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MP Filtri PML2 User Manual

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PML²
Analyser
User Guide
www.mpfiltri.co.uk
200.052-EN

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Summary of Contents for MP Filtri PML2

  • Page 1 PML² Analyser User Guide www.mpfiltri.co.uk 200.052-EN...
  • Page 2 COVERS MODEL NUMBERS All PML² Models SAFETY WARNING Hydraulic systems contain dangerous fluids at high pressures and tempera- tures. Installation, servicing and adjustment is only to be performed by qual- ified personnel. Do not tamper with this device. INTERNAL CLEANING clean the PML²...

  • Page 3: Table Of Contents

    Contents Introduction Scope of Supply Connecting the PML² • Methods of Operation PC Operation • • • • Using the Computer Serial Port Determining the COM Port USB Port Operation • • Settings Normal Test • • Without Moisture Sensor With Moisture Sensor Continuous Sampling •...
  • Page 4 14 Warranty • Recalibration Measuring Water in Hydraulic and Lubricating Fluids ISO4406:1999 Cleanliness Code System NAS1638 Cleanliness Code System SAE AS4059 REV.E Cleanliness Classification For Hydraulic Fluids Recommendations Hydraulic System Target Cleanliness Levels New ISO Medium Test Dust and its effect on ISO Contamination Control Standards •...

  • Page 5: Introduction

    1 Introduction The PML² Contamination Analyser is designed to measure and quantify the num- bers of solid contaminants in Hydraulic, Lubrication and Transmission applica- tions. The PML² is designed to be an accurate, instrument suitable for permanently installed applications utilising mineral oil as the operating fluid. The instrument uses the light extinction principle whereby 2 laser light systems shine through the fluid and land on photodiodes.
  • Page 6 Figure 1 Introduction...

  • Page 7: Scope Of Supply

    • Remote display unit, including cable and connector • 500 µm coarse screen filter ( Part number .SK0040) This is a dedicated unit for the PML² and should not be used with other MP Filtri UK products, especially the 12V Bottle Sampler Units.

  • Page 8: Connecting The Pml

    3 Connecting the PML² Refer to key drawing on page 6. 1. Fix the PML² in place, by bolting through the feet. 2. Power supply and external circuits: These are two alternative arrangements possi- ble, depending on whether or not the external circuit relays are intended to be used. The alternatives are: a.

  • Page 9: Methods Of Operation

    Important! Do not connect Waste Fluid Hose to a pressurised system, as this will cause the Analyser to malfunction and could cause internal leakage. The Waste Fluid Hose must be discharged into a waste disposal bottle, or into a tank/vessel vented to atmosphere if running a Continuous test due to the large quantity of oil discharged during a test.

  • Page 10: Pc Operation

    4 PC Operation PC control of the PML² is performed using the Remote Device Dialogue included in the LPA-View software package - refer to the separate LPA-View user manual for details of software installation. Users may typically wish to operate the Remote Device Dialogue facility in one of two ways:- •...
  • Page 11 Figure 1 LPA-View Figure 2 COM Port selection 2. Press the OK button, and when the correct port is chosen, the Remote Device dia- logue will show the remote device values. The LPA-View program will remember this selection the next time it is used. 4.2 Determining the COM Port To check the COM port number allocated by the computer for the Serial lead or the USB to Serial Connector:...
  • Page 12 Figure 3 Remote Device dialogue − Right click on My Computer icon and then left click on Properties. − Click on the Hardware tab and then click on the Device Manager Button. − Click on the plus sign next to Ports (COM & LPT). •...
  • Page 13 • Follow the installer Wizard, accepting the defaults. • When the Installer has completed, plug in the USB to Serial Adaptor. • A message should pop up indicating successful hardware instillation. Note any COM port number indicated in the message. •...
  • Page 14 (moisture and temperature indication), every test is automati- cally preceded by a 3 minute flush period, to allow the moisture sensor to stabilise and give an accurate reading. Therefore, a separate flush period is unnecessary, unless a Continuous Test flush period greater than 3 minutes is required. For the PML²-W version the moisture and temperature function can be switched off...
  • Page 15 PML² be usually operated in either the Normal test mode or the Continuous test mode, until the user is fully familiar with the features. The PML² test menu is harmonised with that of MP Filtri UK’s other particle analysers and so can also perform Short, Triple and Dynamic tests.
  • Page 16 Dynamic A comprehensive triple test with results average: 30 ml sample volume comprised of three 10ml sampling and emptying cycles. Allows the effect of system fluctuations to be measured over a longer period of time. The system Triple / Bottle Sampling A triple test with results average and quicker than the Dynamic Test: 24ml sample volume comprised of three individual 8 ml samples tested consecutively.

  • Page 17: Normal Test

    5 Normal Test 5.1 Without Moisture Sensor 1. Input settings as described on page 15 for the following:- − Test Reference − Test Type - select Normal − Test Number − Format 2. Press OK button to return to Remote Device dialogue. 3.
  • Page 18 7. At the end of the Sampling cycle the test result will be displayed in the Remote Device dialogue box. If the Remote Device dialogue is open, the test results will be automatically trans- ferred to the test database. Following the sampling results the PML² discharges the sample fluid to waste. Test status is shown as Emptying.

  • Page 19: Continuous Sampling

    6 Continuous Sampling The Analyser can be selected for continuous testing at set time intervals. Once continuous sampling has started the PML²’s flush valve automatically opens and closes before each test. This allows representative fluid to reach the sensing arrangement before the 15ml sampling test commences. The flush valve automati- cally opens at the end of the sampling cycle and remains open whilst the analyser is emptying to waste the sample fluid from the previous test.
  • Page 20 6.1 Continuous Test Basic Operation 1. Follow the instructions on page 15 for inputting settings - select Continuous Test Type. 2. Input Test Interval - input the time in minutes that is required between the end of a test and the begining of a new test. 3.
  • Page 21 11. Press the Stop button at any time in the cycle to end the continuous sampling. The test status will show as Idle. 6.1.1 Continuous Sampling – with Clean Alarm Levels – Alarm Mode 1 Figure 1 Continuous Test Settings This operating mode is similar to the Basic Operation, but in this mode the PML²...
  • Page 22 For continuous testing until the ISO Code is achieved, select ISO Format in the Remote Device Settings dialogue, as described under the previous section on page 15. Testing will automatically continue until each of the three numbers in the Code have been achieved (or cleaner).
  • Page 23 Example, 4A/4B/5C/6D/6E/7F. For continuous testing until the AS4059E Table 2 size codes are achieved, select , as described on page 15. Testing will automatically AS4059E TABLE 2 FORMAT continue until the Class number has been achieved at each of the six Size Codes. Also, the PML²...
  • Page 24 • The Completion progress bar indicates the status of the test. Results will be automatically displayed on the Remote Device dialogue after each test. • The status is shown as Waiting between the ending of one test and the starting of the next test.

  • Page 25: Moisture Sensor

    7 Moisture Sensor The PML² version fitted with the optional moisture sensor module allows both measurement of % saturation of water in oil (Relative Humidity) and temperature. These are displayed as RH % and °C on the main/test progress screen and on the printed results.

  • Page 26: Alarms

    8 Alarms Access the Remote Device dialogue as described on page 15. The Alarm Options will be displayed. 1) Alarm Mode: 1 2) Dirty Alarm Level (ISO): 0 3) Dirty Alarm Level (NAS1638 / AS4059E-1): 0 4) Dirty Alarm Level (AS4059E-2): 1A/2B/3C/4D/5E/6F The PML²...
  • Page 27 Both relays are initially off and remain off until an alarm level has been reached/ex- ceeded. The following illustrates the switching logic of the Relays :- Relay 1 (Dirty) NAS/AS4059E-1 single number result > set limit result <= set limit Off...

  • Page 28: External Circuit Relays

    9 External Circuit Relays Page 8, item b explains actions to be taken if it is intended to use the external circuit relays that are built into the PML². There are two solid state relays for external circuit use. The function of these re- lays is illustrated in the following simple wiring diagram, using a battery and bulb circuit for illustrative purposes.
  • Page 29 Figure 2 Example 2: Bulb illuminates during sam- pling and extinguishes when target cleanliness level is achieved (Completed status). (Relay 1 is also switched during Normal, Dynamic and Triple test types. Relay will open at test end or when stop but- ton is pressed.) External Circuit Relays...

  • Page 30: Remote Display - Optional Equipment

    Humidity) and Temperature °C – only appears on the PML²-W version. When first switched on the display unit will show the letters MP Filtri UK - Remote Display Unit on the first screen shot, followed by a software version number on the second screen shot, e.g.
  • Page 31 Waiting (Continuous testing only) Test Completed (Continuous testing only) 2 Pushbuttons • F – Black – Toggles the flush valve open and closed. • I – Green – Starts a test. • O – Red – Aborts a test. 3 Cleanliness Codes ISO Code –...
  • Page 32 a guide, a 200ml flush volume is recommended when using the 1.5m long minimess hose. Refer to page 36 for more information about flushing times. After the flush volume has been discharged to waste the flush valve may be manu- ally closed by again pressing pushbutton F.
  • Page 33 If the User is carrying out tests at different locations and wishes to give the tests different references it is necessary to download the tests after each location, fol- lowed by changing the Test Reference for the next location. Alternatively, the Test Reference may be edited at a later date by accessing the individual test record using LPA-View - refer to the separate LPA-View test analysis software manual.

  • Page 34: Bottle Sampling

    11 Bottle Sampling An alternative to operating on-line is to use MP Filtri UK’s Bottle Sampling Unit to test oil contained in bottles. Refer to the separate User Guide for details. Bottle Sampling...

  • Page 35: Drain Reservoir And System Pressures

    12 Drain Reservoir and System Pressures The PML² is produced in two standard models, as detailed below. • Model A (Design Reference 30): − Minimum oil inlet pressure: 2 bar − Maximum oil inlet pressure: 400 bar − Drain Reservoir / System: Atmospheric pressure, zero back pressure. •...

  • Page 36: Flush Valve Opening Times

    13 Flush Valve Opening Times The table below shows the flush valve opening times that are required to achieve a 200ml flush volume, for different conditions. Model Oil Inlet Drain Pressure Approximate Time Type Pressure for 200ml Flush Volume Model A 2 bar Atmospheric pressure, zero back pressure 2 minutes 30 seconds...

  • Page 37: Warranty

    User Guide. 14.1 Recalibration MP Filtri UK will only verify the accuracy of the PML² if the unit is recalibrated every 12 months. Please ensure that the test results in the Log are downloaded to LPA-View before the PML²...
  • Page 38 Warranty...

  • Page 39: Measuring Water In Hydraulic And Lubricating Fluids

    Appendix A Measuring Water in Hydraulic and Lubricating Fluids From North Notts Fluid Power Centre In mineral oils and non aqueous fire resistant fluids water is undesirable. Mineral oil usually has a water content of 50-300 ppm which it can support without adverse consequences.
  • Page 40 Appendix A Typical Water Saturation Levels For New Oils Figure I Examples: Hydraulic oil @ 30°C = 200ppm = 100% saturation Hydraulic oil @ 65°C = 500ppm = 100% saturation Measuring Water Content...

  • Page 41: Iso4406:1999 Cleanliness Code System

    Appendix B ISO4406:1999 Cleanliness Code System The International Standards Orga- nization standard ISO 4406:1999 is the preferred method of quoting the number of solid contaminant particles in a sample. The code is constructed from the combination of three scale num- bers selected from the following ta- ble.
  • Page 42 Appendix B Microscope counting examines the particles differently to APCs and the code is given with two scale numbers only. These are at 5 µm and 15 µm equivalent to the 6 µm(c) and 14 µm(c) of the APCs. ISO4406:1999 Cleanliness Code System...

  • Page 43: Nas1638 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 application of this standard was extended to industrial hydraulic systems simply because nothing else existed at the time.

  • Page 44: Sae As4059 Rev.e Cleanliness Classification For Hydraulic Fluids

    Appendix D SAE AS4059 REV.E Cleanliness Classification For Hydraulic Fluids This SAE Aerospace Standard (AS) defines cleanliness levels for particulate cont- amination of hydraulic fluids and includes methods of reporting data relating to the contamination levels. Tables 1 and 2 below provide the Maximum Contamination Limits (Particles/100ml) of differential and cumulative particle counts respectively for counts obtained by an automatic particle counter, e.g.
  • Page 45 Appendix D Size μm(c) >4 >6 >14 >21 >38 >70 Size Code Classes 1,560 3,120 1,217 6,250 2,432 12,500 4,864 25,000 9,731 1,731 50,000 19,462 3,462 100,000 38,924 6,924 1,224 200,000 77,849 13,849 2,449 400,000 155,698 27,698 4,898 800,000 311,396 55,396 9,796 1,696...

  • Page 46: Recommendations

    Appendix E Recommendations Unit Type ISO 4406:1999 Code PUMP Piston (slow speed, in-line) 22/20/16 Piston (high speed, variable) 17/15/13 Gear 19/17/15 Vane 18/16/14 MOTOR Axial piston 18/16/13 Radial piston 19/17/13 Gear 20/18/15 Vane 19/17/14 VALVE Directional (solenoid) 20/18/15 Pressure control (modulating) 19/17/14 Flow control 19/17/14...
  • Page 47 Appendix E The table gives a selection of maximum contamination levels that are typically issued by component manufacturers. These relate to the use of the correct viscosity mineral fluid. An even cleaner level may be needed if the operation is severe, such as high frequency fluctuations in loading, high temperature or high failure risk.

  • Page 48: Hydraulic System Target Cleanliness Levels

    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.
  • Page 49 Appendix F The table above is a guide to the recommended filtration level for various hydraulic components, together with typical target system cleanliness levels. Hydraulic System Target Cleanliness Levels...

  • Page 50: New Iso Medium Test Dust And Its Effect On Iso Contamination Control Standards

    Appendix G New ISO Medium Test Dust and its effect on ISO Contamination Control Standards When General Motors gave advance warning to the International Standards Organiza- tion (ISO) that it was intending to stop the production of AC Fine Test Dust (ACFTD), work commenced immediately on finding an improved replacement dust.

  • Page 51: Standards

    Appendix G New Test Dust Benefits The new ISO Medium Test Dust (ISO MTD) consists of similar materials to the old ACFTD, but to minimize particle counting errors, it is of a slightly coarser grade be- cause ACFTD included too many particles smaller than 5µm which gave problems during testing.

  • Page 52: Standards

    Appendix G In order that users are not confused by the changes to these standards, particularly by reference to them in technical literature, ISO is updating 4402 to ISO 11171, and 4572 to ISO 16889. Two standards which concern our industry are the ISO 4406 coding system and the new ISO 16889 Multi-pass test.

  • Page 53: Standards

    Appendix G Particle Size Obtained Using Correlation ACFTD ISO/NIST (ISO (ISO 11171) 4402:1991) µm µm(c) The table shows the correla- tion between Particle Sizes Ob- tained using ACFTD (ISO 4402:1991) and NIST (ISO 11171) Cali- bration Methods 10.6 This table is only a guide- 11.3 line.
  • Page 54 Appendix G possible due to the different classes and sizes involved. ISO 4406:1999 DEF.STD 05/42 [7] NAS 1638[5] SAE 749[8] Table A Table B ISO 11218[6] 13/11/08 14/12/09 15/13/10 16/14/09 400F 16/14/11 17/15/09 17/15/10 800F 17/15/12 18/16/10 18/16/11 1,300F 18/16/13 19/17/11 1,300 2000F...

  • Page 55: H Clean Working Practises

    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 & 14um you are talking about objects of a cellular/bacterial size.
  • Page 56 Appendix H • 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 reservoir/tank. •...

  • Page 57: I Specification

    Appendix I Specification As a policy of continual improvement, MP Filtri UK reserve the right to alter the spec- ification without prior notice. Technology Automatic Optical Particle Analyser Laser Package Twin Laser and Twin Optical Diode Detectors Sensitivity >4,6,14,21,25,38,50,70 μm(c) sizes to revised ISO 4406:...
  • Page 58 Appendix I Typical test time Result in <2.5 mins. (normal test) Data storage 600 tests Computer interface RS 232 communication port Hose connections Minimess fittings Microbore hose 1.5 metres long Waste fluid hose Dimensions Height 120mm Length 277mm Width 280mm Weight 5.9 kilos IP Rating IP66 Operation...

  • Page 59: Spare Product / Part Numbers

    Appendix J Spare Product / Part Numbers For spares and part numbers please see the website: www.mpfiltri.co.uk Spare Product / Part Numbers...

  • Page 60: K Fault Finding

    Appendix K Fault Finding FAULT CHECK Unexpected results Check that the minimess hose has been fully connected at obtained from sample both the system and the PML² ends. Confirm that there is a free flow of fluid to the PML², by operating the flush valve and observing fluid passing to waste.
  • Page 61 Appendix K However to allow the user to become familiar with the software a Simulate Test facility has been provided - refer to page 15 for details. If the unit is being operated in the Continuous Test mode when low pressure is detected the following will occur automatically: •...
  • Page 62 Appendix K Fault Finding...
  • Page 63 Produced by MP Filtri UK Revision 8.1 As a policy of continual improvement, MP Filtri UK reserve the right to alter specifications without prior notice. Except as permitted by such licence, no part of this publication may be reproduced, stored in retrieval system or transmitted, in any form or any means, electronic, mechanical, recording, or otherwise, without prior written permission of MP Filtri UK.
  • Page 64 Fax: +1.905-303-7256 Email: s.mishra@mpfiltri.com Email: mail@mpfiltricanada.com Website: www.mpfiltri.com Website: www.mpfiltricanada.com RUSSIAN FEDERATION CHINA MP FILTRI RUSSIA INC MP FILTRI (Shanghai) Co Ltd Phone mobile: +7.095-502-5411 Tel: +86.21-58919916 Fax: +7.095-205-9410 Fax: + 86.21-58919667 Email: mpfiltrirussia@yahoo.com Email: sales@mpfiltrishanghai.com Website: www.mpfiltri.ru Website: www.mpfiltrichina.com GERMANY MP FILTRI USA Inc.

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