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Appendix G

40

New ISO Medium Test Dust and its effect on ISO . . .

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.

All section headings indicated with [] are reproduced by kind permission of British Fluid

Power Association from BFPA/P5 1999 issue 3 Appendix 44

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Summary of Contents for ACMU

Page 1: ...ACMU UserGuide 200 189 EN www mpfiltri co uk ...

Page 2: ...emperatures 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 ...

Page 3: ...ting Procedures 13 Mounting Fixing Hydraulics Motor Wiring Communication wiring C version Communication wiring P version 5 Safety precautions 20 6 Fault Finding 21 A Measuring Water in Hydraulic and Lubricating Fluids 23 B ISO4406 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 ...

Page 4: ...Target Cleanliness Levels 33 G 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 H Clean working practises 42 ...

Page 5: ...mum 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...

Page 6: ...uilt motor pump assembly 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 ...

Page 7: ...unctionality required in the more challenging of applications The steel cabinet with integral lifting eyes provides protection and practicality during installation Multi language instructions and smart phone interaction via prod uct markings make installation simple for operators especially in remote locations In built USBi communication box means that diagnostic and ICM set up can be achieved via...

Page 8: ...8 Variants Figure 1 Product map C version ...

Page 9: ...t 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 Lighter weighing only 13kg More compact Supplied with a 3 metre 8 core shielded cable and instructions for ICM communications and power ...

Page 10: ...10 Variants Figure 3 Product map for P version ...

Page 11: ...Variants 11 2 4 Installation dimensions P version Figure 4 Dimensions for P version ...

Page 12: ...12 Materials of Construction 3 Materials of Construction Wetted parts for both C and P units Brass Stainless Steel Aluminium C version case Polyvinyl paint Steel Polyester ...

Page 13: ...ible 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 JIC adaptor Connect the suction side of the pump to the reservoir by means of a hydraulic hose use the correct internal diame ter e g 1 4 It...

Page 14: ...eﬂon 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 Ensure that a qualiﬁed...

Page 15: ...ting Procedures 15 Ensure that the electric motor rotates in accordance with the arrow on the electric motor Wiring Diagram for Electric Motor Description Visual 3 Phase motor Not connected Υ star Δ triangle ...

Page 16: ...Nominal Current RPM Setting mot protection 0 18kW 230 400 VAC 1 03 A 0 60 A 1345 Nominal Current 0 18kW 200 400 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 A 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 ...

Page 17: ...inal Current 0 69kW 265 460 VAC 2 63 A 1 52 A 1655 Nominal Current 1 phase 50Hz Description Voltage Nominal Current RPM Setting mot protection 0 18kW 110 VAC 3 30 A 1415 Nominal Current 0 18kW 230 VAC 1 30 A 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 11...

Page 18: ...rating Procedures 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 CD containing relevant user guides ...

Page 19: ...Operating Procedures 19 4 5 Communication wiring P version Figure 2 Wiring diagram for P version ...

Page 20: ...s 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 consent 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 su...

Page 21: ...the electrical connection Pump is not drawing ﬂuid pre ﬁll the suction hose with oil and start again Electric motor keeps tripping 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 ...

Page 22: ...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 ...

Page 23: ...mulating 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 siﬁed water is more harmful than those of dissolved water water lev els should remain well below the sat uration point However even water in solution can cause...

Page 24: ...Appendix A 24 Measuring Water Content Typical Water Saturation Levels For New Oils Figure I Examples Hydraulic oil 30 C 200ppm 100 saturation Hydraulic oil 65 C 500ppm 100 saturation ...

Page 25: ...id 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 µm c The second number represents the number of particles larger than 6 µm c The third represents the number of particles that are larger than 1...

Page 26: ...06 1999 Cleanliness Code System 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 ...

Page 27: ...permitted of 100ml volume at various size intervals diﬀer ential counts rather than using cumulative counts as in ISO 4406 1999 Al though there is no guidance given in the standard on how to quote the levels most industrial users quote a single code which is the highest recorded in all sizes and this convention is used on the ACMU software Figure I CONTAMINATION LEVEL CLASSES according to NAS1638 ...

Page 28: ...udes 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 II The information reproduced on this and the previous page is a brief extract from SAE AS4059 Rev E revised in May 2005 For furth...

Page 29: ... 178 32 6 1 3 2 000 356 63 11 2 4 4 000 712 126 22 4 5 8 000 1 425 253 45 8 6 16 000 2 850 506 90 16 7 32 000 5 700 1 012 180 32 8 64 000 11 400 2 025 360 64 9 128 000 22 800 4 050 720 128 10 256 000 45 600 8 100 1 440 256 11 512 000 91 200 16 200 2 880 512 12 1 024 000 182 400 32 400 5 760 1 024 Table I AS4059E Table 1 Cleanliness Classes for Differential Parti cle Counts ...

Page 30: ...6 250 2 432 432 76 13 2 4 12 500 4 864 864 152 26 4 5 25 000 9 731 1 731 306 53 8 6 50 000 19 462 3 462 612 106 16 7 100 000 38 924 6 924 1 224 212 32 8 200 000 77 849 13 849 2 449 424 64 9 400 000 155 698 27 698 4 898 848 128 10 800 000 311 396 55 396 9 796 1 696 256 11 1 600 000 622 792 110 792 19 592 3 392 512 12 3 200 000 1 245 584 221 584 39 184 6 784 1 024 Table II AS4059E Table 2 Cleanlines...

Page 31: ...tridge valve 20 18 15 Proportional 18 16 13 Servo valve 16 14 11 ACTUATOR 20 18 15 Table I Typical Manufacturers Recommendations for Component Clean liness ISO 4406 1999 III 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 III It s...

Page 32: ...e 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 componen...

Page 33: ...red 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 com...

Page 34: ...ory servo sys tems 17 15 11 6 3 6 Robotic and servo systems 18 16 13 7 10 12 Very sensitive high reliability systems 20 18 14 9 12 15 Sensitive reliable systems 21 19 16 10 15 25 General equipment of limited reliability 23 21 18 12 25 40 Low pressure equip ment not in continu ous service The table above is a guide to the recommended ﬁltration level for various hydraulic components together with ty...

Page 35: ...leanliness 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 partic...

Page 36: ...ich gave problems during testing ISO MTD is produced to a standard distribution and stringent quality control procedures thereby ensuring excellent batch to batch repeatability These procedures combined with a revised ISO APC calibration method give A traceable and controlled reference test dust with greatly reduced vari ation in particle size distribution This gives the trace ability required by ...

Page 37: ...ystem and the new ISO 16889 Multi pass test As APCs will henceforth count parti cles more accurately there will now be a change in the way sizes are labelled In the new ISO 4406 1999 new calibration sizes are used to give the same cleanliness codes as the old calibration sizes of 5 and 15 µm In this way there will be no necessity to change any system cleanliness speciﬁcations It is proposed that t...

Page 38: ...t the only real eﬀect users will experience will be the improved accuracy in particle counts there will be no change in the performance of ﬁlters nor in the ISO cleanliness levels that they will achieve The following charts shows the correlation between the old ACFTD and the new ISO MTD The ACMU is calibrated with ISO Medium Test Dust to ISO 11171 The correlation between particle sizes and the ACF...

Page 39: ...ry from instrument to in strument depending on the char acteristics of the particle counter and original ACFTD calibration Particle Size Obtained Using ACFTD ISO 4402 1991 ISO NIST MTD ISO 11171 µm µm c 1 4 2 2 4 6 3 5 1 4 5 8 5 6 4 6 7 1 7 7 7 8 8 4 9 9 1 10 9 8 11 10 6 12 11 3 13 12 1 14 12 9 15 13 6 16 14 4 17 15 2 18 15 9 19 16 7 20 17 5 21 18 2 22 19 0 23 19 7 24 20 5 25 21 2 26 22 0 27 22 7 ...

Page 40: ...ry 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 VII All section headings indicated with are reproduced by kind permission of British Fluid Power Association from BFPA P5 1999 issue 3 Appendix 44 ...

Page 41: ...1 08 2 14 12 09 3 0 15 13 10 4 1 16 14 09 400F 16 14 11 5 2 17 15 09 400 17 15 10 800F 17 15 12 6 3 18 16 10 800 18 16 11 1 300F 18 16 13 7 4 19 17 11 1 300 2000F 19 17 14 8 5 20 18 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 ...

Page 42: ...ur systems Do s 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 environment 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 analy...

Page 43: ...n 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 in an un controlled environment E g workshop Don t rely on a single test for a capable representation of your system Don t start ...

Page 44: ...Appendix H 44 Clean working practises ...

Page 45: ...re 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 way conﬂicts ...

Page 46: ...rranty 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 ...

Page 47: ... 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 NO...

Page 48: ...48 ...

Page 49: ...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 ...

Page 50: ......

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