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g icountLCM20 Condition
Monitoring Handbook
P.849101_CM20_GB_VerA
2010, Parker Hannifin Corporation
www.parkerhfde.com
g
Laser Information
This product contains an invisible infrared 5mW laser.
Any dismantling of the product may result in dangerous exposure to laser radiation.
DANGER
INVISIBLE LASER RADIATION
WHEN OPEN. AVOID DIRECT
EXPOSURE TO BEAM.
The internal protective housing label which is mounted on laser module contains the following
information:
This product is a Class I laser product which complies with both USA21 CFR 1040.10 & 1040.11
and (BS) EN 608285-1
NOTE: Users are not required to access the laser radiation source and should never do so.
Contents
Laser Information......................................................................................2
Introduction.............................................................................. 4
Features.....................................................................................................4
Benefits......................................................................................................5
Powering the icountLCM20.......................................................................8
Installing paper and ribbon into the printer...........................................10
Getting started....................................................................... 12
Setting the time.......................................................................................12
Setting the date.......................................................................................13
Basic operation....................................................................... 14
Independent flow test..............................................................................16
ISO mode.................................................................................................17
NAS mode................................................................................................18
SAE mode................................................................................................19
GOST mode..............................................................................................20
Entering a test identification code..........................................................21
Bar code wand.........................................................................................22
Printing test results................................................................................23
Viewing and printing a stored test by ID code or test number...............24
Printing a stored test as a graph.............................................................25
Alarm levels.............................................................................................26
Automatic testing....................................................................................28
Calibration...............................................................................................29
Adjusting screen brightness...................................................................29
Additional (optional) features..................................................................29
Reference............................................................................... 30
Data interpretation..................................................................................30
ISO contamination charts........................................................................37
Component cleaning guidelines..............................................................40
Fluid flow schematic...............................................................................41
Logic diagram..........................................................................................41
Peripherals and serial interface.............................................................42
Measurement accuracy...........................................................................42
Diagnostic codes.....................................................................................43
Technical specifications..........................................................................45
Installation dimensions...........................................................................46
Dual fluids monitor - icountLCM202061.................................................47
Operation checklist.................................................................................48
Ordering information...............................................................................49
Introduction
The icountLCM20 Contamination Monitor from Parker The real benefits to be gained from the icountLCM20 are
represents the most up-to-date technology in solid achieved through regular use, particularly as an effective
particle contamination analysis, and is the first truly comparator.
portable monitor.
With a typical test taking only two minutes, the
The icountLCM20 is a complex instrument, but at the icountLCM20 is ideal for use as your standard fluid
same time has reliability, simplicity and ease of operation contamination monitoring instrument.
designed-in.
Above all, the icountLCM20 has been designed for
This owners manual has been carefully prepared to guide practical use.
you, the user, step-by-step through how to get started,
how to obtain measurements and how to interpret
the results. Information on the Dual fluids monitor
icountLCM202061 is also included on page 47.
Features
Test time 2 minutes
Repeat test time Every 2 minutes
Principle of operation Optical scanning analysis and measurement of actual particulates
Particle counts MTD: 4+, 6+, 14+, 21+, 38+ and 70+ microns
ACFTD: 2+, 5+, 15+, 25+, 50+ and 100+ microns
International Codes ISO 722; NAS 012; SAE 012
Data entry 32 character two line dot matrix LCD. Full alphanumeric entry facility on keypad
Data retrieval Memory access gives test search facility
Calibration By recognised on-line methods confirmed by the relevant International Standard
Organisation procedures.
MTD Via a certified primary ISO 11171 automatic particle counter using ISO 11943
principles, with particle distribution reporting to ISO4406:1999.
ACFTD Conforming to ISO 4402 principles with particle distribution reported to ISO
4406:1996 with the additional 2 channel included for reference.
Recalibration Consult Parker
Max. working pressure 420 bar
Max. flow rate 400 l/min when used with System 20 Sensors. Higher with Single Point Sampler
(Consult Parker)
Working conditions The icountLCM20 will operate with the system working normally
Memory store 300 test (scrolling memory) capacity
Computer compatibility Interface via RS232 connection @ 9600 baud rate
Portability Weighs only 8kg with its own battery pack
Power requirement Battery module or via the 12Vdc input
System connection Via System 20 Inline Sensors or the Single Point Sampler
Printer facility Integral 16-column printer for hard copy data
Leak-free sampling System 20 Sensors ensure sealed fluid extraction and no contamination ingress
Certification This product complies with all relevant EC declarations of conformity.
Rechargeable battery Standard
icountLCM20 cover Weatherproof cover (Standard)
Handset cover Weatherproof cover (Optional extra)
Benefits
Routine contamination monitoring of oil systems with User-friendly instrument improves familiarity and
the icountLCM20 saves time and saves money. awareness of service and maintenance personnel.
Contamination monitoring is now possible while Manufactured from lightweight Lexan expanded
machinery is working icountLCM20 saves on structural foam which is both durable and strong.
production downtime.
Totally portable, the icountLCM20 can be used as
Instant, accurate results are available to international easily in the field as in the laboratory.
standards in hard copy form. That means system
maintenance decisions can be taken immediately. Computer interfacing available for downloading data
on to compatible computer, through icountLCM20s
icountLCM20 ensures that machinery hydraulic RS232 serial port at 9600 baud.
systems are tested in manufacture to ISO cleanliness
standards. An internal diagnostic feature ensures the
icountLCM20 will always work accurately and reliably.
Data entry allows individual equipment test log details
to be recorded. Supplied in an Astraboard carrying case.
Data retrieval of test results from memory via hand set Automatic calibration reminder.
display.
Data graphing of up to 30 test results can be selected
for integral printing.
Automatic test cycle logging of up to 300 tests can be
selected via hand set display.
Carrying strap
Handset
Display
Handset
Hydraulic hose
Battery module
Function keys
Main case
Carrying strap
Hose tidy
Alphanumeric
display
Function Keys
Paper feed
The functions assigned to
each of these three keys is
displayed on the bottom line
of the alphanumeric display
Alphanumeric keys
Note: When the Particle Counter displays a Low Battery Warning, you should
recharge the batteries immediately. Battery packs in storage or fitted to units
should be recharged every three months. The capacity of the battery pack is
severely reduced if batteries are left in a discharged condition for long periods.
Step
1 Unscrew the two retaining screws and remove
the printer cover and reel axle.
Getting started
Setting the icountLCM20 to record the time and date of tests
Step Press
1 Switch on the icountLCM20 from the button on the top of the
casing.
Change
MODE PRINT / Std
3
Press and hold MODE for five seconds. RESET DATA Y/N is RESET DATA
shown on the display. Y/N?
To clear all stored test results from the icountLCM20 memory, press
to move the cursor under Y and press MODE.
If you do not wish to clear the icountLCM20 memory, check that
the cursor is under N (press if it isnt) and press MODE.
4 The time entry screen is displayed with the first digit shown
blinking.
1 :
TIME
5 Enter the correct time using the numeric keypad. Enter the time
using the 24-hour clock. For example, to enter 9:30 am:
09:1
TIME
Press
6
Press .
09:30
When you have entered the last digit, the first digit is again shown
blinking. If you make a mistake, simply key the time in again, TIME
overtyping the previous entry.
7
When the time is shown correctly, press MODE to accept it.
Step
MODE, the date
1 When you have confirmed the time by pressing 1 : :
entry screen is displayed with the first digit shown blinking.
DATE
2 Enter the correct date using the numeric keypad. For example, to
enter 21st August 2010:
21 : 0 :
Press
DATE
3
Press
21 : 08 : 0
DATE
4
Press
21 : 08 : 10
DATE
5
When the correct date is displayed, press MODE.
Basic operation
The icountLCM20 is now ready to check the cleanliness of the hydraulic oil in your system.
You can take readings at full working pressure (max. 420 bar).
NOTE: The icountLCM20 is supplied filled with hydraulic oil and may need to be flushed
prior to use.
Step
1 Disconnect the hydraulic hoses from the hose tidy.
2 The icountLCM20 is designed for use in connection with System 20 size 0, 1 and 2 Industrial Sensors or
the Single Point Sampler. The sensors have the following dimensions:
Size Diameter
0 30.0mm
1 41.0mm
2 66.7mm
NOTE: Dual fluids monitors must be connected to a special System 20 Sensor or Single
Point Sampler. See page 45.
3 Ensure that the Sensor is installed with the arrow matching the direction of flow.
Working viscosity is 2100 cSt. Ensure a minimum working pressure of 2 bar
Ensure adequate oil flow through the sensor:
NOTE: Parker Hannifin recommend that the icountLCM20 is connected to the operating
system sensor for five minutes to allow the fluid condition to stabilise before starting a
test.
We also recommended that you carry out an independent flow check if there is high
viscosity oil and low flow through the System 20 sensor, or the unit is being operated
without the trace heating option in cold ambient temperatures.
Step
1 Switch on the icountLCM20.
2
Press and hold for five seconds.
3 The flow test begins and the display shows:
MANUAL FLOW TEST
IN PROGRESS
4 After about 30 seconds the flow test is completed and the test
Flowrate Test
results are displayed.
Flowrate : Good
Delta T : 2.45C
Press MODE
to Continue
or is displayed.
NOTE: The following screens show MTD calibrated data. During all tests, an interim count
is displayed.
Step
1 When the test is complete, the ISO code is automatically displayed. 22 : 20 : 14
ISO
2 Particle count
All particle counts are indicated per 100 ml sample. >4
3642544
To display a count for the 4 particles press MODE.
ISO
3
Each press of displays the particle counts for 6, 14, 21,
38 and 70 particle sizes respectively. >70
0
ISO
4
Press to display the particle count for a previous class.
>38
11
ISO
Step
Press Change/Std to choose NAS mode. The NAS class code
1 11
is displayed on the screen.
NAS
2 Particle count
4-6
All particle counts are based on 100 ml samples. 2774621
To display the NAS count for the 4 to 6 particles,
press MODE. NAS
3
For MTD, each press of displays the particle counts for 614, >70
421, 2138, 3870, and 70 particle sizes respectively. 0
4
Press to display the particle count for a previous class. 38-70
11
NAS
Step
1 Press Change/Std to choose SAE mode. The AS4059 class
code is displayed on the screen. 11A 11B 8C 6D
AS4059
2 Particle count
>4
All particle counts are based on 100 ml samples. 3642522
To display the AS4059 count for the 4 particles, press MODE.
AS4059
3
For MTD, each press of displays the particle counts for 6, >70
14, 21, 38 and 70 particle sizes respectively. 0
4
Press to display the particle count for a previous class. >38
11
AS4059
Step
1 Press Change/Std to choose GOST mode. The GOST class 11
code is displayed on the screen.
GOST
2 Particle count
5-10
All particle counts are based on 100 ml samples. 180319
To display the GOST count for the 5 to 10 particles,
press MODE. GOST
3
>100
Each press of displays the particle counts for 1025, 2550,
50100 and >100 particle sizes respectively. 11
GOST
4
Press to display the particle count for a previous class. 50-100
440
GOST
Step
MODE three times from idle to step through ISO/NAS and PLEASE ENTER A
1 Press
TEST ID CODE
Count modes to the Serial Number Entry mode. PLEASE ENTER A TEST ID
CODE is displayed.
2 Each key on the keypad has four characters associated with it (similar
to a mobile phone). Press each key repeatedly, up to four times to
obtain the desired character. For example:
1
Press
A
Press again
B
Press again
C
Press again
1
Press
then press 1
When you have completed entering the identification code, turn the
valve control knob.
The code is entered into the icountLCM20s memory and the test
begins.
Step
1 Connect the bar code wand into the socket .
2
Press MODE three times from idle to step through ISO/NAS and PLEASE ENTER A
Count modes to the Serial Number Entry mode. PLEASE ENTER A TEST ID CODE
TEST ID CODE is displayed.
3 Place the bar code wand to the left of the bar code, and with a
continuous motion, swipe the wand across the bar. A successful
entry is confirmed by a single beep.
5 The identification code is printed with the test number on each test
printout.
NOTE: If the test count is outside the range for a particular standard, then 00
(below range) or 99 (above range) is displayed.
Step
DATA RETRIEVAL-
1 Press and hold for two seconds Y/N?
2
Press to select Y DATA RETRIEVAL-
Y/N?
3
Press MODE SERIAL OR TEST
NUMBER- S/T?
Choose S to select a test by serial number, or T to select a test by
test number.
4
Press to select T. SERIAL OR TEST
NUMBER- S/T?
5
Press MODE DATA RETRIEVAL-
ENTER TEST NO ID
6
Press MODE to view the test. >4(c)
8548760
7
Press PRINT to print the test (test 012 in this example).
To print test 012 through to test 001, press the print button again
during printing of test 012
8
Press MODE RETRIEVE MORE
RESULTS Y/N?
To view and print more results select Y. Select N to return to the idle
screen.
Step
TREND PRINTOUT
1 Press and hold for two seconds Y/N?
Press to select Y
2
Press MODE SERIAL OR TEST
NUMBER- S/T?
4
Press MODE ENTER FIRST TEST
NUMBER:
Enter the first test number required.
5
Press MODE ENTER LAST TEST
NUMBER:
Enter the last test number required.
6
Press MODE to start the graph printout. GENERATING TREND
PLEASE WAIT . . .
N/O 1
3
N/C
2
NOTE: the user is responsible for selecting an appropriately rated connector and cable for
the externally controlled device.
Step
EDIT ALARM LEVEL
1 Press and hold for two seconds. Y/N?
2
Press to select Y EDIT ALARM LEVEL
Y/N?
1
Press and hold for two seconds. LEVEL TESTING
Y/N?
2
Press to select Y LEVEL TESTING
Y/N?
3
Press MODE. CONTINUOUS
Y/N?
Press to select Y. The unit will run indefinitely whether the
alarm has been triggered or not.
Press MODE to select N. The unit will stop running tests when
the alarm is triggered.
Step
LIMIT SWITCH
1 Press and hold for two seconds RELAY ON Y/N?
2
Press to select Y LIMIT SWITCH
RELAY ON Y/N?
3
Press MODE.
The limit switch relay is energised (i.e. contact is made between
pins 1 and 2 of the level test relay socket).
Choose N in step 2 to turn off the relay.
Step
AUTOMATIC
1 Press and hold for two seconds. TESTING Y/N?
Press to select Y
2
Press MODE. ENTER TEST START
TIME: 13:48
Enter the start time required.
4
Press MODE. TEST INTERVAL
(6-999 min):
Enter the test interval (the number of minutes between each test).
5
Press MODE. ENTER NUMBER OF
TESTS TO RUN:
Enter the number of tests to be run.
6
Press MODE. PRINT RESULTS
Y/N?
Press to select Y if a printout of each test result is required.
7
Press MODE. START TESTING
Y/N?
Press to select Y to start testing.
8
Press MODE. TIME NOW: 13:42
START AT: 13:45
Testing starts when the two times become equal.
9 This screen is displayed just before the test takes place.
TEST NUMBER 020
FLUSHING
10
Press MODE to abort the current test cycle. WAITING . . .
MODE TO ABORT
11
Press MODE to return to the idle screen.
CALIBRATION DUE
20-09-2011
(The example above is for a calibration due date of 20th September 2011)
To ignore the message for now and continue with testing press MODE
If the unit passes the calibration due date, the following message is displayed when the unit is
switched on:
CALIBRATION
OVERDUE
To ignore the message for now and continue with testing press MODE
NOTE: When the icountLCM20 is switched off, the backlight function is reset. If you
still require the backlight when the icountLCM20 is switched on again, it will need to be
reactivated.
Reference 107
1,6
8
24
24
23
4
2
22
21
Data interpretation 10 6
5
20
For example: code 20/18/13 indicates that there are between 500,000 and 1,000,000 particles
larger than 2 microns, and between 130,000 and 250,000 particles larger than 5 microns, and
between 4000 and 8000 particles larger than 15 microns.
MTD: ISO11171 (Calibration or optical microscope count particle size based on projected area
equivalent diameter)
ACFTD: ISO4402 (Calibration or optical microscope count particle size based on longest dimension)
The GOST standard is developed by the Technical Committee of Standardization TK 184 Ensuring
Industrial Cleanliness introduced by the Government of Russia.
Adopted by the Inter-governmental Committee of Standardization, Metrology and Certification
(Protocol No. 19, dated 24 May 2001).
The above comparisons relate to particle count data only. To conform to any particular standard,
reference should be made to the recommended experimental procedure.
1068 104
6
20 Number of particles per ml greater than indicated size
4
19
2
18
1058 17 103
6
4 16
2 15
10 8
4 14 102
6 13
4
12
2
11
1038 101
6
10
4 9
2 8
1028 7 1
6
4 6
2 5
10 8 4 10-1
6 3
4
2
2
1
1 6 14 21 38
particle size m
20
particle size m
Direction of flow
1 Monitor block System 20 sensor
2 Laser diode P2 P1
3 Optical scanner
4 Changeover valve
5
icountLCM20
Logic diagram
Optical scanner
Unobstructed light
calculator
Area calculator
Reference voltage
generator
4 6 14 21 38 70
comparator comparator comparator comparator comparator comparator
Count-to-code
converter
Switch
Display Memory PC
12V DC
FUSE
Fast blow
fuse 1.25A
RS 232
Measurement accuracy
Calibration
Every monitor is individually calibrated using an accurately determined gravimetric level of test dust
media.
Each channel within the instrument is adjusted to read the number of particles in a prescribed size
range as specified in ISO procedures, thus guaranteeing calibration accuracy.
Repeatability
The icountLCM20 measures and quantifies individual particles using advanced electronics and laser
technology to ensure a high degree of repeatability.
Repeatability is typically better than 5%.
Diagnostic code 1
a. At beginning of test Oil is too dark or it is cloudy. Check sample of oil visually. This can be done as
follows:
DIAG 1A. LIGHT Dark oils: Wet your thumb and forefinger in the oil
SOURCE DEVIATION and press together. Release and look at your thumb.
If you can see through the film of oil it should work in
the icountLCM20. If you cannot, then you may have
problems. (This is most common with engine oils or
very highly contaminated oils above ISO 24).
Emulsions: Put sample in a clear container and hold
up to the light. This will show cloudy or clear. If cloudy,
check the type of oil and change until the oil is clean,
then retry icountLCM20.
b. at the end of the test Unstable fluid opacity may be caused by aeration, Allow machine to work up to operating temperature
water sludge or an amount of cold oil passing before performing condition monitoring. Run tests
DIAG 1B. LIGHT through icountLCM20. with a stable system and ensure that a minimum line
SOURCE DEVIATION pressure of 2 bar is available at the monitor to reduce
the possibility of aeration.
Diagnostic code 2
The changeover valve and a. Control knob turned, either before monitor Switch off the monitor, then switch on and wait for
syringe pump are out of phase switched on, before valve symbol displayed on monitor to reset its position (diagnostic screen 6 is
handset or during a test. displayed).
DIAG 2. VALVE b. Time taken to turn valve fully to next position is
OPERATION ERROR too long (20 seconds).
c. Microswitch setting fault. Return to Parker for repair.
Diagnostic code 3
Uncontrolled power down a. Power to monitor has been disrupted by Wait for monitor to reset itself.
removing power supply without switching
DIAG 3. POWER monitor off.
INTERRUPTION b. Battery power too low. Battery level warning Replace batteries with 6 x 1.5V Alkaline D Cells (or
ignored. recharge battery pack if a rechargeable pack is fitted).
c. Battery contact disconnected by excessive Relocate monitor on a sound surface (May also be
vibration. hung from a carrying strap).
d. External power supply connected (12Vdc)
while unit is on. Leave unit to re-set itself.
Diagnostic code 4
Insufficient flow rate of oil a. Inadequate differential pressure across P1 and i) Select smaller sized sensor
from P1 hose into monitor P2 connections to provide sufficient bypass flow. ii) Reduce viscosity of system oil by increasing test
block to fill syringe pump. b. Air lock in monitor block or high viscosity slug temperature where possible.
Results are suspect and not of oil in bypass hoses. iii) Use Single Point sampler connected to P1. Purge
made available. the system pressure with P2 hose disconnected from
system.
DIAG 4. LOW FLOW Care should be taken to allow oil to discharge safely
IN BYPASS LINE and should only be performed by a competent
operator.
Re-test and if fault reoccurs, return monitor to Parker
for repair.
Diagnostic code 6
Unit trying to reset from last Displayed after switching on, while monitor is Leave the icountLCM20 alone until it has reset.
error. resetting itself from the previous error condition. If it does not reset, or switches itself off, contact
Parker.
DIAG 6. LCM IN
RESET MODE
DIAG 8. REFER
TO LCM20 SUPPLIER
DIAG 9. REFER
TO LCM20 SUPPLIER
Displayed if the monitor block has reached a Remove icountLCM20 from system connections and
DIAG 10. LASER temperature above 60C. allow to cool down.
TEMP TOO HIGH If unit does not reset, contact Parker.
Low battery
Replace or recharge batteries.
The icountLCM20 will not complete a measurement if power is insufficient.
ISO
Fuse 1.25A fast blow fuse included for overload protection (spare supplied)
LCM20 technology Unique optical scanning system
Size, measurement & ranges MTD: 4+, 6+, 14+, 21+, 38+ and 70+
ACFTD: 2+, 5+, 15+, 25+, 50+ and 100+
Analysis range ISO 7 to 22 inclusive; NAS 0 to 12 inclusive; SAE 0 to 12 inclusive
Calibration Each unit is individually tested and calibrated in accordance with ISO procedures
Repeatability/Accuracy Better than 5% (typical)
Viscosity range 2100 centistokes (500cSt with SPS)
Oil temp. range +5C to +80C
Operating temp. range +5C to +40C
Test completion time 2 minutes
Computer Interface RS232 at 9600 baud
Weight icountLCM20: 8kg, Carrying case: 5kg
Commissioning kit 6-off D cell batteries; 1-off print rolls (shrink wrapped); 2-off printer ribbons;
DATm software plus cable; weather protector cover; 12Vdc power supply;
Rechargeable battery pack
Features:
Perfluoroelastomer seals throughout
Totally compatible with aggressive phosphate esters (e.g. SKYDROL LD4/500B), as well as
mineral or synthetic-based fluids.
R
ed control valve knob and handset keys the icountLCM202061 is easily distinguished
from standard icountLCM20 units
High Technology, fused optical windows for high particle definition
A
vailable with complete range of sample extraction options (e.g. System 20 Sensors or the
Single Point Sampler)
5/8 BSF HSP Hose fitting
Parylene treated for additional protection.
WARNING: Any oil splashed onto this product should be removed immediately, to
avoid long-term damage.
System 20 sensors
Industrial Sensors Sizes 0, 1 and 2
Part number Size Flow range Thread Qty
G 8
3
STI.0144.100 0 625 l/min
STI.0344.100 0 0.57 US GPM 43 UNF
G 4
3
STI.1144.100 1 20100 l/min
STI.1344.100 1 526 US GPM 3 12UN-2B
SAE 1 16
G1 4
1
STI.2144.100 2 80380 l/min
SAE 1 8 12UN-2B
5
STI.2344.100 2 21100 US GPM