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Summary of Contents for LPA2

Page 1: ...LPA Analyser UserGuide 200 053 EN www mpfiltri co uk ...

Page 2: ...ers Model Numbers LPA SAFETY WARNING Hydraulic systems contain dangerous ﬂuids at high pressures and temperatures Installation servicing and adjustment is only to be performed by qualiﬁed personnel Do not tamper with this device ...

Page 3: ...r Settings Preparing Analyser For Test Interpreting Results Further Tests Shutting Down 4 Continuous Sampling 19 Continuous Sampling Basic Operation 5 Moisture Sensor 26 6 Alarms 28 7 Wiring 31 8 Bottle Sampling 33 9 Data Logging 34 10 Battery Charging 35 11 Printer Paper 36 12 Computer Analysis 38 Software Installation Results Download ...

Page 4: ...Fluids 46 E Recommendations 49 F Hydraulic System Target Cleanliness Levels 51 G New ISO Medium Test Dust and its effect on ISO Contamination Control Standards 53 Calibration New Test Dust Beneﬁts Eﬀect on Industry Correlation Other Standards H Clean working practises 60 I Specification 62 J Spare Product Part Numbers 64 K COM Ports 65 Connection Using a USB Port Determining the COM Port L Fault F...

Page 5: ... or similar solvents that are not compatible with the seals in the LPA The recommended cleaning ﬂuid for internal ﬂushing is Petroleum Ether see also Fault Finding page 67 The use of a 500μm coarse screen ﬁlter screwed onto the HP con nector is recommended for heavily contaminated systems Refer to page 64 for the part number 1 3 LCD Visibility If the LCD screen remains blank then refer to page 35 ...

Page 6: ...educed Hydraulic and Lubricating Systems consists of sets of continuously moving metal parts which use hydraulic ﬂuid as the power medium Hydraulic ﬂuid is also used to create a lubrication ﬁlm to keep the precision parts separated and it is also used as a cooling medium The very nature of a hydraulic system is that it produces solid par ticulate contaminants and these are ever present in all hydr...

Page 7: ...Introduction 7 ...

Page 8: ...tank ves sel vented to atmosphere 2 Connect WASTE FLUID HOSE to Analyser waste connector Push back quick coupling outer ring before connecting disconnecting hose end 3 Connect FLUID SAMPLING HOSE to Analyser HP connector 4 Connect FLUID SAMPLING HOSE to the system by means of the minimess connector The system to be monitored must not exceed 400 bar or be less than 2 bar 5 Press GREEN BUTTON to swi...

Page 9: ...start with an emptying cycle before the test commences 3 PRINT Prints test results If AUTO PRINT mode has been turned oﬀ a copy of the results is obtained by pressing PRINT button 4 PAPER Ejects printer paper by three blank lines 5 SET Selects settings screen see page 11 6 LOG Selects Data Logging screen see page 34 Transfer log downloads memory to software package2 Clear log Clears memory Clear l...

Page 10: ...10 Online Operation Recall Recalls results from memory Print Prints recalled results 7 8 CONTRAST Adjusts the screen contrast 7 Darker 8 Lighter LOW BATTERY INDICATOR see page 35 ...

Page 11: ... Test Ref machine one 2 Test Number 123 3 Time and Date 4 Result Presentation Options 5 Test Type Normal 6 Test Options 7 Alarm Options Press a Key to Choose or 0 to Exit Figure 2 Main Settings Screen 3 2 1 Test Ref 1 Press 1 then input your reference details e g MACHINE 1 RETURN 15 characters maximum 3 2 2 Test Number 2 Press 2 then input the required test number e g 123 The Test Number will auto...

Page 12: ...levant key to switch between the option selections 1 cycles between the various available formats for the test result These are ISO NAS AS4059E 2 and AS4059E 1 4 2 turns on and oﬀ the printing of detailed counts with the test re sult 3 turns on and oﬀ the printing of the user Test Reference 4 turns on and oﬀ automatic result printing 5 turns on and oﬀ the printing of an additional space for hand w...

Page 13: ...5 Button 5 is used from the Settings Screen to cycle between the available test types These are Normal Dynamic Triple Bot tle Continuous and Short Sample The selection will be dis played on the Main test progression screen Normal Single Test 15ml sample volume Dynamic A comprehensive triple test5 with results average 30 ml sample volume comprised of three 10ml sampling and emptying cycles Allows t...

Page 14: ...ume This provides results in less time than the Normal Test It is not recommended for oil samples cleaner than ISO 17 15 12 NAS 6 as the accuracy of the result might be compromised by the small sample volume Press 5 repeatedly to select desired test type 3 2 6 Test Options Press 6 The Test Options Screen will be displayed The RH Test setting is not displayed if the option is not ﬁtted This mainly ...

Page 15: ...icated the status of the sample Results will be automatically displayed on the screen Results will be automatically printed at the end of the sampling cycle if the Auto Print mode has been turned ON If the Auto Print mode has been turned OFF then press Print key to obtain printed results 12 Following the sampling results the Analyser automatically discharges the sample ﬂuid to waste Test status is...

Page 16: ...line Operation ONLINE Normal Particle count and ISO code to ISO4406 1999 standard ONLINE Dynamic ISO and NAS Code complete with average analysis ONLINE Normal Particle counts displayed NAS code 1638 standard ...

Page 17: ... three part ISO code upper limit has the scale number re placed by an asterisk Also the associated particle counts on the printout are replaced by X s Re fer to the example on the left 3 5 Further Tests 3 5 1 Same Sampling Point To repeat a test on the same sample point press START button 1 Note that the test number will automatically increment ...

Page 18: ...g Down 1 Disconnect the Fluid Sampling Hose from the system by means of the Minimess connector This isolates the ﬂuid supply 2 Operate the Flush Valve to release the pressure 3 Switch oﬀ the Analyser by Pressing the Red Button 4 Remove the Fluid Sampling Hose from the Analyser 5 Remove the Waste Fluid Hose from the Analyser 6 Replace the Hose End Caps on sampling hose wipe clean and store 7 Connec...

Page 19: ...es as follows Time set to 0 At the end of the Analyser s emptying cycle the Flush valve au tomatically closes and the next sampling test immediately starts Time set to between 1 and 5 After the Analyser s emptying cycle has ﬁnished the Flush valve remains open for the time set then automatically closes before the next sampling test Time set to between 6 and 30000 Flush valve automatically closes a...

Page 20: ...ructions 1 to 5 inclusive to select the appropriate LPA settings On the Settings Screen press 5 repeatedly until CONTINUOUS is selected 2 Test Option Press 6 Then press the relevant key to switch between option selections 1 Sets the MINUTES BETWEEN TESTS Press 1 then input the time in minutes that is required between the end of a test and the beginning of a new test Input a value between 1 and 300...

Page 21: ...sh button to close ﬂush valve push button il luminates is cancelled Alternatively proceed to Step 5 below the action of pressing Start button automatically closes the ﬂush valve before sampling commenced 5 Press the START button 1 The LPA will now commence the sampling procedure 6 The completion progress bar indicates the status of the test Results will be automatically displayed on the screen aft...

Page 22: ...lect the appropriate LPA settings On the Settings Screen press 5 repeatedly until CONTINUOUS is selected 10 Test Options 6 Press relevant key to switch between option selections 1 Enter MINUTES BETWEEN TESTS Press 1 then input the time in minutes that is required between the end of a test and the beginning of a new test Input a value between 1 and 30000 followed by RETURN 2 Selects between LOG EVE...

Page 23: ...d under the previous section on page 11 Analyser Settings instruction 4 1 Testing will automatically continue until each of the three num bers in the Code have been achieved or better 5 Clean Alarm Level NAS1638 AS4059E 1 Press 5 then input desired Clean Alarm Level as a single Class number in the range 2 to 12 inclusive example 6 RETURN For continuous testing until the NAS1638 AS4059E 1 Class is ...

Page 24: ... assigned the value The eﬀect of this is a don t care value when used as the cleanliness target For example 6B 6C 7D is translated as A 6B 6C 7D E F In this case testing will continue until the B C and D Classes are less than or equal to 6 6 7 respectively The A E and F Classes are eﬀectively ignored since they cannot ever be worse than a Class Note AS4059E 2 denotes Table 2 of the AS4059E standar...

Page 25: ...dicates the status of the test Results will be automatically displayed on the screen after each test Results will be automatically printed at the end of the emptying cycle if the Auto Print mode has been turned ON 15 The status is shown as Waiting between the ending of one test and the stating of the next test 16 Press Stop button key 2 at any time in the cycle to end continuous sampling The test ...

Page 26: ...ystem tapping point and the RH temperature module the tempera ture reading can be 5 C to 10 C less than the actual system temperature depending on operating conditions The LPA can be conﬁgured to do a test with or without the moisture sensor selected If the moisture sensor has been selected the ﬂush valve will open automatically for a period of 3 minutes before the particle count test commences Th...

Page 27: ...Every Test On 3 Confirm Cleanliness Level Off 4 Clean Alarm Level ISO 0 5 Clean Alarm Level NAS1638 AS4059E 1 0 6 Clean Alarm Level AS4059E 2 1A 2B 3C 4D 5E 6F 7 RH Test On Press a Key to Choose or 0 to Exit Press 7 to change RH Test status to ON or OFF ...

Page 28: ...0 4 Dirty Alarm Level AS4059E 2 1A 2B 3C 4D 5E 6F Press a Key to Choose or 0 to Exit The LPA includes two solid state relays for connections to an ex ternal circuit These can be arranged to function as follows 1 Alarm Mode 0 Selecting option 0 switches relays 1 and 2 always oﬀ 2 Alarm Mode 1 Selecting option 1 will conﬁgure relays 1 and 2 as described on page 31 refer to the examples given on the ...

Page 29: ...Continuous test type refer to page 20 but can be used with all other test types as well Set the Clean and Dirty alarm levels by inputting the desired levels in to both the Test options screen page 14 and the Alarm options screen also setting the appropriate result format to ISO NAS or AS4059 as described on page 12 Both relays are initially oﬀ and remain oﬀ until an alarm level has been reached ex...

Page 30: ... AS4059E 1 single num result set limit On ber result set limit Oﬀ ISO AS4059E 2 multi part all results corresponding set On limit any result corresponding set Oﬀ limit Alarm Modes 3 and 4 These are reserved for future development ...

Page 31: ... battery and bulb circuit for illustrative purposes Each relay is designed for a maximum current of 1 amp at 24 volt nominal AC or DC absolute maximum 60 volt peak Operation above these limits will cause irreparable damage to the relays If the User needs to switch voltages currents in excess of the above maximum limits then separate higher rated interposing relays will need to be incorporated into...

Page 32: ...tatus and is off during sampling Example 2 Bulb illuminates during sampling and extinguishes when Clean alarm level is achieved completed status is shown on LPA Relay 1 is also closed during Normal Dynamic Triple Bottle and Short test types Relay will open when stop button is pressed ...

Page 33: ...Bottle Sampling 33 8 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 ...

Page 34: ...e LPA s memory progress through the following routine Select 4 Recall and enter the number of the test to be retrieved If the test number is not known enter the last test number and scroll through the memory using Next or Previous to se lect the required result To print the result press 0 EXIT then 5 Print A hard copy of the result will then be printed 6 6 The result printed will be viewed in the ...

Page 35: ...lways press RED button to switch oﬀ the Analyser To recharge connect lead from power adaptor to the DC power in put socket on the LPA Observe that the battery charging indicator illuminates on the LPA Battery power may be conserved by Operating LPA whilst connected to power adaptor Switching LPA OFF between samples Turning Auto Print Mode OFF Should the battery become completely discharged it is a...

Page 36: ...ROLLER THERMAL PRINTHEAD Figure 1 Printer Mechanism Using a ﬁnger press down on the print head spring at position A and tilt the print head to the open position by pulling it back at point B B A C Figure 2 Print Head Spring Feed the paper under the roller and pull the paper end out of the mechanism Return the print head back to its normal position by pressing on the green lever at point C Ensure t...

Page 37: ...Printer Paper 37 IMPORTANT The thermal printer must not be operated with out paper as this will damage the printer Therefore replace the roll when the end of the roll indication appears on the paper ...

Page 38: ...3 Switch ON the PC Launch LPA View software From File select Upload Data Transfer Screen will be displayed Select appropriate COM Port Select Transfer Data The Analyser will download all stored results from memory into the software package Upon completion of upload the Analyser memory can be automatically deleted if this option has been selected from the PC menu 4 When the transfer is complete swi...

Page 39: ...e unit is recalibrated every 12 months Please ensure that the test results in the Log are downloaded to LPA View before the LPA is despatched in case action taken by MP Filtri UK during the service recalibration causes the Log to be cleared It is requested that only the LPA not the support case or any other ancilliaries be returned for recalibration MP Filtri UK will not be held responsible for an...

Page 40: ...40 Warranty ...

Page 41: ...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 42: ...Appendix A 42 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 43: ...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 44: ...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 45: ... 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 LPA software Figure I CONTAMINATION LEVEL CLASSES according to NAS1638 ...

Page 46: ... 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 LPA VIII The information reproduced on this and the previous page is a brief extract from SAE AS4059 Rev E revised in May 2005 For further ...

Page 47: ...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 48: ... 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 Cleanliness Cla...

Page 49: ...rtridge 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 IX 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 IX It sh...

Page 50: ...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 51: ...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 52: ...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 53: ...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 54: ...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 55: ...system 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 ...

Page 56: ... 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 LPA is calibrated with ISO Medium Test Dust to ISO 11171 The correlation between particle sizes and the ACFTD...

Page 57: ...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 58: ...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 XIII All section headings indicated with are reproduced by kind permission of British Fluid Power Association from BFPA P5 1999 issue 3 Appendix 44 ...

Page 59: ...11 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 60: ...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 61: ...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 62: ...SO 4406 1999 Standard Accuracy repeatability Better than 3 typical Calibration Each unit is individually calibrated with ISO Medium Test Dust MTD based on ISO 11171 1999 on equipment certiﬁed by I F T S Analysis Range ISO 8 to ISO 24 to ISO 4406 1999 NAS 1638 2 to 12 AS4059E Table 1 2 to 12 AS4059E Table 2 Size Codes A 000 to 12 B 00 to 12 C 00 to 12 D 2 to 12 E 4 to 12 F 7 to 12 Report Print Form...

Page 63: ...e 5 to 80 C Fluid compatibility Mineral oil petroleum based ﬂuids consult MP Filtri UK for other ﬂuids Typical test time Result in 2 5 mins normal test Power Internal rechargeable battery mains charger or External 12 24 volt DC power supply Data storage 600 tests Computer interface RS 232 communication port Hose connections Minimess ﬁttings Microbore hose 1 5 metres long Waste ﬂuid hose Dimensions...

Page 64: ...Appendix J 64 Spare Product Part Numbers Spare Product Part Numbers For spares and part numbers please see the website www mpﬁltri co uk ...

Page 65: ... PL2303_Proliﬁc_DriverInstaller_v110 exe on the provided CD You will need to accept any warnings about making changes to your com puter 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 installation Note any COM port number indicated in the message Connect the LPA to the compu...

Page 66: ...the Hardware tab and then click on the Device Manager But ton Click on the plus sign next to Ports COM LPT Windows 7 View the installed devices using Start Button Devices and Printers You should see an icon representing the port Communications port if using the Serial lead ATEN USB to Serial Cable or Proliﬁc USB to Serial Comm Port if using an adaptor cable Either of these will have a COM number a...

Page 67: ...onnected to Analyser DC Power Input Socket Unexpected results obtained from sample Check that the ﬂuid sampling hose has been fully connected at both the system and Analyser ends Conﬁrm that there is a free ﬂow of ﬂuid to the Analyser by depressing the Flush Valve and ob serving ﬂuid passing into the waste disposal bot tle High water aeration levels If suspected contact MP Filtri UK for further ad...

Page 68: ...he standard Bottle Sampling units are both ﬁtted with Nitrile seals so Petroleum Ether may be used for this purpose Petroleum Ether is not compatible with seals manufactured from EPDM which are used in the Phosphate Ester version of the 250 Bottle Sam pling unit Iso propyl alcohol should be used as the ﬂushing ﬂuid Please consult the website for other compatible ﬂuids DO NOT USE ACETONE ...

Page 69: ...racters to appear on the LCD screen Press key 5 Press key 4 Press key 6 Press key 0 zero for other languages press the required number as listed on the LPA Press Enter key Press key 0 zero Press key 0 zero Wait 5 seconds Press the orange button to switch the LPA OFF Press the green button to switch the LPA ON The LCD screen will now be displayed in the English language ...

Page 70: ...Appendix L 70 Fault Finding ...

Page 71: ...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 72: ... mpfiltrishanghai com Website www mpfiltrichina com GERMANY MP FILTRI D GmbH Tel 49 6894 95652 0 Fax 49 6894 95652 20 Email service mpfiltri de Website www mpfiltri de FRANCE MP FILTRI FRANCE Tel 33 1 40 86 47 00 Fax 33 1 40 86 47 09 Email contact mpfiltrifrance com Website www mpfiltri com INDIA MP FILTRI INDIA Tel 91 9945599899 Email s mishra mpfiltri com Website www mpfiltri com RUSSIAN FEDERAT...

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