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OPERATING INSTRUCTIONS

Pall

®

PCM500 Series Portable Fluid  

Cleanliness Monitor 

Содержание PCM500 Series

Страница 1: ...OPERATING INSTRUCTIONS Pall PCM500 Series Portable Fluid Cleanliness Monitor ...

Страница 2: ...been tested and quality controlled in accordance with Pall standard procedures The customer should carefully inspect the product and ensure it is not damaged and or unsuitable for use It is the user s responsibility to check actual operating conditions to ensure the PCM500 monitor is compatible with the application and is operated within local safety codes NOTICE TO USERS The PCM500 user manual is...

Страница 3: ...tion of the PCM500 monitor including communications to peripheral devices Section 7 Provides communication protocol for PLC control through RS232 Com port Section 8 Details the fluid change procedure Section 9 Describes the PCM500 monitor function codes possible causes and corrective actions Section 10 Spare parts list Section 11 Covers the disposal of equipment Appendix A Details the Pall PCM500 ...

Страница 4: ...4 ...

Страница 5: ...rmation that will aid installation operation or maintenance WARNINGS CAUTIONS AND NOTES Care must be taken in referring to this manual so as to ensure adherence with all warnings cautions and important notes These carry information related to the safety of personnel and the integrity and satisfactory operation of plant Label indicating DC power and Fuse rating Labels affixed to PCM Caution label a...

Страница 6: ...re Line 15 5 2 2 Low Pressure Line 15 5 2 3 Reservoir Sampling 16 5 2 4 Bottle Sampling 16 5 3 Operational Checks 17 5 4 Installation Checks 17 Section 6 PCM500 PCM500W Getting Started 6 1 General 17 6 2 System Requirements 17 6 3 Screen Button Description 18 6 4 The Screens Flow Chart 19 6 5 Example Screen 20 6 6 Start up Sequence 20 6 7 Sampling 21 6 8 Test Point and Fluid Setup 23 6 9 Code Alar...

Страница 7: ...n See Pall Datasheet M EPCM500EN for full technical specification The full technical specification is given below 1 2 Fluid Environment Operating Pressure range 0 to 315 bar 4 570 psi maximum Operating Viscosity range 1 5 to 450 Centistokes 30 to 2 200 SUS Operating System Mineral Oils 10C 80ºC 50 F 176 F Temperature Water Glycols 10ºC 60ºC 50 F 140 F Water Based Fluid 10ºC 60ºC 50 F 140 F Fuels 1...

Страница 8: ...Blow 4A 5x20mm 250V Optional Mains Supply Unit Input 100 240 VAC Auto Ranging Frequency 50 60 Hz Single Phase Output 24VDC Internal Battery 12VDC Lithium Ion rechargeable Battery Life Typically 35 40 samples depending on cleanliness levels oil viscosity Communications USB 1 Data Acquisition USB 2 PC Setup of PCM USB 3 Printer Ethernet Cat5 Remote control Data Acquisition RS232C PLC Control Voltage...

Страница 9: ...00 full range C3 C4 fluid constant input Contact PALL representative Enclosure Material and Flammability ABS UL94 V 0 Enclosure Gasket Seals Silicone Rubber Noise Level 70 dBA Foreseen misuse of equipment Within this manual are cautions and warnings to highlight potential dangers associated with operation of the PCM500 Here are a few points of note on misuse of the equipment A danger to the user c...

Страница 10: ...mportant to keep this in a safe place and return them with the unit for future annual service requirements Caution Health and Safety Ensure there is adequate lighting to operate the equipment Observe local regulations for factory use Section 3 Pall PCM500 and PCM500W Fluid Cleanliness Monitors 3 1 Description of the Monitor The PCM500 is designed and built for light Industrial use while maintainin...

Страница 11: ...riance in temperature viscosity and pressure to ensure results are not spurious The PCM500 will advise the user by function codes if any excessive variance occurs 4 2 HMI Control Panel There are three light emitting diodes LED to indicate PCM500 operational status and two soft touch control buttons BUTTONS START STOP REPEAT test ON OFF The test Start Stop button is active on release The ON button ...

Страница 12: ... of the display External Supply 1 6 2 3 4 5 1 USB A Socket 1 Text file upload download from memory device 2 USB B Socket PC connection for setup control of PCM500 3 USB A Socket 2 Printer connection 4 DB9 Female RS232 PLC control See section 7 5 2 Pin Socket Voltage free contact Relay 6 RJ45 Cat5 Ethernet 10 100 base U E P R Align the red dots and push to connect Grip connector outer body and pull...

Страница 13: ...ody Do not rotate the connector otherwise damage will result 5 When connecting the new battery align the red dots between connector and receptacle before insertion 6 Replace the printer and battery covers and fix with the M4 hex socket screws Important The monitor should not be operated with the battery pack disconnected If a power outage occurs on mains supply during testing the battery will main...

Страница 14: ...opriate to achieve representative sampling It is important to note that due to the very small bore through the high pressure connector it must be removed from the inlet hose when sampling below 1 bar pressure If not an error may occur through insufficient fluid flow into the PCM When sampling a closed system it is advised to flush the PCM with one test to waste to prevent cross contamination by fl...

Страница 15: ...5 2 Connection Options 5 2 1 High Pressure Line 1 to 315 bar 5 2 2 Low Pressure Line 0 1 bar 1 bar at test point remove HP connector and couple hose direct 15 ...

Страница 16: ...pending on viscosity and cleanliness the PCM500 may require up to a litre of fluid sample for a bottle test Always ensure the containers are thoroughly cleaned prior to introducing a fluid sample When bottle sampling it is important to prevent extraneous contaminant entering the sample such as may be found on the outer surface of the HP hose connection It is advised to use the sampling stalk provi...

Страница 17: ...e sampled 1 Access the hoses at the rear of the PCM500 2 Ensure the hose connectors are clean and free from any visual contaminants 3 Ensure the installation to be sampled is in operation and has been running for a minimum of 30 minutes prior to taking the sample in order to distribute the contamination as evenly as possible within the fluid This is necessary to allow a representative fluid sample...

Страница 18: ...tact Set Label Clock Date Format Print ISO 4406 Format AS 4059 Format Temp Format Export Bluetooth Setup Wi Fi Setup Comms Port Tools and Functions Communi cation Testing Test Point Fluid Test Label Water in Oil Repeat Alarm Set up Upload to Flash Drive Download to PCM Test Label Result Warning Select All Graph Data Management Information PCM500 Spec Mesh Settings Battery Data Control Panel Comms ...

Страница 19: ...ecome familiar with the PCM500 display operating sequence The flow chart consists of a number of views using the previous Icon listing to indicate their access within the screens Test Result Current setup Tools Data Manager Testing Language Information MAIN MENU START MAIN MENU 19 ...

Страница 20: ...ers up the display will activate and the following screens appear Splash screen If the PCM500 is out of calibration requires an annual service or other intervention a warning screen will inform the user at start up This is to ensure the user keeps the PCM500 fully serviced and helps ensure the integrity of the high pressure part of the instrument Press the contact button to open a contact details ...

Страница 21: ...ly Germany France Spain USA UK 6 7 Sampling Sample can be on line from a reservoir or bottled oil sources Refer to sections 1 Specifications and section 5 1 Connection Options On Line or Tank Sampling Routine From the main menu press the test button The user will be presented with a Test Configuration screen If the parameters are correct then advance to the next screen using the right arrow button...

Страница 22: ...esult detail screen A single test result screen Screen for multiple test results UP and DOWN buttons allow access to all test results in the sequence The results are automatically saved to memory and can also be viewed through the Data Manager screens The options from the result screens above are to transfer on USB Print Repeat the test sequence or return to the Home screen Transfer via USB will b...

Страница 23: ...time switches to calculator screen Code alarm screen is determined by the code format selected Tools Screens Temperature and water in oil alarm points are edited on the calculator screen Save the setup using the tick button To return to test setup screen or cancel editing without saving use the Return button Important The trigger period begins at the start of one test to the beginning of the next ...

Страница 24: ...ation contact Pall for availability Save the setup through the tick button and use the Return button to go back to the Test Point screen QWERTY Keybaord Number Entry screen Load a stored Test Point From the OPEN button in Test point select a stored Test Point and make current by pressing the TICK button Load a stored Fluid From the OPEN button in Fluids select a stored Fluid and make current by pr...

Страница 25: ...example below the alarm is set to trigger if 6µm is greater than ISO 14 code This could signal the start of system filtration pumps To change a code number touch to highlight and use the UP and DOWN arrows To change an alarm action the options are and X not applicable Example ISO4406 AS4059 Table 1 AS4059 Table 2 6 10 Data Manager Screens Any results saved on the PCM500 can be viewed and managed u...

Страница 26: ...etail can be uploaded to Flash Drive or Printed A flag to the side of a test indicates a warning is attached TEST POINTS TEST POINT A TEST POINT B TEST POINT C TEST POINT D TEST POINT E TEST POINT F TEST POINT B TESTS TEST POINTS TEST POINT A TEST POINT B TEST POINT C TEST POINT D TEST POINT E TEST POINT F SELECT TEST POINT TEST POINT A TEST POINT B TEST POINT C TEST POINT D TEST POINT E TEST POIN...

Страница 27: ...sed to go to a password screen The password is entered and TICK button pressed This next screen is a last chance before the data is removed Pressing the TICK button removes the selected data To abort this action the back arrow or Home button is pressed 6 11 Tools PCM Label Edited through the QWERTY screen Code Format Remote Assistance Printer Test Calculator Temperature Press to toggle between Fah...

Страница 28: ...al standard format to ISO 8601 Temperature Temperature reporting is changed by simply pressing the button to switch between Fahrenheit and Celsius Remote Assistance In the course of PCM operation a situation may arise that requires the intervention of a PCM Engineer to investigate operational issues The Engineer screen provides such access Pressing the Remote Assist button opens a code input scree...

Страница 29: ...ss the Printer button A progress screen will open to show the two connection options Press the option required and a corresponding progress bar indicates the communication attempt between PCM and Printer If a connection is made the Printer will print a Printer Detected message TEST ...

Страница 30: ...s 0 The unit is in standby 1 The unit has ended a test and it is waiting to start a new test at the set time interval 2 The unit is currently performing a test D E F G Latest error codes if any See below for details L Request last result The latest valid result is transmitted via DB9 communications port An example data string appears like this PCM R 2005 11 20 20 28 00 1 2 00 00 00 00 AST1 11 50 2...

Страница 31: ...nd is ignored The PCM500 is in standby the test series is initiated with the maximum number of tests as previously entered from the display The PCM500 is waiting between tests a test is initiated and the scheduled test is then started at the appropriate time The total number of tests is decremented by one Once a test is started the results will be sent to the PLC on completion of the test A Abort ...

Страница 32: ...om the PCM500 or from the PLC If an additional test is required whilst in a test cycle delay period then the PLC can initiate this without compromising the existing delay in the test cycle setting Please be aware the delay period entered will start from the beginning of a test b Test timing set by the PLC In the PCM500 Test Point setup enter the number of tests to 1 one and enable the PLC to start...

Страница 33: ...fluid Repeat testing until there are no traces of Rust Veto NTP32 in the return line Water based fluids to mineral oil Run a single test to waste using clean Rust Veto NTP32 to flush out the water based fluid Run a test to waste using the mineral oil sample Repeat testing until there are no traces of Rust Veto NTP32 in the return line Important The PCM500W should not be used on water based fluids ...

Страница 34: ...urn hose is not blocked Decrease fluid viscosity Contact Pall 203 Low line pressure Unit halts the test and puts error message on screen indicating low line pressure Red L E D on HMI panel flashing on detection No fluid Last Chance Filter LCF blocked Pump Malfunction Pressure transducer failure Check fluid supply and inlet hose connection Remove clean or replace Pressure Relief Valve LCF Contact P...

Страница 35: ...panel flashing on detection Mesh element currently in the flow is blocked blocking with contaminant causing differential mesh pressure to exceed operational limits Flush by testing with clean low viscosity oil Contact Pall or an approved agent 104 Low mesh differential pressure PCM500 will abort current test cycle and report error warning message on the display screen Red L E D on HMI panel flashi...

Страница 36: ...y testing with clean low viscosity oil 305 Mesh test limit exceeded Display warning message on screen at PCM500 start up or at the end of current test operation Tests performed on the same mesh set above set limit Contact Pall or an approved agent for service details 306 Calibration period exceeded Display warning message on screen at PCM500 start up 12 month calibration interval expired Contact P...

Страница 37: ... 401 Solid Contaminatio n Alarm Display warning message on screen VFC relay activated Pre set Solid contamination level exceeded Repeat test to verify Investigate process 402 Water Saturation Alarm Display warning message on screen Red L E D flashing Pre set Fluid water saturation level exceeded Investigate cause of elevated water contents 403 High fluid Temperature Alarm Display warning message o...

Страница 38: ...ement PCM200 122 High Pressure Hose Assembly PCM200 197 Low pressure Sampling Stalk PCM200 154A Metric Test Point Connector PCM200 154B Imperial Test Point Connector PCM200 154C NPT Test Point Connector 500 470A Operating Instructions PCM500 CD ROM 500 470B Operating Instructions PCM500 Quick Reference Card PCM500 520A Printer Kit UK PCM500 520B Printer Kit EUROPE PCM500 520C Printer Kit USA PCM50...

Страница 39: ...lter element is a user serviceable part and can be accessed by releasing the housing end plug The element is removed by inserting an M5 thread bolt into the end cap and is then retracted Ensure no external contaminant enters the housing before a new element is fitted 39 Disposal of Equipment At the end of its life the monitor should be dismantled and disposed of in accordance with all applicable l...

Страница 40: ...mmends returning the PCM monitor for Service and Calibration annually Mesh replacement should be carried out when 3000 usage points is exceeded The annual service includes Analysis of engineers diagnostic report and rectification of any faults found Battery Power supply and clock check Performance evaluation on calibration fluid Software update to latest release level Check for oil leaks and recti...

Страница 41: ... 3000 depending on sample condition Procedure 1 Place the PCM500 on a clean surface and have adsorbent lint free paper wipes available 2 Ensure the PCM500 is switched OFF 3 Cap off both hoses 4 Remove the rubber manifold cover 1 Use an M5 socket driver to remove four M5 Flange securing nuts 2 Carefully remove the mesh manifold by pulling on the outer body and place in protective packaging that cam...

Страница 42: ...olts and push firmly onto the O rings 6 Fit the four M5 Flange nuts Be very careful not to cross thread onto the bolts 7 Tighten the nuts to a maximum of 3 Newton Metre 8 Re fit the rubber cover 9 When the PCM500 is switched on it will automatically detect the new mesh manifold and reset the points total in program memory to zero 3Nm 42 ...

Страница 43: ...p when properly installed and operated at design conditions All parts proven to be defective within this period will be replaced free of charge FOB England or original FOB point as applicable However claims for damage or labour will not be allowed nor can the seller s equipment be warranted of failure where the operating conditions are beyond the control of the seller or beyond monitor specificati...

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