Cosmos SDM-72 User manual

SDM-72
Portable Grease Steel Dust Meter
Model SDM-72
Instruction Manual
 Please keep this instruction manual available for quick reference
when needed.
Before use, carefully read this instruction manual and fully
understand the content.
Instruction Manual No.: SDM-72CEET

- TABLE OF CONTENTS -
1. Introduction
2. Features
3. Safe Operation
4. Component Names and Functions
4-1. Exterior View
4-2. Component Names and Functions
5. Operation Procedures
5-1. Installing Batteries
5-2. Battery Check
5-3. Measurement
5-4. Collection of Grease Sample
5-5. How to Fill the Sampling Container
6. Troubleshooting
7. Specifications
8. Handling & Storage
9. Warranty
Appendix
1. Measuring Principle
2. Metal Materials Measurable
3. Practical Use
3-1 Management and Simplified Diagnosis of
Grease Lubricated Bearing & Gears
3-2 Correlation Between the Abrasion of the Bearing
and Steel Dust Concentration in the Grease
3-3 Criterion
3-4 Cycle of Measurement
3-5 Simplified Diagnose of the Management Trend
and Abrasion of the Bearing
1
2
2
3
4
5
6
7
9
10
10
11
13
14
15
16
17
18
18
19
19

1
1. Introduction
We thank you for purchasing the Portable Grease Steel Dust Meter
Model SDM-72 for the measuring of steel dust in the lubricating grease.
The Portable Grease Steel Dust Meter employs a magnetic balance
type electromagnet induction method as the measuring principle, and is
a useful simplified diagnosis tool for the inspecting the abrasion status
of the bearings and gears.
The steel dust can be measured simply by collecting from the waste
(expelled) grease sample in a sampling container when fresh grease is
applied to the machinery.
This Manual describes the specifications, functions and operating
instructions, carefully read and thoroughly understand this manual
before operating the Portable Grease Steel Dust Meter SDM-72.

2
2. Features
♦The employed magnetic balance type electromagnetic induction
method is a highly sensitive for the detection of the abrasion in
the initial stage.
♦Suitable for diagnose of irregularity in the ultra slow speed
revolution range where diagnosis by vibration method is difficult.
♦Very simple operate.
Only requiring the sampling container to be filled with the sampled
grease and inserted for instant measurement.
♦Compact portable instrument and useful for field measurement.
3. Safe Operation
Read and understand the contents of the manual before operating the
instrument. The following safety symbols are used in this manual and
must be observed without fail:
Warning
WARNING indicates a situation, which if not
avoided, could result in malfunction or abnormal
performance of the instrument.
Caution
CAUTION indicates a situation, which if not
avoided may cause damage to the instrument,
or an accurate measurement may not be
obtained.
MEMO indicates operational advice and or
instructions.
!
!
MEMO

3
4. Component Names and Functions
4-1. Exterior View

4
4-2. Component Names and Functions
No.
Name Functions
1 Change-over
selector switch
Rotate the switch to “MEAS” position to
commence measurement, with the
sampling container removed from the
instrument.
To check the voltage level of the batteries,
rotate the switch to “BATT” position.
2 Sample insert port
Insert port for sampled grease.
The measurement of the steel dust is
conducted when the sampling container is
inserted, while the selector switch is set at
“MEAS” position.
3 LCD display
The display will indicate a digital reading of
the steel dust in the sampled grease.
Also, to indicate the reading of battery
voltage.
4 BATTERY alarm lamp To indicate the low battery status, when the
battery voltage becomes lower than 3.6V,
the alarm lamp will turn ON.
5 Calibration switch
Calibration switch of the indicated value.
(The instrument is calibrated at factory prior
to shipment. Do not attempt to make any
calibrations.)
6 DC jack The exclusive jack to accept the plug of the
AC Adapter.
7 Battery compartment The battery compartment accommodates 4
AA size dry cells.
8 Sampling container A quantitative sample container to collect
0.8ml of sampling grease.
9 Spatula A tool used for the collection of sample
grease.
10 AC adapter Exclusive AC adapter. (Option)

5
5. Operation Procedures
5-1. Installing Batteries
Open the battery compartment cover located on the lower right side of
the instrument, press and slide off the cover, secure a fresh set of 4
AA size (LR6) alkaline dry batteries, and carefully observe the battery
polarity illustration inside the battery compartment to make sure that
the batteries are installed correctly. It is recommended that a fresh
new set of batteries be installed; do not use a set of partial used and
new batteries.
To close the battery compartment, place the cover on the batteries
leaving an opening of about 10mm, and while pressing the cover
downward push it forward to close the compartment.
Front panel
About 10mm
Battery compartment
cover

6
5-2. Battery Check
Rotate the selector which from the “OFF” position to the “BATT”
position, the LCD display will indicate - - - - for a period of 2-3
seconds, then the voltage of the battery will be displayed.
Examples of battery voltage display.
(Battery voltage = 5.6V)
can be operated if the voltage is higher than 3.6V
the BATTERY alarm lamp will turn ON if the
voltage is lower than 3.6V, and instrument can not
be operated. Secure a fresh set of batteries and
make replacements.
when the battery voltage drops below 3.2V, the
BATTERY alarm lamp will commence to blinking
with an audible buzzer sound.
Warning
Measurement conducted under low battery condition
will not provide an accurate or reliable reading.
In case the battery voltage should drop below 3.2V
during measurement at “MEAS”
mode, the BATTERY
alarm lamp will turn ON and the audible alarm buzzer
will sound.
Caution It is recommended to replace the ba
tteries with a fresh
set of 4 AA size (LR6) alkaline batteries.
b 5. 6
b 3. 6
b 3. 6
b 3. 2
!
!
Memo

7
5-3. Measurement
1) Rotate the selector switch to “MEAS” and shift to the
measurement mode.
2) Check to see that the display indicates 0. 000 , then insert the
sampling container containing the sample grease into the sample
port. (Refer to 5-4. regarding procedures for the collection of
sample grease.)
* The sampling container must be inserted with the collected
grease facing upward (same direction as the front surface of the
instrument.)
3) An audible beep will sound for 2-3 seconds after the sampling
container has been inserted indicating the measurement has
been completed, and the reading is held, read and record the
reading.
This surface to face upward
when inserting
Sampling container

8
4) When the sampling container with the holder is removed from the
sample port, the display will return to zero 0.000 by the auto
zeroing adjustment function.
5) After the measurement has been completed, make sure to return
the selector switch to “OFF” position.
Caution
 When the reading exceeds the upper limit of the numeral display
reading (approximately 6.5%Wt), the display will indicate - - - - .
Caution
•It is recommended to insert the sampling container gently. Do not
apply an impact when inserting the sampling container. If the insert is
too slow, the reading may drift and may not be accurate. In such case
pull out the sampling container once and reinsert for the
measurement.
•After the sampling container has been inserted for measurement, do
not move the instrument until the “BEEP” sound for the completion of
the measurement. If the instrument is moved the reading may drift.
•For the measurement, do not hold the portion of the sampling
container to be inserted, as the body temperature of the operator may
effect the measurement. Hold the ejected portion of the sampling
container when handling and for insertion.
 If the collected sample grease is of high temperature, allow it to cool
to normal room temperature before measurement.
!
!

9
5-4. Collection of Grease Sample
For the measurement of steel dust to be conducted with this instrument,
the grease sample is to be collected from rotating portion of the
machinery. When a fresh supply of grease supplied to bearing, the old
discolored waste grease is expelled, collect this waste grease with the
spatula and fill sampling container.
The grease expelled from the bearing is the discolored waste grease
expelled from the interior of bearing together with a layer of the freshly
supplied grease. Therefore, the collect and use the discolored waste
grease for the measuring purpose.
Caution
•This instrument employs the electromagnetic induction method as
the measuring principle, and should not be operated in the vicinity
where a strong electromagnetic wave is generated.
(Example: inverter controlled motor, welding machine, electric spark
machine)
It is recommended to conduct measurement in a location not effected
by such electrical equipment.
•Do not operate the instrument in a location where walkie-talkie or
cellular phone may be used.
•During measurement do not use or place a metal tool (object) near
the sample port.
In case the collected grease sample contains large volume of iron
oxide, the reading of the measurement with this instrument may
indicate a slight difference from the SOAP method analyzed value.
!
MEMO

10
5-5. How to Fill the Sampling Container
The sample container has a
quantitative groove to accommodate
the waste grease sample, use the
spatula and fill this groove with a
sufficient amount of waste grease.
Use the edge of the spatula and
scrape off the excessive waste
grease to obtain a quantitative
volume of 0.8ml.
Then wipe off any excessive waste
grease that may adhere to sampling
container with tissue or a soft cloth,
and cover the collected waste
grease sample with the protective
cover.
Spatula
Grease
Attach the protective cover
Scrape off the excessive grease

11
6. Troubleshooting
Problems, which may be experienced during the use of the Grease
Steel Dust Meter SDM-72, are listed in the table below, together with
indications of probable causes and recommendations for corrective
actions. Contact our authorized distributor if your problem is not listed or
when the remedy fails to correct the problem.
Problem Cause Remedy
No indication appears
on the display when
the selector switch is
set at “BATT” or
“MEAS” using fresh
set of batteries.
• Bad battery contacts.
• The polarities of the
battery are not correctly
installed.
• Take out the batteries
and reinstall. (page 5)
• Reinstall the batteries
with the polarity
correctly positioned.
(page 5)
The battery alarm
lamp turns ON when
selector switch is set
at “BATT” or “MEAS”
using fresh set of
batteries.
• The battery may be
installed with the polar-
ity in wrong position.
• Reinstall the batteries
with the polarity
correctly positioned.
(page 5)
The reading of the dis-
play does not stabilize
or is not held when
the sampled grease is
inserted. The reading
is held at an unstable
condition.
• The sampled grease is
of high temperature and
cannot be measured.
• Measurement con-
ducted nearby a source
of strong electromagnet
wave. (Inverter con-
trolled motor)
• Cellular phone or
walkie-talkie used while
conducting
measurement.
• Allow the sampled
grease to cool off and
conduct measurement.
(page 8)
• Move away from the
source of
electromagnet wave.
(page 9)
• Turn OFF the cellular
phone or walkie-talkie
and perform
measurement. (page 9)

12
7. Specifications
Items Specifications Remarks
Model SDM-72
Measuring
principle
Magnetic balance type electromagnetic
induction method.
To measure Concentration of iron particles in the
waste
grease.
Measurement
range 0 – 5.000 %Wt %Wt = weight ratio%
Display 4 digit liquid crystal display
Minimum
resolution 0.001 %Wt
Accuracy ±(10 %rdg + 10 dgts)
* The analyzed value of standard grease
by atomic absorption method
%rdg =
measured value%
Zero
adjustment Automatic adjustment
Sample volume 0.8 ml
Power
requirement 4 AA size dry batteries
Battery life 30+ hours of continuous operation using alkaline
batteries
Operating
temperature 0 to 40 degrees C
Dimensions 84W x 40D x 190H (mm)
Weight Approximately 480g
Standard
accessories
Spatula for collecting grease sample
Sampling container SMC-01-G
AA size dry batteries
Carrying case
Operation Manual
1 pc
1 box
4 pcs
1 pc
1pc
(10 pcs/box)
Consumables Sampling container (10pcs/box) SMC-01-G
Option AC Adapter TC-420
Approval CE (EMC Directive 2004/108/EC)

13
8. Handling & Storage
!
CAUTION
• This instrument is not explosion-proof. It must be used in a
safe location.
• Remove the batteries and store the instrument if it is not be
used for a long time.
• Do not disassemble or modify the instrument or change the
structure or electric circuits.
• Do not leave the instrument in high-temperature or highly
humid places.
• Keep the instrument away from radical temperature or
humidity changes, walkie-talkie, mobile phone, or its
performance may be adversely affected.
• Do not drop, hit, or apply a strong mechanical shock to the
instrument, or its performance may be adversely affected.
• The instrument is not drip-proof. Keep the instruments away
from water.

14
9. Warranty
New Cosmos Electric Company Limited (New Cosmos) offers the
following as the sole and exclusive limited warranty available to
Customer.
This warranty is in lieu of, and customer waives, all other warranties of
any kind or nature, expressed or implied, including without limitation,
any warranty for merchantability or fitness for a particular purpose. The
remedies set forth herein are exclusive.
New Cosmos warrants to the original purchaser and no other person or
entity (customer) that gas detection product supplied by New Cosmos
shall be free from defects in materials and workmanship for a period of
one (1) year from the date of purchase. This warranty does not include
consumables, such as fuses, filters, etc. Certain other accessories not
specifically listed here may have different warranty periods.
After examination of allegedly defective product return to New Cosmos,
with freight prepaid, should the product fail to conform to this warranty,
customer’s only remedy and New Cosmos’s only obligation shall be, at
New Cosmos’s sole option, replacement or repair of such
non-conforming product or refund of the original purchase price of the
non-conforming product. In no event will New Cosmos be liable for any
other special, incidental or consequential damages or losses of any kind
whatsoever, including but not limited to, loss of anticipated profits and
any other loss caused by reason of non-operation of the product.
This warranty is valid only if the product is maintained and used in
accordance with New Cosmos’s instructions and /or recommendations.
New Cosmos shall be released from all obligations under this warranty
in the event repairs or modifications are made by persons other than its
own or authorized service personnel or if the warranty claim results
from physical abuse or misuse of the product.

15
Appendix
Reference Materials
1. Measuring Principle
The measuring principle of the magnetic balance electromagnetic
induction method is shown in the illustration below, the magnetic
circuit sensor is composed of an exciter coil connected to the both
sides of the detection coil, the magnetic field generated by both
exciter coils are blanketed in the vicinity of the center detection coil.
Normally, the center detection coil does not generate an induction
voltage, on the other hand when the sampled grease containing iron
particles is inserted into the exciter coil, the magnetic field is offset
by the magnetic permeability variation, and an induction voltage is
generated in the detection coil. The induction voltage can measure
the concentration of the iron particles in the sampled grease.
Amplifier
circuit
Transmission
circuit
Sampled grease
Exciter coil 1
Output
Detection coil 2
Exciter coil 2

16
2. Metal Materials Measurable
Table 1 of Metal Materials that can be Measured
(○:Measurable, ×:Not measurable)
Metal and Materials Magnetism Measurable Remarks
Iron, nickel, cobalt Ferromagnetism ○
Aluminum, chrome,
manganese, titan,
stainless steel
(SUS-304, SUS-316)
Para magnetism ×
Copper, silver, lead,
zinc, tin Diamagnetic ×
Iron oxide (α-Fe2O3)
Ferruginous
(Hydroxide iron) Para magnetism ×*1
Iron oxide
(γ-Fe2O3, Fe3O4) Ferromagnetism ○
Sodium, calcium,
lithium, molybdenum Para magnetism ×*2
*1: Iron oxide has several isomers, as can be noted from the table above
there are substance that can be measured with the Grease Steel Dust
Meter and substance that can not be measured. Specially in case the
environment allows the oxidation of iron particles easily and where the
collected sample contains red rust the measurement conduct may
indicate a reading lower than the actual concentration.
*2: When the grease contains a filler agent, the Grease Steel Dust Meter
does not have any sensitivity against such substance, and does not
affect the measured reading.

17
3. Practical Use
3-1. Management and Simplified Diagnosis of Grease Lubricated
Bearings & Gears
♦To be used to diagnose the steel dust contents in the grease
applied for lubrication of low speed rotation to high speed rotation
machinery.
Most useful for the diagnosis of the abrasion of the bearing and
gears used at low speed rotation and difficult to diagnose with the
vibration method, and to improve the accuracy of diagnosis when
jointly used with the vibration method for medium and high speed
rotation machinery.
♦Preliminary diagnosis for SOAP method, ferrography method, etc.
Useful tool for preliminary diagnosis as a cost saving for
maintenance.
♦Example of various use

18
3-2. Correlation between the Abrasion of the Bearing and Steel Dust
Concentration in the Grease.
Table 2 shows the inspection results of correlation between the
abrasion of the bearing and steel dust concentration by disassembling
and inspecting the bearing of various rotating machinery such as
motors, pumps and blowers.
Table 2 Correlation between the Abrasion of the Bearing
and Steel Dust concentration in the Grease
Fe concentration %Wt Number of bearing and status of abrasion
0.3 – 1.0 ◆◆◆
0.1 – 0.3 ●●▲▲▲▲
0.05 – 0.1 ●●●●●
0.03 – 0.05 ○○
0.01 – 0.03 ○○○○○○○○○
0 – 0.01 ○○○○○○○○○○○
Table number of bearings 36 pieces
◆= Large damage (continuous flaking of inner and outer rings)
▲= Medium damage (partial flaking of inner and outer rings)
●= Slight damage (slight flaking, discolored abrasion of inner and outer rings)
○= No abnormality
3-3. Criterion
The following table is an example of the criterion.
This criterion is relatively strict in order to carry out appropriate
corrective lubrication improvements, to detect the abnormal trend at
an early stage.
Table 3 Criterion of the Steel Dust Concentration in the Grease
Criterion Countermeasure
Normal
value Smaller than 0.05%
Management of steel dust contents
in the grease at normal cycle
Precaution
value 0.05 – 0.1% Repeat grease lubrication and
remeasure the steel dust
concentration 1 month later.
Irregular
value Greater than 0.1% Countermeasure for improvement of
lubrication, precision diagnosis at
short cycle management.