Our PML2 ATEX User Guide
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1. LPA2 AZ2 MODBUS User Guide RAPFEILT el www mpfiltri co uk 200 160 EN DOCUMENT REVISION 18 2 1 Introduction The LPA2 Contamination Analyser is designed to measure and quantify the num bers of solid contaminants in Hydraulic Lubrication and Transmission applica tions The LPA2 is designed to be an accurate instrument for permanently installed applications utilising mineral oil as the operating fluid The instrument uses the light extinction principle whereby two laser light systems shine through the fluid onto photodiodes When a particle passes through the beam it reduces the amount of light received by the diode and from this change in con dition the size of the particle can be deduced The LPA2 W has the additional feature to allow the measurement of the saturation percentage of water in oil YoRH and temperature C The temperature measurement provides a reference temperature for the Relative Humidity reading RH Due to the temperature 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 the precision parts separated and it is also used as a cooling2. low number Example for register 19 high 56 and register 20 low 26738 the Actual Value for the 4 um c count 56 x 65536 26738 3 696 754 Modbus Operations 3 4 Operating Sequence 3 4 1 Overview a Flushing The Flush Valve must be opened to allow fluid to pass through the LPA2 so that any fluid from the previous test is flushed out of the connecting pipe to eliminate the possibility of cross contamination between tests The time for which the Flush Valve is left open depends on the distance of the LPA2 from the system being sampled and the conditions existing in the drain reservoir refer to 3 5 for guidance However for version LPA2 W moisture and temperature indication every test is automatically preceded by a 3 minute flush period to allow the moisture sensor to stabilise and give an accurate reading Therefore a separate flush period is unnecessary unless a flush period greater than 3 minutes is required The flush valve will automatically close before a test is started b Sampling A 15ml volume of fluid is drawn into the LPA2 pump during which time the oil particles contained in the fluid are counted in specific sizes c Emptying At the end of the sampling cycle the LPA2 pump reverses and expels the fluid to waste via the waste connection When the pump has emptied the LPA2 is ready to start the next test as indicated by a 0 in register O d Productio
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4. 17 4 Warranty and Recalibration The LPA2 is guaranteed for 12 months from date of receipt The LPA2 should be recalibrated every 12 months Return to MP Filtri UK for recalibration 18 Warranty and Recalibration Produced by MP Filtri UK Revision 18 2 As a policy of continual improvement MP Filtri UK reserve 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 MP FILTRI UK Limited Bourton Industrial Park Bourton on the Water GL54 2HQ U K Tel 44 1451 822522 Fax 44 1451 822282 Email sales mpfiltri co uk Website www mpfiltri co uk ITALY HEADQUARTERS MP FILTRI S p A Tel 39 02 95703 1 Fax 39 02 95741497 95740188 Email sales mpfiltri com Website www mpfiltri com CANADA MP FILTRI CANADA INC Tel 1 905 303 1369 Fax 1 905 303 7256 Email mail mpfiltricanada com Website www mpfiltricanada com CHINA MP FILTRI Shanghai Co Ltd Tel 86 21 58919916 Fax 86 21 58919667 Email sales 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 4
5. ble on version LPA2 W Modbus Operations 11 3 2 4 200 201 202 3 3 Registers used for command functions Start Test Abort Test Toggle Flush Valve Operating Commands A few examples of these commands are given below a b 12 To Start a Test write the value of 1 to register 200 To Abort a Test write the value of 1 to register 201 To Toggle the state of the Flush Valve write the value of 1 to register 202 To determine the status of the Flush Valve the Status Flag register 124 is read Refer to the notes under register 124 To determine the Test Status read register 0 The value of 0 indicates that the LPA2 is ready to do a test The value of 1 indicates that the pump inside the LPA2 is in the emptying mode The value of 2 indicates that the pump inside the LPA2 is in the sampling mode The value of 4 indicates that the pump inside the LPA2 has stalled This is a fault condition which should not be encountered under normal circumstances A value of 6 indicates that the flush valve is open The value of 9 indicates that a low oil inlet pressure has been detected by the LPA2 which will cause the test to stop see also Section 15 Note For those Registers that comprise a High and Low component the fol lowing methodology is used to determine the actual value Actual Value high number x 65536
6. en Signals RS232 preferred RS485 available on request Node address 4 3 2 Modbus Register Addresses In the text below we depict the modbus register with address n as in 3 2 1 Registers used to indicate status amp test results read only 0 System State 0 Ready Test finished or User Stop Emptying 2 Sampling 4 Pump Stalled 6 Flushing Choose which one at the time of placing LPA2 purchase order Other Baud rates available on request The addresses shown here are those appearing on the wire The users application may translate these addresses to different ones For example for some controllers the user will need to use addresses starting at 40000 instead of 0 Modbus Operations 7 Ul GY NJ H 3 2 2 10 11 12 13 14 15 16 17 19 20 9 Pressure Low Other numbers indicated in this Register should be ignored as they are associated with the internal working of the LPA2 Laser Level microwatts Pumped Volume ml 10 e g 150 2 15ml Pump Current mA Result Ready Registers used for test results read only ISO code for 4u count ISO code for 6u count ISO code for 14u count Machine Serial Number high Machine Serial Number low Test Number high Test Number low Final recorded R H relative humidity in units
7. ive write command will toggle the state of the flush valve e Wait appropriate time refer to 3 5 e Start Test by writing a value of 1 to register 200 Once the test has been started it will automatically carry out the sampling and emptying cycles and produce the test results Flush valve automatically closes at the start of the test e If register 5 reads 1 Result Ready the ISO Code can be read from the fol lowing Registers 14 Modbus Operations 9 for the 4u ISO Code 10 for the 6u ISO Code 11 for the 14 u ISO Code 3 4 5 Sequence for version LPA2 W water and temperature The User programs their Modbus system to instruct the LPA2 to carry out a test and then read the results from the respective addresses As a simple example if a test is required to be performed and the results are re quired to display only as a three part ISO code the following sequence should be followed e Check that register 0 reads 0 e Start Test by writing a value of 1 to register 200 Once the test has been started it will automatically carry out a 3 minute flush cycle to allow moisture and temperature readings to be obtained before commencing the sampling Af ter the sampling cycle it will automatically empty and produce the test results Flush valve automatically closes before the sampling cycle commences e If register 5 reads 1 Result Ready the ISO Code can be read from the f
8. medium The very nature of a hydraulic system is that it produces solid particulate contaminants and these are ever present in all hydraulic systems There is a revised standard ISO cleanliness codes ISO 4406 which classifies the numbers of particles that can be tolerated within the system and it is these levels of contamination that the particle counter is designed to measure Each LPA2 supplied consists of the following e LPA2 particle counter e Calibration certificate e User manual e Supply cable x 2 5m length with appropriate connector Introduction 3 e Minimess hose x 1 5m length e Waste Hose x 1 5m length 1 1 Installation Procedure AZ2 Connector Figure 1 a Fix the LPA2 in place by bolting through the feet b Connect the cable as follows 1 Connect to zero volts ground 3 connect to Rx Data signal 4 connect to Tx Data signal 6 connect to a 24VDC regulated supply 7 Screen of supplied cable c Screw the power and signal cable connector into the LPA2 d Connect the drain hose Push back the quick coupling outer ring on the LPA2 before connecting disconnecting the hose end Also refer to 2 2 Drain Reser voir and System Pressures e Connect the Minimess pressure line to the oil inlet connector Also refer to 2 2 4 Introduction 2 2 1 2 2 2 3 Characteristics Seal Material Compatibility The internal seals used in the build of the LPA2 are made from Nit
9. n of Results The test results are available to be read at the end of the sampling stroke A value of 1 in register 5 indicates when the result is available to be read Note the sampling and emptying cycles take several minutes to complete Modbus Operations 13 3 4 2 3 4 3 3 4 4 NAS Classes AS4059 Rev E Classes Due to the nature of the Modbus system NAS Class 00 cannot be displayed so 1 or Oxffff in hexadecimal 65535 is used to denote this particular cleanliness Class Similarly AS4059 Class 000 and 00 cannot be displayed so 2 and 1 respectively are used to denote these cleanliness Classes or Oxfffe and Oxffff in hexadecimal respectively 65535 and 65534 decimal Also since NAS and AS4059 Classes greater than 12 are not defined if the LPA2 records a count that is above 12 it will show on Modbus as 15 ISO Codes Codes above 24 that are shown in Modbus are invalid as they are outside the analy sis range of the LPA2 Sequence for version LPA2 The User programs their Modbus system to instruct the LPA2 to carry out a test and then read the results from the respective addresses As a simple example if a test is required to be performed and the results are re quired to display only as a three part ISO code the following sequence should be followed e Check that register 0 reads 0 e Open Flush Valve by writing a value of 1 to register 202 Note each suc cess
10. of 0 0196 Only available on version LPA2 W Final recorded Temperature units of 0 01 degrees C Only available on version LPA2 W ISO Style Cumulative Counts count 4um C high count 4um C low 8 Modbus Operations 21 22 23 24 25 26 27 28 29 30 31 32 33 34 39 40 41 42 43 44 count 6um C high count 6um C low count 14um C high count 14um C low count 21um C high count 21um C low count 25um C high count 25um C low count 38um C high count 38um C low count 50um C high count 50um C low count 68um C high count 68um C low NAS Classes for particle sizes 5 15um 15 25um 25 50um 50 100um 100um Basic NAS Class largest out of Registers 39 to 43 inclusive Modbus Operations 45 49 50 51 52 53 54 55 56 57 58 99 116 117 118 Basic AS4059 Class largest of Registers 116 to 121 inclusive Note For all above NAS numbers we represent NAS Class 00 as the signed in teger 1 or Oxffff in hexadecimal 65535 decimal NAS is not defined for Classes more than 12 so out of range gt 12 Classes are indicated by the number 15 NAS S
11. ol lowing Registers register O for the 4u ISO Code register 1O for the 6u ISO Code register 11 for the 14u ISO Code If register 5 reads 1 Result Ready the Relative Humidity R H and Tem perature can be read from the following Registers register 16 for RH register 17 for Temperature The Relative Humidity measurement can be switched off by writing a value of 0 to register 14 or value 1 to switch measurement on If the RH measurement is switched off the LPA2 will perform as per the sequence described in 3 4 4 Modbus Operations 15 3 5 Flush Valve Operation The Table below shows the flush valve opening times that are required to achieve a 200ml flush volume for different system conditions Model Inlet Pres Drain Pressure Time 200ml Flush sure Model A 2bar Atmospheric pressure zero 2 minute 30 seconds Model B 10 bar Model B 10 bar back pressure Back pressure not exceeding 0 5 1 minute 20 seconds bar Back pressure not exceeding 1 0 2 minutes bar The above flushing times assume that the oil inlet hose from the sampling point to the LPA2 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 How ever if a hose length greater than 1 5m in length is used the flushing time should be increased pro
12. rata 3 6 Initial Communications Check First ensure that your software is communicating using the settings included in 3 1 To perform a simple check to confirm that communication to the LPA2 has been established read register number is 421 V4 21 99 for the software version number A typical version 3 7 Simulated Test Results The LPA2 must always be connected to an oil supply when carrying out a Test as operating the unit dry could cause internal damage to the pump etc To prevent 3 Refer to 2 2 5 Approximate ISO 32 oil grade at 35 C 16 Modbus Operations this happening a switch is incorporated inside the LPA2 which detects low oil pres sure and stops the test If this occurs a value of 9 will be indicated in register 0 Once the pressure has been restored the next test can be started by sending the appropriate flush valve and start commands However to enable the User to initially prove the communications with the LPA2 etc a facility has been included to generate dummy counts without having to do an actual test To generate the dummy counts write a value of 1 to register 129 When this is done a User Start Test command will not cause an actual test but will just produce some dummy count values which can then be read from their respective addresses This dummy count setting is not remembered when the LPA2 is powered down Modbus Operations
13. rile NBR material suitable for use with mineral oil based fluids Do not use the LPA2 with any fluid that is incompatible with the Nitrile seals Drain Reservoir and System Pressures The LPA2 is produced in two standard models as detailed below e Model A Design Reference 30 Minimum oil inlet pressure 2 bar Maximum oil inlet pressure 400 bar Drain Reservoir System Atmospheric pressure zero back pressure e 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 LPA2 model suffix letter is stamped on the serial number plate after the num ber Analysis Range The LPA2 has an analysis range specified for each standard Characteristics 5 Controlling Standard Analysis Range ISO 4406 NAS 1638 AS4059 Rev D ISO 8 to ISO 24 NAS 2 to 12 Size Code A 000 to 12 Size Code B 00 to 12 Size Code C 00 to 12 Size Code D 2 to 12 Size Code E 4 to 12 Size Code F 7 to 12 Characteristics 3 Modbus Operations The LPA2 Particle Counter is commanded to perform tests by the Modbus Master e g User s PC or a PLC The User will provide write their own specific program using the Modbus protocol based on the addresses and operation sequence detailed in 3 2 and 3 4 3 1 Standard Modbus Protocol Settings Protocol type RTU not ASCII Baud 19200 57600 or 115200 Parity Ev
14. tyle Differential Counts 5 15um high 5 15um low 15 25um high 15 25um low 25 50um high 25 50um low 50 100um high 50 100um low 100um high 100um low Version Number Software version number 421 V4 21 etc AS 4059 Classes for Size Codes AS4059 A Class Number AS4059 B Class Number AS4059 C Class Number 10 Modbus Operations 119 120 121 124 3 2 3 128 140 AS4059 D Class Number AS4059 E Class Number AS4059 F Class Number Note For all above AS4059 numbers we represent Class 000 as the signed integer 2 or Oxfffe in hexadecimal 65534 deci mal Class 00 is represented by the signed integer 1 or Oxffff in hexadecimal 65535 decimal Classes 0 and above are represented directly as positive numbers AS4059 is not defined for Classes more than 12 so out of range gt 12 Classes are indicated by the number 15 Status Flags Status Flags Flush valve on Note The status flags register above currently only defines the function of the least significant bit However in future versions of the software other bit positions will be defined Customer written software using this register should therefore extract the value of this single bit rather than that of the register as a whole e g logical AND with the value 0x0001 Registers used for settings Simulated results Relative Humidity amp Temperature Only availa
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