HYDAC International ALPC 9000 Series Operating And Maintenance Instructions Manual Download

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Automated Laboratory
Particle Counter

ALPC 9000 series

Operating and Maintenance Instructions

English (translation of original instructions)

Document No.: 3601005

Summary of Contents for ALPC 9000 Series

Page 1: ...Automated Laboratory Particle Counter ALPC 9000 series Operating and Maintenance Instructions English translation of original instructions Document No 3601005 ...

Page 2: ...ability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors The content of the manual is checked regularly Any corrections required will be incorporated in future editions We welcome any suggestions for improvements All details are subject to technical modifications Technical specifications are subject to change without notice HYDAC FILTER ...

Page 3: ...0 Structural Modifications to the ALPC 11 Electrical Hazards 11 Training and Instruction of Personnel 12 Transporting the ALPC 13 Storing the ALPC 13 Checking the Scope of Delivery 14 Description of the ALPC 15 Restrictions pertaining to use 16 Setting up the ALPC 16 ALPC dimensions work areas 17 ALPC components 18 Components of basic unit ALPC 9000 1 20 Safety door to the analysis room 21 Mains b...

Page 4: ...ome 48 Clean the suction screen on the flushing fluid tank suction hose 48 Cleaning the oil pan 49 Check replace hoses 50 Maintaining the maintenance unit 51 Replacing the silencer 51 Changing the filter insert 52 Drain condensate 53 Cleaning the sealing disk 54 Change the sealing disk on the vacuum hand 55 Replacing the vacuum hoses on the robot 56 Dismantling the rear wall on the protective hous...

Page 5: ...tation cannot always keep up with changes made to the product as we attach considerable importance to keeping our products cutting edge Consequently there might be deviations in technical details illustrations and dimensions If you discover errors while reading the documentation or have suggestions or other useful information please don t hesitate to contact us HYDAC FILTER SYSTEMS GMBH Technische...

Page 6: ...t changes to the product e g purchasing options etc may result in the information in the operating instructions no longer being completely accurate or sufficient When making modifications or performing repair work to components affecting the safety of the product the product may not be put back into operation until it has been examined and released by a HYDAC representative Please notify us immedi...

Page 7: ... find the information I m looking for The document has a table of contents at the beginning I select the chapter I m looking for and the corresponding page number de HYDAC Filtertechnik GmbH BeWa 123456a de Seite x Produkt Kapitel 200x xx xx Chapter Page number Edition date Document language Documentation No with Index File name The documentation number with its index enables you to order another ...

Page 8: ...he ALPC has been designed and constructed in accordance with the current state of the art and recognized safety regulations Nevertheless hazard may be posed to the life and limb of the individual using the product or to third parties The ALPC is only to be used as follows Solely for its designated use only when in a safe perfect condition Immediately remedy any malfunctions that might impair safet...

Page 9: ...ge if safety precautions are not observed Proper Designated Use The ALPC is a fully automated laboratory particle counter for the analysis of hydraulic and lubricating fluids in oil analysis laboratories Analyzing the size and quantity of contamination enables quality standards to be verified and documented and the requisite optimization measures to be implemented Any other use shall be deemed to ...

Page 10: ...ment maintenance servicing and inspection work is to be conducted in a timely fashion All operating media are to be protected in case the product is accidentally started up When performing any maintenance servicing inspection or repair work disconnect the ALPC from the power supply and ensure that it cannot be switched back on inadvertently Any screwed fittings which have been undone removed are t...

Page 11: ...ly original spare parts OEM Electrical Hazards DANGER Electric shock Danger of fatal injury Any work involving electrical equipment may only be done by a properly trained certified electrician Pull the power plug before performing work on live parts Regularly check the ALPC electrical equipment Fix any loose connections immediately Always keep the control cabinet locked HYDAC FILTER SYSTEMS GMBH e...

Page 12: ...d only by properly trained and instructed personnel The areas of responsibility of your staff must be established in a clear cut manner Staff undergoing training may not use the ALPC unless supervised by an experienced staff member Individuals Individuals undergoing training Individuals with technical training engineering background Electrician HYDAC Service Activity Packing Transportation X X X P...

Page 13: ...r transport Storing the ALPC Pull power plug Coil up the power cable and fix it to the ALPC Drain the reservoirs and filters of the ALPC completely before putting it into extended storage Store the ALPC in a clean dry room with the following conditions Storage temperature 0 70 C 32 158 F Humidity Maximum 90 non condensing Air dust free no salty air not in the vicinity of oxidizing substances flash...

Page 14: ...6 Checking the Scope of Delivery The ALPC is handed over ready for operation The following items are supplied Qty Description 1 ALPC 9000 series 1 Operating and maintenance instructions 1 ALPCDesk Software Manual 1 Documentation on the robot 1 Calibration certificate 1 EC declaration of conformity 1 Support CD 1 CD with driver to the PC ...

Page 15: ...ing a key on the PC keyboard or by clicking on the mouse the particle counter carries out an automatic analysis of the sample The analsysis of a sample is only accepted if the measurement values of two subsequent sample runs lie within a predefined tolerance The analysis of a sample is rejected if it does not lie within a predefined tolerance after five sample runs The number of maximum sample run...

Page 16: ...ed materials and the sealing materials Only use fluids with a flashpoint 55 C 131 F Ensure that the flushing fluid has a substantially better cleanliness class than the cleanliness class expected from the sample e g ISO 15 12 9 Setting up the ALPC In order to set up and operate the ALPC please provide the following at the building site Supply voltage 230 V AC 50 Hz Clean dry compressed air Space o...

Page 17: ...LPC dimensions work areas Please observe the work areas marked green and grey around the ALPC which are always freely accessible All dimensions in mm HYDAC FILTER SYSTEMS GMBH en Page 17 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 18: ...ALPC 9000 series ALPC components ALPC components The ALPC consists of the following components HYDAC FILTER SYSTEMS GMBH en Page 18 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 19: ...ains box Fehler Textmarke nicht definiert 8 Electrical control 23 9 Maintenance unit 24 10 Flushing fluid tank 25 11 Suction hose with suction strainer 25 12 Return tank 25 13 Return hose 25 20 Extension unit ALPC 9000 2 26 21 Protective housing with safety door 27 22 Safety door 27 24 Robot 29 25 Robot controller 30 26 Teaching box for robot controller 31 27 Vacuum hand 28 Sample pallet 37 29 Sam...

Page 20: ...nsists of the following components Item Description 1 Pressure dome 2 Suction tube 3 Dome closure 4 Flushing funnel 5 Safety door to the analysis room B1 Particle sensor M1 Metering pump M2 Flushing pump HYDAC FILTER SYSTEMS GMBH en Page 20 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 21: ...he stop The ALPC 1 only works if the safety door is closed If you use the extension unit ALPC 2 in automatic function the safety door must always stay open The safety door to the analysis room has a door contact in open and closed setting If these contacts signalize an incorrect door position the ALPC will not work HYDAC FILTER SYSTEMS GMBH en Page 21 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 201...

Page 22: ...tion Power ON C Lamp test LAMP TEST D Fault lamp robot Fault robot E Fault lamp flushing pump Fault flushing pump F No function Reserve G Fault message sample shaker Fault shaker H Sockets for peripheral devices HYDAC FILTER SYSTEMS GMBH en Page 22 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 23: ...lowing components in the electrical control cabinet Item Description A4 Power supply unit sensor A5 Control metering pump P2 Pressure switch Y2 Vacuum retaining valve 1 Valve terminal HYDAC FILTER SYSTEMS GMBH en Page 23 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 24: ... valve manual V1 9 2 Filter control valve FR 9 3 Filter element 5 µm 9 4 Pressure gauge 0 10 bar 9 5 Branch module 9 6 Switch on valve electrical Y0 9 7 Fine filter FF 9 8 Filter element 1 µm 9 9 Branch module 9 10 Pressure switch P3 9 11 Silencer HYDAC FILTER SYSTEMS GMBH en Page 24 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 25: ...erting it into the flushing fluid tank Insert the suction line S including the suction screen down to the floor of the flushing fluid tank Return hose Return tank The return tank must be provided by the customer Empty the return tank daily prior to the start of the analysis Ensure that the return line is always above the flushing fluid Only this guarantees quick drainage of the flushing fluid HYDA...

Page 26: ...nts Extension unit ALPC 9000 2 The extension unit with the robot serves the automatic analysis of sample bottles on a prepared sample pallet HYDAC FILTER SYSTEMS GMBH en Page 26 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 27: ...pen the sample room by lifting the safety door handle A After filling the pallet with samples close the safety door down to the stop The ALPC only works if the safety door is closed HYDAC FILTER SYSTEMS GMBH en Page 27 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 28: ...ir supply is blocked Any vacuum is interrupted immediately Sustain vacuum manually S5 On actuating the Emergency stop switch or on opening the safety door manually the vacuum is interrupted immediately The means that any sample located on the vacuum hand will drop off In order to sustain the vacuum press the Vacuum ON button HYDAC FILTER SYSTEMS GMBH en Page 28 68 BEWA ALPC9000 3601005 en 2011 04 ...

Page 29: ...bot consists of the following components Item Description 1 Robot 2 Vacuum hand with drip catcher 3 Sealing disc 4 Vacuum hose 5 Silencer 6 Vacuum generator HYDAC FILTER SYSTEMS GMBH en Page 29 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 30: ...efore and during operation that the Emergency stop button is not actuated and that the key switch is in the AUTO Ext position The robot is stopped immediately by pressing the Emergency stop button on the robot controller In order to release the Emergency stop button turn it to the right Item Description 1 Emergency stop switch 2 On Off switch 3 Key switch HYDAC FILTER SYSTEMS GMBH en Page 30 68 BE...

Page 31: ...d the Teaching box to carry out robot position corrections In standard ALPC operation you do not require the Teaching box Always keep the Teaching Box at hand for HYDAC Service centre service procedures HYDAC FILTER SYSTEMS GMBH en Page 31 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 32: ...ker has the following components Item Description 1 Plate for holding the sample pallet 2 Register pins for centring the sample pallet 3 Quick action chuck 4 Sample shaker HYDAC FILTER SYSTEMS GMBH en Page 32 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 33: ...eck the O ring on the pressure dome as described on page 48 8 Clean the sealing disk on the vacuum hand as described on page 54 9 Check the position on the EMERGENCY STOP switch see page 28 10 Check the switch positions on the robot controller see page 30 11 Check the maintenance unit 9 Switch the compressed air for module V1 on Check the pressure on the pressure gauge At least 6 bar are required ...

Page 34: ...ou have undertaken the steps in Chapter Prior to switching the unit on on page 33 2 Switch the PC on at the on off switch 3 Switch the ALPC on at the mains box main switch 4 Carry out a lamp test on the mains box see page 48 5 Start the program ALPCDesk on the PC A detailed description of the ALPCDesk software can be found in the enclosed software instructions 6 The ALPC is now ready for the analy...

Page 35: ... 50 ml fluid are required 2 Shake the sample bottle vigorously for 1 minute Afterwards the deposited sedimented contamination is dissolved and evenly distributed in the fluid 3 Let the sample bottle sit 15 minutes or place the bottle in an ultrasonic bath This allows air bubbles which resulted from the Test fluid to escape HYDAC FILTER SYSTEMS GMBH en Page 35 68 BEWA ALPC9000 3601005 en 2011 04 07...

Page 36: ...he vacuum hand the sample bottle must be smooth and undamaged Deformed or damaged sample bottles cannot be automatically checked Add these sample bottles manually to the ALPC 6 If the sample bottle is filled up to the edge remove the fluid to the filling mark 7 The sample bottle is now prepared for analysis HYDAC FILTER SYSTEMS GMBH en Page 36 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 37: ... The ALPC is damaged the analysis is cancelled Use only one sample bottle size per sample pallet Place the prepared sample pallet onto the sample shaker and align the pallet at the stops X Secure the sample pallet with the fast clamping device L HYDAC FILTER SYSTEMS GMBH en Page 37 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 38: ...or rings The ALPC will be damaged Use only one sample bottle size per sample pallet Only use the permitted sample bottles in the appropriate pallet Replace the appropriate adaptor ring in the pressure dome when the pallet is changed The optionally available change pallets always have the same raster for holding max 45 sample bottles Each change pallet is suitable for holding a certain type of samp...

Page 39: ...ing you will find the allocation of the colour code to the sample bottle type Adaptor ring Colour Sample jar red 30 ml glass blue 100 ml plastic MIDLAND Monroe green 100 ml glass HYDAC FILTER SYSTEMS GMBH en Page 39 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 40: ... room or B to the analysis room Start the analysis of the sample bottles via the ALPCDesk software on the PC All further processes and the sample analysis for the ALPC using the data you have entered HYDAC FILTER SYSTEMS GMBH en Page 40 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 41: ...divided into nine phases which are presented below in the individual Figs 1 2 4 3 5 6 Item Description 1 Particle sensor 2 Pressure dome 3 Suction tube 4 Flushing funnel 5 Sample bottle 6 Dome floor dome closure HYDAC FILTER SYSTEMS GMBH en Page 41 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 42: ... is adjusted in the dome manually or using the robot 3 The optical sample bottle detector automatically detects the adjusted sample bottle The pressure dome will close 4 The pressure dome is pressurized Here the pressure switch monitors the required pressure in the dome HYDAC FILTER SYSTEMS GMBH en Page 42 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 43: ...2011 04 06 Phase Description 5 The sample bottle is analysed The sample is brought to the sensor due to the pressure in the pressure dome The metering pump specifies the flow rate through the sensor 6 The pressure dome is depressurized 7 The pressure cover opens 8 The sample bottle is removed from the pressure dome ...

Page 44: ...ption 9 The optical sample bottle detector detects the empty dome and swivels the funnel shaped collector under the pressure dome Then the ALPC starts by flushing the suction tube inside and outside This flushing process can be controlled through the level of contamination or through time 1 The ALPC is ready for the next sample analysis ...

Page 45: ...ch it off 2 Switch off the ALPC at the main switch on the mains box 3 Close the compressed air supply at the maintenance unit with the lever B The pressure from the ALPC is released via the silencer 4 The ALPC is switched off and depressurized HYDAC FILTER SYSTEMS GMBH en Page 45 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 46: ...eck clean the sealing disk on the vacuum hand 54 X Check the sealing ring on the pressure dome 48 X Clean the oil collecting pan 49 X Check all warning guidelines safety stickers for legibility X Check all compressed air hoses for Damage due to kinks Flexibility Tightness leakages Tight fit of the screw in and plug in connections X Check all the electrical connections Look for any damage to wires ...

Page 47: ... 300 hours or every six months Every 6000 hours of operation or yearly Flexibility Tightness leakage Tight fit of screw in and plug in connections Check all screw in connections X Replace the sealing disk on the vacuum hand 55 X Replace the filter elements on the maintenance unit 51 X Replace all compressed air hoses 50 X Replace all flushing fluid return hoses X ...

Page 48: ...heck the sealing ring on the pressure dome Check the sealing ring on the pressure dome daily for damage and swelling Replace it if necessary The O Ring must lie against the pressure dome Clean the suction screen on the flushing fluid tank suction hose Clean the suction screen on the flushing fluid suction hose by blowing it out with compressed air HYDAC FILTER SYSTEMS GMBH en Page 48 68 BEWA ALPC9...

Page 49: ...an this oil collecting pan daily To do this pull the oil collecting pan on the handle B out forwards and rub off any fluid residues Observe that these residues may indicate a leakage on the ALPC If this is the case contact HYDAC HYDAC FILTER SYSTEMS GMBH en Page 49 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 50: ... The hoses used must have been designed for use with the permissible test liquids concerned The hoses must be checked regularly for brittleness Replace them if necessary HYDAC FILTER SYSTEMS GMBH en Page 50 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 51: ...nit regularly as described below Replacing the silencer Replace the silencer by screwing it out using an open jaw wrench clockwise Then screw in the new silencer counterclockwise by hand and tighten it slightly using an open jaw wrench HYDAC FILTER SYSTEMS GMBH en Page 51 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 52: ...ly in an environmentally correct manner 4 Clean the inside of the filter bowl A using a soft lint free cloth 5 Insert the new filter element B into the mount 6 Screw the filter bowl A from below into the filter head counterclockwise and tighten it slightly using a wrench 7 Open the compressed air supply on valve V1 8 The filter element change is now complete HYDAC FILTER SYSTEMS GMBH en Page 52 68...

Page 53: ...rside of the filter bowl 3 Collect the condensate with a suitable container 4 Then screw the drain plug into the filter bowl again and tighten it firmly 5 Open the compressed air supply on valve V1 6 The condensate drainage procedure is now complete HYDAC FILTER SYSTEMS GMBH en Page 53 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 54: ...sk will become damaged unusable Clean the sealing disk daily by rubbing it with a lint free cloth For severe contamination use kerosene or n heptane Do not use any aggressive severe cleaning agents or those containing solvent HYDAC FILTER SYSTEMS GMBH en Page 54 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 55: ...dispose of it in an environmentally friendly manner 4 Clean the sealing surface on the vacuum hand 5 Put the screw A including the lock washer and washer B through the hole in the new sealing disk C 6 Screw in this package with the screw manually in counterclockwise direction into the underside of the vacuum hand and tighten the screw slightly with a wrench wrench opening 10 7 The procedure for ch...

Page 56: ...6 Replacing the vacuum hoses on the robot In order to replace the vacuum hoses on the robot please proceed as follows Step Description Page 1 Dismantling the rear wall on the protective housing 57 2 Replace the vacuum hoses 58 3 Changing the silencer on the vacuum generator 58 4 Mounting the rear wall of the protective housing 59 ...

Page 57: ...sing In order to dismantle the rear wall for protective housing proceed as follows 1 Carefully unscrew the four safety screws counterclockwise using a 3 mm Allen wrench Only unscrew until the bolts in the closure are loose 2 Lift the rear wall out upwards out of the closure 3 Then pull the rear wall back out of the protective housing HYDAC FILTER SYSTEMS GMBH en Page 57 68 BEWA ALPC9000 3601005 en...

Page 58: ...ards 1 and pull out the hose upwards 2 Changing the silencer on the vacuum generator Change the silencer by screwing it out using an open jaw wrench clockwise then screw in the new silencer counterclockwise manually and tighten it slightly using the open jaw wrench HYDAC FILTER SYSTEMS GMBH en Page 58 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 59: ... housing proceed as follows 1 Lift the rear wall in the protective housing over the closures 2 Lower the rear wall evenly downwards into the four closures 3 Screw in the four safety screws clockwise using a 3mm Allen wrench and tighten them slightly HYDAC FILTER SYSTEMS GMBH en Page 59 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 ...

Page 60: ...y release Y1 5 Vacuum Generator Y1 4 V1 FR FF Y0 2 4 2 4 2 4 2 4 2 4 M1 M2 V5 V6 V7 VG Sample Bottle A10 A11 A12 V2 I P 2 1 Y2 Item Description V1 Compressed air manual switch V2 Manual actuation dome slide V3 Check valve flushing path suction tube inside V4 Check valve flushing path suction tube outside V5 Throttle valve fine adjustment flushing path inside V6 Throttle valve coarse adjustment flu...

Page 61: ...tering pump M2 Flushing pump B1 Particle sensor Y0 Compressed air valve compressed air supply Y1 0 Compressed air valve dome pressure Y1 1 Compressed air valve flushing funnel Y1 2 Compressed air valve dome closure Y1 3 Compressed air valve cylinder dome open Y1 4 Compressed air valve cylinder dome off Y1 5 Compressed air valve vacuum generator Y2 Compressed air valve to sustain vacuum A10 Cylinde...

Page 62: ...ction hose 3524412 1 Sealing disk on vacuum hand 3092667 2 Vacuum hose exchange set consisting of 2x vacuum hoses on robot 1x silencer 3600716 1 O ring on the pressure dome 685498 1 Disposing of the ALPC When decommissioning and or disposing of the unit observe all local guidelines and regulations pertaining to occupational safety and environmental protection This applies in particular to the anal...

Page 63: ...Germany HYDAC Service GmbH Product Support Werk 10 66128 Saarbruecken Telephone 49 0 6897 509 1938 Telefax 49 0 6897 509 1933 E mail service hydac com USA HYDAC Technology Corporation HYCON Division 2260 City Line Road USA Bethlehem PA 18017 P O Box 22050 USA Lehigh Valley PA 18002 2050 Telephone 1 0 610 266 01 00 Telefax 1 0 610 231 04 45 E mail sales hydacusa com Internet www hydacusa com Austra...

Page 64: ... 68 BEWA ALPC9000 3601005 en 2011 04 07 doc 2011 04 06 Brazil HYDAC TECNOLOGIA LTDA Estrada Fukutaro Yida 225 CEP 09852 060 Cooperativa BR São Bernardo do Campo SÃO PAULO Telephone 55 11 4393 6600 Telefax 55 11 4393 6617 E mail hydac hydac com br Homepage www hydac com br ...

Page 65: ...ble Analysis volume At least 50 ml Measurement flow rate 30 ml min Permissible viscosity range 1 320 mm s at 20 C Permitted fluid temperature range sample 0 50 C 32 122 F Flushing fluid Fluids on mineral oil basis preferably kerosene with a flash point 55 C 131 F Cleanliness class substantially better than the expected cleanliness class of the sample e g ISO 15 12 9 Flushing flow rate 200 ml min S...

Page 66: ...counter Series 9000 9000 series Sample supply 1 Manual 2 Automatic Supply voltage M 230 V AC 50 60 Hz 1 Phase PC Operating system WXPUS Windows XP language US WXPDE Windows XP language DE W7 Windows 7 Multilingual Keyboard layout BE Belgium CH Switzerland DE Germany DK Denmark ES Spanish FR France GB England IT Italy NO Norway PO Portugal SF Sweden Finland US USA RU Russia PL Poland SK Slovakia ...

Page 67: ......

Page 68: ...iet Postfach 1251 66280 Sulzbach Saar 66273 Sulzbach Saar Germany Germany Phone 49 0 6897 509 01 Central Fax 49 0 6897 509 846 Technical Department Fax 49 0 6897 509 577 Sales Department Internet www hydac com E Mail filtersystems hydac com ...

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