Automated Laboratory Particle Counter ALPC 9000 series

Automated Laboratory Particle Counter ALPC 9000 series

Operating and Maintenance Instructions

English (translation of original instructions)

Document No.: 3601005

ALPC 9000 series Trademarks

Trademarks

The trademarks of other companies are exclusively used for the products of those companies.

Copyright © 2011 HYDAC FILTER SYSTEMS GMBH all rights reserved

All rights reserved. This manual may not be reproduced in part or whole without the express written consent of HYDAC Filter Systems GmbH. Contraventions are liable to compensation.

Exclusion of Liability

We have made every endeavour to ensure the accuracy of the contents of this document. However, errors cannot be ruled out. Consequently, we accept no liability for such errors as may exist nor for any damage or loss whatsoever which may arise as a result of such errors. The content of the manual is checked regularly. Any corrections required will be incorporated in future editions. We welcome any suggestions for improvements.

All details are subject to technical modifications.

Technical specifications are subject to change without notice.

HYDAC FILTER SYSTEMS GMBHPostfach 12 5166273 Sulzbach / Saar

Germany

Documentation Representative

Mr. Günter Harge

c/o HYDAC International GMBH, Industriegebiet, 66280 Sulzbach / Saar

Telephone: ++49 (0)6897 509 1511

Telefax: ++49 (0)6897 509 1394

E-mail: [email protected]

HYDAC FILTER SYSTEMS GMBH en Page 2 / 68

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ALPC 9000 series Content


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Content

Trademarks ...............................................................................................................2

Documentation Representative...............................................................................2

Content......................................................................................................................3

Preface ......................................................................................................................5

Technical Support...................................................................................................6 Modifications to the Product ...................................................................................6 Warranty .................................................................................................................6 Using the Documentation .......................................................................................7

Safety information....................................................................................................8

Obligations and Liability..........................................................................................8 Explanation of Symbols and Warnings, etc. ...........................................................9 Proper/Designated Use ..........................................................................................9 Improper Use ........................................................................................................10 Procedure in an Emergency .................................................................................10 Maintenance, Servicing and Troubleshooting.......................................................10 Structural Modifications to the ALPC ....................................................................11 Electrical Hazards.................................................................................................11 Training and Instruction of Personnel ...................................................................12

Transporting the ALPC ..........................................................................................13

Storing the ALPC....................................................................................................13

Checking the Scope of Delivery............................................................................14

Description of the ALPC ........................................................................................15

Restrictions pertaining to use ...............................................................................16

Setting up the ALPC...............................................................................................16

ALPC dimensions / work areas .........................................................................17

ALPC components .................................................................................................18

Components of basic unit ALPC 9000-1...............................................................20 Safety door to the analysis room.......................................................................21 Mains box..........................................................................................................22 Electrical control................................................................................................23 Maintenance unit...............................................................................................24 Suction hose with suction screen - Flushing fluid tank - ...................................25 Return hose - Return tank.................................................................................25

Extension unit ALPC 9000-2.................................................................................26 Protective housing with safety door ..................................................................27 Emergency stop (S0) ........................................................................................28 Sustain vacuum manually (S5) .........................................................................28 Robot.................................................................................................................29 Robot controller.................................................................................................30

ALPC 9000 series Content


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Sample shaker ..................................................................................................32

Prior to switching the unit on................................................................................33

Switching on the ALPC..........................................................................................34

Preparing sample bottles for analysis..................................................................35

Adjust and secure the sample pallet in ALPC ...................................................37 Change sample pallets 100 / 100 / 30 (optional)...............................................38

Perform analysis.....................................................................................................40

Analysis and flushing process ..............................................................................41

Switching off the ALPC..........................................................................................45

Performing Maintenance........................................................................................46

Maintenance intervals / plan .................................................................................46 Carry out a lamp test on the mains box ................................................................48 Check the sealing ring on the pressure dome ......................................................48 Clean the suction screen on the flushing fluid tank suction hose. ........................48 Cleaning the oil pan ..............................................................................................49 Check / replace hoses ..........................................................................................50 Maintaining the maintenance unit .........................................................................51

Replacing the silencer.......................................................................................51 Changing the filter insert ...................................................................................52 Drain condensate ..............................................................................................53

Cleaning the sealing disk......................................................................................54 Change the sealing disk on the vacuum hand......................................................55 Replacing the vacuum hoses on the robot ...........................................................56

Dismantling the rear wall on the protective housing..........................................57 Replace the vacuum hoses...............................................................................58 Changing the silencer on the vacuum generator ..............................................58 Mounting the rear wall of the protective housing...............................................59

Pneumatic / hydraulic diagram .............................................................................60

Spare Parts List ......................................................................................................62

Spare Parts...........................................................................................................62

Disposing of the ALPC...........................................................................................62

Calibrating the ALPC..............................................................................................62

Customer Service...................................................................................................63

Germany ...............................................................................................................63 USA ......................................................................................................................63 Australia................................................................................................................63 Brazil .....................................................................................................................64

Technical data ........................................................................................................65

Model Code .............................................................................................................66

ALPC 9000 series Preface

Preface

For you, as the owner of a product manufactured by us, we have produced this manual, comprising the most important instructions for its operation and maintenance.

It is intended to help you become acquainted with the ins and outs of the product and use it properly.

You should keep it in the vicinity of the product so it is always at your fingertips.

Sometimes the information contained in the documentation cannot always keep up with changes made to the product as we attach considerable importance to keeping our products cutting-edge.Consequently, there might be deviations in technical details, illustrations and dimensions.

If you discover errors while reading the documentation or have suggestions or other useful information, please don’t hesitate to contact us:

HYDAC FILTER SYSTEMS GMBHTechnische DokumentationPostfach 12 5166273 Sulzbach / Saar

Germany

We look forward to receiving your input.

Our motto: “Putting experience into practice”


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Technical Support If you have any questions, suggestions, or encounter any problems of a technical nature, please don't hesitate to contact us. When contacting us, please always include the model/type designation and article no. of the product:

Fax: +49 (0) 6897 / 509 - 846


Modifications to the Product We would like to point out that changes to the product (e.g. purchasing options, etc.) may result in the information in the operating instructions no longer being completely accurate or sufficient.

When making modifications or performing repair work to components affecting the safety of the product, the product may not be put back into operation until it has been examined and released by a HYDAC representative.

Please notify us immediately of any modifications made to the product whether by you or a third party.

Warranty For the warranty provided by us, please refer to the General Terms of Sale and Delivery of HYDAC FILTER SYSTEMS GmbH.

Refer to these at www.hydac.com ð General terms and conditions.

http://www.hydac.com/


Using the Documentation

Please note that the method described above of locating specific information does not release you from your responsibility for carefully reading the entire manual prior to starting the unit up for the first time and carefully rereading the manual at regular intervals in the future.

WHAT do you want to know?

I determine which topic I am looking for.

WHERE can I find the information I’m looking for?

The document has a table of contents at the beginning. I select the chapter I'm looking for and the corresponding page number.

deHYDAC Filtertechnik GmbHBeWa 123456a de

Seite x

Produkt / Kapitel

200x-xx-xx

Chapter

Page number

Edition date

Document language Documentation No.with Index /

File name

The documentation number with its index enables you to order another copy of the operating and maintenance instructions. The index is incremented every time the manual is revised or changed.


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ALPC 9000 series Safety information


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Safety information

These operating instructions contain the key instructions for properly and safely operating the ALPC.

Obligations and Liability

The basic prerequisite for the safe and proper handling and operation of the ALPC is knowledge of the safety instructions and warnings.

These operating instructions in general, and the safety precautions in particular, are to be adhered by all those who work with the ALPC.

Adherence is to be maintained to pertinent accident prevention regulations applicable at the site where the product is used.

The ALPC has been designed and constructed in accordance with the current state of the art and recognized safety regulations. Nevertheless, hazard may be posed to the life and limb of the individual using the product or to third parties.

The ALPC is only to be used as follows:

Solely for its designated use

only when in a safe, perfect condition

Immediately remedy any malfunctions that might impair safety.

Always keep the operating and maintenance instructions near the measurement device.

As a supplement to the operating instructions, the general as well as the local regulations regarding accident prevention and environmental protection should be made available and observed.

Ensure that all information relating to safety and potential hazards of the ALPC are kept in a legible condition. Replace them if necessary.

Check the hoses and connectors for leaks on a daily basis.


Explanation of Symbols and Warnings, etc.

The following designations and symbols are used in this manual to designate hazards, etc.:

DANGER DANGER denotes situations which can lead to death if safety precautions are not observed.

WARNING WARNING indicates hazardous situations which can result in fatal injuries if not complied with.

DANGER DANGER denotes situations which can lead to severe injuries if safety precautions are not observed.

NOTICE NOTICE denotes situations which can lead to property damage if safety precautions are not observed.

Proper/Designated Use

The ALPC is a fully automated laboratory particle counter for the analysis of hydraulic and lubricating fluids in oil analysis laboratories.

Analyzing the size and quantity of contamination enables quality standards to be verified and documented, and the requisite optimization measures to be implemented.

Any other use shall be deemed to be improper and not in keeping with the product's designated use.

Proper or designated use of the product extends to the following:

Maintaining adherence to all the instructions contained herein.

Performing requisite inspection and maintenance work.


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Improper Use

Any use deviating from the proper/designated use described above is prohibited.

Improper use may result in hazard to life and limb.

Example of improper use:

Sampling of fluid with a flash point of < 55°C

Flushing with fluid with a flash point of < 55°C

Procedure in an Emergency

Activate the EMERGENCY STOP switch in an emergency (S0).

Maintenance, Servicing and Troubleshooting

The prescribed adjustment, maintenance/servicing and inspection work is to be conducted in a timely fashion.

All operating media are to be protected in case the product is accidentally started up.

When performing any maintenance, servicing, inspection or repair work, disconnect the ALPC from the power supply and ensure that it cannot be switched back on inadvertently.

Any screwed fittings which have been undone/removed are to be checked to see that they have been properly resecured.

Once maintenance work is complete, check that the safety devices are still working properly.


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Structural Modifications to the ALPC

Do not make any modifications to the ALPC.

Any modifications require written permission from HYDAC FILTER SYSTEMS GMBH.

Immediately replace any parts which are not in perfect condition. Use only original spare parts (OEM).

Electrical Hazards

DANGER Electric shock

Danger of fatal injury

► Any work involving electrical equipment may only

be done by a properly trained, certified electrician.

► Pull the power plug before performing work on live parts.

Regularly check the ALPC electrical equipment.

Fix any loose connections immediately.

Always keep the control cabinet locked.


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Training and Instruction of Personnel

The owner is obliged to only let persons work on the ALPC, who:

are familiar with the fundamental occupational safety and accident prevention regulations and have been properly instructed in the use of the ALPC.

have read and understood these operating instructions.

The ALPC may be operated only by properly trained and instructed personnel.

The areas of responsibility of your staff must be established in a clear-cut manner.

Staff undergoing training may not use the ALPC unless supervised by an experienced staff member.

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Activity

Packing Transportation X X X

Putting into operation X X X

Operation X X X X

Troubleshooting/ locating the source of malfunction

X X X

Remedying of mechanical faults X X

Remedying of electrical faults X X

Maintenance X X X X

Repair work X

Decommissioning/storage X X X

X = other

voltage

ALPC 9000 series Transporting the ALPC


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Transporting the ALPC

Dismantle the ALPC completely into its individual components for transport.

Storing the ALPC

Pull power plug. Coil up the power cable and fix it to the ALPC.

Drain the reservoirs and filters of the ALPC completely before putting it into extended storage.

Store the ALPC in a clean, dry room, with the following conditions:

Storage temperature: 0 … 70°C / 32 … 158°F

Humidity: Maximum 90%, non-condensing

Air: dust-free, no salty air, not in the vicinity of oxidizing substances (flash rust, rust bloom)

ALPC 9000 series Checking the Scope of Delivery


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Checking the Scope of Delivery

The ALPC is handed over ready for operation.

The following items are supplied:

Qty. Description

1 ALPC 9000 series

1 Operating and maintenance instructions

1 ALPCDesk Software Manual

1 Documentation on the robot

1 Calibration certificate

1 EC declaration of conformity

1 Support CD

1 CD with driver to the PC

ALPC 9000 series Description of the ALPC


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Description of the ALPC

The ALPC is a fully automated laboratory particle counter for the analysis of hydraulic and lubricating fluids in oil analysis laboratories.

A sample pallet with samples is positioned on a sample shaker next to the particle counter; each sample is individually added to the particle counter.

The sample shaker serves to keep the samples homogenized. Prepare the samples before adding them into the sample pallet.

You can file an ID number for each sample as a reference in the ALPCDesk software.

Initiated by pressing a key on the PC keyboard or by clicking on the mouse, the particle counter carries out an automatic analysis of the sample.

The analsysis of a sample is only accepted if the measurement values of two subsequent sample runs lie within a predefined tolerance.

The analysis of a sample is rejected if it does not lie within a predefined tolerance after five sample runs. The number of maximum sample runs can be defined in the ALPCDesk software.

The ALPC flushes the sensor manually after the key is pressed, or automatically after each sampling procedure. The flushing fluid is analysed during the flushing process. The flushing process can be controlled according to the level of contamination or the time.

The recorded data (particle numbers and ISO codes) are stored on the hard drive. You can call up these measurement values again at any time using the ALPCDESK software.

ALPC 9000 series Setting up the ALPC

Restrictions pertaining to use

WARNING Fire hazard

Danger of bodily injury

► Only test / check fluids with a flash point 55°C /

131°F 56°C / 133°F 55°C / 131°F

NOTICE

Unpermitted fluids

The ALPC will be damaged.

► The ALPC is only to be used with mineral oils or mineral oil-based raffinates.

► Only use liquids which are compatible with the installed materials and the sealing materials.

► Only use fluids with a flashpoint 55°C / 131°F

► Ensure that the flushing fluid has a substantially better cleanliness class than the cleanliness class expected from the sample (e.g. ISO 15/12/9).

Setting up the ALPC

In order to set up and operate the ALPC, please provide the following at the building site:

- Supply voltage 230 V AC / 50 Hz

- Clean, dry compressed air

- Space or a table with a load capacity of at least 260 kg

- Flushing fluid tank

- Return tank


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ALPC 9000 series Setting up the ALPC

ALPC dimensions / work areas

Please observe the work areas marked green and grey around the ALPC, which are always freely accessible.

All dimensions in mm.


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ALPC 9000 series ALPC components

ALPC components

The ALPC consists of the following components:


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Item Designation Further details

on page

1 Basic unit ALPC 9000-1 20

2 PC

3 Monitor

4 Keyboard with touchpad

5 Flushing pump

6 Collecting pan

7 Mains box Fehler! Textmarke

nicht definiert.

8 Electrical control 23

9 Maintenance unit 24

10 Flushing fluid tank 25

11 Suction hose with suction strainer 25

12 Return tank 25

13 Return hose 25

20 Extension unit ALPC 9000-2 26

21 Protective housing with safety door 27

22 Safety door 27

24 Robot 29

25 Robot controller 30

26 Teaching box for robot controller 31

27 Vacuum hand

28 Sample pallet 37

29 Sample shaker 32

30 EMERGENCY STOP switch (S0) 28

31 Vacuum manual on (S5) 28


Components of basic unit ALPC 9000-1

The ALPC basic unit consists of the following components:

Item Description

1 Pressure dome

2 Suction tube

3 Dome closure

4 Flushing funnel

5 Safety door to the analysis room

B1 Particle sensor

M1 Metering pump

M2 Flushing pump


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Safety door to the analysis room

Open the analysis room by pushing back the safety door (B). After adjusting the sample bottle, close the safety door by pulling it forward to the stop. The ALPC-1 only works if the safety door is closed.

If you use the extension unit ALPC-2 in automatic function, the safety door must always stay open.

The safety door to the analysis room has a door contact in open and closed setting. If these contacts signalize an incorrect door position, the ALPC will not work.


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Mains box

Item Function Inscription

A Main switch

B Readiness indication Power ON

C Lamp test LAMP TEST

D Fault lamp, robot Fault, robot

E Fault lamp, flushing pump Fault, flushing pump

F No function Reserve

G Fault message, sample shaker Fault shaker

H Sockets for peripheral devices


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Electrical control

You will find the following components in the electrical control cabinet:

Item Description

A4 Power supply unit sensor

A5 Control, metering pump

P2 Pressure switch

Y2 Vacuum retaining valve

1 Valve terminal


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Maintenance unit

The maintenance unit consists of the following components:

Item Description

9.1 Start-up valve, manual V1

9.2 Filter control valve FR

9.3 Filter element, 5 µm

9.4 Pressure gauge, 0-10 bar

9.5 Branch module

9.6 Switch-on valve, electrical Y0

9.7 Fine filter FF

9.8 Filter element, 1 µm

9.9 Branch module

9.10 Pressure switch P3

9.11 Silencer


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Suction hose with suction screen - Flushing fluid tank -

The flushing fluid tank must be provided by the customer.

Check daily prior to starting the analysis for sufficient flushing fluid

Rub the suction hose (S) down with a clean, lint-free cloth prior to inserting it into the flushing fluid tank.

Insert the suction line (S) including the suction screen down to the floor of the flushing fluid tank.

Return hose - Return tank

The return tank must be provided by the customer.

Empty the return tank daily prior to the start of the analysis.

Ensure that the return line is always above the flushing fluid. Only this guarantees quick drainage of the flushing fluid.


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Extension unit ALPC 9000-2

The extension unit with the robot serves the automatic analysis of sample bottles on a prepared sample pallet.


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Protective housing with safety door

Open the sample room by lifting the safety door handle (A). After filling the pallet with samples, close the safety door down to the stop.

The ALPC only works if the safety door is closed.


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Emergency stop (S0)

Actuate the Emergency stop switch in hazardous situations.

After actuating the Emergency stop switch, the ALPC is de-energized after the mains box and the compressed air supply is blocked. Any vacuum is interrupted immediately.

Sustain vacuum manually (S5)

On actuating the Emergency stop switch or on opening the safety door manually, the vacuum is interrupted immediately. The means that any sample located on the vacuum hand will drop off.

In order to sustain the vacuum, press the "Vacuum ON" button


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Robot

The robot consists of the following components:

Item Description

1 Robot

2 Vacuum hand with drip catcher

3 Sealing disc

4 Vacuum hose

5 Silencer

6 Vacuum generator


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Robot controller

The robot controller controls the robot. The programs required for the ALPC operation are stored and can be called up. This controller has a separate supply voltage and its own On / Off switch.

Ensure before and during operation that the Emergency stop button is not actuated and that the key switch is in the "AUTO (Ext.)“ position.

The robot is stopped immediately by pressing the Emergency stop button on the robot controller. In order to release the Emergency stop button, turn it to the right.

Item Description

1 Emergency stop switch

2 On/Off switch

3 Key switch


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Teaching box for robot controller

You or HYDAC Service need the Teaching box to carry out robot position corrections. In standard ALPC operation, you do not require the Teaching box.

Always keep the Teaching Box at hand for HYDAC Service centre service procedures.


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Sample shaker

The sample shaker has the following components:

Item Description

1 Plate for holding the sample pallet

2 Register pins for centring the sample pallet

3 Quick action chuck

4 Sample shaker


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ALPC 9000 series Prior to switching the unit on


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Prior to switching the unit on

Before switching the ALPC on, proceed through the following steps:

1. Check the flushing fluid tank for sufficient stocks of flushing fluid.

2. Check the suction hose. The suction hose must be located in the flushing fluid and may not draw in any air.

3. Empty the flushing return tank.

4. Check the return hose. The return hose must be located in the return tank.

5. Check all hoses for leaks and screw connections for signs of leakage.

6. Empty the collecting pans. If there is a lot of fluid located here, this may be an indication of leakage.

7. Check the O-ring on the pressure dome as described on page 48.

8. Clean the sealing disk on the vacuum hand as described on page 54.

9. Check the position on the EMERGENCY STOP switch (see page 28)

10. Check the switch positions on the robot controller (see page 30).

11. Check the maintenance unit (9).

Switch the compressed air for module V1 on.

Check the pressure on the pressure gauge. At least 6 bar are required for operation.

Drain any condensate / oil on the modules FR and FF.

12. Check the pressure dome position. If the pressure dome is located in the upper position, you can continue with Step (13).

If the pressure dome is located in a intermediate position, switch on the output (A003 - move dome upward) manually via the ALPCDesk software on I/O mode, and the pressure dome will move into the required upper position.

13. The preparations for switch-on have been completed. Continue to Chapter "Switching on the ALPC“ on page 34.

ALPC 9000 series Switching on the ALPC


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Switching on the ALPC

To switch on the ALPC, proceed as follows:

1. After you have undertaken the steps in Chapter "Prior to switching the unit on“ on page 33:

2. Switch the PC on at the on/off switch.

3. Switch the ALPC on at the mains box main switch.

4. Carry out a lamp test on the mains box (see page 48).

5. Start the program ALPCDesk on the PC.

A detailed description of the ALPCDesk software can be found in the enclosed software instructions.

6. The ALPC is now ready for the analysis.

ALPC 9000 series Preparing sample bottles for analysis

Preparing sample bottles for analysis

Prepare the sample bottles for use as follows:

1. Check the sample bottles for sufficient filling. For an analysis, at least 50 ml fluid are required.

2. Shake the sample bottle vigorously for ~ 1 minute. Afterwards, the deposited (sedimented) contamination is dissolved and evenly distributed in the fluid.

3. Let the sample bottle sit ~ 15 minutes or place the bottle in an ultrasonic bath.. This allows air bubbles which resulted from the "Test fluid" to escape.


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4. Turn over the sample bottle for ~ 1 minute.

5. Check the sample bottle for deformation and damage to the bottle neck.

In order to be taken up by the vacuum hand, the sample bottle must be smooth and undamaged.

Deformed or damaged sample bottles cannot be automatically checked. Add these sample bottles manually to the ALPC.

6. If the sample bottle is filled up to the edge, remove the fluid to the filling mark.

7. The sample bottle is now prepared for analysis.


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Adjust and secure the sample pallet in ALPC

NOTICE

Different sample bottle sizes

The ALPC is damaged; the analysis is cancelled.

► Use only one sample bottle size per sample pallet.

Place the prepared sample pallet onto the sample shaker and align the pallet at the stops (X). Secure the sample pallet with the fast clamping device (L).


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Change sample pallets 100 / 100 / 30 (optional)

NOTICE

Deviating sample bottle sizes / adaptor rings

The ALPC will be damaged

► Use only one sample bottle size per sample pallet.

► Only use the permitted sample bottles in the appropriate pallet.

► Replace the appropriate adaptor ring in the pressure dome when the pallet is changed.

The optionally available change pallets always have the same raster for holding max. 45 sample bottles.

Each change pallet is suitable for holding a certain type of sample bottle and has a colour code.


In the following you will find the allocation of the colour code to the sample bottle type:

Adaptor ring Colour Sample jar

red

30 ml, glass

blue

100 ml, plastic MIDLAND, Monroe

green

100 ml, glass


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ALPC 9000 series Perform analysis

Perform analysis

Close the safety door (A) to the sample room or (B) to the analysis room.

Start the analysis of the sample bottles via the ALPCDesk software on the PC.

All further processes and the sample analysis for the ALPC using the data you have entered.


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Analysis and flushing process

The analysis and flushing process is divided into nine phases which are presented below in the individual Figs.

1

2

4

3

5

6

Item Description

1 Particle sensor

2 Pressure dome

3 Suction tube

4 Flushing funnel

5 Sample bottle

6 Dome floor / dome closure


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Phase description:

Phase Description

1. The ALPC is ready.

The cleaned system is waiting for sample analysis.

2. The sample bottle is adjusted in the dome manually or using the robot.

3. The optical sample bottle detector automatically detects the adjusted sample bottle.

The pressure dome will close.

4. The pressure dome is pressurized. Here the pressure switch monitors the required pressure in the dome.


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Phase Description

5. The sample bottle is analysed.

The sample is brought to the sensor due to the pressure in the pressure dome.

The metering pump specifies the flow rate through the sensor.

6. The pressure dome is depressurized.

7. The pressure cover opens.

8. The sample bottle is removed from the pressure dome.



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Phase Description

9. The optical sample bottle detector detects the empty dome and swivels the funnel-shaped collector under the pressure dome. Then the ALPC starts by flushing the suction tube inside and outside.

This flushing process can be controlled through the level of contamination or through time.

1. The ALPC is ready for the next sample analysis.

ALPC 9000 series Switching off the ALPC

Switching off the ALPC

To switch off the ALPC, proceed as follows:

1. Shut down the PC and switch it off.

2. Switch off the ALPC at the main switch on the mains box.

3. Close the compressed air supply at the maintenance unit with the lever (B).

The pressure from the ALPC is released via the silencer.

4. The ALPC is switched off and depressurized.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

ALPC 9000 series Performing Maintenance


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

Performing Maintenance

The maintenance and servicing to be performed periodically is described here. The ALPC's serviceability, operational reliability and life substantially depend on performing maintenance and servicing work regularly and carefully.

Maintenance intervals / plan

Det

ails

on

pag

e

8 h

ou

rs o

r d

aily

300

ho

urs

or

ever

y si

x m

on

ths

Eve

ry 6

000

ho

urs

o

f o

per

atio

n o

r ye

arly

Perform a lamp test on the mains box 48 X

Test / fill the flushing fluid tank 25 X

Test / empty the flushing fluid return tank 25 X

Check / clean the sealing disk on the vacuum hand 54 X

Check the sealing ring on the pressure dome 48 X

Clean the oil collecting pan 49 X

Check all warning guidelines / safety stickers for legibility

X

Check all compressed air hoses for: - Damage due to kinks - Flexibility - Tightness / leakages - Tight fit of the screw-in and plug-in connections

X

Check all the electrical connections. Look for any damage to wires, connectors, sensors, cabling and electrical equipment in the control cabinet.

X = other volta

ge

Check all compressed air hoses for: - Damage due to kinks - Flexibility - Tightness / leakages - Tight fit of the screw-in and plug-in connections

X = other volta

ge

Check that all of the shut-off valves are working properly

X

Check the maintenance unit for: - Adjusted air pressure - Condensate / water

51 X

Check all flushing and return hoses for: - Damage due to kinks

X



BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

Det

ails

on

pag

e

8 h

ou

rs o

r d

aily

300

ho

urs

or

ever

y si

x m

on

ths

Eve

ry 6

000

ho

urs

o

f o

per

atio

n o

r ye

arly

- Flexibility - Tightness / leakage - Tight fit of screw-in and plug-in connections

Check all screw-in connections X

Replace the sealing disk on the vacuum hand 55 X

Replace the filter elements on the maintenance unit 51 X

Replace all compressed air hoses 50 X

Replace all flushing fluid / return hoses X


Carry out a lamp test on the mains box

Press the (B) key on the mains box to test the lamp. All the lamps in the keys / switches should now light up.

Do not replace lamps which are not lit up immediately.

Check the sealing ring on the pressure dome

Check the sealing ring on the pressure dome daily for damage and swelling.

Replace it if necessary.

The O-Ring must lie against the pressure dome.

Clean the suction screen on the flushing fluid tank suction hose.

Clean the suction screen on the flushing fluid suction hose by blowing it out with compressed air.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06


Cleaning the oil pan

The ALPC has an oil collecting pan under each module.

Clean this oil collecting pan daily. To do this, pull the oil collecting pan on the handle (B) out forwards and rub off any fluid residues.

Observe that these residues may indicate a leakage on the ALPC. If this is the case, contact HYDAC.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06


Check / replace hoses

The hoses used must have been designed for use with the permissible test liquids concerned.

The hoses must be checked regularly for brittleness. Replace them if necessary.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06


Maintaining the maintenance unit

Carry out the maintenance work on the maintenance unit regularly as described below.

Replacing the silencer

Replace the silencer by screwing it out using an open-jaw wrench clockwise. Then screw in the new silencer counterclockwise by hand and tighten it slightly using an open-jaw wrench.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06


Changing the filter insert

1. Close the compressed air supply on valve V1.

2. Unscrew the filter bowl (A1) using a wrench clockwise.

3. Remove the filter element, 5 µm (B1) / filter element, 1 µm (B2) and dispose of it properly in an environmentally correct manner.

4. Clean the inside of the filter bowl (A) using a soft, lint-free cloth.

5. Insert the new filter element (B) into the mount.

6. Screw the filter bowl (A) from below into the filter head counterclockwise and tighten it slightly using a wrench.

7. Open the compressed air supply on valve V1.

8. The filter element change is now complete.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06


Drain condensate

1. Close the compressed air supply on valve V1.

2. Unscrew the drain plug on the underside of the filter bowl.

3. Collect the condensate with a suitable container.

4. Then screw the drain plug into the filter bowl again and tighten it firmly.

5. Open the compressed air supply on valve V1.

6. The condensate drainage procedure is now complete.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06


Cleaning the sealing disk

NOTICE

Unpermitted cleaning agents

The sealing disk will become damaged / unusable

► Clean the sealing disk daily by rubbing it with a lint-free cloth.

► For severe contamination, use kerosene or n-heptane.

► Do not use any aggressive, severe cleaning agents or those containing solvent.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06


Change the sealing disk on the vacuum hand

To change the sealing disk on the vacuum hand, proceed as follows:

1. Screw out the screw (A) using a wrench (wrench opening 10) out clockwise.

2 Remove the lock washer and washer (B).

3. Pull the lower, old sealing disk (C) carefully off the vacuum hand and dispose of it in an environmentally friendly manner.

4. Clean the sealing surface on the vacuum hand.

5. Put the screw (A) including the lock washer and washer (B) through the hole in the new sealing disk (C).

6. Screw in this package with the screw manually in counterclockwise direction into the underside of the vacuum hand and tighten the screw slightly with a wrench (wrench opening 10)

7. The procedure for changing the sealing disk (C) is completed.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06



BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

Replacing the vacuum hoses on the robot

In order to replace the vacuum hoses on the robot, please proceed as follows:

Step Description Page

1. Dismantling the rear wall on the protective housing 57

2.. Replace the vacuum hoses 58

3. Changing the silencer on the vacuum generator 58

4. Mounting the rear wall of the protective housing 59


Dismantling the rear wall on the protective housing

WARNING Caution: Working robots

Danger of bodily injury

► Switch off the main switch at the mains box before opening the protective housing.

In order to dismantle the rear wall for protective housing, proceed as follows:

1. Carefully unscrew the four safety screws counterclockwise using a 3 mm Allen wrench. Only unscrew until the bolts in the closure are loose.

2. Lift the rear wall out upwards out of the closure.

3. Then pull the rear wall back out of the protective housing.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06


Replace the vacuum hoses

In order to change the vacuum hoses on the robot, press the upper rung on the fitting downwards (1) and pull out the hose upwards (2).

Changing the silencer on the vacuum generator

Change the silencer by screwing it out using an open-jaw wrench clockwise, then screw in the new silencer counterclockwise manually and tighten it slightly using the open-jaw wrench.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06


Mounting the rear wall of the protective housing

In order to mount the rear wall of the protective housing, proceed as follows:

1. Lift the rear wall in the protective housing over the closures.

2. Lower the rear wall evenly downwards into the four closures.

3. Screw in the four safety screws clockwise using a 3mm Allen wrench and tighten them slightly.


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

ALPC 9000 series Pneumatic / hydraulic diagram

Pneumatic / hydraulic diagram

Y1.3 Y1.2 Y1.1 Y1.0

B1.2B1.3

Compressed AirInlet

B1.0B1.1

Domelock

Funnel

Waste Flushing Fluid

Metering Pump

Particle Sensor

Flushing Pump

Pressure Dome

B1.5

B1.4

Vacuum Hand

Vacuum Gauge

Valve terminal

P3

P2

P4

P1

B1

V4V3

Emergency release

Y1.5

Vacuum Generator

Y1.4

V1 FR FFY0

242424

24

24

M1

M2

V5

V6V7

VG

SampleBottle

A10

A11

A12

V2

IP

2

1

Y2

Item Description

V1 Compressed air manual switch

V2 Manual actuation, dome slide

V3 Check valve, flushing path suction tube inside

V4 Check valve, flushing path suction tube outside

V5 Throttle valve, fine adjustment flushing path inside

V6 Throttle valve, coarse adjustment flushing path outside


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

ALPC 9000 series Pneumatic / hydraulic diagram


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

V7 Throttle valve, coarse adjustment flushing path inside

P1 Pressure switch, vacuum

P2 Pressure switch, dome pressure

P3 Pressure switch, compressed air supply

P4 Pressure switch, flushing pressure

M1 Metering pump

M2 Flushing pump

B1 Particle sensor

Y0 Compressed air valve, compressed air supply

Y1.0 Compressed air valve, dome pressure

Y1.1 Compressed air valve, flushing funnel

Y1.2 Compressed air valve, dome closure

Y1.3 Compressed air valve, cylinder dome open

Y1.4 Compressed air valve, cylinder dome off

Y1.5 Compressed air valve, vacuum generator

Y2 Compressed air valve, to sustain vacuum

A10 Cylinder flushing funnel

A11 Cylinder dome closure

A12 Cylinder dome, open/close

FR Filter regulator, 5 µm

FF Fine filter, 1 µm

VG Vacuum generator

ALPC 9000 series Spare Parts List


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

Spare Parts List

Use only original spare parts to ensure safe operation of the attachment.

When ordering spare parts, always indicate the unit designation (type, material no., serial no., year of manufacture).

Spare Parts

Description P/no. Qty.

Prefilter cartridges, 5 µm (maintenance unit) 6003897 1

Fine filter cartridges, 1 µm (maintenance unit) 6029421 1

Silencer (maintenance unit) 6006823 2

Suction screen on suction hose 3524412 1

Sealing disk on vacuum hand 3092667 2

Vacuum hose, exchange set, consisting of : - 2x vacuum hoses on robot - 1x silencer

3600716 1

O-ring on the pressure dome 685498 1

Disposing of the ALPC

When decommissioning and/or disposing of the unit, observe all local guidelines and regulations pertaining to occupational safety and environmental protection. This applies in particular to the analysis fluid in the unit, components covered with oil and electronic components.

After disassembling the unit and separating the various materials, reuse them or dispose of them properly in accordance with local regulations.

Calibrating the ALPC

We recommend a recalibration through one of the stated service facilities each year.

ALPC 9000 series Customer Service


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

Customer Service

Current contacts for product support/customer service, repair and spare parts can always be found on our website at www.hydac.com.

For calibration, contact one of the following HYDAC national subsidiaries:

Germany

HYDAC Service GmbH Product Support, Werk 10 66128 Saarbruecken

Telephone: +49 (0) 6897 509 1938

Telefax: +49 (0) 6897 509 1933


USA

HYDAC Technology Corporation, HYCON Division 2260 City Line Road USA-Bethlehem, PA 18017 P.O. Box 22050 USA-Lehigh Valley, PA 18002-2050 Telephone: +1 (0) 610 266 01 00

Telefax: +1 (0) 610 231 04 45


Internet: www.hydacusa.com

Australia

HYDAC Pty. Ltd. 109 Dohertys Road P.O. Box 224 AUS-3025 Altona North

Telephone: +61 - 3 - 92 72 89 00

Telefax: +61 - 3 - 93 69 89 12


http://www.hydac.com/

ALPC 9000 series Customer Service


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

Brazil

HYDAC TECNOLOGIA LTDA Estrada Fukutaro Yida, 225 CEP 09852-060 Cooperativa BR-São Bernardo do Campo – SÃO PAULO

Telephone: +55 - 11 - 4393.6600

Telefax: +55 - 11 - 4393.6617


Homepage www.hydac.com.br

ALPC 9000 series Technical data


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

Technical data

Self-diagnosis: Continuous self-monitoring with error indication on the PC

Measurement range (calibrated): ISO 0/0/0 … 23/21/18

Calibration according to ISO 4402 Particle sizes: 5, 10, 15, 20, 25, 50, 75 and 100 µm

Calibration acc. ISO 11171 Particle sizes: 4, 6, 10, 14, 18, 21, 38 and 50 µm(c)

Measured volume per test run 5 ml

Analysis volume per measurement 10 … 25 ml (adjustable)

Analysis volume At least 50 ml

Measurement flow rate: 30 ml/min

Permissible viscosity range: 1 … 320 mm²/s at 20 °C

Permitted fluid temperature range (sample)

0 … 50°C / 32 … 122°F

Flushing fluid Fluids on mineral oil basis (preferably kerosene) with a flash point > 55 °C / 131 °F

Cleanliness class substantially better than the expected cleanliness class of the sample (e.g. ISO 15/12/9)

Flushing flow rate 200 ml/min

Supply voltage 230 V AC , 50/60 Hz

Power consumption Max. 2000 W

Permissible ambient temperature 10 … 45 °C / 50 … 113 °F

Permitted relative air humidity 30 … 70 %

Permitted temperature range for storage

0 … 70 °C / 32 … 158 °F

Compressed air supply > 6 bar, flow rate ~ 60 l/min

Weight

ALPC 9000-1 ~ 100 kg

ALPC 9000-2 ~ 160 kg

ALPC 9000 series Model Code


BEWA ALPC9000 3601005 en 2011-04-07.doc 2011-04-06

Model Code

ALPC 9000 - 1 - M - WXPDE - DE

Product ALPC = Automated laboratory particle counter Series 9000 = 9000 series Sample supply 1 = Manual 2 = Automatic Supply voltage M = 230 V AC , 50/60 Hz / 1 Phase PC-Operating system WXPUS = Windows XP, language US WXPDE = Windows XP, language DE W7 = Windows 7, Multilingual Keyboard layout BE = Belgium CH = Switzerland DE = Germany DK = Denmark ES = Spanish FR = France GB = England IT = Italy NO = Norway PO = Portugal SF = Sweden / Finland US = USA RU = Russia PL = Poland SK = Slovakia

HYDAC FILTER SYSTEMS GMBH Industriegebiet Postfach 1251 66280 Sulzbach/Saar 66273 Sulzbach/Saar Germany Germany Phone: +49 (0) 6897 509 01 Central Fax: +49 (0) 6897 509 846 Technical Department Fax: +49 (0) 6897 509 577 Sales Department Internet: www.hydac.com E-Mail: [email protected]

Documents

Automated Laboratory Particle Counter ALPC 9000 series