Pall PCM500 Operating Instructions Manual
OPERATING INSTRUCTIONS
Pall®PCM500 Series Portable Fluid
Cleanliness Monitor
PREFACE
The Pall PCM500 On-line Fluid Monitor has been developed to provide accurate and continuous information
on the cleanliness of aqueous solutions, hydraulic fluids and circulatory lubrication system fluids. Fluid
contamination levels monitored are then converted to the widely used contamination codes: ISO4406, SAE
AS4059 table 1 (NAS 1638) and AS4059 table 2. The result data can be exported to Flash Drive, Printer,
PC, PLC or network device..
The self-contained unit provides a portable fluid contamination monitor that can be used with a range of
fluids, including mineral oils and aqueous solutions. Fluid change procedures are included in this manual
and these help ensure the PCM500 monitor is adequately flushed prior to testing on an alternative fluid
application.
The contents of these operating instructions should be read before attempting any aspects of installation,
operation or maintenance.
The product has been tested and quality controlled in accordance with Pall standard procedures. The
customer should carefully inspect the product and ensure it is not damaged and or unsuitable for use. It is
the user’s responsibility to check actual operating conditions to ensure the PCM500 monitor is compatible
with the application and is operated within local safety codes.
NOTICE TO USERS
The PCM500 user manual is provided to assist users in maximising the benefits of the PCM500 portable
fluid cleanliness monitor.
As part of the continuous improvement process that Pall adopt in the development of technology and
satisfying customer requirements, this information or procedure may be subject to change.
Pall welcomes feedback from users who should contact their designated Pall Service Centre.
Please note the PCM500 is shipped to users with, a protective fluid, Rust veto NTP 32, which is miscible in
both aqueous liquids and oils. Please ensure the unit is flushed out before running tests. The unit should
be run for at least three full test cycles on the system fluid before performing a reliable test.
!
!
!
Important: Some fluids may react with Rust Veto to create gels,
which can result in functional issues within the PCM500. One
example is Mono Ethylene Glycol (MEG).
Please check with Pall if there is doubt over the compatibility of test
sample and Rust Veto transit fluid.
Important:
If the equipment is used in a manner not specified by the
manufacturer, the protection provided by the equipment may be
impaired.
Important:
The PCM500W model is fitted with a sensor measuring relative humidity
in oil.
Do not use with water bearing fluids or permanent damage will occur.
2
Contents
Section 1 Describes the environmental, mechanical and electrical aspects of the PCM500
monitor to include product specifications.
Section 2 Inspection, packaging and guidance note
Section 3 Description of the PCM500 monitors main items
Section 4 PCM500 principle of operation
Section 5 Pre-check and connection of the PCM500 to a fluid system
Section 6 General operation of the PCM500 monitor, including communications to
peripheral devices.
Section 7 Provides communication protocol for PLC control through RS232 Com port
Section 8 Details the fluid change procedure
Section 9 Describes the PCM500 monitor function codes, possible causes and corrective
actions.
Section 10 Spare parts list
Section 11 Covers the disposal of equipment
Appendix A Details the Pall PCM500 series worldwide aftermarket and calibration service.
Appendix B Details the Mesh Screen Manifold exchange procedure
MANUAL PART NUMBER ISSUE DATE
MA-PCM500 (Draft) 31/08/2015
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WARNINGS, CAUTIONS AND NOTES
Care must be taken in referring to this manual so as to ensure adherence with all warnings,
cautions and important notes. These carry information related to the safety of personnel and
the integrity and satisfactory operation of plant.
WARNINGS: THESE ARE INSTRUCTIONS THAT DRAW
ATTENTION TO THE RISK OF INJURY OR DEATH.
Cautions: These are instructions that draw attention to the risk
of damage to the product, the process, the equipment or the
surroundings.
Important: These are instructions that draw attention to information
that will aid installation, operation or maintenance.
!
Labels affixed to PCM
Fuse
DC
F4A
H250
Caution label attached to Battery cover
VDC
Label indicating DC power and Fuse rating
Label indicating refer to manual
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Contents
Page
Preface 2
Declaration of Conformity 4
Warnings, Cautions and Notes 5
Section 1: PCM500 and PCM500W
Specification and Requirements
1.1 General Description 7
1.2 Fluid Environment 7
1.3 Ambient Environment 8
1.4 Electrical Requirements 8
1.5 Fluid System Connections 8
1.6 Product Specification 9
Section 2: PCM500/PCM500W Inspection
and Packaging. 10
Section 3: PCM500/PCM500W Description
of Monitor. 10
Section 4: PCM500/PCM500W Principles
of Operation
4.1 General Principles 11
4.2 HMI Control Panel 11
4.3 Test Sampling 11
4.4 Communication Panel 12
4.5 Power Schematic 12
4.5 Battery 13
Section 5: PCM500/PCM500W
Connecting the Monitor
5.1 Connection Options 14
5.2 Connections 15
5.2.1 High Pressure Line 15
5.2.2 Low Pressure Line 15
5.2.3 Reservoir Sampling 16
5.2.4 Bottle Sampling 16
5.3 Operational Checks 17
5.4 Installation Checks 17
Section 6: PCM500/PCM500W
Getting Started
6.1 General 17
6.2 System Requirements 17
6.3 Screen Button Description 18
6.4 The Screens Flow Chart 19
6.5 Example Screen 20
6.6 Start-up Sequence 20
6.7 Sampling 21
6.8 Test Point and Fluid Setup 23
6.9 Code Alarm Set-up 25
6.10 Data manager Screens 25
6.11 Tools Screens 27
Section 7: Interface Protocol – PLC
control through DB9 Serial Port 30
Section 8: PCM500 / PCM500W Fluid
Change Procedure 33
Section 9: PCM500 / PCM500W Function
Codes and Corrective Actions 34
Section 10: PCM500 / PCM500W Spare
Parts List 38
Section 11: PCM500 / PCM500W
Cleaning, Maintenance & Disposal of
Equipment 39
Appendix A: Calibration and Aftermarket
Services 40
Appendix B: PCM500/PCM500W Mesh
Manifold Exchange procedure 41
Pall World wide warranty 43
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Section 1: Pall PCM500 and PCM500W Fluid
Cleanliness Monitors
Specification and Requirements
1.1 General Description
The Pall PCM500/PCM500W is specifically developed as a portable diagnostic
monitoring device that provides an assessment of system fluid cleanliness. A fixed
display/controller allows for simple menu driven input of sample identification, monitor
configuration and data output in ISO4406, SAE AS 4059 Table 1 (NAS 1638) or SAE
AS 4059 Table 2 formats. The display/controller shows the test results, an option to
graph results and this data is automatically stored for subsequent trending and
evaluation. The self-contained design provides for a portable fluid contamination
monitor that can be used with a range of fluids including mineral oils and aqueous
solutions. Note: The PCM500W should not be used for aqueous solutions.
Fluid change procedures are included in this manual and these help to ensure the
PCM500 monitor is adequately flushed ready for an alternative fluid application
See Pall Datasheet M&EPCM500EN for full technical specification
The full technical specification is given below.
1.2 Fluid Environment
Operating Pressure range 0 to 315 bar (4,570 psi) maximum
Operating Viscosity range 1.5 to 450 Centistokes (30 to 2,200 SUS)
Operating System Mineral Oils 10C - 80ºC (50°F - 176°F)
Temperature Water Glycols 10ºC - 60ºC (50°F - 140°F)
Water Based Fluid 10ºC - 60ºC (50°F - 140°F)
Fuels 10ºC - 40ºC (50°F - 104°F)
Industrial Phosphate
Esters & Polyesters 10ºC - 80ºC (50°F - 176°F)
Be aware of possible danger associated with high oil temperatures and
exposed metal surfaces of the PCM500
Fluid Compatibility
Aqueous solutions having a pH <11.0, water glycols, high water based
fluids, petroleum based fluids, industrial phosphate esters, mineral oils
and synthetic fluids.
Do not use Acetone based fluid.
Seals Fluorocarbon (Viton)
WARNING: Health and Safety.
Observe caution when handling fluids and pay attention to instructions of
safe use in the Material Safety Data sheet and COSHH regulations.
Wear protective clothing if prescribed; e.g. safety gloves, clothing and
footwear.
Caution: Health and Safety.
Ensure there is adequate lighting to operate the equipment.
Observe local regulations for factory use.
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Section 1: Pall PCM500 and PCM500W Fluid
Cleanliness Monitors
Specification and Requirements
1.3 Ambient Environment
Operating Temperature range 5°C - 40°C (41°F - 104°F)
Storage Temperature range
(Monitor drained of fluid) -20°C to 55°C ( -4°F to 131°F)
Dust and water protection IP65 (NEMA 4)
Relative Humidity 95%rh non-condensing
Operating Altitude <2000 metres
WARNING: Do not use the PCM500 Series Monitor in an explosive
atmosphere
1.4 Electrical
External Mains Power Supply Unit Input 100 – 240 VAC (Auto Ranging)
(PSU) Accessory Frequency 50 – 60 Hz Single Phase.
Output 48V DC
Input Fuse Quick Blow, 4A 5x20mm (250V)
Optional Mains Supply Unit Input 100 – 240 VAC (Auto Ranging)
Frequency 50 – 60 Hz Single Phase.
Output 24VDC
Internal Battery 12VDC Lithium Ion rechargeable.
Battery Life Typically 35 - 40 samples depending on
cleanliness levels & oil viscosity
Communications USB 1 (Data Acquisition)
USB 2 (PC Setup of PCM)
USB 3 (Printer)
Ethernet Cat5 (Remote control & Data
Acquisition)
RS232C (PLC Control)
Voltage Free Contacts
(Alarm output – contact rating 1 Amp @
24VDC)
1.5 Fluid Connections
Inlet – 2 options High Pressure:
Hose with ¼” BSP female swivel fitting and Metric,
Imperial or NPT Test Point connector options.
Low Pressure:
Hose direct coupled on ¼” BSP female swivel fitting.
Sampling stalk (for bottle sampling)
Outlet M10 male fitted to 6mm OD. Clear plastic hose, with
straight adapter and cap.
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Section 1: Pall PCM500 and PCM500W Fluid
Cleanliness Monitors
Specification and Requirements
1.6 Product Specification
Weight 11 Kg (24 lb)
Dimensions 400 x 260 x 250 mm (15.75” x 10.2” x 10“)
Monitoring range ISO4406 11/9/7 to 23/21/17
Monitoring range SAE AS4059F Table 1
(NAS1638) 1 to 12
Monitoring range SAE AS4059F Table 2 >4µm: 1 to 12, >6µm: 1 to 12 and >14µm:
1 to 12
Accuracy ±1/2 ISO4406 Code
Water-in-Oil (PCM500W only) %rh. ± 2% at 5 to 95%rh (non-condensing)
(PPM switchable but requires C1, C2, 0 to 100% full range
C3 & C4 fluid constant input. Contact
PALL representative).
Enclosure Material and Flammability ABS UL94 V-0
Enclosure Gasket Seals Silicone Rubber
Noise Level <70 dBA
Foreseen misuse of equipment
Within this manual are cautions and warnings to highlight potential dangers associated
with operation of the PCM500. Here are a few points of note on misuse of the
equipment.
A danger to the user can arise from connecting the PCM500 to a pressured system
above the working limit, and / or, using an incorrect high-pressure connection.
Damage to the PCM500 can occur from using incompatible fluids.
A danger to the user and damage to the PCM500 can be from an incorrect mains
voltage supply.
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Section 2: Pall PCM500 and PCM500W
Fluid Cleanliness Monitors
Section 3: Pall PCM500 and PCM500W
Fluid Cleanliness Monitors
2.1 Inspection and Packaging
The PCM500 is shipped in a transportation
case. Use this case for re-shipping the PCM.
Visually inspect the case for signs of external
damage that may have occurred during
shipping and bring any damage to the
attention of the shipper.
Inspect the interior of the case for damage to
the contents as listed below. Compare the
contents of the case with the shipping papers
to assure all the content is present. If any
items are missing, contact Pall or an
approved agent.
The PCM500 package comprises of:
• Integrated PCM500 series monitor with
sample hoses
• Power supply unit
• Mains power lead
• PCM500 to PC communications cable
• PCM500 series Operating Instructions on
CD ROM
• PCM500 series Quick Reference Guide
• Fluid Sampling stalk
• High Pressure test point connector
(Choice of Imperial, Minimess or NPT)
• Certificate of Conformity
• Certificate of Calibration Verification
• Packing note checklist
3.1 Description of the Monitor
The PCM500 is designed and built for light
Industrial use while maintaining aesthetic
and user friendly ergonomics. See section 1
for full specification. The materials are
selected to meet the various fluid and
environmental conditions that the PCM500 is
likely to be subjected during operation.
As a self-contained unit, including sampling
hose and adapters, the user is able to
connect the PCM500 on-line or sample fluid
directly from a system reservoir without
breaking lines thereby avoiding extraneous
contamination.
The PCM500 cleanliness monitor provides
numerous display functions to assist the user
at all stages of operation and provides
function codes to warn of any problems with
both the PCM500 and system fluid.
1. HMI (display/controller)
2. Communication Ports
3. Robust case with carry handle.
4. Integral 12VDC battery
5. Printer storage compartment
6. Last Chance Filter Housing
7. Hose Storage
8. Mesh Screen block
9. Power input and Fuse
The instruments’ specific serial number and
calibration/service record sheet is also
included. It is important to keep this in a safe
place and return them with the unit for future
annual service requirements.
Caution: Health and Safety.
Ensure there is adequate
lighting to operate the
equipment.
Observe local regulations for
factory use.
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❾
❸
❶
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Section 4: Pall PCM500 and PCM500W
External power connected and
Series Fluid Cleanliness Monitor
Principles of Operation
4.1 General Principles
Upon starting a test sequence the PCM500
will self-prime and perform internal checks on
the sample fluid condition. This is an
automatic part of the test time. After
approximately 30 seconds the PCM500 will
start the analysis. The screen will display a
progressive time bar for the duration of the
sampling period and identify the specific
stage in the monitoring cycle above the
progress bar.
During the analysis cycle the sample fluid is
presented to mesh screens in a specified
sequence, which captures contamination that
is larger than mesh pore size.
Particle concentrations are measured and
computed for each specific mesh.
BUTTONS:
• START/STOP/REPEAT (test)
• ON /OFF
The test Start/Stop button is active on
release. The ON button is active on
release but OFF requires pressing for 2 3 seconds to shut down.
Blue LED
On Off Flash On On
x
4.3 Test sampling
Green
LED
x No external power (battery
x PCM500 On - Operational /
Red Description
battery in charge mode.
only)
Standby
x Test in Progress
x Hardware/Sampling problem
detected
During the sampling sequence, data is
constantly analysed to identify any excessive
variance in temperature, viscosity, and
pressure to ensure results are not spurious.
The PCM500 will advise the user by function
codes, if any excessive variance occurs.
4.2 HMI Control Panel
The HMI LCD display is designed to provide
clear viewing of the screen menus and test
data. The test sample sequence is initiated
by use of the primary function keys. In edit
mode a keyboard is displayed on the screen,
which enables users to enter, or edit data
including sample points and fluid types.
There are three light emitting diodes (LED) to
indicate PCM500 operational status and two softtouch control buttons.
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4.4 Communications Panel
1
1 USB-A Socket 1 Text file upload/download from memory device
2 USB-B Socket PC connection for setup/control of PCM500
3 USB-A Socket 2 Printer connection
4 DB9 Female RS232 / PLC control (See section 7)
5 2-Pin Socket Voltage free contact. Relay
6 RJ45 Cat5 Ethernet 10/100 base
Screen indication of valid port connection
2
3
An indication of battery charge can be seen
in the lower right corner of the display.
4 5
U E PR
A row of four small boxes in the bottom right
corner of the display screen indicates when a
port connection is active.
U = USB-A 1
E = USB-A 2
R = RS232/PLC
P = Ethernet
External Supply
6
Align the red
dots and push
to connect
4.5 Power Schematic
The PCM500 is normally powered by a
battery located in the front of the unit behind
a plain panel. This has capacity at full charge
to power the monitor for an average of 40
tests (depending on oil viscosity). A power
supply unit (PSU), supplied as part of the
PCM500 package, allows the monitor to be
run from mains power and to charge the
battery.
!
Grip connector outer body and
pull straight to disconnect.
Important:
The PSU cable connection uses a
push – pull action on the outer body
and both connector and receptacle
align through a ‘red dot’ location mark.
DO NOT attempt to remove by rotating
the connector.
Important:
The monitor should not be operated
with the battery pack disconnected.
If a power outage occurs on mains
supply during testing the battery will
maintain power to the PCM to
prevent loss of data and allow for a
safe shut down
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4.5 Battery
Important:
The monitor should not be
!
In the event of a battery replacement the
following procedure should be followed.
operated with the battery pack
disconnected. If a power outage
occurs on mains supply during
testing the battery will maintain
power to the PCM to prevent
loss of data and allow for a safe
shut down.
WARNING: Use only battery
packs supplied by the
manufacturer or Pall agent.
Serious damage will occur if a
battery of different chemistry or
specification is used.
4. The battery connector is removed by
pulling straight on the outer body. Do not
rotate the connector, otherwise damage
will result.
5. When connecting the new battery,
align the red dots between connector and
receptacle before insertion.
1. Ensure the PCM500 is OFF and the
external mains power supply disconnected.
2 . Remove the two M4x10 hex socket
screws from the battery cover and lift out the
cover and then the printer storage cover.
6. Replace the printer and battery covers
and fix with the M4 hex socket screws.
3. Remove the printer if present to allow full
access to the battery connector
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