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GlyCount User Manual.book

1. 80 40 20 10 5 RPS 12 December 2007 Edition 1 RPS 12 December 2007 Edition 1 GlyCount Cleanliness Codes Table E 1 ISO 4406 1987 E Continued Number of Particles Per Milliliters Counts ml More Than Up to and Including Scale Number 0 16 0 32 0 08 0 16 0 04 0 08 0 02 0 04 0 01 0 02 0 00 0 01 Table E 2 NAS 1638 Contamination Classification System 53 of 72 Maximum Particles 100mL in Specified Size Range um 5 15 15 25 25 50 50 100 gt 100 125 22 4 1 250 44 8 500 89 16 1 000 178 32 2 000 356 63 4 000 712 126 8 000 1 425 253 16 000 2 850 506 32 000 5 700 1 012 64 000 11 400 2 025 128 000 22 800 4 050 256 000 45 600 8 100 512 000 91 200 16 200 1 024 000 182 400 32 400 Table E 3 Equivalent APC Sizes Relating to Calibration Method Particle sizes ISO 11171 Size um c gt 4 gt 6 gt 14 gt 21 gt 38 gt 70 ISO 4402 Size um gt 1 gt 5 gt 15 gt 25 gt 50 gt 100 Operator Manual 54 of 72 Cleanliness Codes GlyCount Table E 4 SAE AS4059 SAE AS4059 Rev E Table 2 Cleanliness Classes for Cumulative Counts Particles per 100
2. 1 Set the sampling mode to BOTTLE and verify the other operation variables are programmed as needed See Programming Operation Variables on page 17 for more information 2 Verify that a CO Bottle or shop air pressure source has been connected to the GlyCount and that there is 90 to 110 psi 6 2 to 7 6 bar shown on the pressure gauge Due to regulation variances the pressure shown on the pressure gauge may creep up to 120 psi 8 3 bar during no flow conditions The pressure should drop when a sample is started 3 Disconnect the bottle adapter from the GlyCount by turning counter clockwise 4 Filla sample bottle with the fluid to be tested 5 Place the sample bottle into the bottle adapter and re connect it to the GlyCount by sliding the pick up tube into the sample bottle and turning clockwise until locked 6 Double check to make sure the waste bottle can accommodate the fluid 7 Press START The sampling process begins The Bottle Adapter pressurizes and fluid exits from the drain port The GlyCount has a fixed flow rate 50 ml min There are three consecutive sample runs at 5 10 or 20 ml depending on what was programmed When this process is completed the test results are stored in the buffer presented on the display and or printed if the printer is enabled 6 2 Online Mode In this mode a sample can be fed directly from a filter system The reduced probability of contamination makes this the
3. Damage may cause leakage or misalignment with the online adapter The CO bottle is a compressed gas cylinder under high pressure Do not alter this cylinder in any way Do not over pressurize the cylinder Do not expose the pressurized cylinder to temperatures in excess of 350 F 177 C Valves must be installed or removed only by trained personnel Cylinders exposed to a fire or heated to temperatures in excess of 350 F 177 C should be condemned or hydrostatically tested prior to filling Do not use caustic cleaners Do not remove or cover the label on the cylinder WARNING Release of the gas under uncontrolled conditions will result in a freezing spray Improper use filling storage or disposal of this cylinder may result in death personal injury and property damage Keep cylinder out of reach of children This cylinder must only be filled by properly trained personnel in accordance with CGA Pamphlets P 1 and G 6 3 available from the Compressed Gas Association 1235 Jefferson Davis Highway Arlington Virginia 22202 It is unlawful to ship a filled CO bottle within the USA due to the high pressure of its contents Follow all described procedures in Return Procedures on page 43 before shipping a unit to a service center for repair or re calibration Laser Safety Class 1 Laser Product Complies with 21 CFR Chapter 1 Subchapter J CAUTION Use of controls adjustments or performance of procedures other than those
4. Glossary um Hm c ACFTD ACFTD Sizes Calibration Primary Calibration Secondary Concentration ISO MTD Light Extinction Light Scattering NIST Micron Particle size unit of measurement according to the former ACFTD calibration Particle size unit of measurement according to the new ISO 11171 calibration Air Cleaner Fine Test Dust is a filter test dust which has been used for 25 years in hydraulics for filter testing and was manufactured by General Motors Company until 1992 when production ceased ACFTD was used until recently for the calibration of particle counters The particle number concentration particles ml in oil for a given dust addition mg L was standardized in ISO 4402 During the years it became more and more apparent that this distribution was incorrect With the introduction of ISO 11171 1999 the old calibration standard ISO 4402 becomes invalid and ACFTD is no longer a valid calibration standard GlyCount users can choose between ISOMTD and ISOACF standard settings With ISOMTD the results are printed along with the NIST sizes with ISOACF the results are printed with the ACFTD sizes New particle counters must have a primary calibration by the manufacturer For recalibration at the service centers secondary calibration may be used The concentration in Particles per Milliliter P ml is calculated by dividing the number of counts P by the measured fluid volume ml If needed the r
5. GlyCount Functional Verification 13 of 72 3 Functional Verification 3 1 Self test Verification When the POWER key is pressed the GlyCount startup screen appears as shown in Figure 3 1 GlyCount T x Qu Fig 3 1 GlyCount Startup Screen Next the GlyCount initialization screen appears as shown in Figure 3 2 INITIALIZING SYSTEM PLEASE WAIT Serial Number 000000000 208XXXX XX Fig 3 2 GlyCount Initialization Screen At this point the GlyCount checks its internal systems for any problems If a problem is found the GlyCount displays an error message For an explanation of the possible reasons for these errors please see Troubleshooting on page 35 The firmware number can be verified at this stage for questions concerning firmware a System Status Menu Under the main menu there is a system status menu It can be accessed by pressing the F3 SYS key This menu displays various system parameters that the GlyCount measures The displayed parameters include Power Supply nternal Temperature Printer Status Operator Manual 14 of 72 Operator Manual Functional Verification GlyCount The Power Supply screen will indicate whether the GlyCount is connected to the external power supply or is operating from the internal battery During external power supply operation the battery icon will indicate that the internal battery is under charging control During battery operation the battery i
6. Operator Manual 42 of 72 Troubleshooting GlyCount 11 3 Non Fatal Error Messages The following errors are non fatal errors that are displayed on the results page buffer and printout a Sensor Flow Cell Error Results Page SNSR CELL ERROR Printout SENSOR FLOW CELL ERROR Displayed when the sensor signal drops below a pre determined value The sample run will continue until finished and the error will be tagged onto the record and displayed on the printout Several conditions can cause this error The sensor cell could be blocked within the view area preventing the laser light to be seen by the detector the sensor could be out of calibration resulting in a low signal the laser or sensor electronics could have failed or there is insufficient sample fluid Perform the cell cleaning procedure as described on page 35 Return unit to service center for calibration or repair Insufficient sample fluid b High Internal Temperature Warning Results Page INTL TEMP WARN Printout HIGH INTERNAL TEMPERATURE WARNING Displayed when the internal ambient temperature of the unit rises above 55 C 131 F The sample run will continue until finished and the error will be tagged onto the record and displayed on the printout A combination of high outside ambient temperature and high fluid temperature can cause this warning or the unit could have been exposed to direct sunlight in hot conditions or the unit could
7. filter housing nut Fig 10 1 Filter Housing Nut Location 2 Using a one inch socket wrench loosen the filter housing nut in a counter clockwise direction 3 Carefully remove the nut and the filter assembly containing Ten 10 micron filter element Spring Stainless washer Note Some glycol may come out with the filter assembly 4 Check the contents of the new filter kit part number 540 400 0025 to make sure the kit includes the filter element a spring and a stainless washer 5 Install the new parts in the installation sequence shown in Figure 10 2 Install filter with the open end up filler spring nut Fig 10 2 Filter Installation Sequence Operator Manual 32 of 72 Maintenance and Service GlyCount 6 Discard the old filter element spring and stainless washer 7 Retighten the filter housing nut firmly but do not overtighten as the O ring may be damaged Note Do not replace o ring with non Aflas O ring 10 2 Charging the Battery The GlyCount can be powered by two sources internal rechargeable battery or external power supply In addition to supplying power to the GlyCount for operation the external power supply has an additional purpose of charging the internal battery The GlyCount can be operated while the internal battery is being charged 1 Tocharge the internal battery retrieve the external power supply and power cord from the shipping container 2 Plug the power c
8. key will delete the entire buffer contents The GlyCount will display a confirmation message and to prompt the user to accept or deny the operation Press the F3 PRT BUF key to print the entire buffer contents The GlyCount will display a confirmation message and prompt the user to accept or deny the operation To delete or print an individual sample test result simply press the F1 DEL SMP or F2 PRT SMP key while in the average count AVG CNT menu The average count menu can be accessed while viewing a sample selection 8 3 Sample Data The sample data are viewed under two pages When a sample selection has been made the GlyCount displays the sample statistics for that particular sample The remainder of the sample data can be viewed by pressing the average count AVG CNT function key Operator Manual 28 of 72 Operator Manual Buffer Operation GlyCount RPS 12 December 2007 Edition 1 GlyCount Communications 9 Communications 9 1 Remote Serial Interface RS 232 Port 29 of 72 The GlyCount is equipped with an RS 232 communications port This port is used to communicate with a computer for data acquisition analysis and remote operation This section gives the specifications and wire pin outs for the RS 232 Port BAUD RATE 9600 baud Data Bits 8 bits Parity None Stop Bits 2 bits a DB 9 Serial Connection If the computer or terminal has a 9 pin serial port with a male connector use a st
9. 1 Changing the E 31 102 Charging the Battery varon iii 32 10 3 Changing the Printer Paper EE 33 10 4 Removing Flow Sensor Blockages uk 33 11 Troubleshooting 11 1 Procsda ral Problems acidos 35 11 2 Fatal Error Messages AAA 35 11 3 Non Fatal Error Messages cuina lolis 42 Appendix A Service Procedures rrnnnnnnnvnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnr 43 A1 S rer MN ACT tet needed 43 A2 Return reegen a 43 AS Technical Support Information vic 44 Appendix B Performance Specifications 45 Appendix C ACcessorieS rrmmnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnnr 47 Appendix D Reference Documents 49 PANELS A e ES ooo aeae eaaa Eeeeh 49 Appendix E Cleanliness Codes 51 E1 CIC IU RTT 51 E2 ESA 52 Appendix F Applicable Standards 55 Appendix H NA QA 57 Operator Manual RPS 12 December 2007 Edition 1 GlyCount Manual Overview 3 of 72 Manual Overview About This Manual The information in this manual has been carefully checked and is believed to be accurate However Hach Ultra assumes no responsibility for any inaccuracies that may be contained in this manual In no event will Hach Ultra be liable for direct indirect special incidental or consequential damages resulting from any defect or omission in this manual even if advised of the pos
10. BREACH OF Operator Manual 6 of 72 Operator Manual Manual Overview GlyCount THIS WARRANTY HACH ULTRA AND ITS VENDORS WILL NOT BE LIABLE FOR ANY INDIRECT SPECIAL INCIDENTAL OR CONSEQUENTIAL DAMAGES EVEN IF HACH ULTRA OR ITS VENDORS HAS BEEN GIVEN ADVANCED NOTICE OF THE POSSIBILITY OF SUCH DAMAGES Acknowledgements Aflas is a registered trademark of Asahi Glass Co Ltd Corporation Microsoft Windows Windows 98 Windows 2000 and Windows XP are trademarks or registered trademarks of Microsoft Corporation Minimess is a registered trademark of Hydrotechnik GmbH Corporation of the Federal Republic of Germany Skydrol is a registered trademark of Solutia Inc GlyCount Introduction 1 Introduction 7 of 72 The Portable Glycol Analysis System GlyCount is an intelligent portable and robust analysis instrument for measuring storing and reporting glycol contamination important for reliable filter system operation The GlyCount provides the means to analyze pressurized fluids and lubricants in online or bottle sampling modes without interrupting machine operations The GlyCount is compatible with glycol hydraulic fluids including MIL H 5606 and Skydrol It is capable of online sampling at pressures up to 207 bar 3000 psi and temperatures to 65 149 F The GlyCount comes with refillable CO bottles for low running costs while in the field and a shop air port fitting for in house operation Not
11. MAREN MA PHSB SJ T11363 2006 E SERES EE SERR ELT X R HERBES EVE Sos mm MAPHS SMH SJ T11363 2006 THREZK ZH ZH ARRE REM FER mP eXEMERBETR EB E BRIE SMR BU GE OO m l AA ZG SETE ISS A AA RRA Ol Boh x80 EE St fo it REAR AT BSE AER RIIT bp Form 011360 EUROPE HACH LANGE HACH LANGE GMBH Willst tterstraBe 11 40549 D sseldorf Germany Phone 49 0 21 1 5288 143 info hach lange de USA AND REST OF WORLD Hach Company P O Box 389 Loveland Colorado 80539 0389 USA Phone 800 227 4224 Fax 970 669 2932 techhelp hach com Global Headquarters 6 route de Compois C P 212 CH 1222 Vesenaz Geneva Switzerland Tel 41 0 22 594 64 00 Fax 41 0 22 594 64 99 Americas Headquarters 481 California Avenue Grants Pass Oregon 97526 USA Tel 1 800 866 7889 1 541 472 6500 Fax 1 541 472 6170 www hachultra com 2007 Hach Ultra Analytics Inc All rights reserved Trademarks are property of their respective owners Specifications are subject to change without notice
12. a partir de 12 de Agosto de 2005 De acordo com as normas locais e europeias Directiva Europeia 2002 96 EC os utilizadores europeus de equipamentos el ctricos dever o agora devolver os seus equipamentos velhos ou em fim de vida ao produtor para o respectivo tratamento sem quaisquer custos para o utilizador Nota No que toca devolu o para reciclagem por favor contacte o produtor ou fornecedor do equipamento para instru es de devolu o de equipamento em fim de vida para a sua correcta elimina o Documento importante Mantenha junto dos registos do produto Form No 011229 Dieses Informationsblatt enth lt Angaben die ausschlieBlich f r den Export dieses Ger tes in die Volksrepublik China erforderlich sind This document contains information which is only required for the export of this instrument into the People s Republic of China Ce document contient les informations n cessaires pour l exportation d instruments vers la R publique Populaire de Chine DR D SO ARAB SIDE ER 2 Optical Particle Counter with Display BEEN RIER ABE A K KP E Z cx Pb Hg Cd Cr6 PBB PBDE SEE MNBA S X O X X O O FD WIR PCBA X O X O X X A AR Wire Conn X O X O X X 1 AV miis Pump or Fan X O X X X X A FIT 14 Optical Comps X O O O O O INI Glass Fuses X O O O O O TG Display X X O O O O O T ABBAS GE
13. also an essential procedure to obtain an accurate and representative sample Upon finishing the previous series of tests the sample still resides in the GlyCount This fluid must be flushed out with a fluid that will not contaminate the next sample Reducing contamination results in more statistically significant results For best results flush the GlyCount with the same fluid type as intended for the next sample Mixing or using other fluid types may cause sampling errors due to fluid incompatibility With online operation the GlyCount will be flushed with the fluid to be tested For proper flushing the flush volume must be approximately twice that of the internal volume of the hydraulic hose that connects the GlyCount to the system to be tested Maximum flushing before sampling will ensure an accurate sample measurement However excessive flushing will result in premature clogging of the filter See Flushing the GlyCount on page 21 for flushing instructions 5 1 Bottle Sampling Common sources of contamination inadvertently added to fluid samples come from the bottles pick up tube and airborne particles Only clean sample bottles should be used and they should be kept covered at all times As with any light blockage optical technology sample inaccuracies will result from excess air and entrained gas Both will be counted as particles Ideally air bubbles should be removed by applying a vacuum to the sample in a vacuum chamber or
14. damage to the internal electronics Empty the waste container Remove the sample bottle from the sample adapter Operator Manual 44 of 72 Service Procedures GlyCount A 3 Technical Support Information Operator Manual Technical Support Engineers are available to provide high quality advice and recommendations for applications product operation measurement specifications hardware and software factory and customer site training Please provide name company phone fax model number serial number and comment or question Call 1 541 472 6500 Toll Free 800 866 8854 US CA Fax 1 541 474 7414 6 00 AM to 5 00 PM Pacific Time Monday through Friday E mail TechSupportGP hachultra com GlyCount Performance Specifications 45 of 72 Appendix B Performance Specifications Number of Channels Size channels Flow Rate Light Source Calibration Counting Efficiency Concentration Limit Fluid Temperature Range Measured Fluid Temperature Viscosity Range Wetted Materials Cleanliness Classification Data storage Serial Communication Bottle Operation Sample Volume Purge Volume Pressure Cartridge Operating Time Shop Air Online Operation Sample Volume Purge Volume Fluid Pressure 8 ISO MTD 4 4 6 6 9 8 14 21 2 38 68 um ACFTD 1 2 5 10 25 50 100 um 50 ml min Laser Diode PSL spheres in water ISO MTD in glycol Meets JIS B9925 1997 20 000 particles per ml
15. function key and use the left right arrow keys to select the proper setting or use the keypad to input numbers letters or symbols Press the F4 LI function key to accept the new setting or press CANCEL to return to the Setup menu and maintain the previous selection To view test results in a different Standard or Temperature simply program the desired variables and view or print the test results from the buffer see Test Results on page 25 1 To input letters simply press the numeric key that contains the letter to use in succession Press once for the number twice for the first letter three times for the second letter etc The interval between the key presses determines if the current character is selected or if the next character will be selected c 2 To input symbols simply press the function key that indicates the symbol to use Press F1 for a space F2 for a forward slash and F3 for a period A Operator Manual GlyCount Sample Handling Procedures 19 0f 72 5 Sample Handling Procedures Sample handling procedures are very important for obtaining a representative sample of the contamination level of the system under test The sample should be taken from a source with moving fluid Note If the sample is taken from a slow moving stream a dead leg a non representative sample may result It is recommended that a system be running for at least 30 minutes before a sample is taken Flushing of the GlyCount is
16. to the Producer for disposal at no charge to the user Note For return for recycling please contact the equipment producer or supplier for instructions on how to return end of life equipment for proper disposal Important document Retain with product records GERMAN Elektroger te die mit diesem Symbol gekennzeichnet sind d rfen in Europa nach dem 12 August 2005 nicht mehr ber die ffentliche Abfallentsorgung entsorgt werden In bereinstimmung mit lokalen und nationalen europ ischen Bestimmungen EU Richtlinie 2002 96 EC m ssen Benutzer von Elektroger ten in Europa ab diesem Zeitpunkt alte bzw zu verschrottende Ger te zur Entsorgung kostenfrei an den Hersteller zur ckgeben Hinweis Bitte wenden Sie sich an den Hersteller bzw an den H ndler von dem Sie das Ger t bezogen haben um Informationen zur R ckgabe des Altger ts zur ordnungsgem en Entsorgung zu erhalten Wichtige Informationen Bitte zusammen mit den Produktinformationen aufbewahren FRENCH A partir du 12 ao t 2005 il est interdit de mettre au rebut le mat riel lectrique marqu de ce symbole par les voies habituelles de d chetterie publique Conform ment la r glementation europ enne directive UE 2002 96 EC les utilisateurs de mat riel lectrique en Europe doivent d sormais retourner le mat riel us ou p rim au fabricant pour limination sans frais pour l utilisateur Remarque Veuillez vous adresser au fabricant ou au fournisseur du mat
17. 11 High Fluid Temperature Error Message Figure 11 11 shows the message displayed when the sample fluid temperature increases above operational limits during a sample test Sampling will terminate Printer Error Operator Manual PRINTER E ERROR BELOW ERROR R Fig 11 12 Insufficient Pressure Error Message Figure 11 12 shows the message displayed when an attempt to print has been executed and a printer error condition exists These error messages may appear on the printer e PAPEROUT No printer paper installed HEAD V Printer head voltage error Contact the customer service center for repair HEAD UP Printer head lever is in the up position Lower lever HEAD T Printer head temperature error Ambient temperature too high FAILURE Printer head failure Contact the customer service center for repair GlyCount Troubleshooting 41 of 72 m Low Battery kkkkkkkkkkkkkkk LOW w BATTERY ERROR PLEASE TURN GlyCount S OFF E kkkkkkkkkkkkkkk Fig 11 13 Low Battery Failure Error Message Figure 11 13 shows the message displayed when the absolute minimum battery voltage has been reached The system terminates any sample or print job in progress shuts system down into an idle state An audible transducer beeper sounds once per second for approximately five seconds and then automatically turns the GlyCount off Connect external power supply to GlyCount for operation and charging
18. 4 of 72 Operator Manual Maintenance and Service GlyCount RPS 12 December 2007 Edition 1 GlyCount Troubleshooting 35 of 72 11 Troubleshooting The following list describes problems and error codes with recommended actions If the described actions do not solve the problem contact the customer service center For program malfunctions the GlyCount can be defaulted by pressing and holding the F4 key while power is cycled Note This will erase the entire buffer contents and reset all of the operation variables to their factory settings The message GlyCount DEFAULTING and the Firmware part number will be displayed as the GlyCount reinitializes its systems 11 1 Procedural Problems Sample runs out before test is complete Sample bottle not properly filled Programmed sample or purge volumes too large for the amount of sample Trapped air volume in internal hydraulic tubing Purge internal hydraulic tubing including clean out port Internal hydraulic leak Contact the customer service center for repair The GlyCount will not turn ON when POWER key is pressed Battery voltage too low Connect external power supply to GlyCount for operation and charging 11 2 Fatal Error Messages a Flow Controller Failure FLOW CONTROLLER i FAILURE PLEASE SEE i OPERATING y MANUAL Fig 11 1 Flow Controller Failure Error Message Shown in Figure 11 1 the GlyCount is unable to detect the HO
19. Blockages Follow the steps below to remove blockages from the flow cell Use all precautionary steps to prevent damage to the instrument and personnel injury 1 Disconnect the power supply 2 Disconnect the air source 3 Remove the sample cup and adapter 4 Place glycol absorbent cloth under the unit to capture any glycol draining from the clean out port 5 Retrieve the Allen wrench and cleaning brush from the shipping container 6 Insert the wrench and turn counterclockwise to remove the clean out port cap 7 Slide the brush into the clean out port until resistance is encountered 8 Gently push the brush into the sensor flow cell with a twisting motion CAUTION Excessive pressure will result in brush and possible cell damage If the brush will not go into the cell pull the brush out and inspect the cleaning tip for damage 9 10 11 12 Remove the cleaning brush and snug the clean out port cap Reconnect the air source to the unit Run clean sample fluid through the instrument Cover the wrench with glycol absorbent cloth and slightly loosen the clean out cap while the sample run is in progress to purge any trapped air in the clean out line Fluid and air will squirt out of the clean out port when the cap is loosen Continue the process until there is no remaining air exiting from the port Tighten the clean out port cap snugly To avoid damaging the threads do not over tighten the cap Operator Manual 3
20. DEL s PODS PART NUMBER s 2087009 ALL conforms to Directive 2004 108 EC for Electromagnetic Compatibility and Directive 2006 95 EC for Low Voltage Compliance is accordance to the following specifications as listed in the official Journal of the European Communities EN 61326 2003 Class A Group 1 Emissions EN 55011 1991 Class A Radiated EN 55011 1991 Class A Conducted EN 61326 2003 Immunity EN 61000 4 2 Electrostatic Discharge EN 61000 4 3 Radiated Immunity Amplitude Modulated EN 61000 4 4 Electrical Fast Transient EN 61000 4 5 Surge Transient EN 61000 4 6 Conducted Immunity EN 61000 4 8 Immunity to Power Frequency Magnetic Fields EN 61000 4 11 Voltage Dips and Interrupts EN 61010 1 2001 Amendments 1 amp 2 Safety Requirement for Electrical Equipment for Measurement Control and Laboratory Use EN60825 1 2001 Safety of Laser Products Equipment Classification Requirements and User s Guide Hach Ultra Analytics Terry Stange Vice President of Engineering TT St g 22 07 lea Heng Place and date of issue Name signat re of authorized person Form 011375 Rev 03 Aug 07 Electrical equipment marked with this symbol may not be disposed of in European public disposal systems after 12 August of 2005 In conformity with European local and national regulations EU Directive 2002 96 EC European electrical equipment users must now return old or end of life equipment
21. GlyCount A clean lubricant is recommended for ease of use and to prevent damage to the O ring To use a CO bottle as an external pressure source 1 Screw a bottle clockwise into the CO port of the GlyCount As the bottle is threaded into the CO port the bottle valve will be opened and pressure will be applied to the GlyCount When this occurs the bottle will become difficult to turn 2 Continue another Lo turn until the bottle stops If CO begins to vent around the bottle threads when this pressurization occurs remove the CO bottle and inspect the O ring for damage b Shop Air A compressed air source can also be connected to GlyCount at the shop air port It must be clean dry and between 90 to 110 psi 6 2 to 7 6 bar If the shop air nipple included does not interchange with the system install a new one A 1 8 inch male NPT connection is required Be sure to clean the port threads thoroughly before installing the new fitting to prevent debris from entering the pneumatic system Before attempting to connect any pressure source to the GlyCount be sure to read the General Safety Considerations on page 3 4 2 Programming Operation Variables The operation variables are located under the Setup menu They consist of the following Operator Manual 16 of 72 a Setup Menu Operator Manual Setup and Programming GlyCount 1 SAMPLE LABEL Selecting this variable will display a second menu Sample Text men
22. Hach Ultra service support center on or before the expiration of the warranty period and follow their instructions for return of the defective instrument The customer is responsible for all costs associated with packaging and transporting the defective unit to the service support center and must prepay all shipping charges Hach Ultra will pay for return shipping if the shipment is to a location within the same country as the service support center This warranty shall not apply to any defect failure or damage caused by improper use or maintenance or by inadequate maintenance or care This warranty shall not apply to damage resulting from attempts by personnel other than Hach Ultra representatives or factory authorized and trained personnel to install repair or service the instrument to damage resulting from improper use or connection to incompatible equipment or to instruments that have been modified or integrated with other products when the effect of such modification or integration materially increases the time or difficulty of servicing the instrument THIS WARRANTY IS GIVEN BY HACH ULTRA WITH RESPECT TO THIS INSTRUMENT IN LIEU OF ANY OTHER WARRANTIES EXPRESSED OR IMPLIED HACH ULTRA ANALYTICS AND ITS VENDORS DISCLAIM ANY IMPLIED WARRANTIES OF MERCHANTABILITY OR FITNESS FOR A PARTICULAR NON CONTRACTUAL PURPOSE HACH ULTRAS RESPONSIBILITY TO REPAIR OR REPLACE DEFECTIVE PRODUCTS IS THE SOLE AND EXCLUSIVE REMEDY PROVIDED TO THE CUSTOMER FOR
23. ME switch on the flow controller during system initialization or at the end of a sample test Cycle the power to allow the GlyCount to re initialize its systems Flow controller wire harness disconnection Flow controller malfunction Contact the customer service center for repair Operator Manual 36 of 72 Troubleshooting GlyCount b Threshold Communication Failure THRESHOLD COMMUNICATION FAILURE R PLEASE SEE OPERATING MANUAL Fig 11 2 Threshold Communication Failure Error Message Shown in Figure 11 2 the GlyCount is unable to communicate with the Threshold Board Sampling will terminate and will not be allowed Threshold Board wiring harness disconnection C Printer Initialization Failure Operator Manual PRINTER INITIALIZATION 1 FAILURE 1 i PLEASE SEE R R OPERATING R MANUAL a Fig 11 3 Printer Initialization Failure Error Message Shown in Figure 11 3 the GlyCount is unable to detect printer logic during system initialization Printer Board wiring harness disconnection Edition 1 RPS 12 December 2007 GlyCount Troubleshooting 37 of 72 d Flow Regulation Failure FLOW REGULATION FAILURE i PLEASE SEE i OPERATING MANUAL Fig 11 4 Flow Regulation Failure Error Message Figure 11 4 shows the message displayed when the GlyCount is unable to regulate flow rate within operational parameters The sample test in progress will
24. Operator Manual HIAC GLYCOUNT PORTABLE GLYCOL ANALYSIS SYSTEM EXCELLENCE IN PROCESS ANALYTICS Operator Manual HIAC GLYCOUNT PORTABLE GLYCOL ANALYSIS SYSTEM r 2007 Edition 1 12 Decembe RPS GlyCount Table of Contents Table of Contents 1 Introduction 1 1 General Equipment Description EE 7 1 2 Unpaekngnerud suuaseseagasmmmeneesemten aja teas 10 Display and Keypad Operation 2 1 Using the Keypad bonne sne an cerdas 11 2 2 Understanding the Display er eee ient oder escann 12 Functional Verification 3 1 Self test Verification PP neet 13 Setup and Programming 4 1 External Pressure SOURCES ecc easi taste 15 4 2 Programming Operation Vartables 15 Sample Handling Procedures 51 Bottle Sambil usina iio 19 5 2 Online SAP 20 53 Flushing the GlyCount canica iii 21 5 4 Fluid Compabibllily asar 22 Taking a Sample 6 1 CU luc 23 62 Online Mode m O 23 63 adu 24 Test Results Zelt Displayed Mo Mal cin 25 7 2 Interpretation of Hesuhts AAA 26 Buffer Operation 8 1 Viewing the Contents AEN 27 8 2 Deleting and PING as 27 B amperios oo 27 Communications 9 1 Remote Serial Interface RS 232 Pom 29 9 2 Input Output Interface I O Port rerrrnrrnnnronrrrnnnnnnvrnnnnnnnrnnnrerrrrrennrnnnnne 30 1 0f 72 Operator Manual 2 of 72 Table of Contents GlyCount 10 Maintenance and Service 10
25. agram Operator Manual 50 of 72 Operator Manual Reference Documents GlyCount RPS 12 December 2007 Edition 1 GlyCount Cleanliness Codes 51 of 72 Appendix E Cleanliness Codes E 1 Classification The GlyCount is equipped to handle four cleanliness standards ISO 4406 1999 for NIST ISO 11171 um c internally named ISO C SO 4406 1999 for ACFTD ISO 4402 sizes um internally named ISOACF NAS 1638 1992 SAE AS4059 The cleanliness standards correlate to six internal standard settings Select the applicable standard during setup The selected standard is printed and stored in memory At the time of printing no cleanliness standard except ISO 4406 1999 specifies a specific calibration method Usually users work with ACFTD calibrations however since ACFTD is no longer considered valid calibration material particle counter manufacturers must change to ISO MTD calibrations The other standards also have to use the ISO MTD sizes if cleanliness codes remain the same Operator Manual 52 of 72 E 2 Codes Operator Manual Table E 1 ISO 4406 1987 E Number of Particles Per Milliliters Counts ml More Than Up to and Including Cleanliness Codes GlyCount Scale Number 2500000 1300000 2500000 640000 1300000 320000 640000 160000 320000 160000 80000 40000 20000 10000 5000 2500 1300 640 320 160
26. amp 596 coincidence loss per ISO 11171 30 000 particles ml 10 coincidence 0 to 65 C 25 C ambient 32 to 150 F 77 F 0 to 65 C 0 5 C 32 to 150 F 0 9 F 2 to 50 cSt Brass stainless steel sapphire PTFE and Aflas9 ISO 4406 1991 ISO 4406 1999 NAS 1638 SAE AS 4059 500 Sample Records RS 232 3 runs averaged of 5 10 or 20 ml run programmable 15 to 30 ml programmable CO replaceable rechargeable 60 samples 120 ml sample bottle 90 to 110 psi 6 2 to 7 6 bar clean dry 3 runs averaged of 5 10 20 50 or 100 ml run programmable 25 to 999 ml programmable 100 to 3000 psi 7 to 207 bar Operator Manual 46 of 72 Power DC Input AC Adapter Battery Battery Operating Time Battery Recharge Time Environment Operating Storage Dimensions D X W x H Weight Accessories Included Operator Manual Performance Specifications GlyCount 24 VDC 2 A max Universal 100 240 VAC 50 60 Hz 60 W Nickel Metal Hydride 100 samples or 4 hours continuous 2 5 hours 32 to 122 F 0 to 50 C 20 to 85 relative humidity non condensing 40 to 158 F 40 to 70 C up to 98 relative humidity non condensing 7 x 12 5 x 14 in 17 8 x 38 0 x 35 6 cm 18 Ibs 8 5 kg Carrying case High pressure hose adapter CO bottles Sample bottles glass Hand pump Carrying strap Cleaning brushes 1 8 in Allen wrench Printer paper Power supply and cord Online adapter U
27. andard serial cable with one end male and the other female The GlyCount is already configured as Data Communication Equipment DCE so the use of a null modem cable is not required The cable pin diagram is shown in Figure 9 1 GlyCount DCD TX RX DTR SG DSR CTS RTS RI ech o AN DO Om A CO Iv DB9 FEMALE o ON OO PO PD PC DCD RX TX DTR SG DSR RTS CTS RI Cable DB9 DB9 MALE FEMALE Fig 9 1 RS 232 Cable Pin Diagram DB9 MALE Operator Manual 30 of 72 9 2 Input Output Interface I O Port Operator Manual Communications GlyCount I O Port Connection Used for turning filter pump low voltage solenoid or relay Table 9 1 I O Connector Pin Function I 5 Function Specification ch Unused Unused Unused Unused Unused Unused Digital switch source voltage 5VDC 25mA max 2 3 4 5 6 7 8 Digital switch driver Unused Open drain NFET Unused PES m y 24 0 AD 9020 6010 O BD 50 O Front view Fig 9 2 VO Connector Pin Diagram RPS 12 December 2007 Edition 1 Edition 1 RPS 12 December 2007 GlyCount Maintenance and Service 31 of 72 10 Maintenance and Service This section describes how to clean and maintain the GlyCount 10 1 Changing the Filter 1 Locate the filter housing above the waste container as shown in Figure 10 1
28. by placing the sample in an ultrasonic bath for several seconds Particles settle to the bottom of a sample bottle within minutes so a sample should be shaken to re suspend the particles and degas to remove bubbles Highly contaminated samples will saturate the sensor making particle count data invalid The GlyCount s limit is 20 000 particles per ml at 5 coincidence loss per ISO11171 and 30 000 particles per ml at 10 coincidence loss of fluid for a specific size A general rule of thumb to follow is that if contamination can be seen suspended in a fluid sample the sample may contain concentrations beyond the saturation limits of the GlyCount The average person can only see particles greater than 40 um in size Operator Manual 20 of 72 Sample Handling Procedures GlyCount Sample fluids can be drawn from reservoirs with the use of the vampire pump that is included in the shipping container 1 Cuta length of clean tube that can extend from the fluid in the reservoir to a point accessible from outside the reservoir 2 Thread a clean sample bottle into the vampire pump Install one end of the tube into the vampire pump so that it extends into the sample bottle and tighten the knurled knob 3 Install the other end of the tube into the reservoir being careful not to contaminate the end of the tube 4 Actuate the vampire pump s piston until the sample bottle is filled to the desired level 5 Disconnect the sample b
29. con will indicate the relative battery supply voltage capacity remaining The useful battery voltage range for the GlyCount is 13 8 to 11 5 volts The amount of battery life remaining below this range is minimal so preparation for charging should be made before continuing operation The Internal Temperature screen indicates the temperature inside the GlyCount enclosure It does not indicate the ambient temperature This measurement determines if it is too hot or cold to perform a sample test The Printer Status screen shows the different status conditions or errors of the internal printer A condition of NORMAL indicates the printer is functioning properly An error message displays if a problem exists See Troubleshooting on page 35 for an explanation of these error codes These system parameters display convenient information and diagnostic troubleshooting GlyCount Setup and Programming 15 of 72 4 Setup and Programming 4 1 External Pressure Sources A CO bottle or a shop air pressure source can be connected to the GlyCount to supply the external pressure The following sections describe the requirements for each option a CO Bottles Due to varying shipping rules and regulations the CO bottles contained in the shipping container will not be filled with CO The bottles must be filled by a certified CO supplier before use Once filled inspect the threads and O ring for damage before connecting to the
30. counts per individual run and the average of the three runs GlyCount GLYCOL SAMPLE REPORT Sample SAMPLENAME 1 Serial 000000000 APRIL 15 2004 Time 12 00 00 Sample Mode ONLINE Volume 5 ml RUN Flowrate 50 ml min Fluid Temp 73 2 F Reported Concentration Parts 1 ml ISO Code 18 116 8 4um 6um 14um um c SIZES RUN1 RUN2 RUN3 AVG 4 0um 1352 80 1324 00 1385 40 1353 40 4 6um 405 00 406 00 427 60 412 87 6 0um 330 40 323 00 333 20 328 87 9 8um 7 00 11 40 13 00 10 47 14 0um 2 20 1 60 2 20 2 00 21 2um 0 60 0 00 0 00 0 20 38 0um 0 00 0 00 0 00 0 00 68 0um 0 00 0 00 0 00 0 00 E Ok ck ck ck ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck Ck KKK KKK Fig 7 1 Sample Test Report For ISO Standard reporting the run volume determines the lowest level of the contamination code For a run volume of 5 ml the lowest reported ISO code level is 03 03 03 For a run volume of 10 ml the lowest reported ISO code level is 02 02 02 For a run volume of 20 ml the lowest reported ISO code level is 01 01 01 For additional information on this subject see ISO 4406 Hydraulic fluid power Fluids Code for defining the level of contamination by solid particles The temperature displayed is the temperature at the end of the hydraulic circuit inside the flow controller It is not a measurement of the incoming fluid temperature The hydraulic circuit has thermal masses that influence the temperature of the fl
31. d stored or transferred to the computer in the remote mode For USA Canada Hach Ultra Analytics delivers the GlyCount with an SAE 4 quick connect fitting with a male 1 8 inch NPT thread This material is a certified NIST standard for Primary Calibration of particle counters which consists of two bottles a 400 ml Mil H 5606 with 2 8 mg L ISO MTD TAN the Total Acid Number is the amount of KOH needed to neutralize the acid in the glycol being tested and is measured in mgKOH g GlyCount Annex 59 of 72 Annex Tables and illustrations Fig 1 1 F L VIEW APO PR E UE A A A E E REEE 8 Fig 1 2 Right Side VPN siii 9 OT FER Se 9 Fig 2 1 A EN EE 11 Fig 3 1 ee E 13 Fig 3 2 GlyCount Initialization Screen 13 Fig 7 1 Sample Test Report E 25 Fig 9 1 AS 238 Cable Pin Dig Ora eiie bid wetdeasspetdacoess 29 Table 9 1 I O Connector Pin Function AE 30 Fig 9 2 VO Connector Pin DAN senaste 30 Fig 10 1 Filter Housing Nut e e E 31 Fig 10 2 Filter Installation ZGeoguence AAA 31 Table 10 1 Charging Status Indicators AAA 32 Fig 11 1 Flow Controller Failure Error Message sss 35 Fig 11 2 Threshold Communication Failure Error Message 36 Fig 11 3 Printer Initialization Failure Error Message nnnnnnnrnnnnnnnnnnnnnrrrnnnnnnn 36 Fig 11 4 Flow Regulation Failure Error Message 37 Fig 11 5 Low Flow Rate Error Message esee 37 Fig 11 6 Insufficient Hydraulic Pressure Err
32. e Due to US shipping restrictions the GlyCount is shipped with empty CO bottles Features of the GlyCount include Eight channel display Bottle or online sampling 500 sample memory High speed thermal printer Flash programmable Aluminum alloy sheet metal construction Built in bottle sampler pressure chamber Compact power supply Refillable CO bottle 1 1 General Equipment Description The GlyCount is shown in Figure 1 1 Figure 1 2 and Figure 1 3 Operator Manual 8 of 72 Introduction GlyCount slot for printout of key pad displays keypad display area keypad left side right side Fig 1 1 Front View Operator Manual Edition 1 RPS 12 December 2007 Edition 1 2007 12 December GlyCount Introduction sample bottle adapter waste bottle 9 of 72 handle shoulder strap D ring CO bottle Fig 1 2 Right Side View shoulder strap D ring clean out port pressure gauge power input port H RS 232 port shop air port Ken Fig 1 3 Left Side View Operator Manual 10 of 72 Introduction GlyCount 1 2 Unpacking Instructions Operator Manual The GlyCount comes in a rugged plastic shipping container that includes casters and a convenient extension handle that makes transportation much easier There are thre
33. e counting process error codes sample test results and the status of the operating variables The Battery Charging Status lights indicate the current mode of operation for the charging system See Charging the Battery on page 32 for more information The alphanumeric keys allow the user to input letters and numbers into the program To input letters simply press the key that contains the letter successively until the letter appears Press once for the number twice for the first letter three times for the second letter etc Press the right arrow key to accept the current letter and move the cursor to the next character location In certain programming menus symbols may be entered by pressing the function keys that indicate the symbol to be used Press F1 for a space F2 for a forward slash and F3 for a period Operator Manual 12 of 72 Display and Keypad Operation GlyCount 2 2 Understanding the Display Operator Manual Along the bottom of the display are four bordered areas that correspond to four function keys shown in Figure 2 1 These bordered areas display the attributes of the function keys and will change for different menus To activate an attribute press the function key that corresponds to the desired attribute The remainder of the display area shows information about the current menu the results of a sample test error messages and act as a user interface during operation in combination with the keypad 2007
34. e standard handles and seven locking tabs around the perimeter of the lid The container can be secured with the two padlock holes located on the front of the lid 1 Remove any cardboard packaging material and place the shipping container on a level surface with the lid oriented on the top side 2 Unlatch the seven locking tabs and lift the lid to an upright position 3 Lift the GlyCount from the shipping container and place it on a flat surface in an upright position 4 Remove the protective layer of plastic The GlyCount is now ready to set up and operate GlyCount Display and Keypad Operation 11 of 72 2 Display and Keypad Operation 2 1 Using the Keypad Figure 2 1 shows the features included on the keypad There are four function keys that are reused throughout the menu tree The POWER key toggles the power ON and OFF The START key initiates a sample test The CANCEL key cancels a sample test or cancels a programming function and maintains the previous selection The LINE FEED key feeds the printer paper The arrow keys are used to select operating variables and move the cursor left and right power key BATTERY battery charging sis status light display area START key alphanumeric keypad CANCEL key LINE FEED key 1 function keys arrow keys TER Fig 2 1 Keypad Features The display area provides the user with information on th
35. esult may also be displayed as P 10 ml ISO MTD is the filter test dust used in primary particle counter calibration Its number distribution in dependence of the mass concentration is standardized in ISO 12103 1 1997 for filter testing ISO MTD replaced ACFTD as calibration material and material for the Multipass Test It is available from PTI Inc in USA or their European representative ELIS COMPONENT One certified batch of ISO MTD is available from NIST as SRM 2806 for primary particle counter calibration For secondary calibration NIST supplies dry dust RM 8631 to be dispersed in oil Light extinction also called light blockage or light obscuration is a shadow measurement in the bright field The laser projects a thin light sheet across the cell which hits directly on the single detector PIN diode on the other side of the cell Without the presence of a particle in the beam the detector generates a maximum signal 10 Volt When a particle enters the beam it absorbs the light cutting off part of the signal to the detector This blockage detected by the detector is proportional to the cross section of the particle The light scattering principle is used to measure submicroscopic particles 1 um because particles 1 um are too small to be measured by light extinction Instead of a single detector multiple detectors are placed in the cell The laser projects a thin light sheet across the cell When a particle enters the beam
36. f enabled the GlyCount will automatically shut off after 15 minutes of no activity Idle state C Screen SIZ Programmable size menu When MODE is set to P 1ml or P 10ml PG2 menu becomes available for programming of any of the eight size channels The minimum and maximum size programming is limited to a range of 4 0 to 68 0 um respectively Size programming must also be in an ascending order from the smallest size on channel 1 to the largest size on channel 8 Note The DEFAULT key F2 may be used to reset all sizes to factory default settings d Screen I O 1 2 UNIT ID 01 99 This programmable variable is used to set a unique device address used in serial communication of the GlyCount MODBUS protocol CNTRL LOCAL REMOTE or DOWNLOAD Set to LOCAL when the GlyCount is manually operated Set to REMOTE when a computer program operates and controls sampling of the GlyCount Set to DOWNLOAD when a computer program is retrieving the records from the sample buffer only The setting of this variable can also be changed automatically through the serial MODBUS protocol Operator Manual 18 of 72 Setup and Programming GlyCount e Screen CLK 1 TIME Hours Minutes Seconds Current time in 24 hour format 2 DATE Month Day Year Current date To program any operation variable press the numeric number on the keypad that corresponds to the number on the left side of the variable to program Press the F1 PRG
37. f fluid has been flushed press CANCEL to stop flushing and return to the main menu CAUTION Turning the power off while flushing causes the internal flow controller to remain open and allows fluid to continue flowing Always cancel the flushing process and allow five seconds to pass before turning the GlyCount off Operator Manual 22 of 72 Sample Handling Procedures GlyCount 5 4 Fluid Compatibility Operator Manual The GlyCount is compatible with most glycol based fluids within the specified viscosity and temperature ranges If the compatibility of a desired fluid is in question its compatibility should be checked against the wetted material list included in the Performance Specifications on page 45 If the compatibility cannot be determined submit a request to a local Hach Ultra representative for a recommendation on the fluid s use within the GlyCount Refer to Technical Support Information on page 44 for contact information Note GlyCount internal components are not compatible with water Water may cause instrument malfunction and damage Glycount is only compatible with fluids containing lubricating and corrosion protection properties such as Ethylene Glycol GlyCount Taking a Sample 23 of 72 6 Taking a Sample 6 1 Bottle Mode In this mode a sample fluid is placed into the Bottle Adapter and connected to the GlyCount An external pressure source is used to force the sample fluid through the GlyCount
38. have been stored in a high temperature location like a closed car Place unit in a cool area until it cools off Reduce ambient or fluid temperature conditions C Steady Red Indicator Operator Manual Possible causes for a Steady Red indicator Repeated attempts to begin a charging cycle on a fully charged battery New charging cycles begin when external power is applied Attempting to charge battery in a higher than normal ambient temperature condition Batteries will get hot near their end of charge cycle If ambient conditions are too hot then a battery over temperature condition will result and the Red indication will illuminate The battery has been detected as faulty and should be replaced GlyCount Service Procedures 43 of 72 Appendix A Service Procedures A 1 Calibration The GlyCount must be returned annually for recalibration The calibration date is displayed on the calibration sticker located on the serial plate inside the left side door behind the waste container Each GlyCount unit is aligned and calibrated at the factory using procedures in accordance with the requirements of JIS B 9925 1997 Further the particle sizing accuracy of the GlyCount is assured by using instruments and particle size standards whose accuracy is traceable either to NIST standards or to those of comparable national laboratories in Japan Hach Ultra Analytical provides its customers documentary evidence of this compliance in t
39. he form of calibration certificates that accompany every unit shipped from the factory A 2 Return Procedures To return the Portable Glycol Analysis System for service complete the appropriate form that appears at the end of this section For the most recent return procedure information including copies of all required forms call Hach Ultra at 800 866 8854 or 1 541 472 6500 To return an instrument for credit please contact the local sales representative A WARNING The following actions must be performed when returning any unit for any reason to prevent personal injury and or damage to the unit If installed remove the CO bottle from the unit and or bottles from the carrying case It is unlawful to ship filled CO bottles in the USA due to their high pressure contents The service center does not require use of customer CO bottles Flush the system with clean glycol fluid The service center technicians must handle the fluids within the unit when performing a service If flushing is not possible indicate what type of fluid is in the unit and if any safety precautions should be followed during servicing Place the caps supplied with the unit over the sample and drain tubes to prevent fluid from leaking from the unit during shipment and causing damage to the internal electronics Wipe the unit down to remove any fluid from the outside surfaces of the unit to prevent fluid from leaking from the unit during shipment and causing
40. it scatters the light throughout the cell in a pattern proportional to its volume This scattered light is collected by detectors which then determine the size of the particle from its size scatter pattern National Institute of Standards of the USA Address SRM Sales Department Building 202 Room 204 Gaithersburg MD 20898 USA Tel 1 301 975 6776 Fax 1 301 948 3730 Operator Manual 58 of 72 NIST ISO Sizes Run Sample Shop Air connector SRM 2806 TAN Operator Manual Glossary GlyCount The ISO 4406 1999 is unchanged with respect to the concentrations of the cleanliness codes However since ISO MTD has higher concentrations under 10 um and lower concentrations over 10 um than ACFTD and the ISO Code shall not change particle counters with ISO MTD calibration must measure with the NIST sizes count equivalent to the ACFTD sizes Thus a counter like the GlyCount calibrated with ISO MTD measures the same counts and ISO codes at 4 4 6 6 4 9 8 13 6 21 2 38 68 um c as an ACFTD calibrated counter at 1 2 5 10 15 25 50 100 um With each run the particles in 5 10 or 20 ml of glycol are counted The three runs of each sample are measured one after another without interrupting the flow Each sample consists of a purge run and 3 consecutive runs The purge run is necessary to measure and set the flow rate and to purge the last sample which may have introduced other contamination All runs are printed an
41. lator failure or adjustment setting out of tolerance Contact the customer service center for repair Edition 1 RPS 12 December 2007 GlyCount Troubleshooting 39 of 72 h Low Pressure LOW PRESSURE ERROR R PLEASE SEE i 8 OPERATING MANUAL Fig 11 8 Low Pressure Error Message Figure 11 8 shows the message displayed in bottle mode after one minute of waiting for hydraulic pressure to increase above operational lower limit Sampling will terminate External pressure source insufficient Pick up tube cap not removed i Insufficient Pressure PRESSURE S DROPPEDTO AN INSUFFICIENT E LEVEL i Fig 11 9 Insufficient Pressure Error Message Figure 11 9 shows the message displayed when internal hydraulic pressure drops below operational limit Sampling will terminate External pressure was depleted during sample test Internal hydraulic regulator failure or adjustment setting out of tolerance Contact the customer service center for repair j High Internal Temperature HIGH INTERNAL s TEMPERATURE SAMPLING i NOT ALLOWED Fig 11 10 High Internal Temperature Error Message Figure 11 10 shows the message displayed when the sample fluid temperature is above operational limits Sampling will not be allowed Operator Manual 40 of 72 Troubleshooting GlyCount k High Fluid Temperature HIGH FLUID y TEMPERATURE SAMPLING i ABORTED Fig 11
42. level required Verify the other operation variables are programmed as needed See Programming Operation Variables on page 15 for more information Connect the Online Adapter to the GlyCount by sliding the pick up tube into the hole in the center of the adapter and turning counterclockwise until locked Connect a hydraulic hose with a M16 X 2 test hose thread to the online adapter Connect the other end of the hydraulic hose to the fluid source e OPTIONAL Connect the filter pump solenoid control to the GlyCount I O connector See Input Output Interface I O Port on page 30 for I O port pin configurations Press the START button on the keypad after the filtering process has begun to ensure adequate press to deliver fluid to GlyCount unit The GlyCount will run samples at the program interval When the target cleanliness is detected GlyCount will terminate the sampling process Up to 500 test results will be stored in the buffer presented on the display and or printed if the printer is enabled GlyCount Test Results 25 of 72 7 Test Results 7 1 Displayed Information Figure 7 1 shows a typical test report It indicates the name of the sample serial number of the unit that took the sample date and time the sample was taken volume per sample run flow rate measured fluid temperature concentration units measured cleanliness in the desired format and the count data per micron size The count data show the number of
43. ltrasonic bath RPS 12 December 2007 Edition 1 GlyCount Accessories Appendix C Accessories 47 of 72 Table C 1 and Table C 2 show the standard and optional accessories for the GlyCount Table C 1 Standard Accessories Item Name Re order Part Number Reusable Shipping Container SA 000197 01 Foam Insert for shipping container MP000172 01 02 Online Adapter SA000008 01 Shoulder Strap VP753400 AC DC Power Supply VP624002 U S Power Cord VP6235001 U S DOT Rated CO Bottles VP760000 Sensor Cleaning Brushes Pack of 2 SA000066 01 Printer paper 460 511 High Pressure Hose VP350000 Ultrasonic Benchtop PC 3 690 500 1172 100 ml Glass Sample Bottles Table C 2 U S Optional Accessories Item Name Re order Part Number 570 396 9217 Description GlyCount Control Software 2087044 Software utility for data collection compatible with Microsoft Windows 98 Windows 20009 and Windows XP RS 232 Serial Interface Cable EP096010 Cable that will connect a computer to a GlyCount for downloading data into software Operator Manual 48 of 72 Operator Manual Accessories GlyCount RPS 12 December 2007 Edition 1 ember 2007 Edition 1 RPS 12 Dec GlyCount Reference Documents 49 of 72 Appendix D Reference Documents D 1 Flow Diagram me PAELMATIC DIAGRAM Fig D 1 Flow Di
44. ml 1 gt 1um gt 5um gt 15um gt 25um gt 50um gt 100um 2 gt 4um c gt 6um c gt 14um c gt 21um c gt 38um c gt 70um c Size code A B C D E F Classes 000 119 7 14 3 14 0 00 390 152 127 8 14 o of 780 304 saj 10 CC 1 teo 609 10 204 1 Ss 25000 ea 1731 me amp 53 8 6 50000 19462 3462 612 106 6 l 200000 77849 13849 2449 424 64 9 400000 155698 27698 4898 848 128 1 Size range Optical microscope based on longest dimension as measured per ARP598 or APC Calibrated per ISO 4402 1991 2 Size range APC Calibrated per ISO 11171 or Electron Microscope based on projected area equivalent diameter Complete standard available from www sae org Operator Manual GlyCount Applicable Standards 55 of 72 Appendix F Applicable Standards The following standards govern various aspects of the performance and use of particle counters described in this manual Copies of these standards are available at cost from Hach Ultra JIS B 9925 1997 Light Scattering Automatic Particle Counter ASTM F 658 87 Re approved 1992 Standard Practice for Defining Size Calibration Resolution and Counting Accuracy of a Liquid Borne Particle Counter Using Near Monodispersed Spherical Particulate Material Operator Manual 56 of 72 Operator Manual Applicable Standards GlyCount RPS 12 December 2007 Edition 1 GlyCount Glossary 57 of 72 Appendix G
45. most accurate method of sampling The CO or shop air external pressure sources are not used in this mode because the hydraulic pressure forces the fluid through the GlyCount However they can remain connected during the sampling process if desired 1 Set the sampling mode to ONLINE and program the desired number of runs hold time and purge volume The purge volume should be approximately twice the internal volume of the hydraulic tube that connects the GlyCount to the system Verify that the other operation variables are programmed as needed See Programming Operation Variables on page 17 for more information 2 Connect the online adapter to the GlyCount by sliding the pick up tube into the hole in the center of the adapter and turning clockwise until the adapter is locked 3 Connect a hydraulic hose with a Minimess test hose thread to the online adapter Connect the other end of the hydraulic hose to the system to be tested Operator Manual 24 of 72 Taking a Sample GlyCount 4 Press START The sampling process begins and fluid will begin to exit from the drain port The GlyCount has a fixed flow rate 50 ml min There are three consecutive sample runs at 5 10 20 50 or 100 ml depending on what was programmed When this process is completed the test results will be stored in the buffer presented on the display and or printed if the printer is enabled CAUTION Turning the power off on the GlyCount while
46. nd unit to purge any contamination before sampling The longer the hydraulic hose the greater the purge volume must be 3 STD ISO C ISO NAS C NAS NAV C NAV SAE C SAE MIL P 10ml or P 1ml Determines the Standard format to display the sample results 4 VOL 5 10 20 50 or 100 ml Volume of fluid that will be run three times during a sample Volume RUN BOTTLE mode sampling is limited to 5 10 or 20 ml per RUN only 5 FLOW The flow rate is fixed at 50 ml min 6 PRINT ENBL DSBL or SETUP Enables or disables the printer from automatically printing at the end of a sample SETUP will print the current GlyCount setup 7 CONTRAST Left right arrow keys Controls the display contrast GlyCount Setup and Programming 17 of 72 b Screen PG 2 LANG English French German Span and Ital Determines the language that will be used in the operation and control of the GlyCount TEMP C or F Determines the units to display temperature PRESS BAR or PSI Determines the units to display pressure DISPL NORM or REV Display viewed as light background Normal or dark background Reversed BKLT ON OFF or AUTO Controls the LCD display s back light If AUTO is selected the back light will turn off after five minutes of inactivity BEEP KEY or DSBL Controls audio feedback of the beeper when a key is pressed BSAVE battery save feature This item is either ENBL Enabled or DSBL Disabled I
47. nect the bottle adapter from the GlyCount by turning the adapter clockwise Fill a sample bottle with the fluid to be flushed Place the sample bottle into the Bottle Adapter and reconnect it to the GlyCount by sliding the pick up tube into the sample bottle and turning the adapter clockwise until locked From the main menu press the F4 key to go into the flush menu and press START Press F1 SOL ON The bottle adapter pressurizes and fluid begins to exit the drain port The amount of fluid being flushed is indicated on the display When the desired amount of fluid has been flushed press CANCEL to stop flushing and return to the main menu CAUTION If the flushed volume exceeds the amount of fluid in the bottle adapter pneumatic pressure will be flushed through the GlyCount and out of the drain port This can create air pockets in the filter system and lead to sampling errors b Flushing in Online Mode Connect the online adapter to the GlyCount by sliding the pick up tube into the hole in the center of the adapter and turning counter clockwise until locked Connect a hydraulic hose with a Minimess test hose thread to the online adapter Connect the other end of the hydraulic hose to the system to be tested From the main menu press the F4 key to go into the flush menu and press START Fluid will begin to exit the drain port and the amount of fluid being flushed is indicated on the display When the desired amount o
48. or Message ssss 38 Fig 11 7 High Pressure Error Message rbi ti 0 38 Fig 11 8 Low Pressure Error Message eene 39 Fig 11 9 Insufficient Pressure Error Message A 39 Fig 11 10 High Internal Temperature Error Message 39 Fig 11 11 High Fluid Temperature Error Message 40 Fig 11 12 Insufficient Pressure Error Message Aa 40 Fig 11 13 Low Battery Failure Error Message eese 41 Table G 1 Standard Accessories cansa ia 47 Table C 2 U S Optional Accessories AAA 47 gos For Da esse seanse 49 Table E 141 ISO 4406 1997 1B Luna dria dun 52 Table E 2 NAS 1638 Contamination Classification System 53 Table E 3 Equivalent APC Sizes Relating to Calibration Method 53 Table E 4 SAE ASI Oia 54 Operator Manual 60 of 72 Operator Manual Annex GlyCount RPS 12 December 2007 Edition 1 RPS 12 December 2007 Edition 1 GlyCount User Notes User Notes 61 of 72 Operator Manual 62 of 72 Operator Manual User Notes GlyCount RPS 12 December 2007 Edition 1 DECLARATION of CONFORMITY We Hach Ultra Analytics 481 California Avenue Grants Pass OR 97526 Formerly Pacific Scientific Instruments Inc declare under sole responsibility that the MO
49. ord into the external power supply and the other end of the power cord into a 110V outlet 3 Plug the external power supply jack into the GlyCount at the power port location Listen for a click and verify that the Battery Charging Status light located on the keypad is illuminated This light will indicate one of three charging status modes shown in Table 10 1 Table 10 1 Charging Status Indicators Indicator Charging Status Steady green Charging Flashing green Maintenance mode Steady red Battery charging failure While operating on a fully charged internal battery the GlyCount can perform a minimum of 100 samples before needing to be recharged Operator Manual GlyCount Maintenance and Service 33 of 72 10 3 Changing the Printer Paper Note Open the printer door Open the new roll of printer paper and orient it so the paper feeds from the bottom of the roll toward the GlyCount While the GlyCount is ON insert the paper into the printer and press the LINE FEED key The paper will feed through the printer Roll up the slack in the paper roll and push it into the paper holder Lift the free end of paper and close the printer door Tear off the excess paper In case of paper misalignment lifting the lever on the left side of the printer will raise the printer carriage The paper can then be pulled straight and aligned Lower the carriage before operating printer 10 4 Removing Flow Sensor
50. ottle from the vampire pump and install the cap until the sample is ready to test 5 2 Online Sampling If handled properly this is the most reliable method of obtaining a representative sample from a system The hydraulic hose that connects the GlyCount to the system being tested must be purged to remove the previous fluid that was tested Program the GlyCount for a purge volume approximately twice that of the internal volume of the hydraulic hose to be used The importance of the location of the systems test port for accurate sampling should not be underestimated An application specialist should be consulted before installation of this port Additional fluid control devices should not be installed on the hydraulic sample hose or the system s test port These devices can generate bubbles and create particle traps that may cause sample inaccuracies Suitable sampling points for online measurements with the GlyCount Upstream of the high pressure filter condition after pump Upstream of the return filter condition after system Upstream of the bypass filter tank condition Operator Manual GlyCount Sample Handling Procedures 21 of 72 5 3 Flushing the GlyCount The GlyCount can be flushed in both bottle and online modes a Flushing in Bottle Mode Verify that a CO bottle or shop air pressure source has been connected to the GlyCount and that there is 90 to 110 psi 6 2 to 7 6 bar indicated on the pressure gauge Discon
51. riel pour les instructions de retour du mat riel us ou p rim aux fins d limination conforme Ce document est important Conservez le dans le dossier du produit ITALIAN Le apparecchiature elettriche con apposto questo simbolo non possono essere smaltite nelle discariche pubbliche europee successivamente al 12 agosto 2005 In conformit alle normative europee locali e nazionali Direttiva UE 2002 96 EC gli utilizzatori europei di apparecchiature elettriche devono restituire al produttore le apparecchiature vecchie o a fine vita per lo smaltimento senza alcun costo a carico dell utilizzatore Nota Per conoscere le modalit di restituzione delle apparecchiature a fine vita da riciclare contattare il produttore o il fornitore dell apparecchiatura per un corretto smaltimento Documento importante Conservare con la documentazione del prodotto DANISH Elektriske apparater der er maerket med dette symbol m ikke bortskaffes i europaeiske offentlige affaldssystemer efter den 12 august 2005 I henhold til europ iske lokale og nationale regler EU direktiv 2002 96 EF skal europaeiske brugere af elektriske apparater nu returnere gamle eller udtjente apparater til producenten med henblik p bortskaffelse uden omkostninger for brugeren Bem rk I forbindelse med returnering til genbrug skal du kontakte producenten eller leverand ren af apparatet for at f instruktioner om hvordan udtjente apparater bortskaffes korrekt Vigtigt dokument Opbe
52. sampling will cause the internal flow controller to remain open and allow fluid to continue flowing Always allow the sampling process to finish or press cancel and allow five seconds to pass before turning the GlyCount off 6 3 Filter Mode Operator Manual The Filter Mode is designed to allow the user to monitor the fluid cleanliness level while filtering fluid The user has to program sampling parameters including sampler intervals and target cleanliness levels The GlyCount will take samples at programmed intervals while the system fluid is being filtered When the system fluid meets the programmed cleanliness level the GlyCount will run an additional sample to confirm the fluid cleanliness level is stable The GlyCount will then beep stop sampling and print the last two sample results if the printer is enabled If the filter pump ON OFF control solenoid is connected to the GlyCount via the optional I O connection then the pump will be turned ON when the filter start function is selected The filter pump will automatically be turned OFF when the cleanliness level is achieved The GlyCount fluid pressure requirement varies with the fluid viscosity Minimum pressure must be maintained to regulate fluid flow through the GlyCount unit The GlyCount self regulates based on fluid pressure and viscosity variation during sampling and filtering Set the sampling mode to FILTER program the desired hold time purge volume and cleanliness
53. sibility of such damages In the interest of continued product development Hach Ultra reserves the right to make improvements in this manual and the products it describes at any time without notice or obligation Published in the United States of America Hach Ultra P N 701247 Edition 1 12 December 2007 Copyright 2007 by Hach Ultra Analytics Inc All rights reserved No part of the contents of this manual may be reproduced or transmitted in any form or by any means without the written permission of Hach Ultra Analytics Inc Safety Conventions A WARNING A warning is used to indicate a condition which if not met could cause serious personal injury and or death Do not move beyond a warning until all conditions have been met CAUTION A caution is used to indicate a condition which if not met could cause damage to the equipment Do not move beyond a caution until all conditions have been met Note A note is used to indicate important information or instructions that should be considered before operating the equipment General Safety Considerations These safety guidelines should be read carefully and understood before operating the HIAC GlyCount All service procedures should be conducted by properly trained service personnel Make sure the Portable Glycol Analysis System is properly installed and all hydraulic connections are correctly installed before operation Online operation may use high pressure All safety g
54. specified herein may result in hazardous radiation exposure GlyCount Manual Overview 5 of 72 WARNING The following DANGER label is clearly visible on the body of the laser sensor inside the unit Do not disassemble or attempt to service due to the possibility of eye damage The bottle adapter is a pressure vessel used for sample delivery through the GlyCount It is critical that it is installed in the locked position before sampling The bottle adapter must be aligned on the GlyCount and in the locked position WARNING If the bottle adapter is not installed properly when pressurization begins it can be forced off of the GlyCount and personal injury and or damage to the GlyCount may occur Although the GlyCount is designed for rugged use it is still an instrument that should be cared for and maintained as described in this manual Following proper safety and handling instructions will promote accident free operation and prolong product life Warranty Hach Ultra warrants that this instrument will be free of defects in materials and workmanship for a period of one 1 year from the shipping date If any instrument covered under this warranty proves defective during this period Hach Ultra will at its option either repair the defective product without charge for parts and labor or provide an equivalent replacement in exchange for the defective product To obtain service under this warranty the customer must notify the nearest
55. terminate External pressure was depleted during sample test The GlyCount was not purged before a change in viscosity of the sample fluid Insufficient sample fluid e Attempt to flush the system See Flushing the GlyCount on page 21 e Low Flow Rate LOW FLOW RATE ERROR POSSIBLE i HIGH Fig 11 5 Low Flow Rate Error Message Figure 11 5 shows the message displayed when the GlyCount is unable to regulate flow rate above the operational lower limit The sample test in progress will terminate External pressure was depleted during sample test GlyCount not purged before a change in viscosity of the sample fluid Pick up tube cap not removed Operator Manual 38 of 72 Troubleshooting GlyCount f Insufficient Hydraulic Pressure 5 INSUFFICIENT R HYDRAULIG PRESSURE R FOR SAMPLING R Fig 11 6 Insufficient Hydraulic Pressure Error Message Figure 11 6 shows the message displayed in online mode after one minute of waiting for hydraulic pressure to increase above operational lower limit Sampling will terminate Hydraulic pressure source insufficient g High Pressure Detected Operator Manual HIGH PRESSURE DETECTED s i POSSIBLE REGULATOR E i FAILURE Fig 11 7 High Pressure Error Message Figure 11 7 shows the message displayed when internal hydraulic pressure increases above operational limit Sampling will terminate Internal hydraulic regu
56. tuur die is voorzien van dit symbool mag na 12 augustus 2005 niet meer worden afgevoerd naar Europese openbare afvalsystemen Conform Europese lokale en nationale wetgegeving EU richtlijn 2002 96 EC dienen gebruikers van elektrische apparaten voortaan hun oude of afgedankte apparatuur kosteloos voor recycling of vernietiging naar de producent terug te brengen Nota Als u apparatuur voor recycling terugbrengt moet u contact opnemen met de producent of leverancier voor instructies voor het terugbrengen van de afgedankte apparatuur voor een juiste verwerking Belangrijk document Bewaar het bij de productpapieren POLISH Sprz t elektryczny oznaczony takim symbolem nie moze by likwidowany w europejskich systemach utylizacji po dniu 12 sierpnia 2005 Zgodnie z europejskimi lokalnymi i pa stwowymi przepisami prawa Dyrektywa Unii Europejskiej 2002 96 EC u ytkownicy sprz tu elektrycznego w Europie musz obecnie przekazywa Producentowi stary sprz t lub sprz t po okresie u ytkowania do bezp atnej utylizacji Uwaga Aby przekaza sprz t do recyklingu nale y zwr ci si do producenta lub dostawcy sprz tu w celu uzyskania instrukcji dotycz cych procedur przekazywania do utylizacji sprz tu po okresie u ytkowania Wa ny dokument Zachowa z dokumentacj produktu PORTUGESE Qualquer equipamento el ctrico que ostente este s mbolo n o poder ser eliminado atrav s dos sistemas p blicos europeus de tratamento de res duos s lidos
57. u Under this menu the operator can program the following items 2 MODE SAMPLE LABEL SAMPLE NAME User input name for samples The sample labels can be 10 characters long For each sample label there is an auto counter extension that increments up to 500 This extension is reset to one every time a new sample label is programmed reentered or exceeds a count of 500 REMARKS User input remarks for any additional sample labeling as desired These optional remarks become part of the record of any completed samples Records retrieved from the sample buffer can have their remarks reviewed and reedited as necessary The sample remarks can be 10 characters long on any of three lines Any existing remarks display on printed sample reports BOTTLE or ONLINE FILTER Sampling method If BOTTLE mode is selected or reentered a second screen displays to allow programming of the following variable PURGE VOL 15 30 ml Volume of fluid that will flow through the unit to purge any contamination before sampling If ONLINE mode is selected or reentered a second screen displays to allow programming of the following variables NUM SAMPLES 1 500 Numbers of samples that will run during the sampling period HOLD TIME Hours Minutes Time delay from the end of a sample to the start of the next sample If set for 00 00 a minimum 5 second hold time will be set PURGE VOL 15 999 ml Volume of fluid that will flow through the hydraulic hose a
58. uid If the GlyCount is colder then the Operator Manual 26 of 72 Test Results GlyCount fluid there will be a temperature drop of the fluid while sampling If the GlyCount is hotter there will be a temperature increase of the fluid while sampling 7 2 Interpretation of Results The reported results should be compared to the corresponding target ranges for the system being tested Fluid treatment or replacement can then be determined Operator Manual RPS 12 December 2007 Edition 1 GlyCount Buffer Operation 27 of 72 8 Buffer Operation 8 1 Viewing the Contents The contents of the buffer can be accessed by several means Under the buffer menu selecting LAST SAMPLE will display the results of the last sample that was performed Selecting LIST BUFFER will display the eight most recent sample names for further review Selecting SEARCH BUFFER will allow searching for a particular sample name by entering the entire or partial name of the sample to be found Once a sample selection has been made the next or previous samples can be selected by pressing the corresponding function keys The buffer contents will be displayed in the configuration that the GlyCount is currently programmed for To display the results in a different configuration change the operation variables to the desired configuration and view the buffer contents again 8 2 Deleting and Printing Under the buffer menu pressing the F2 DEL BUF
59. uidelines should be observed when using high pressure devices Follow all procedures in Return Procedures on page 43 before shipping a unit to a service center for repair or re calibration A WARNING Only factory certified personnel should perform service of the GlyCount Attempts by untrained personnel to disassemble alter modify or adjust the electronics and or hydraulics may result in personal injury and damage to the GlyCount Operator Manual 4 of 72 Operator Manual Manual Overview GlyCount HIAC GlyCount Operator Manual Addendum Cleaning Instructions Warning ZN WARNING Do not spray the GlyCount with cleaning solutions to clean the unit Apply all cleaning solutions including combustible solvents with a clean cloth Remove all combustible solvent residues before connecting or removing the power supply otherwise injury or death to personnel and or damage to the GlyCount may occur Like all power supplies the GlyCount power supply may produce and electrical spark when connected or disconnected to the GlyCount The unit is not hermetically sealed and a spark may ignite residual solvent Spraying the GlyCount with any cleaning solutions will void the warranty and may result in injury or damage The pick up tube is used to make the hydraulic connection between the GlyCount and the online adapter CAUTION Care must be taken not to bend the pick up tube or scratch the lower end where the seal connection is made
60. vares sammen med produktdokumenterne Form No 011229 SWEDISH Elektronikutrustning som r m rkt med denna symbol kanske inte kan l mnas in p europeiska offentliga sopstationer efter 2005 08 12 Enligt europeiska lokala och nationella f reskrifter EU direktiv 2002 96 EC m ste anv ndare av elektronikutrustning i Europa nu aterlamna gammal eller utrangerad utrustning till tillverkaren f r kassering utan kostnad f r anv ndaren Obs Om du ska terl mna utrustning f r tervinning ska du kontakta tillverkaren av utrustningen eller terf rs ljaren f r att f anvisningar om hur du terl mnar kasserad utrustning f r att den ska bortskaffas p r tt s tt Viktigt dokument Spara tillsammans med dina produktbeskrivningar SPANISH A partir del 12 de agosto de 2005 los equipos el ctricos que lleven este s mbolo no deber n ser desechados en los puntos limpios europeos De conformidad con las normativas europeas locales y nacionales Directiva de la UE 2002 96 EC a partir de esa fecha los usuarios europeos de equipos el ctricos deber n devolver los equipos usados u obsoletos al fabricante de los mismos para su reciclado sin coste alguno para el usuario Nota S rvase ponerse en contacto con el fabricante o proveedor de los equipos para solicitar instrucciones sobre c mo devolver los equipos obsoletos para su correcto reciclado Documento importante Guardar junto con los registros de los equipos DUTCH Elektrische appara

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