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Appendix G

50

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

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. ACFTD was

used extensively within the ﬂuid power and automotive industries for calibrating Au-

tomatic Particle Counters (APCs) and for the testing of components.
APCs are used for testing oil ﬁlters, and also for contaminant sensitivity testing of hy-

draulic components. For 25 years, APCs have been the main stay in the measurement

of solid particles in hydraulic ﬂuids. The growth in demand for measuring ﬂuid clean-

liness 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

particle size distribution was determined using an optical microscope. This particle

size distribution subsequently formed the basis of ISO 4402, the method for calibrat-

ing APCs. Due to the limitations of that method of measurement, the particle size

distribution was questioned below about 5µm. It was also not traceable to any national

standard of measurement - a critical requirement for today’s quality management sys-

tems.
There was also an absence of formal controls over the distribution of the test dust, and

batch-to-batch variability was much greater than is acceptable nowadays.
ISO therefore deﬁned the requirements for the replacement for ACFTD and asked the

National Institute of Standards and Technology (NIST) in the USA to produce a stan-

dard, traceable reference material. The new dust’s particle size distribution has been

accurately determined with the aid of modern scanning electron microscope and image

analysis techniques.

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Summary of Contents for PML2

Page 1: ...PML Analyser UserGuide 200 052 EN www mpfiltri co uk ...

Page 2: ...l iﬁed personnel Do not tamper with this device INTERNAL CLEANING DO NOT clean the PML or Bottle Sampler with Acetone or similar solvents that are not compatible with the seals The recommended cleaning ﬂuid for internal ﬂushing is listed in the Fault Finding section page 60 The use of a 500μm coarse screen ﬁlter screwed onto the HP connector is recommended for heavily contaminated systems Refer to...

Page 3: ...ttings 5 Normal Test 17 Without Moisture Sensor With Moisture Sensor 6 Continuous Sampling 19 Continuous Test Basic Operation With Moisture Sensor 7 Moisture Sensor 25 8 Alarms 26 9 External Circuit Relays 28 10 Remote Display Optional Equipment 30 Using the Pushbuttons Downloading the Results 11 Bottle Sampling 34 12 Drain Reservoir and System Pressures 35 13 Flush Valve Opening Times 36 ...

Page 4: ...liness Classification For Hydraulic Fluids 44 E Recommendations 46 F Hydraulic System Target Cleanliness Levels 48 G New ISO Medium Test Dust and its effect on ISO Contamination Control Standards 50 Calibration New Test Dust Beneﬁts Eﬀect on Industry Correlation Other Standards H Clean working practises 55 I Specification 57 J Spare Product Part Numbers 59 K Fault Finding 60 Low Pressure ...

Page 5: ...ature gradient existing between the system tapping point and the RH temperature module the temperature reading can be 5 C to 10 C less than the actual system temperature depending on operating conditions Hydraulic and Lubricating Systems consist 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 th...

Page 6: ...6 Introduction Figure 1 ...

Page 7: ... LPA View CD Rom software package 1 x LPA View test analysis software manual 1 x USB to serial converter used when computer has only USB ports 1 x PC download cable 1 x Multi core cable x 2 5m long Optional Equipment Remote display unit including cable and connector 500 µm coarse screen ﬁlter Part number SK0040 2 This is a dedicated unit for the PML and should not be used with other MP Filtri UK p...

Page 8: ...and discard the connector supplied with the 24 V DC power supply Identify which is the positive and zero volt cores in the two core cable using a voltmeter Connect the 24 V DC positive core to the red core in the multi core cable supplied with the PML Connect the 24 V DC zero volt core to the blue core in the multi core cable Connect the black white and yellow cores in accordance with the external...

Page 9: ...NG HOSE to the system by means of the minimess con nector The system to be monitored must not exceed 400 bar or be less than 2 bar 7 Installing LPA View Software refer to the LPA View User Manual and follow the CD Installation instructions 8 Connect Multi core cable into the PC and the other end into the small connector on the PML If the PC has only USB ports use the USB to serial converter and fo...

Page 10: ...us Test Occasionally the operator connects a PC and uses LPA View to download the accumulated test data 4 1 Using the Computer Serial Port This connection is made using the standard computer connecting cable supplied with the PML If the computer has only USB to serial ports use the USB to serial converter and follow the instructions on page 12 Apply power to the PML make the PC connection and then...

Page 11: ...hosen 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 Windows 2000 Windows XP Windows Vista ...

Page 12: ...ing 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 after it This is the number you should use when selecting the Com Port 4 3 USB Port When a built in computer serial port is not available the USB to serial converter can be used Connect PML to the computer using the Serial lead and the USB to Serial Conve...

Page 13: ...tion of the buttons on the Remote Device dialogue Figure 4 Remote Device dialogue Start Starts sampling and emptying cycle Stop Stops test at any point in the sampling emptying cycle Next test will start with an emptying cycle before the test commences Flush The Flush Valve must be opened to allow ﬂuid to pass through the PML so that any ﬂuid from the previous test is ﬂushed out of the connecting ...

Page 14: ...vice dialogue open This allows the user to set up a continuously updated trend graph and list view As each test is completed the trend graph and list view are updated However it is not necessary to keep the Remote Device dialogue open and com puter connected after the test has been initiated although most users will ﬁnd this more convenient This fact is especially useful for the continuous test mo...

Page 15: ... new settings Or press Cancel to leave the settings as they were Test Reference Type in this box the description you wish to use for the test e g Vehicle 012 Up to 14 characters may be used Test Type Used to select one of the ﬁve available test types It is recommended that the PML be usually operated in either the Normal test mode or the Continuous test mode until the user is fully familiar with t...

Page 16: ...the small sample volume Test Number Input desired number e g 123 Test number will automatically increment for each successive test Simulate Test Results This is useful for checking device communications and familiarisation with the software especially when an oil supply is not available When a simulated test is performed the particle counter will generate test results without being connected to a ...

Page 17: ...ss Flush button to open ﬂush valve ﬂush indicator turns yellow colour to indi cate valve is open Leave valve open until at least 200ml has passed to waste Refer to page 36 for more information about ﬂushing times 4 Press Stop button to close ﬂush valve 5 Press Start button The PML will now commence the sampling cycle 6 The completion bar indicates progress of the test and the status is shown as Sa...

Page 18: ...tus is shown as Ready and another test can then be started Figure 2 A Completed Test 5 2 With Moisture Sensor For the PML W the procedure is similar to that detailed for the PML without moisture sensor previous section except when the Start button is pressed the ﬂush valve will open automatically for a period of 3 minutes to allow the moisture sensor to stabilise and give an accurated reading Meas...

Page 19: ...ending on the time set for Minutes Between Tests the Flush valve operates as follows Time set to 0 At the end of the analyser s emptying cycle the ﬂush valve auto matically 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 te...

Page 20: ...ts box This will log every test that is carried out in the continuous test mode into the memory of the PML If the box is not ticked none of the test results will be stored in the memory of the PML 5 Press OK button to save settings and return to Remote Device dialogue 6 Press Flush button to open ﬂush valve ﬂush indicator turns yellow to indicate valve is open Leave valve open until at least 200ml...

Page 21: ...d clean alarm level is achieved A status of COMPLETED is shown when the speciﬁed clean alarm level is achieved For other Alarm Modes refer to page 27 Follow the instructions on page 15 for inputting settings select Continuous Test Type Input Test Interval input the time in minutes that is required between the end of a test and the begining of a new test Cleanliness Target options Clean Alarm Level...

Page 22: ...e Class number in the range 2 to 12 inclusive For continuous testing until the NAS1638 AS4059E 1 Class is achieved select NAS Format or AS4059E Table 1 as described on page 15 Testing will automatically continue until the Class number has been achieved at each of the ﬁve micron size ranges covered by NAS 1638 AS4059E Table 1 Note AS4059E 1 denotes Table 1 of the AS4059E standard Clean Alarm Level ...

Page 23: ...is carried out on the continuous test mode into the memory of the PML If the box is not ticked then the PML will only store the results of the test when the Target Cleanliness Level is achieved this saves on memory space The PML has a memory capacity of approximately 600 tests When this mem ory is full the earliest of the test records will be over written by the newest tests Inserting a tick in th...

Page 24: ...arget Cleanliness Level The procedure is similar to that detailed for the PML without moisture sensor previous section except when the Start button is pressed the ﬂush valve will open automatically for a period of at least 3 minutes before the test commences this is to allow the moisture sensor to stabilise and give an accurate reading Measure Water Content box in the Remote Device Setting dialogu...

Page 25: ...mperature module the temperature reading can be 5 C to 10 C less than the actual system temperature depending on operating conditions The PML can be conﬁgured to do a test with or without the moisture sensor se lected If the moisture sensor has been selected the ﬂush valve will open automat ically for a period of 3 minutes before the particle count test commences This is to allow the moisture sens...

Page 26: ... the simple wiring diagrams Clean alarm levels are set in accordance with the instructions starting on page 21 Alarm mode 1 is used in conjunction with the Continuous Sampling test type enabling the Analyser to operate continuously until the speciﬁed clean alarm level is achieved 3 Alarm Mode 2 Selecting option 2 arranges the relays to operate when the Clean and Dirty alarm levels are reached exce...

Page 27: ...e number result set limit On result set limit Oﬀ ISO AS4059E 2 multi part any result corresponding set limit On all results corresponding set limit Oﬀ Relay 2 Clean NAS AS4059E 1 single number result set limit On result set limit Oﬀ ISO AS4059E 2 multi part all results corresponding set limit On any result corresponding set limit Oﬀ Alarm Modes 3 and 4 These are reserved for future development ...

Page 28: ...ute maximum 60 volt peak Operation above these limits will cause irreparable damage to the relays If the User requires to switch voltages currents in excess of the above maximum limits then separate higher rated interposing relays will need to be incorporated into the ﬁnal electrical scheme designed by the User In the multi core cable that is supplied with the PML there are three cores that are us...

Page 29: ...le 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 ...

Page 30: ... alpha numeric characters The top line is used to display the test code the bottom line showing RH Relative Humidity and Temperature C only appears on the PML 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 RDU V0 6 1 Status Letters During a test a Sta...

Page 31: ...0 1 Using the Pushbuttons All new PML s are factory set to perform a Normal test which consists of one test sampling 15ml of ﬂuid Other test types can be selected using a PC running LPA View refer to page 10 When running a Normal test the user will ﬁrst make the oil and power supply con nections as described on page 8 Follow the actions below to perform a Normal test Press Flush Pushbutton F This ...

Page 32: ...initiate the commencement of a test Each test comprises a sampling cycle that sizes and counts the particles in a 15ml volume of test ﬂuid followed by an emptying cycle during which the 15ml of ﬂuid is discharged to waste At the end of the emptying cycle the PML will come to rest and the test results will be displayed on the LCD screen Stop Pushbutton O This optionally aborts the test at any point...

Page 33: ...s 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: ...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 ...

Page 35: ...0 Minimum oil inlet pressure 2 bar Maximum oil inlet pressure 400 bar Drain Reservoir System Atmospheric pressure zero back pressure Model B Design Reference 31 Minimum oil inlet pressure 10 bar Maximum oil inlet pressure 400 bar Drain Reservoir System Back pressure not exceeding 1 bar The PML model suﬃx letter is stamped on the serial number plate after the num ber ...

Page 36: ...minutes 30 seconds Model B 10 bar Back pressure not exceeding 0 5 bar 1 minute 20 seconds Model B 10 bar Back pressure not exceeding 1 0 bar 2 minutes The above ﬂush times assume that the oil inlet hose from the sampling point to the PML does not exceed 1 5m in length Longer lengths of hose should be avoided as they can become a source of cross contamination between tests However if a hose length ...

Page 37: ...recalibrated every 12 months Please ensure that the test results in the Log are downloaded to LPA View before the PML 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 PML not the support case or any other ancilliaries be returned for recalibration MP Filtri UK will not be held responsible for any items re...

Page 38: ...38 Warranty ...

Page 39: ...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 emulsi ﬁed water is more harmful than those of dissolved water water levels should remain well below the saturation point However even water in solution can cause d...

Page 40: ...Appendix A 40 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 41: ...id contaminant particles in a sample The code is constructed from the combination of three scale num bers selected from the following ta ble 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 ...

Page 42: ...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 43: ... permitted of 100ml volume at various size intervals diﬀerential counts rather than using cumulative counts as in ISO 4406 1999 Although 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 PML software Figure I CONTAMINATION LEVEL CLASSES according to NAS1638 Ja...

Page 44: ...particle counter e g PML Size range μm c 6 14 14 21 21 38 38 70 70 Class 00 125 22 4 1 0 0 250 44 8 2 0 1 500 89 16 3 1 2 1 000 178 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 18...

Page 45: ... 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 46: ...evels They state that operating components on ﬂuids which are cleaner than those stated will increase life However the diversity of hydraulic systems in terms of pressure duty cycles environments lubrication required con taminant types etc makes it almost impossible to predict the components service life over and above that which can be reasonably expected Furthermore without the beneﬁts of signiﬁ...

Page 47: ...ination 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: ...greater reliability may also necessitate an improved cleanliness level The level of acceptability depends on three features the contamination sensitivity of the components the operational conditions of the system the required reliability and life expectancy Contamination Corresponding Recommended Typical Codes Codes Filtration Applications ISO 4406 1999 NAS 1638 Degree 4 6 14 Bx200 μm c μm c μm c ...

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

Page 50: ...itical 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 particle size distribution was determined using an optical microscope This particle size distribution subsequently formed the basis of ISO 4402 the method for calibrat ing APCs Due ...

Page 51: ...e size distribution This gives the trace ability required by ISO 9000 QS9000 and similar quality management systems A procedure for determining the performance of APCs so that minimum acceptable levels can be set by the user Improved calibration techniques and procedures More accurate calibration Improved levels of particle count reproducibility with diﬀerent equipment More accurate and consistent...

Page 52: ... ensure consistency in data reporting As the counts derived by microscope counting methods are not aﬀected the particle sizes used for microscopy will remain unchanged i e at 5 and 15 µm To clarify matters still further ISO standards written around the new test dust will utilize a new identiﬁer c Hence µm sizes according to the new ISO 11171 will be expresses as µm c and Beta ratios according to I...

Page 53: ...ize 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 28 23 5 29 24 2 30 24 9 31 25 7 32 26 4 33 27 1 34 27 9 35 28 5 36 29 2 37 29 9 38 30 5 39 31 1 40 31 7 Other Standards Although the ...

Page 54: ... 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 XII All section headings indicated with are reproduced by kind permission of British Fluid Power...

Page 55: ...ks 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 analysis in a controlled environment such as a laboratory which should contain fewer airborne contaminants that where the sample ...

Page 56: ... 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 using your system process until it has gone through a commissioning period whereby contamination levels are relatively stabl...

Page 57: ...ust MTD based on ISO11171 1999 on equipment cer tiﬁed 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 PML Sample volume 15 ml normal 30 ml dynamic 24 ml bottle sampler 15 ml continuous 8ml short Operation Max system working pressure 400 bar Min working pres...

Page 58: ...l B Design Reference 31 Minimum oil inlet pressure 10 bar Maximum oil inlet pressure 400 bar Drain Reservoir System Back pressure not exceeding 1 bar Analyser Upper Contamination Limmit The analyser upper operating limit is set at 24 22 20 Tests that result in particle counts exceeding any scale number in the three part ISO upper limit has the scale number replaced by asterisk on the remote Displa...

Page 59: ...Appendix J Spare Product Part Numbers 59 Spare Product Part Numbers For spares and part numbers please see the website www mpﬁltri co uk ...

Page 60: ...M port has been selected in the Re mote Device dialogue Disconnect power supply to PML and then reconnect it If excessive system contamination is suspected ﬂush out the Analyser using a Bottle Sampling Unit in conjunction with a suitable solvent Refer to the website for more information on ﬂushing ﬂuids www mpﬁltri co uk DO NOT USE ACETONE Low Pressure The PML must always be connected to an inlet ...

Page 61: ...e following will occur automatically The sampling cycle will stop The ﬂush valve will open and the internal PML syringe pump will empty Flush valve closes PML waits for oil inlet pressure to be restored at which point the PML will automatically resume testing Note If the PML had been set to carry out a relative humidity test when the low pressure event occurred the ﬁrst RH result after pressure ha...

Page 62: ...Appendix K 62 Fault Finding ...

Page 63: ... 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: ... 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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