the
remaining relative battery supply voltage capacity. The useful Setup menu and keep the previous selection.
battery voltage range for the instrument is 11.5 to 13.8 volts. 5. To see the test results in a different Standard, Viscosity or
The amount of battery life that stays below this range is
minimal, so charge the battery before operation is continued.
Temperature, set the variables and see or print the test results from
the buffer. Refer to Test results on page 15.
Internal Shows only the temperature inside the instrument enclosure.
temperature This measurement tells if the temperature is too hot or cold to
do a sample test.
Printer status Shows the different status conditions or errors of the internal
printer. If the printer is good, a condition of NORMAL shows.
An error message shows if a problem exists.
10 English
Table 2 Setup menu Table 2 Setup menu (continued)
Variable Description Variable Description
SAMPLE Shows a second menu, Sample Text menu. Under this menu, VOL Volume of fluid that runs 3 times during a sample
LABEL set the following items: (Volume/RUN). The BOTTLE mode sampling is limited (5, 10 or
• SAMPLE LABEL “SAMPLE NAME”—The user-input name for 20 ml per RUN).
samples. The sample labels limit is 10 characters. For each FLOW Sets the flow rate selections between 15 and 50 ml/min or
sample label, there is an auto-counter extension that increments AUTO. The AUTO mode automatically uses the optimum flow
up to 500. This extension is reset to one every time a new rate for the current sample conditions.
sample label is programmed, re-entered or exceeds a count of
500. PRINT Enables or disables the printer so that it does not automatically
• REMARKS—User-input remarks for any additional sample print at the end of a sample. The SETUP option prints the
labeling, as necessary. These optional remarks become part of current instrument setup (ENBL, DSBL or SETUP).
the record of any completed samples. Records retrieved from
the sample buffer can have their remarks reviewed and re- CONTRAST Use the navigation keys to control the display contrast.
edited as necessary. The sample remarks limit is 10 characters
on any of 3 lines. Any existing remarks show on printed sample
Table 3 Screen: PG 2
reports.
Variable Description
MODE Sampling method (BOTTLE or ONLINE or FILTER)
If BOTTLE mode is selected or re-entered, a second screen is LANG Shows the language used in the operation and control of the
shown and it allows the following variable to be set. instrument (English, French, German, Span and Ital).
• PURGE VOL—Volume of fluid that flows through the VISC Controls the units that show the viscosity (cSt, mm2/s or SUS).
instrument to purge any contamination before samples are
taken (15–30 ml). TEMP Shows the temperature units (°C or °F).
If ONLINE mode is selected or re-entered, a second screen is
shown and it allows the following variable to be set. PRESS Shows the pressure units (BAR or PSI).
• NUM SAMPLES—Numbers of samples that run during the DISPL Controls the brightness of the background: light background (Normal)
sampling period (1–500). or dark background (Reversed) (NORM or REV).
• HOLD TIME—Time delay from the end of a sample to the start
BKLT Controls the back light on the LCD display. If AUTO is selected, the
of the next sample. If set for 00:00, a minimum 5-second hold
back light turns off after 5 minutes of inactivity (ON, OFF or AUTO).
time is set (hh:mm).
• PURGE VOL—The volume of fluid that flows through the BEEP Controls audio feedback of the beeper when a key is pushed (KEY or
hydraulic hose and unit to purge any contamination before DSBL).
samples are taken. The longer the hydraulic hose, the greater
the purge volume must be (15–999 ml). BSAVE Battery save feature. If enabled, the instrument automatically turns off
after 15 minutes of no activity (Idle state) ((ENBL (Enabled) or DSBL
STD Controls the standard format to show the sample results (Disabled)).
(ISO(C), ISO, NAS(C), NAS, NAV(C), NAV, SAE(C), SAE, MIL,
P/10 ml or P/1 ml).
English 11
Table 4 Screen: SIZ CAUTION
Programmable size menu. When MODE is set to P/1 ml or P/10 ml, the
PG2 menu becomes available for any of the eight size channels to be Chemical exposure hazard. Dispose of chemicals and wastes in
programmed. The minimum and maximum size program limit is 4.0 to 68.0 μm. accordance with local, regional and national regulations.
The size must be programmed in an ascending order from the smallest size on
channel 1 to the largest size on channel 8.
Note: If needed, use F2 (DEFAULT) to reset all sizes to factory default settings. Procedure to take a sample
Use proper techniques to take a sample. It is important to get a
Table 5 Screen: I/O representative sample of the contamination level of the system under
test. Take the sample from a source with moving fluid.
Variable Description Note: If the sample is taken from a slow-moving stream, a non-representative
sample can result. Let the system run for at least 30 minutes before a sample is
UNIT_ID Sets a unique device address that is used in the serial communication
taken.
of the instrument MODBUS protocol (01–99).
Note: The Filter mode is no longer active. Use one of the other modes to take a
CNTRL Set to LOCAL when the instrument is manually operated. Set to sample.
REMOTE when a computer program operates and controls the
instrument sampling. Set to DOWNLOAD when a computer program When a series of tests is complete, there is still some sample inside the
retrieves the records from the sample buffer only. The setting of this instrument. This instrument must be flushed with a fluid that does not
variable can also be changed automatically through the serial contaminate the next sample. To flush the instrument:
MODBUS protocol (LOCAL, REMOTE or DOWNLOAD).
1. Use the same fluid type as intended for the next sample. Do not mix
Table 6 Screen: CLK fluid types. If other fluid types are used, fluid incompatibility causes
sampling errors.
Variable Description 2. If an online operation is used, the instrument is flushed with the fluid
TIME Current time in 24-hour format (Hours/Minutes/Seconds) to be tested. For proper flush of the instrument, the flush volume
must be approximately twice that of the internal volume of the
DATE Current date (Month/Day/Year) hydraulic hose that connects the instrument to the system to be
tested.
Operation 3. Do a maximum flush before a sample is taken to make sure that an
accurate sample measurement. To flush the instrument, refer to
WARNING Flush the instrument in bottle mode on page 13 or Flush the
instrument in the online mode on page 13.
Note: An excessive amount of flushes causes prematurely clogged filters.
Chemical exposure hazard. Obey laboratory safety procedures and
wear all of the personal protective equipment appropriate to the Prepare to take a sample with a bottle
chemicals that are handled. Refer to the current safety data sheets
(MSDS/SDS) for safety protocols. Common sources of contamination inadvertently added to fluid samples
come from the bottles, pick-up tube, and airborne particles. Use only
clean sample bottles and keep them covered at all times.
12 English
Sample inaccuracies result from excessive air bubbles and water 2. Remove the previously tested fluid.
contamination. Both are counted as particles. To remove the air bubbles, 3. Set the purge volume to two times the internal volume of the
apply a vacuum to the sample in a vacuum chamber or put the sample in hydraulic hose.
an ultrasonic bath for several seconds.
4. Speak to an application specialist before the port installation.
Particles settle to the bottom of a sample bottle within minutes, so a Note: Do not install any additional fluid control devices on the hydraulic sample
sample should be shaken to re-suspend the particles and degassed to hose or the system test port. These devices make bubbles and create particle
remove bubbles. traps that cause sample inaccuracies.
Highly contaminated samples soak the sensor and make the particle-
count data invalid. The instrument limit is 20,000 particles per ml at 5% Flush the instrument in bottle mode
coincidence loss (per ISO11171) and 30,000 particles per ml at 10% Note: If the flushed volume exceeds the amount of fluid in the bottle adapter,
coincidence loss of fluid for a specific size. If contamination is seen pneumatic pressure is flushed through the instrument and out of the drain port.
suspended in a fluid sample, the sample contains concentrations beyond This creates air pockets in the hydraulic system and leads to sampling errors.
the saturation limits of the instrument. The average person only sees
particles greater than 40 μm in size. 1. Make sure that a CO2 bottle or shop air is connected to the
instrument and that the pressure gauge shows 90 to 110 psi (6.2 to
Use the fluid sampling vacuum pump to take sample fluid from 7.6 bar).
reservoirs.
2. Turn the bottle adapter counterclockwise to disconnect the adapter
1. Cut a length of clean tube that extends from the fluid in the reservoir from the instrument.
to a point accessible from outside the reservoir. 3. Fill a sample bottle with the fluid to be flushed.
2. Connect a clean sample bottle to the fluid sampling vacuum pump 4. Put the sample bottle into the bottle adapter and connect it to the
(VP633001). Install one end of the tube to the pump so that it instrument.
extends into the sample bottle and tighten the knob. 5. From the main menu, push F4 to go to the flush menu.
3. Install the other end of the tube into the reservoir. Do not 6. Push START.
contaminate the end of the tube.
7. Push F1 (SOL ON). The bottle adapter pressurizes and fluid begins
4. Use the pump to fill the sample bottle to the applicable level. to exit the drain port. The amount of fluid that is flushed is shown on
5. Disconnect the sample bottle from the pump. the display.
6. Install the cap until the sample is ready to test. 8. When the fluid has been flushed, push CANCEL to stop the fluid and
return to the main menu.
Prepare to take an online measurement
Suitable places for an online measurement include: Flush the instrument in the online mode
• Upstream of the high pressure filter (condition after pump) 1. Connect the online adapter to the instrument. Move the pick-up tube
• Upstream of the return filter (condition after system) into the hole in the center of the adapter and turn the adapter
• Upstream of the bypass filter (tank condition) clockwise until the pick-up tube is locked.
®
2. Connect a hydraulic hose with a Minimess test hose thread to the
1. Disconnect the hydraulic hose that connects the instrument to the online adapter.
system to be tested.
English 13
3. Connect the other end of the hydraulic hose to the system to be 5. Make sure that a CO2 bottle or shop air is connected to the
tested. instrument.
4. From the main menu, push F4 to go to the flush menu. 6. Make sure that there is 90 to 110 psi (6.2 to 7.6 bar) shown on the
5. Push START. The fluid goes out of the drain port and the amount of pressure gauge. Due to regulation variances, the pressure shown on
fluid is shown on the display. the pressure gauge moves up to 120 psi (8.3 bar) during no-flow
conditions. The pressure drops when a sample is started.
6. When the fluid is flushed, push CANCEL to stop the flush process
and return to the main menu. 7. Turn the bottle adapter counterclockwise to disconnect it from the
instrument.
Note: If the power is set to off while the system is flushed, it causes the
internal flow controller to stay open and allows fluid to continue to flow. Always 8. Fill a sample bottle with the fluid to be tested.
cancel the flushing process and allow five seconds to pass before the 9. Put the sample bottle into the bottle adapter.
instrument power is set to off.
10. Connect the sample adapter to the instrument.
Note: The system stays pressurized after the pressure source is removed. To
remove the system pressure, remove the pressure source and push START, 11. Make sure that the waste bottle holds the fluid.
or select "SOL ON” and then “SOL OFF” until the pressure gauge reads 0 psi. 12. Push START. The sampling process begins.
When this process is complete, the test results are put in the buffer,
Fluid compatibility shown on the display and/or printed.
The instrument is compatible with most petroleum and phosphate ester
based fluids within the specified viscosity and temperature ranges. If the Take a sample in the online mode
compatibility of a fluid is in question, compare the compatibility to the In the online mode, a sample moves directly from a hydraulic system.
wetted material list included in the Specifications on page 3. If the The CO2 or shop air external pressure sources are not used in this
compatibility cannot be found, submit a request to a local manufacturer mode, but they remain connected during the sampling process.
representative for a recommendation on the fluid use within the
instrument. 1. From the main menu, push F1 (SETUP) to go to the setup menu.
NOTICE 2. Set the sampling mode to ONLINE and set the program to the
The internal components of this instrument are not compatible with water. Water number of runs, hold time and purge volume. The purge volume
causes instrument malfunction and damage. The instrument is only compatible should be approximately twice the internal volume of the hydraulic
with fluids that contain lubricating properties. tube that connects the instrument to the system.
3. Make sure that the other operation variables are programmed as
Take a sample in the bottle mode
needed. For more information, refer to Set the operation variables
on page 10.
1. Put a sample fluid in the bottle adapter.
4. To connect the online adapter to the instrument, move the pick-up
2. Connect the adapter to the instrument. tube into the hole in the center of the adapter and turn the tube
3. From the main menu, push F1 (SETUP) to go to the setup menu. clockwise until the adapter is locked.
4. Set the sampling mode to BOTTLE and make sure that the other 5. Connect a hydraulic hose with a Minimess®1 test hose thread to the
operation variables are programmed as needed. For more online adapter.
information, refer to Specifications on page 3. 6. Connect the other end of the hydraulic hose to the system to be
tested.
14 English
7. Push START. The sampling process begins. incoming fluid temperature. The hydraulic circuit has thermal masses
When this process is complete, the test results are put in the buffer, that influence the temperature of the fluid.
shown on the display and/or printed.
Note: If the power is set to off while the instrument is flushed, it causes the • If the instrument is colder than the fluid, there is a temperature drop of
internal flow controller to remain open and allows fluid to move. Always cancel the fluid while the fluid is sampled.
the flushing process and allow five seconds to pass before the instrument • If the instrument is hotter, there is a temperature increase while the
power is set to off. fluid is sampled.
English 15
Delete or print data NOTICE
Use the buffer menu to delete or print the buffer contents. Make sure not to bend the pick-up tube or scratch the lower end where the seal
connection is made. Damage causes leakage or misalignment with the online
1. Push F2 (DEL BUF) to delete the entire buffer contents. The adapter.
instrument shows a confirmation message and asks for the operation
to be accepted or cancelled. 1. Clean the instrument with a cleaning brush and a clean glycol base
2. Push F3 (PRT BUF) to print the entire buffer contents. The solution.
instrument shows a confirmation message and asks for the operation 2. Flush the instrument.
to be accepted or cancelled.
3. Push F1 (DEL SMP) or F2 (PRT SMP) while in the average count Change the filter
(AVG CNT) menu to delete or print an individual sample test result.
When a sample selection is shown, the average count menu is To remove the filter, refer to Figure 5.
available.
Maintenance
DANGER
Multiple hazards. Only qualified personnel must conduct the tasks
described in this section of the document.
WARNING
Personal injury hazard. Never remove covers from the instrument. This
is a laser-based instrument and the user risks injury if exposed to the
laser.
16 English
Figure 5 Filter removal Charge the battery
Power the instrument with:
Indicator Status
English 17
4. Fold up the slack in the paper roll and push it into the paper holder. 4. Operate the instrument with clean sample fluid. To purge any
5. Lift the free end of the paper and close the printer door. trapped air in the clean-out line:
6. Remove the excess paper. a. Put an absorbent cloth over the wrench and slightly loosen the
Note: In the case of paper misalignment, lift the lever on the left side of the clean-out cap while the sample run is in progress. Fluid and air
printer to raise the printer carriage. Pull the paper straight and align it. Lower come out quickly when the cap is loosened.
the carriage before the printer is operated.
b. Continue the process until no more air comes from the port.
Remove the flow sensor blockages 5. Tighten the clean-out port cap snugly. To avoid damage to the
threads, do not over tighten the cap.
CAUTION
Figure 6 Sensor blockage removal
Chemical exposure hazard. Obey laboratory safety procedures and
wear all of the personal protective equipment appropriate to the
chemicals that are handled. Refer to the current safety data sheets
(MSDS/SDS) for safety protocols.
NOTICE
Excessive force can result in brush and possible cell damage. If the brush does
not go into the cell, pull the brush out and examine the cleaning tip for damage.
• Absorbent cloth
• Allen wrench
• Cleaning brush
1. Put an absorbent cloth under the instrument to catch any liquid that
drains from the clean-out port. Refer to Figure 6.
2. Put the brush into the clean-out port until there is resistance.
3. Gently push the brush into the sensor flow cell with a twisting motion.
Calibration
Return the instrument annually for calibration. The calibration date is
shown on the calibration sticker that is located on the serial plate inside
the left side door (behind the waste container). Each instrument is
calibrated at the factory.
18 English
Troubleshooting Table 8 Critical errors
For help with potential problems, refer to Table 7, Table 8 and Table 9. Error Possible cause Solution
If the program malfunctions and the instrument needs to be reset to the Flow controller The unit is unable to find Start the instrument again.
default settings, push and hold F4 while the power is cycled. failure the HOME switch on the
flow controller during
Note: This erases all buffer contents and all of the operation variables to their
system initialization or at
factory settings. A default message and the firmware part number are shown as the
the end of a sample test.
instrument initializes its systems again.
Table 7 Procedural problems There is a flow controller Contact technical support.
malfunction.
Problem Possible cause Solution
There is trapped air in Remove the air from the
The sample runs out The sample bottle is not Fill the bottle properly. the internal hydraulic internal hydraulic tubing
before the test is properly filled. tubing. (PODS only) including the clean-out port with
complete. a clean fluid.
The programmed sample Decrease the
or purge volumes are too programmed sample or The instrument was not Clean the system with a new
large for the amount of purge volume. purged before a change fluid.
sample. in the viscosity of the
sample fluid occurred.
There is a trapped air Purge the internal (PODS only)
volume in the internal hydraulic tubing and the
hydraulic tubing. clean-out port. Flow regulation The external pressure Make sure that the external air
failure was decreased during source is stable and set near
There is an internal Contact technical the sample test. 100 psi. Make sure that there
hydraulic leak. support. are no leaks on the sample cup
O-ring.
The instrument does not The battery voltage is too Connect the external
operate when POWER low. power supply to The instrument was not Purge the instrument.
is pushed. instrument to operate the purged before a change
instrument and charge in The viscosity of the
the battery. sample fluid occurred.
English 19
Table 8 Critical errors (continued) Table 8 Critical errors (continued)
Error Possible cause Solution Error Possible cause Solution
Low flow rate, External pressure was Make sure that the external air Pressure dropped The external pressure Make sure that the external air
possible high decreased during sample source is stable and set near to a level that is was decreased during source is stable and set near
viscosity test. 100 psi. Make sure that there not sufficient the sample test. 100 psi. Decrease the flow rate,
are no leaks on the sample cup especially with high viscosity
O-ring. fluids. Make sure that there are
no leaks on the sample cup O-
The instrument was not Purge the instrument. ring.
purged before a change
in the viscosity of the The sample fluid Decrease the flow rate or dilute
sample fluid. viscosity is too high. the sample with a suitable
(PODS only) clean, filtered and miscible fluid
The sample fluid Decrease the flow rate or dilute that will decrease the sampling
viscosity is too high. the sample with a suitable viscosity to within the range of
(PODS only) clean, filtered and miscible fluid the counter (10–424 cSt).
that will decrease the sampling
viscosity to within the range of There is an internal Contact technical support.
the counter (10–424 cSt). hydraulic regulator failure
or adjustment setting that
The pick-up tube cap Remove the cap. is out of tolerance.
was not removed.
High internal The sample fluid Stop the sampling process and
Hydraulic pressure The hydraulic pressure Make sure that the fluid temperature. temperature is too hot. purge the instrument with
for online sampling source is not sufficient. pressure is more than 40 psi for Sampling not ambient fluid and let the
is not sufficient all of the sample period. Make allowed. instrument cool. Find a solution
sure that there are no leaks on to cool the fluid before the
the online adapter O-ring. sampling process starts.
High pressure An internal hydraulic Contact technical support. High fluid The sample fluid Stop the sampling process and
found regulator failure occurred temperature. temperature is too hot. purge the instrument with
or the adjustment setting Sampling aborted. ambient fluid and let the
is out of tolerance. instrument cool. Find a solution
to cool the fluid before the
Low pressure The external pressure Make sure that the external air sampling process starts.
source is not sufficient. source is stable and set near
100 psi. Decrease the flow rate, Printer errors: A printer error condition Refer to the specific printer
especially with high viscosity exists. error message.
fluids. Make sure that there are
no leaks on the sample cup O- - PAPEROUT No printer paper is Install a new roll of paper.
ring. installed.
The pick-up tube cap is Remove the pick-up tube cap. - HEAD_V There is a printer head Contact technical support.
installed. voltage error.
20 English
Table 8 Critical errors (continued) Table 9 Non-critical errors (continued)
Error Possible cause Solution Error Possible cause Solution
- HEAD_UP The printer head lever is Move the lever down. INTL TEMP The unit could have been in direct Put the unit in a cool area
in the up position. WARN sunlight and/or in hot conditions. until it cools off.
- HEAD_T There is a printer head Set the instrument power to off. The unit could have been put in a Decrease the ambient or
temperature error. The Let the instrument cool for a high temperature location. fluid temperature conditions.
ambient temperature is minimum of 30 minutes, and
too high. then try to print again. Low Battery Repeated attempts to begin a Make sure that the charger
Failure charging cycle on a fully charged is connected and works
- FAILURE There is a printer head Contact technical support. battery. New charging cycles properly. If problem
failure. begin when external power is continues, contact technical
applied. support.
Low battery failure. Need to recharge the Connect the external power
Please turn PODS battery. supply to the instrument to Attempts to charge battery in a Put the unit in a cool area
off. operate and charge the battery. higher than normal ambient until it cools off. If it fails
temperature condition. Batteries again, replace the battery.
get hot near their end-of-charge
Table 9 Non-critical errors cycle. If ambient conditions are
too hot, then a battery over-
Error Possible cause Solution temperature condition can result
SNSR FLOW There is a blockage in the sensor Do the cell cleaning and the red indicator illuminates.
CELL cell within the view area and the procedure as described in The battery is faulty. Replace the battery.
ERROR detector does not see the laser Remove the flow sensor
light. blockages on page 18.
The amount of sample fluid is not Add more sample fluid. Replacement parts and accessories
sufficient.
WARNING
The sensor is out of calibration. Return the unit to the factory
This results in a low signal. for calibration or repair. Personal injury hazard. Use of non-approved parts may cause
personal injury, damage to the instrument or equipment malfunction.
The sample is contaminated with Remove the water or try The replacement parts in this section are approved by the
water or high particle another sample. If the manufacturer.
contamination. sample is highly
contaminated, dilute the Note: Product and Article numbers may vary for some selling regions. Contact the
sample. appropriate distributor or refer to the company website for contact information.
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Standard accessories (continued) Prepare for shipping
Description Item no. Note: The instrument must be sent back with a decontamination certificate. To get
a certificate, contact the manufacturer.
Online adapter SA000008-01 If residual oil stays in the flow path of the counter, the optical switches
that operate the flow controller may be contaminated with oil during
Shoulder strap VP753400
transportation. Potential issues are a Flow Controller Failure error
AC/DC power supply VP624002 message or the keypad may not operate. Do the steps that follow before
transportation.
U.S. power cord VP6235001
DOT rated CO2 bottles VP760000 1. Remove any sample bottles from the sample bottle adapter.
120 ml plastic sample bottles VP104400
2. Attach the sample bottle adapter to the instrument.
3. Do a flush procedure without any fluid in the adapter. From the main
Sensor brushes (pack of 2) SA000066-01 menu, push F4 to go to the Flush menu. Push START.
Printer paper 460 511 4. Push F1 (CO2 ON).
High pressure hose VP350000 5. Flush the air until the flow meter switches on and the fluid in the
system moves into the waste container.
Filter kit (contains filter element, a spring and stainless
540-400-0025 6. Push F2 (CO2 OFF) to stop the purge process.
washer)
RS232 serial interface cable (connects a computer to the • ISO 4406:1999 for NIST/ISO 11171 (μm(c)), internally named ISO(C)
EP096010
instrument for data download into the software) • ISO 4406:1999 for ACFTD/ISO 4402 sizes (μm), internally named
ISOACF
Sample cup O-ring VP588215
• MIL-STD 1246C:1994
Communication protocol DC100000-01 • NAS 1638:1992
1 ®
Teflon is a registered trademark of Dupont. • SAE AS4059
• NAVAIR 01-1A-17:1998
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The cleanliness standards correlate to six internal standard settings Table 10 ISO 4406: 1987 (E) (continued)
(Table 10 – Table 15). Select the applicable standard during setup. The
selected standard is printed and kept in memory. At the time of printing, Number of particles per milliliters (counts/mL)
Scale number
no cleanliness standard except ISO 4406:1999 specifies a specific More than Up to and includes
calibration method. Usually users work with ACFTD-calibrations; since
ACFTD is no longer considered valid calibration material, particle 40 80 13
counter manufacturers must change to ISO-MTD calibrations. The other
20 40 12
standards also have to use the ISO-MTD sizes if the cleanliness codes
remain the same. 10 20 11
Table 10 ISO 4406: 1987 (E) 5 10 10
Number of particles per milliliters (counts/mL) 2.5 5 9
Scale number
More than Up to and includes 1.3 2.5 8
2,500,000 — > 28 0.64 1.3 7
1,300,000 2,500,000 28 0.32 0.64 6
640,000 1,300,000 27 0.16 0.32 5
320,000 640,000 26 0.08 0.16 4
160,000 320,000 25 0.04 0.08 3
80,000 160,000 24 0.02 0.04 2
40,000 80,000 23 0.01 0.02 1
20,000 40,000 22 0 0.01 <1
10,000 20,000 21
Table 11 MIL-STD 1246C (revised 1994)
5000 10,000 20
Number of particles per liter
2500 5000 19 (counts/ml)
1300 2500 18 Level Particle size (µm) Counts per liter
640 1300 17 1 1 10
320 640 16 5 1 28
160 320 15 5 2 23
80 160 14 5 5 10
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Table 11 MIL-STD 1246C (revised 1994) (continued) Table 11 MIL-STD 1246C (revised 1994) (continued)
Number of particles per liter Number of particles per liter
(counts/ml) (counts/ml)
Level Particle size (µm) Counts per liter Level Particle size (µm) Counts per liter
10 1 84 300 25 74,550
10 2 70 300 50 10,210
10 10 10 300 250 23
200 50 1700
200 200 10
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Table 12 NAS 1638 Contamination Classification System Table 14 SAE AS4059 cleanliness levels by particle count
Maximum particles/100 mL in specified size range (µm) Maximum contamination limits (particles/100 mL)
Class
5–15 15–25 25–50 50–100 > 100 Size > 1 µm > 5 µm > 15 µm > 25 µm > 50 µm > 100 µm
range1
00 125 22 4 1 0
Size > 4 µm(c) > 6 µm(c) > > > >
0 6-Sep 44 8 2 0 range2 14 µm(c) 21 µm(c) 38 µm(c) 70 µm(c)
1 500 89 16 3 1 Size A B C D E F
code
2 1000 178 32 6 1
Class 195 76 14 3 1 0
3 2000 356 63 11 2 000
4 4000 712 126 22 4 Class 390 152 27 5 1 0
00
5 8000 1425 253 45 8
Class 780 304 54 10 2 0
6 16,000 2850 506 90 16
0
7 32,000 5700 1012 180 32
Class 1560 609 109 20 4 1
8 64,000 11,400 2025 360 64 1
12 1,024,000 182,400 32,400 5760 1024 Class 12,500 4860 864 152 26 4
4
Table 13 Equivalent APC sizes that relate to calibration method Class 25,000 9730 1730 306 53 8
5
Code and size Particle sizes
Class 50,000 19,500 3460 612 106 16
ISO 11171 Size - µm(c) >4 >6 > 14 > 21 > 38 > 70 6
ISO 4402 Size - µm >1 >5 > 15 > 25 > 50 > 100 Class 100,000 38,900 6920 1220 212 32
7
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Table 14 SAE AS4059 cleanliness levels by particle count
(continued)
Maximum contamination limits (particles/100 mL)
0 1 2 3 4 5 6
> 100 1 3 5 11 21 41 92
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