Continuous Oil Condition Monitoring

Transcription

1 Continuous Oil Condition Monitoring LubCos H 2 O+ Lubrication Condition Sensor Application area Stationary screw-in sensor for the continuous determination of the oil condition in hydraulic and lubricating oils. Performance features Measurement and documentation of changes in hydraulic fluids and lubricants. Data is continuously documented and stored. In that way deterioration and changes in the oil (e.g. water inleakage, oil change,...) can be indicated. Through this, damage can be recognized or completely avoided at an early stage. This offers the opportunity to prevent machine failures as well as to prolong maintenance and oil change intervals by means of appropriate measures. Furthermore, by monitoring the lubricant, correctly performed maintenance work and the use of the required lubricant quality may be documented. LubCos H 2 O+ Design characteristics The sensor is provided with a ¾ thread and can be e.g. integrated in a return line or the tank. Optionally, with an integrated LED status indicator with 1 segments on the back side of the sensor which visualizes the oil condition. Sensor head LED status indicator The communication with the sensor takes place over a serial RS232 interface. Optionally, the signals are sent over two analog outputs (4...2 ma). In order to also enable a long-term record of data up to half a year, the sensor has a data storage unit which can be read out over the serial interface. Measuring principle The sensor records four different physical oil characteristics as well as its periodic change: Temperature, relative oil humidity and water activity, relative permittivity and conductivity of the fluid respectively. As especially the conductivity and the relative permittivity show a strong connection to the temperature, next to the characteristic values at current temperature the sensor also sends the data at reference temperature. Subject to change 4.6 1/2

2 Technical data / Example of use Example of use By using the sensor different changes of the oil condition can be detected. The following example shows a typical course of relative permittivity, conductivity and relative humidity during various changes of the condition in the system. By means of the characteristics, different oil types may be differed, oil refreshing and oil change can be detected and the relative humidity, free water as well as the deterioration and deterioration rate can be defined respectively. Relative permittivity ε at 4 ºC [-] Total acid number NZ [mg KOH /g oil ] Conductivity at 4 ºC [ps/m] Relative humidity r.h. [%] Conductivity G at 4 ºC [ps/m] 3,4 3,2 3, 2,8 2,6 2, Refill oil 1 5 l ε Refill oil 1 5 l Water penetration r.h. NZ Oil 1 11 l Oil change to Oil 2 11 l Time Oil 1 11 l Oil change to Oil 2 11 l Time Free water Drying 2, 1,6 1,2,8, Sensor data Size Unit Operating pressure Operating temperature Ambient conditions, operation: Temperature Humidity Ambient conditions, storing: Temperature Humidity Pressure fluids Wetted materials Sealing material Power supply Power input Output Power output (2x) Interface Optical indicator, optional Measuring range 1) rel. permittivity rel. humidity Conductivity Temperature Measuring resolution rel. permittivity rel. humidity Conductivity Temperature Measuring accuracy rel. permittivity 2) rel. humidity Conductivity Temperature 1) Additional display of temperature gradient and trend 2) Measured with n-pentan at 25 C Mineral and ester fluids (HLP, HEES) galvanized steel, FPM, polyurethane resin, epoxy resin NBR ,2 typ.,3 max RS232 1 segment LED *1-4,1,1,3 ±,15 ± 3 < 3 ±,3 bar C C % r.h. C % r.h. V A ma - % r.h. ps/m C - % r. H. ps/m K - % r. H. ps/m K Time G We produce fluid power solutions ARGO-HYTOS GMBH P.O. Box 116 D Kraichtal-Menzingen Phone Fax info.de@argo-hytos.com 2/2

3 Oil Diagnostic Systems Online and bottle measurement Mobile and stationary operation Lab quality accuracy

4 The new generation of oil diagnostics Mobile and stationary operation: Shop-air connector for laboratory measurement and gas bottle for field measurement Online and bottle measurement: Bottle adapter for batch sampling and minimess connector for online measurement 274

5 The new generation of oil diagnostics PODS Pro is the new generation of portable oil-diagnostic instruments for simple, quick and reliable monitoring of oil cleanliness. PODS Pro is based on many years of know how and represents the advanced version of PODS with newest technology. Many features were improved, thus PODS Pro is not only lighter than its predecessor, but also offers the classification according to SAE AS 459. Productive Online & Bottle sample analysis by one instrument. As before you can rely on PODS Pro even under severest operating conditions. The measurement results are reported simply, quickly and reliably. With PODS Pro you have the option to run online or bottle sample analysis with the same instrument. Profitable the PODS Pro Special: The all-inclusive delivery program includes a robust rollerbox with all necessary accessories. The ARGO-HYTOS software PODSWare sets new standards for service statistics and allows, for example, a detailed mapping of the machine life. Proving PODS Pro live We would be happy to show you PODS Pro live. Simply ask for a noncommittal demonstration. Rely on hightech oil diagnostic systems from ARGO-HYTOS. Certificate for measurements according to the different standards. These certificates can be issued with individual labels. 275

6 Advantages at a glance Online and bottle sample analysis With two turns of your hand, using the two fluid adapters in the allinclusive delivery, PODS Pro is converted from a "Monitor" to a "Lab analyzer". In the online mode PODS Pro is connected directly to the hydraulic circuit via Minimess tubing and allows specific and continuous monitoring of the oil cleanliness. 2. Flexibility Due to its lower weight PODS Pro can be easily carried to each location. For longer distance transport the rollerbox is used All-included delivery PODS Pro is supplied with a very robust rollerbox, which is air- and water tight and contains all necessary accessories such as gas cartridges, power adapter, fluid adapters for online and bottle mode, handpump for oil sampling as well as clean sample bottles. The box is lockable and can be used for safe shipping to the ARGO-HYTOS Service Center, for instance for calibration. 4. Pressure range up to 69 psi By direct measurement at system pressures up to 69 psi without bypassing, the risk of outgasing and bubble counting is drastically reduced. 5. High viscosity and high contamination PODS Pro can measure particle contamination up to code 24 according to ISO 446:1999. This is achieved by a sensor with a limit concentration of 9. particles/ml at 1% optical coincidence and avoids time consuming and complicated dilution procedures. Another important advantage is its ability to measure oils with a viscosity up to 394 SUS. 6. Variable flow rate PODS Pro automatically regulates the flow rate to an appropriate value between 15 and 5 ml/min, depending on the oil pressure and the viscosity. This feature makes it insensitive to variations in the hydraulic system during the measurement. 7. Controlled cleaning with ECOLINE The oil service filter unit ECOLINE cleans oils up to a selected cleanliness class with PODS Pro. For this purpose ECOLINE pumps the oil over a filter. At the same time PODS Pro measures the cleanliness of the oil in front of the filter online and turns off ECOLINE when the target cleanliness class is reached. The cleanliness class is documented on a printout. 276

7 Software PODSWare A powerful software! PODSWare as supplement to PODS Pro is a tool to record and evaluate the measured data in a comfortable manner. Apart from this PODS Pro may be completely controlled from the control window of the software. The PODSWare includes the following languages: German, English, French, Italian Starting and stopping measurements. Setting parameters and downloading stored data. Graphical tracking of online measurements by time graphics. Build-up of a data bank and linking of measurements to machines. Historic review of the oil cleanliness. Particle concentration-size distribution. Chronological review of the particle concentration. 277

8 Technical information Detection Sensitivity Size ranges Size channels Flow rate Light extinction complies with Japanese Industry Standard (JIS-B-9925:1997) 4 1 µm(c) (ISO-MTD); ~1-1 µm (ACFTD) 4 1 µm(c) (ISO-MTD); ~1-1 µm (ACFTD) 8 channels ISO-MTD sizes [µm (c)] ACFTD sizes [µm] ~1 2 ~5 1 ~15 25 ~ ml/min automatic regulation Calibration ISO-MTD in oil (ISO 11171:1999) Cleanliness classification ISO 446; NAS 1638; MIL-STD-1246C; NAVAIR 1-1A17, SAE AS 459 Cleanliness classes ISO 446 code 1 to 24 Concentration limit Measurement results Light source Counting efficiency Wetted materials Fluid pressure Temperature Relative humidity Viscosity Material compatibility Pressure medium Sample bottles System properties Operating modes Software (optional) Weight Dimensions 9. 1% optical coincidence Oil cleanliness classes (according to standard), concentration (particles/ml), viscosity (mm 2 /s, cst or SUS), temperature Laser diode By JIS-B-9925:1997 Stainless steel, sapphire, aluminium, Aflaz, PTFE psi F oil at 77 F ambient; F ambient; F housing 2 85% non-condensing, up to 98% when stored SUS particle counting with viscosity measurement, SUS particle counting only Mineral oils, Skydrol, environmentally compatible pressure fluids and phosphate esters CO 2 liquid (1 cartridge for about 6 oil samples), or pressurized shop air 1 ml Metal housing / Carry handle and shoulder strap / Universal power adapter/charger (9 24 VAC) Built-in thermal printer / LCD-display and keyboard / Memory for 5 samples / RS232C-interface Tube connector for filtered and dry pressurized shop air / Exchangeable CO 2 -gas cartridges, refillable, 1 g filling NiMH-battery, computer controlled recharging for extended battery life Digitaloutput -5VDC / < 2 ma, potential-free output -5VDC / Online-adapter with Minimess tubing M16x2 Bottle sample analysis (58 12 psi); online-analysis ( psi); Monitoring of ECOLINE UMP-45 by ARGO-HYTOS PODSWare for download, storage and management of PODS Pro data under Windows 9X/Me/2 and XP 18.7 lbs (B x H x T) 13 x 13.8 x 7.9 inches We produce fluid power solutions ARGO-HYTOS Inc. P.O. Box 28 Bowling Green, OH 4342 USA Tel: Fax: info.us@argo-hytos.com Subject to change us

9 Portable Particle Monitor OPCom portable Particle Counting The Easy Way Easy Compact Cost-Efficient

10 OPCom Portable Particle Counting The Easy Way Particle Counting Compact, Easy and Beneficial OPCom portable is a Plug and Play - Instrument with which the oil cleanliness of hydraulic and hydrostatic lubrication systems can be measured quickly and easily. It is simply connected to the sample port, switched on and gives results regularly. There is no easier way for particle monitoring. OPCom portable displays the cleanliness class according to ISO 446:1999. A computer can be connected to display curves graphically, to archive data and to display how the cleanliness in the system changes over the time. A lot of arising damages can be recognized and prevented. By setting up a database and observing over a longer period of time, the progress of cleanliness in a system at different operating states can be noticed. These insights could enable operators and engineers to optimize the machine and process. With this instrument everybody is easily able get a picture of the cleanliness of his hydraulic system. Technical Data Voltage: Pressure Range: Viscosity Range: 1 24 VDC Internal battery 12 VDC psi (see diagram) 1 2 cst (see diagram) Display: ISO-Classes according to ISO 446:1999 Size Channels: 4, 6, 14, 21 µm (c) Operating Conditions: Oil Temperature: F (viscosity has to be in the specified range) Ambient temperature: F Relative humidity: 1 9 % (non condensing) Interface: Weight: Dimensions L x W x H: Standard accessories: RS lbs 11.6 x 15.4 x 5.7 inches 2 minimess tubes, power cable, RS 232 data cable, software for data recording, manual Pressure and viscosity range Viscosity in SUS psi Permitted operating range 29 psi 3625 psi 116 SUS Pressure in psi Dimensions 11.6 inches 5.7 inches 15.4 inches We produce fluid power solutions ARGO-HYTOS Inc. P.O. Box 28 Bowling Green, OH 4342 USA Tel: Fax: info.us@argo-hytos.com Subject to change us

11 OPCom AS Particle Monitor for aerated lubricating fluids Eliminates Air Bubbles Compact Assembly Continuous monitoring Field of Application: Monitoring of Hydraulic Fluids or Lubricants such as Gear Oil that suffers from aeration. Design Description: The OPCom AS system consists of a pump, an OPCom particle monitor and a pressure relief valve. The pump delivers the oil to the OPCom particle monitor and the pressure relief valve which is set to a high pressure. Any air bubbles are compressed so that they either are solved by the oil or so small that they are not detected by the particle counter. A typical application is particle monitoring in aerated gear oil. NEW! Optionally with LubCos H 2 O+ Function Principle: Particle size and concentration is determined using the ISO recommended light extinction principle. The oil flows through the sensor at between 5 and 5 ml/min. A laser beam shines through the oil and is detected by a photo diode. A particle in the beam will decrease the detected intensity. The rate of decrease corresponds to the particle size. This optical principle detects everything which differs optically from the surrounding medium, such as air bubbles. Until now, it has been impossible to monitor gear oil using a particle counter for this very reason. The OPCom AS now allows Continuous Particle Monitoring for applications in this important field. Subject to change /2

12 Technical Data Power Supply Power Flow Rate Viscosity Range Weight Dimensions Connections Max. Inlet Pressure Media Size Channels Display Temperature Range Interface Data Memory 4 VAC,9 KW ca.,3 L/min mm 2 /s ca. 12,5 kg 32 x 383 x 135 inlet: G 1/8 outlet: G 3/8,5 Bar Mineral Oil and Biodegradable Hydraulic Liquids (HETG, HEES...) 4, 6, 14, 21µm(c) Cleanliness Classes acc.iso 446: C C RS 232 > 5 measurements We produce fluid power solutions ARGO-HYTOS GMBH Postfach 116 D Kraichtal-Menzingen Tel Fax info.de@argo-hytos.com 2/2

13 Pa r t i c l e M o n i t o r OPCom With laser diode Measurement range 4, 6,14 and 21 µm(c) Operating pressure up to 725 psi 1.1-1us

14 D e s c r i p t i o n Application As stationary particle monitor in hydraulic and hydrostatic lubrication systems. Performance features Protection: By continous controlling of the oil cleanliness, damage can already be recognized in the early stage. This offers the possibility of avoiding machine faults by suitable measures and of extending maintenance and oil change intervals. Special design features Modular Construction: The particle monitor consists of a sensor module and a communication module. The sensor module is selected according to the pressure and viscosity conditions in the working range, the communication module is chosen according to the requirements for data processing. Each sensor module is optionally also availabe with a display, from which the degrees of purity can be read off according to ISO 446:1999. Measurement principle: Standard Accessories DDE-Software Optical fibre optic cable, 19.7 ft Operating instructions The particle monitor operates according to the light extinction principle. The oil flows through the sensor with system pressure and approx ml/min. It is analyzed by a laser. Opposite of the laser a photodiode measures the weakening of the light with presence of a particle and calculates from it the particle size and number. For the tuning of the monitor on different pressure and viscosity ranges different variations of the sensor are selectable. For the installation of the particle monitor particularly lines are suitable in which no large pressure fluctuations and pressure peaks occur, like e. g. pilot oil lines. Under the designation OPCom portable a portable on-line monitor is available, with which by connection to a computer the measuring data can also be plotted and filed. For dimensions and technical data see brochure OPCom portable. Te c h n i c a l D a t a Size channels 4, 6, 14, 21 µm(c) Display Cleanliness classes according to ISO 446:1999 with additional decimal Concentration limit Class 29 according to ISO 446:1999 Operating pressure VDC at approx. 15 ma charging rate Fluid pressure max. 725 psi Temperature range -4 F F Viscosity range > 9 SUS Ambient conditions operation -4 F F, % rel. humidity, non condensing Ambient conditions storing -4 F F, < 98% rel. humidity, non condensing Dimensions System with display LxWxH: 3.7 x 3.4 x 1.8 inches System without display LxWxH: 3.7 x 3.4 x 1.4 inches Weight System with display 2.82 lbs System without display 2.78 lbs Hydraulic fluids Mineral oils and biodegradable fluids (HEES, HETG...) On request: Phosphate ester (e.g. Skydrol) Wetted materials SAE 12 steel, spring steel, synthetic sapphire, chrome, zinc, bronze, aflas, Buna-N Attention: Sensors for Skydrol do not contain Buna-N 268

15 D i a g ra m s Viscosity diagrams / permitted ranges for different sensor versions (see order terms) Viscosity as a function of the pressure (within working range) High pressure ( psi) 14 Medium pressure ( psi) ν [SUS] ν [SUS] p [psi] p [psi] Low pressure ( psi) 14 Without orifice ( psi) ν [SUS] ν [SUS] p [psi] p [psi] C o m m u n i c a t i o n I n t e r f a c e D e s c r i p t i o n Configuration only possible by infrared interface (IrDA). Data recording by computer or data logger over the following interfaces: RS-232 standard RS-232 DTE for serial printers or PDA connections Data logger or PLC systems: 8 channels with in each case - 5 VDC analog output RS-485 with MODBUS record for operation in the network Separate indication with programmable alarm limit and floating contact 269

16 O rder Te r m s The selection of the suitable OPCom takes place in two steps: OPCom 1. Definition of the sensor module and the indication 2. Selection of the communication version For the selection of the sensor module viscosity and pressure in the work area must be known. By means of these parameters the suitable version can be selected on the basis of the permissible ranges in the diagrams. High pressure with display 4 High pressure without display 1 Medium pressure with display 8 Medium pressure without display 7 Low pressure with display 9 Low pressure without display Without orifice with display 6 Without orifice without display 3 High flow with display 5 High flow without display 2 Standard RS RS-232 with DTE-configuration 2 Analog output -5 Volt and RS Separate display and alarm contact 4 Q u a l i t y A s s u ra n c e Quality management according to DIN EN ISO 91 Various quality controls during the production process guarantee the leakfree function and solidity of our filters. Our engineers will be glad to assist you with questions concerning filter application, selection and cleanliness class of the filtered medium attainable under practical operating conditions. Illustrations may sometimes differ from the original. ARGO-HYTOS is not responsible for any unintentional mistake in this specification sheet. We produce fluid power solutions ARGO-HYTOS Inc. P.O. Box 28 Bowling Green, OH 4342 USA Tel: Fax: info.us@argo-hytos.com Subject to change us 26 27