Pall PCM500 Series Manuale utente

OPERATING INSTRUCTIONS

Pall®PCM500 Series Portable Fluid

Cleanliness Monitor

!Important: Some fluids may react with Rust Veto to create gels,

which can result in functional issues within the PCM500. One

example is Mono Ethylene Glycol (MEG).

Please check with Pall if there is doubt over the compatibility of test

sample and Rust Veto transit fluid.

PREFACE

The Pall PCM500 On-line Fluid Monitor has been developed to provide accurate and continuous information

on the cleanliness of aqueous solutions, hydraulic fluids and circulatory lubrication system fluids. Fluid

contamination levels monitored are then converted to the widely used contamination codes: ISO4406, SAE

AS4059 table 1 (NAS 1638) and AS4059 table 2. The result data can be exported to Flash Drive, Printer,

PC, PLC or network device..

The self-contained unit provides a portable fluid contamination monitor that can be used with a range of

fluids, including mineral oils and aqueous solutions. Fluid change procedures are included in this manual

and these help ensure the PCM500 monitor is adequately flushed prior to testing on an alternative fluid

application.

The contents of these operating instructions should be read before attempting any aspects of installation,

operation or maintenance.

The product has 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 provided to assist users in maximising the benefits of the PCM500 portable

fluid cleanliness monitor.

As part of the continuous improvement process that Pall adopt in the development of technology and

satisfying customer requirements, this information or procedure may be subject to change.

Pall welcomes feedback from users who should contact their designated Pall Service Centre.

Please note the PCM500 is shipped to users with, a protective fluid, Rust veto NTP 32, which is miscible in

both aqueous liquids and oils. Please ensure the unit is flushed out before running tests. The unit should

be run for at least three full test cycles on the system fluid before performing a reliable test.

!Important:

If the equipment is used in a manner not specified by the

manufacturer, the protection provided by the equipment may be

impaired.

!Important:

The PCM500W model is fitted with a sensor measuring relative humidity

in oil.

Do not use with water bearing fluids or permanent damage will occur.

Contents

Section 1 Describes the environmental, mechanical and electrical aspects of the PCM500

monitor to include product specifications.

Section 2 Inspection, packaging and guidance note

Section 3 Description of the PCM500 monitors main items

Section 4 PCM500 principle of operation

Section 5 Pre-check and connection of the PCM500 to a fluid system

Section 6 General operation 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 series worldwide aftermarket and calibration service.

Appendix B Details the Mesh Screen Manifold exchange procedure

MANUAL PART NUMBER ISSUE DATE

MA-PCM500 (Draft) 31/08/2015 3

WARNINGS: THESE ARE INSTRUCTIONS THAT DRAW

ATTENTION TO THE RISK OF INJURY OR DEATH.

Cautions: These are instructions that draw attention to the risk

of damage to the product, the process, the equipment or the

surroundings.

!Important: These are instructions that draw attention to information

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 attached to Battery cover

VDC

Fuse

F4A

H250

Label indicating refer to manual

Contents

Page

Preface 2

Declaration of Conformity 4

Warnings, Cautions and Notes 5

Section 1: PCM500 and PCM500W

Specification and Requirements

1.1 General Description 7

1.2 Fluid Environment 7

1.3 Ambient Environment 8

1.4 Electrical Requirements 8

1.5 Fluid System Connections 8

1.6 Product Specification 9

Section 2: PCM500/PCM500W Inspection

and Packaging. 10

Section 3: PCM500/PCM500W Description

of Monitor.10

Section 4: PCM500/PCM500W Principles

of Operation

4.1 General Principles 11

4.2 HMI Control Panel 11

4.3 Test Sampling 11

4.4 Communication Panel 12

4.5 Power Schematic 12

4.5 Battery 13

Section 5: PCM500/PCM500W

Connecting the Monitor

5.1 Connection Options 14

5.2 Connections 15

5.2.1 High Pressure 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 Alarm Set-up 25

6.10 Data manager Screens 25

6.11 Tools Screens 27

Section 7: Interface Protocol – PLC

control through DB9 Serial Port 30

Section 8: PCM500 / PCM500W Fluid

Change Procedure 33

Section 9: PCM500 / PCM500W Function

Codes and Corrective Actions 34

Section 10: PCM500 / PCM500W Spare

Parts List 38

Section 11: PCM500 / PCM500W

Cleaning, Maintenance & Disposal of

Equipment 39

Appendix A: Calibration and Aftermarket

Services 40

Appendix B: PCM500/PCM500W Mesh

Manifold Exchange procedure 41

Pall World wide warranty 43

Section 1: Pall PCM500 and PCM500W Fluid

Cleanliness Monitors

Specification and Requirements

1.1 General Description

The Pall PCM500/PCM500W is specifically developed as a portable diagnostic

monitoring device that provides an assessment of system fluid cleanliness. A fixed

display/controller allows for simple menu driven input of sample identification, monitor

configuration and data output in ISO4406, SAE AS 4059 Table 1 (NAS 1638) or SAE

AS 4059 Table 2 formats. The display/controller shows the test results, an option to

graph results and this data is automatically stored for subsequent trending and

evaluation. The self-contained design provides for a portable fluid contamination

monitor that can be used with a range of fluids including mineral oils and aqueous

solutions. Note: The PCM500W should not be used for aqueous solutions.

Fluid change procedures are included in this manual and these help to ensure the

PCM500 monitor is adequately flushed ready for an alternative fluid application

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 10ºC - 40ºC (50°F - 104°F)

Industrial Phosphate

Esters & Polyesters 10ºC - 80ºC (50°F - 176°F)

Be aware of possible danger associated with high oil temperatures and

exposed metal surfaces of the PCM500

Fluid Compatibility

Aqueous solutions having a pH <11.0, water glycols, high water based

fluids, petroleum based fluids, industrial phosphate esters, mineral oils

and synthetic fluids.

Do not use Acetone based fluid.

Seals Fluorocarbon (Viton)

WARNING: Health and Safety.

Observe caution when handling fluids and pay attention to instructions of

safe use in the Material Safety Data sheet and COSHH regulations.

Wear protective clothing if prescribed; e.g. safety gloves, clothing and

footwear.

Caution: Health and Safety.

Ensure there is adequate lighting to operate the equipment.

Observe local regulations for factory use. 7

Section 1: Pall PCM500 and PCM500W Fluid

Cleanliness Monitors

Specification and Requirements

1.3 Ambient Environment

Operating Temperature range 5°C - 40°C (41°F - 104°F)

Storage Temperature range

(Monitor drained of fluid) -20°C to 55°C ( -4°F to 131°F)

Dust and water protection IP65 (NEMA 4)

Relative Humidity 95%rh non-condensing

Operating Altitude <2000 metres

WARNING: Do not use the PCM500 Series Monitor in an explosive

atmosphere

1.4 Electrical

External Mains Power Supply Unit Input 100 – 240 VAC (Auto Ranging)

(PSU) Accessory Frequency 50 – 60 Hz Single Phase.

Output 48V DC

Input Fuse Quick 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 Free Contacts

(Alarm output – contact rating 1 Amp @

24VDC)

1.5 Fluid Connections

Inlet – 2 options High Pressure:

Hose with ¼” BSP female swivel fitting and Metric,

Imperial or NPT Test Point connector options.

Low Pressure:

Hose direct coupled on ¼” BSP female swivel fitting.

Sampling stalk (for bottle sampling)

Outlet M10 male fitted to 6mm OD. Clear plastic hose, with

straight adapter and cap. 8

Section 1: Pall PCM500 and PCM500W Fluid

Cleanliness Monitors

Specification and Requirements

1.6 Product Specification

Weight 11 Kg (24 lb)

Dimensions 400 x 260 x 250 mm (15.75” x 10.2” x 10“)

Monitoring range ISO4406 11/9/7 to 23/21/17

Monitoring range SAE AS4059F Table 1

(NAS1638) 1 to 12

Monitoring range SAE AS4059F Table 2 >4µm: 1 to 12, >6µm: 1 to 12 and >14µm:

1 to 12

Accuracy ±1/2 ISO4406 Code

Water-in-Oil (PCM500W only) %rh. ±2% at 5 to 95%rh (non-condensing)

(PPM switchable but requires C1, C2, 0 to 100% 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 can arise from connecting the PCM500 to a pressured system

above the working limit, and / or, using an incorrect high-pressure connection.

Damage to the PCM500 can occur from using incompatible fluids.

A danger to the user and damage to the PCM500 can be from an incorrect mains

voltage supply.

Section 2: Pall PCM500 and PCM500W

Fluid Cleanliness Monitors

2.1 Inspection and Packaging

The PCM500 is shipped in a transportation

case. Use this case for re-shipping the PCM.

Visually inspect the case for signs of external

damage that may have occurred during

shipping and bring any damage to the

attention of the shipper.

Inspect the interior of the case for damage to

the contents as listed below. Compare the

contents of the case with the shipping papers

to assure all the content is present. If any

items are missing, contact Pall or an

approved agent.

The PCM500 package comprises of:

• Integrated PCM500 series monitor with

sample hoses

• Power supply unit

• Mains power lead

• PCM500 to PC communications cable

• PCM500 series Operating Instructions on

CD ROM

• PCM500 series Quick Reference Guide

• Fluid Sampling stalk

• High Pressure test point connector

(Choice of Imperial, Minimess or NPT)

• Certificate of Conformity

• Certificate of Calibration Verification

• Packing note checklist

The instruments’ specific serial number and

calibration/service record sheet is also

included. It is important 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 maintaining aesthetic

and user friendly ergonomics. See section 1

for full specification. The materials are

selected to meet the various fluid and

environmental conditions that the PCM500 is

likely to be subjected during operation.

As a self-contained unit, including sampling

hose and adapters, the user is able to

connect the PCM500 on-line or sample fluid

directly from a system reservoir without

breaking lines thereby avoiding extraneous

contamination.

The PCM500 cleanliness monitor provides

numerous display functions to assist the user

at all stages of operation and provides

function codes to warn of any problems with

both the PCM500 and system fluid.

1. HMI (display/controller)

2. Communication Ports

3. Robust case with carry handle.

4. Integral 12VDC battery

5. Printer storage compartment

6. Last Chance Filter Housing

7. Hose Storage

8. Mesh Screen block

9. Power input and Fuse

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