Argo-Hytos OPCom User manual

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OPCom Portable Oil Lab
PPCO 300-1000
Manual
Safety and operating instructions
Read the safety and operating instructions before use.
Note: The indicated data only serve to describe the product.
Information regarding the use of this product are only examples and suggestions.
Catalog specifications are no guaranteed features.
The information given does not release the user from his / her own assessments and inspection.
Our products are subject to a process of natural wear and aging.
© All rights are reserved by ARGO-HYTOS GMBH, even in the event of industrial property rights.
Any right of disposal such as copying and distribution rights shall remain with us.
The picture on the title page shows a configuration example. The delivered product may thus
differ from the illustration.
Original operating instructions

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Contents
OPCom Portable Oil Lab
Contents........................................................................................................................................................................ 2
1. About this documentation.......................................................................................................................................... 4
1.1 Applicability of this documentation................................................................................................................................. 4
1.2 Required and supplementary documentation .................................................................................................................. 4
1.3 Presentation of information ............................................................................................................................................ 4
1.3.1 Safety instructions in this documentation ....................................................................................................................... 4
1.3.2 Symbols.......................................................................................................................................................................... 5
2. Safety instructions....................................................................................................................................................... 6
2.1 About this chapter.......................................................................................................................................................... 6
2.2 Intended use................................................................................................................................................................... 6
2.3 Improper use ................................................................................................................................................................. 6
2.4 Reasonably foreseeable misuse ....................................................................................................................................... 6
2.5 Qualification of personnel .............................................................................................................................................. 6
2.6 General safety instructions.............................................................................................................................................. 7
2.7 Product and technology related safety instructions ......................................................................................................... 7
3. General instructions .................................................................................................................................................... 8
4. Scope of delivery ......................................................................................................................................................... 9
5. About this product..................................................................................................................................................... 10
5.1 Functional description................................................................................................................................................... 10
5.2 Measured values ........................................................................................................................................................... 10
5.3 Component overview ................................................................................................................................................... 11
5.4 Controls........................................................................................................................................................................ 12
5.5 Control panel................................................................................................................................................................ 12
5.6 Printer........................................................................................................................................................................... 13
5.4 Identification of the product ......................................................................................................................................... 13
6. Transport and storage ............................................................................................................................................... 14
7. Assembly .................................................................................................................................................................... 15
7.1 Operating site............................................................................................................................................................... 15
7.2 Hydraulic connection .................................................................................................................................................... 15
7.3 Electrical connection ..................................................................................................................................................... 17
7.4 Charging process .......................................................................................................................................................... 18
8. Commissioning........................................................................................................................................................... 19
8.1 Before commissioning .................................................................................................................................................. 19
9. Operation.................................................................................................................................................................... 20
9.1 Operation ..................................................................................................................................................................... 20
9.2 Menu structure ............................................................................................................................................................. 21
9.2.1 Switching on the device ................................................................................................................................................ 23
9.2.2 Start screen................................................................................................................................................................... 24
9.2.3 Measurement quick menu............................................................................................................................................. 25
9.2.4 Memory quick menu..................................................................................................................................................... 25
9.2.5 Main menu ................................................................................................................................................................... 26
9.2.5.1 Memory menu .............................................................................................................................................................. 26
9.2.5.2 Measurement settings................................................................................................................................................... 28
9.2.5.3 System settings ............................................................................................................................................................. 31
9.2.5.4 Select start screen ......................................................................................................................................................... 31

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9.2.5.5 Print selection ................................................................................................................................................................ 33
9.2.5.6 Display........................................................................................................................................................................... 35
9.2.5.7 Time / date .................................................................................................................................................................... 36
9.2.5.8 Language....................................................................................................................................................................... 36
10. Maintenance / repair .................................................................................................................................................. 37
10.1 Maintenance.................................................................................................................................................................. 37
10.2 Repair ............................................................................................................................................................................ 37
10.3 Spare parts..................................................................................................................................................................... 37
11. Software ...................................................................................................................................................................... 38
12. Decomissioning ........................................................................................................................................................... 39
13. Disassembly................................................................................................................................................................. 40
14. Disposal........................................................................................................................................................................ 41
14.1 Environmental protection ............................................................................................................................................... 41
15. Extension and conversion .......................................................................................................................................... 42
15.1 Accessories .................................................................................................................................................................... 42
16. Troubleshooting .......................................................................................................................................................... 43
16.1 Basic procedures ............................................................................................................................................................ 43
17. Technical data.............................................................................................................................................................. 44
17.1 Dimensional drawing ..................................................................................................................................................... 45
18. Appendix ..................................................................................................................................................................... 46
18.1 Declaration of conformity............................................................................................................................................... 46

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1. About this documentation
1.1 Applicability of this documentation
This documentation is applicable for the following product:
›Particle Monitor OPCom Portable Oil Lab
This documentation is written for service engineers, technicians, operators and system operators.
This document contains important information for safe and appropriate assembly, transport, activation, operation, usage, servicing,
dismantling and simple troubleshooting.
›Read this document completely and in particular Chapter 2, “Safety Instructions”, before you work with the product.
1.2 Required and supplementary documentation
›Do not commission the product until you have received the documentation marked with the book icon  and you have
understood and complied with the information therein.
Title Number of document Document type
Data sheet 100.60 Data sheet
1.3 Presentation of information
So that this document can help you to work quickly and safely with your product, we use standardized safety instructions, symbols,
terms and abbreviations. For better understanding, these are explained in the following sections.
1.3.1 Safety instructions in this documentation
In this documentation, safety instructions are faced with a sequence of actions which would result in the danger of personal injury or
damage to equipment. The measures described to avoid theses hazards must be observed.
Safety instructions are structured as follows:
SIGNAL WORD
Type and source of danger
Consequences of non-compliance
›Measures for safety and hazard defense
›<List>
›Warning signal: draws attention to the danger
›Signal word: indicates the severity of the danger
›Type and source of danger: specifies the type and source of danger
›Consequences: describes the consequences of non-compliance
›Measures: describes how to deal with the risk
Warning sign, signal word Meaning
DANGER Indicates a dangerous situation which results in death or serious injury if not avoided.
WARNING Indicates a dangerous situation which may result in death or serious injury if not avoided.
CAUTION Indicates a dangerous situation which may result in light to moderate injury if not
avoided.
NOTE Indicates equipment damage: The product or surrounding could be damaged.
Table 1: Required and supplementary documentation
Table 2: Danger classes acc. ANSI Z535.6-2006

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1.3.2 Symbols
The following symbols indicate notes which are not safety-relevant but increase the intelligibility of the documentation.
Symbol Meaning
If this information is not observed, the product cannot optimally be used or operated
This symbol warns against laser beams.
Singular, independent action step / instruction
1.
2.
3.
Numbered instruction
The numbers indicate that the action steps follow one another
Table 3: Meaning of symbols

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2. Safety instructions
2.1 About this chapter
This product was manufactured according to the generally recognized standards of engineering. Nevertheless, there is a danger of
injury or damage if you do not observe this chapter and the safety instructions in this documentation.
 Read this document thoroughly and completely before working with the product.
 Retain this document and ensure that it is available for all users at all times.
 Always include the necessary documentation when passing the equipment along to a third party.
2.2 Intended use
This product is a hydraulic component.
The device serves to monitor the condition of fluids.
You may use the product for the following:
›Condition monitoring of a fluid
The product is intended for professional use only, not for private use.
"Intended use" also includes that you have completely read and understood this documentation, in particular Chapter 2
"Safety Instructions".
2.3 Improper use
Any other use than the intended use described, is improper and therefore inadmissible.
If unsuitable products are installed or used in safety-related applications, unintended operating states can occur in the application,
which can cause personal injury and / or material damage. Therefore only use this product in safety-related applications if this use is
expressly specified and permitted in the product‘s documentation, e.g. in explosion protection areas or in safety-related parts of a
control system (functional safety).
ARGO-HYTOS GMBH assumes no liability for damages resulting from improper use.
The risks associated with improper use are solely with the user.
2.4 Reasonably foreseeable misuse
The delivery of the following media is forbidden:
›Others than listed in Chapter 18.1 "Technical Data".
The operator alone is liable for damages resulting from improper use.
2.5 Qualification of personnel
The operations described in this document require fundamental knowledge of mechanics and hydraulics as well as knowledge of the
appropriate technical terms. In order to ensure safe use, these operations may therefore only be carried out by a correspondingly
skilled worker or an instructed person under the guidance of a skilled worker.
A skilled worker is someone who can - based on his / her technical education, knowledge and experience as well as knowledge of
the respective regulations of the jobs assigned to him / her - recognize possible dangers and ensure appropriate safety measures. A
skilled worker must observe the relevant technical regulations.

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2.6 General safety instructions
›Observe the valid regulations for accident prevention and environmental protection.
›Observe the safety regulations and requirements of the country in which the product is used / applied.
›Only use ARGO-HYTOS products that are in technically perfect condition.
›Observe all instructions on the product.
›People who assemble, operate, disassemble or maintain ARGO-HYTOS products may not do so under the influence of alcohol,
other drugs or medications that affect the responsiveness.
›Only use manufacturer-approved accessories and spare parts, in order to prevent personal danger due to unsuitable
spare parts.
›Observe the technical data and ambient specifications specified in the product documentation.
›If unsuitable products are used or installed in safety-relevant applications, unintended operating states can occur in the application,
which can cause personal injury and / or material damage. Therefore only use the product in safety-relevant applications if this use
is expressly specified and permitted in the product‘s documentation.
›You may only put the product into operation, when it has been established that the final product (e.g. a machine or system), into
which the ARGO-HYTOS products are installed, complies with the country-specific regulations, safety regulations and standards of
the application.
2.7 Product and technology related safety instructions
CAUTION
Laser
The OPCom Portable Oil Lab contains a laser sensor that is classified for intended use as a class 1 laser according to DIN EN
60825-1:2001-11.
In reasonably foreseeable circumstances, the accessible laser radiation is not dangerous.
 With direct exposure to class 1 lasers in the upper power range, injury, such as blinding, impairment of color vision and
disruption, cannot be ruled out.

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3. General instructions
For prevention of material damage and product damage
CAUTION
Danger due to improper handling
Material damage
 The Particle Monitor may only be used in accordance with Section 2.2, “Intended use”.
Leakage or spillage of hydraulic fluid
Environmental pollution and ground water pollution
 Use oil binding agents in order to bind leaked hydraulic oil.
Contamination due to fluids and foreign bodies
 Premature wear - malfunction - risk of damage - material damage
 Pay attention to cleanliness when assembling in order to prevent foreign bodies, such as welding beads or metal chips, from
entering the hydraulic lines and leading to premature wear or malfunction.
 Make sure that connections, hydraulic lines and attachment parts (e.g. gauges) are free of dirt and chips.
 Check prior to commissioning that all hydraulic and mechanical connections are connected and tight and that all gaskets and
seals of the plug connectors are correctly assembled and undamaged.
 For removal of lubricants and other contaminants, use residue-free industrial wipes.
 Make sure that connections, hydraulic lines and attachment parts are clean.
 Ensure that no contaminants enter when closing the connections.
 Make sure that no detergents enter the hydraulic system.
 Do not use cotton waste or faying cleaning rags for cleaning.
Do not use hemp as sealing agent.

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4. Scope of delivery
The package includes:
›1 OPCom Portable Oil Lab
›1 Operating manual
›1 Power supply 100-240 VAC
›1 Power cable
›1 Low-pressure hose set including connection couplings
›1 High-pressure hose
Fig. 1: Scope of delivery

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5. About this product
5.1. Functional description
The OPCom Portable Oil Lab is a mobile oil laboratory for service, with which oil cleanliness and oil condition in hydraulic and
lubricating systems can be examined.
The OPCom Portable Oil Lab enables measuring of particles to the latest standards and indicates the cleanliness classes in accordance
with ISO 4406:1999 and SAE AS4059.
Additionally it displays the relative humidity and oil temperature. Optionally, further information about the oil condition
can be obtained from the conductivity and permittivity of the oil and shown on the integrated display.
The OPCom Portable Oil Lab is an optical particle monitor that works according to the principle of light absorbance. The use of the
OPCom Portable Oil Lab allows the monitoring of contaminant levels as well as the observance of the trend
of changes in fluid cleanliness. With this, in the most precise cases, differences can occur compared to particle monitors that
are calibrated to ISO 11171:99. The discrepancy is, however, smaller than an ordinal number. Variances are very precisely
indicated.
Through continual monitoring of fluid conditions, changes in the machine can be detected very quickly. With quick
warning, measures can be taken to prevent increased contamination, which can lead to possible damage to the hydraulic
system.
5.2 Measured values
The following values are determined during a measurement:
Parameter Abbre-
viation
Unit Description
Temperature coefficient T °C / °F Fluid temperature
rel. permittivity (rel. DK) P The relative permittivity is a parameter for the polarity of the fluid. Oils
change their polarity during the aging process.
Conductivity C pS/m Fresh oils show a characteristic conductivity. Oil change, oil mixtures and
oil deposits can be detected by their conductivity.
rel. oil humidity RH % Relative humidity between 0 und 100 %
Cleanliness level acc. to ISO ISO Indicates the respective ordinal number (OZ) according to ISO 4406:99
Cleanliness level acc. to SAE SAE Indicates the respective ordinal number (OZ) according to SAE AS4059
Cleanliness level acc. to NAS NAS Indicates the respective ordinal number (OZ) following NAS 1638
Cleanliness level acc. to GOST GOST Indicates the respective ordinal number (OZ) following GOST 17216
Concentration Conc p/ml Indicates the number of particles per milliliter
Flow index FIndex ml/min Calculated volume flow

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5.3 Component overview
1 Motor with pump and electric gear 4 Top side with control panel
2 Rechargeable battery pack 5 Particle monitor
3 Control electronics 6 Oil condition sensor (not displayed)
1 Motor with pump
Pumps the fluid from the supply line through the device to the return line.
2 Rechargeable battery pack
Energy source for operation without a power adapter, as well as for operation both with and without
the pump.
3 Control electronics
The control electronics include battery management, supply connections and various measuring functions.
4 Control panel
In the case of an alarm, this indicator lights up red.
Observe the instructions in the course of this operating manual (Chapter 9).
5 Particle monitor
The device is an optical particle monitor, used for the monitoring of the fluid cleanliness. It works according to the principle of light
extinction (reduction of light radiation) and detects particles and other foreign bodies in the fluid.
6 Oil condition sensor
The oil condition sensor measures changes in the features of the hydraulic and lubricating medium (conductivity,
permittivity) along with concurrent humidity and temperature measurements.

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5.4 Controls
1
2
3
4
5
6
7
8
Fig. 3: Control elements
1 2 345 6
12 11 10 9 8 7
Fig. 4: Control panel
1 Control panel
2 Printer
3 Charger connection
4 USB-B connection
5 SD card slot
6 Oil out CPC-LC
7 Pressure line Minimess® M16x2
8 Suction line internal pump CPC-LC
1 Power button
2 Alarm-LED green
3 Alarm-LED yellow
4 Alarm-LED red
5 Standby indicator
6 Select previous menu item /
numerical value
7 Select next menu item /
numerical value
8 Cancel button
9 Confirm button
10 Select previous data record /
numerical value in the menu
11 Select next data record /
numerical value in the menu
12 Display
5.5 Control panel

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5.6 Printer
Data can be printed out with the printer.
Fig. 5: Printer
The blue button on the top right above the printer (see arrow)
›signals the operational readiness of the printer
›initiates the line feed by pressing it
Pull the flap in order to open the cover.
Then replace the paper roll and insert the paper as shown in the
figure.
Fig. 6: Label
Paper changing
5.7 Identification of the product

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2
1
3
4
Fig. 7: Transport
6. Transport and storage
The case can be closed with the fastening hooks (4).
The transport case is equipped with a pressure compensating valve (3).
A handle is embedded in the lid (2).
Alternatively, the transport case may be transported with a shoulder strap, which can be fastened to the movable belt mounts (1)
(see Chapter 15.1 accessories).
There are no special transport notes for this product.
In the case of air transport, it must be stated in the air waybill that the device contains lithium batteries.
 Observe the instructions in Chapter 2, “Safety instructions".
 For storage and transport, keep the OPCom Portable Oil Lab within the ambient conditions that are stated in
Chapter 17, “Technical data".

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7. Assembly
7.1 Operating site
Please follow these instructions when determining the operating site:
›The installation location of the device is variable. These can be:
1) Measuring point at a pressure line.
This measuring point should be representative of the machine. The device itself provides the necessary volume flow via an
integrated volumetric flow controller.
2) Measuring a sample from a tank or a bottle over the pump.
Connect the device to a pressure line in the off-line flow by means of a T-junction.
›At the connection point, constant pressure conditions should prevail. The pressure may vary, but pressure peaks or strong
fluctuations must not occur.
›The connection to the control line is recommended, alternatively the filter or cooling circuit is suitable.
7.2 Hydraulic connection
CAUTION
Danger due to improper handling
Material damage.
 Always connect the oil return first.
The device is provided with three connections.
1 2 3
1 Oil outlet CPC-LC
2 Pressure line Minimess M16x2 (for operation without pump), max. 320 bar / 4600 psi
3 Suction line CPC-LC (for operation with internal pump)
Fig. 8: Hydraulic connections

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Fig. 9: Oil outlet
Fig. 10: Pressure line (for operation without pump)
Fig. 11: Suction line (for operation with pump)
1 Oil outlet
This is a CPC-LC coupling with slide protection, which prevents unintended unlocking of the plug-in nipple.
In order to unplug the hose from the coupling, the slider (see arrow) must be pressed in the direction of the intake
hole.
After use, close the connection with the included sealing plug.
2 Pressure line (for operation without pump)
When the pressure in the oil suction line is sufficiently high (min. 10 bar (145 psi) / max. 320 bar (4600 psi) /
min. 50 ml/min depending on viscosity), the oil inlet can be attached to this Minimess pressure connection (M16x2).
3 Suction line (for operation with internal pump)
After use, close the connection with the included sealing plug.

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7.3 Electrical connection
DANGER
Risk of death
Danger of electrical shock.
 The electrical connection of the portable particle monitor may only be performed by a qualified electrician.
WARNING
Faulty power supply
Risk of death - injury
 Always consider the country-specific prescriptions.
Power supply according to EN50178, SELV, PELV, VDE0100-410/A1.
The OPCom Portable Oil Lab works with battery as well as with connected power.
In battery mode, the cells, with a total capacity of 6.900 mAh, supply the necessary power.
They are charged by connecting a power cord to the charging connection.
Once the power has been connected to the OPCom Portable Oil Lab, this is switched on independently without having to press the
power button.
DANGER
Fig. 12: Electrical connection
Preparing the network operation
›Insert the polarity-proof plug with the blue locking ring (2) into the charging port of the switched off OPCom Portable Oil Lab and
screw it down.
›Plug the "cold-device plug" (3) (according to IEC60320-C13) into the power supply (1).
›Connect the power plug (4) to the local power supply.
1
2
3
4

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7.4 Charging process
Please note the following procedure to ensure correct charging.
1. Open the cover of the device.
2. Connect the charger connector of the device to the power supply
3. Connect the power supply to the supply network (100-240 VAC), then a plug symbol is shown on the display.
4. To ensure a full charge, the device must be connected to the power cable for at least 1 h.
5. When a charging state of 100 % is reached, the charging circuit automatically terminates the charging.
Please note that the device cannot be switched off while charging due to technical reasons.
When operating without pump, the runtime is min. 24 hours, with pump operation the runtime reduces depending on the
viscosity of the medium.

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8. Commissioning
8.1 Before commissioning
Be sure to read and understand the operating manual before putting the device into operation.
 The information for intended use, the operating conditions and the technical specifications must be adhered to.
 Connect the portable Particle Monitor OPCom Portable Oil Lab to the hydraulic connection lines according to Chapter 7.2
"Hydraulic connection" .
 Cables and hoses must be outside of the movement range of the operating personnel (tripping hazard).

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9. Operation
Button Functions
To turn the device on / off
To confirm a selected option / value
To cancel the current input / back
Within the menu: scroll up
Within the menu: scroll down
To select next data set / numerical value in menu
To select previous data set / numerical value in menu
Fig.13: Control panel
9.1 Operation