HYDAC International ALPC 9000 Series Manual

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 GMBH
Postfach 12 51
66273 Sulzbach / Saa
r
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]
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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 GMBH
Technische Dokumentation
Postfach 12 51
66273 Sulzbach / Saar
Germany
We look forward to receiving your input.
Our motto: “Putting experience into practice”
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ALPC 9000 series Preface
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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: [phone] / 509 - 846
E-mail: [email protected]
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.

ALPC 9000 series Preface
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.
de
HYDACFiltertechnikGmbH
BeWa123456ade
Se ite 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.

ALPC 9000 series Safety information
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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ALPC 9000 series Safety information
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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ALPC 9000 series Safety information
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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ALPC 9000 series Safety information
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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.
Individuals Individuals undergoing training
Individuals
wi
th
technical training/ engineering background Electrician HYDAC Service
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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ALPC 9000 series ALPC 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

ALPC 9000 series ALPC components
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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