EPK- EasyTest Patch Test Kit Manual

Transcription

1 EPK- EasyTest Patch Test Kit Manual L-2730 The Patch Test Kit from Schroeder provides the necessary tools to determine levels of both water and solid particulate contamination present in a particular fluid sample. Using the vacuum pump contained in the kit, the fluid sample is drawn through a membrane patch. The residual dirt left on the patch is viewed under a microscope and compared to photos of known contamination levels in the Schroeder Contamination Handbook (included) for a visual assessment.

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3 Table of Contents Introduction... 3 Getting Started... 3 Kit Components Replacement Parts... 4 Obtaining Fluid Samples... 4 Patch Test Instructions After the sample has been taken... 7 Troubleshooting Guide... 7 Sampling Procedures Appendix A: How to Take an Oil Sample Through a SchroederCheck Test Point Kit Components... 8 Appendix B: Recommended Practices For Taking Oil Samples From A Hydraulic Reservoir... 9 Page 3 of 12

4 The EasyTest Patch Test Kit (EPK) from Schroeder is designed to enable you to: 1. Perform visual evaluation of the solid particulate contamination level of a fluid sample in the field 2. Identify specific contaminants present in the fluid 3. Determine the amount of water present in the fluid sample Instructions for items 1 & 2 are covered in this manual with references to the Schroeder Contamination Handbook, L-2711, a full color booklet containing photos of various samples, also enclosed. Instructions for item 3 above are included as a separate manual entitled EWC: Operating and Maintenance Instructions, L-2694, also enclosed in this kit. All three documents should always remain with the kit. Getting Started The components enclosed in the kit are described in Figure 1. A list of their part numbers appears in Table 1, and a list of replacement part numbers is listed in Table 2. EPK-101 Vacuum Pump and stand EPK-120 Fluid patch holder EPK um solvent filter patches EPK-108 Microscope, 100X EPK-114 Funnel EPK-110 Water Reaction Chamber EPK-116 Sample fluid patches EPK-104 Solvent Filter Bottle *EPK-112 Figure 1 Page 4 of 12

5 Table 1: Kit as supplied includes: Quantity Description Quantity Description 1 Mixing chamber 50 Plastic covered slides 2 Reagent A (solvent), 500 ml bottle 1 Microscope, 100x, with flashlight 1 Reagent B, 50 packets 1 Vacuum pump with folding stand 3 Syringe, 5 ml 1 Receptacle bottle, threads onto vacuum pump 1 Syringe, 10 ml 1 Plastic funnel 1 Syringe, 30 ml 1 Solvent dispenser bottle with filter assembly 1 Disposable rubber gloves, bag containing 50 pairs 3 Plastic sample bottle, 4 oz. 1 Scissors 1 Case with foam insert 1 Tweezers 1 Contamination handbook 50 Membrane patches, 0.8 μm, 25 mm diameter 1 Instruction manual Table 2: Replacement Parts: Part No. Description Part No. Description EPK-115 EPK-116 Plastic sample bottle Membrane patches, 0.8 μm, 25 mm diameter, qty. 50 EPK-120 Plastic covered slides, slides, qty. 50 EPK-112 Replacement parts pack, includes: 2 Reagent A (solvent), 500 ml bottle 1 Reagent B, 50 packets 3 Syringe, 5 ml 1 Disposable rubber gloves, bag containing 50 pairs 1 Scissors 1 Tweezers Obtaining Fluid Samples To ensure that your samples are representative of the hydraulic system s current state of contamination, make sure that: samples are taken at system operating temperature turbulent conditions exist at sampling point sample is taken while the system is operating or immediately after it is shut down Refer to Appendix A for instructions on how to take an oil sample through a test point. Refer to Appendix B for instructions on how to take an oil sample from a reservoir. Page 5 of 12

6 Patch Test Instructions Reference the photo in Figure 1 (page 3) for all part number designations: 1) Remove EPK-101, vacuum pump, and install stand. 2) Remove EPK-114 funnel 3) Grip the top and bottom part of the funnel and pull the stem. This will cause the funnel to separate into two pieces. 4) Install the stem of the funnel into the vacuum pump and tighten the nut on the vacuum pump. 5) Remove a patch from EPK-113 and install it in the lid assembly of solvent bottle (EPK-104). Once the patch is installed, fill the solvent bottle with Reagent A and place the lid assembly. 6) Using the tweezers provided, place a fluid patch (EPK-116) into the base of the funnel stem. Place the top part of the funnel back onto the stem that is now in the vacuum pump. 7) After aggressively agitating the sample, open the sample bottle and pour the sample into the funnel until it covers the first line; this represents approximately 28 ml. This is the line that is closest to the bottom of the funnel. This oil volume matches the Contamination Handbook patch photo examples, and allows enough remaining oil to send the bottle sample into either Schroeder s Lab or a lab of your choice. 9) Once this is done, pump the vacuum handle until all the fluid is pulled through the patch. 10) After the fluid has been pulled through the patch, take the solvent bottle and squirt solvent around the edges of the funnel. This will wash any contaminates that were stuck on the funnel onto the patch. Page 6 of 12

7 11) Remove the top part of the funnel. 12) Using the tweezers, remove the dirty patch and place it in one of the EPK-120 containers, leave the lid off of the container. 13) Turn on the flashlight and insert it into the bracket attached to the microscope. Remove the glass plate on the bottom of the microscope. Place the microscope onto the plastic container and adjust the microscope until the contaminates become clear. Once you have focused in on the patch surface, scan the surface for debris left from pulling the oil through, move the patch around on the slide using the tweezers and find an overall average representation of the debris or patch cleanliness. (each view with the microscope is about 1/64 of the patches surface area) Now use the Contamination Handbook to determine the Estimated ISO Cleanliness Code. 14) Install the top part of the funnel back onto the stem and rinse the funnel with solvent so it will be clean for the next use. Page 7 of 12

8 After the sample has been taken Assuming that a 100 ml sample was drawn initially, a total of 72 ml will remain after 28 ml are used for the patch test kit. If desired and rather than discarding it, this remaining fluid could be submitted for an automated particle count under the new THF-PC testing performed at Schroeder s on-site lab. Not only would this provide verification for the patch test, but it would also generate a hard copy and/or electronic report of the sample s cleanliness level. Part number for this service is THF-PC. Request L-2533 for ordering information on this service. Be sure to identify the slides with either a permanent marker or a label: Date the sample was pulled, Customer, Equipment Id Note where the sample was pulled (i.e., return line before the filter, at the case drain return, off the reservoir sample valve, off the reservoir bottom, etc.) Note the oil s ISO Viscosity Grade (if known) Trouble Shooting Guide Problem Cause Solution Oil Can not be pulled through the patch Can not see anything through the microscope Can not create a vacuum 1) Viscosity is too high 2) Contamination level is too high 1) There is not enough light present 2) Microscope is zoomed in all of the way 1) Bottle is not properly screwed on the vacuum pump 2) Check that the valve on the vacuum pump is not open or damaged 1) Use solvent to dilute the sample 2) Do not pour the entire 28 ml of sample fluid in at once. Instead pour a small amount and pull through the vacuum 3) Ensure the 0.4 um patch is not being used 1) Ensure the penlight is pointed directly onto the portion of the patch that is under the microscope 2) Move the microscope to a location with improved lighting 3) Zoom out and then begin to zoom in on the patch. 1) Unscrew the bottle and then screw it onto the vacuum pump 2) Ensure the o-ring and spring is still enacted. If it is not contact Schroeder Industries, LLC. Page 8 of 12

9 Sampling Procedures- Appendix A: How to Take an Oil Sample Through a SchroederCheck Test Point This procedure assumes that a Schroeder Check test point has been permanently installed at a location where turbulent flow exists. Sampling Procedure: 1. To initiate the sampling process, simply screw the Microflex hose end into the Schroeder Check test point until resistance is encountered. This indicates the probe has made contact with the poppet (or ball in the case of ball check test point). The flow rate of the fluid through the hose will be directly affected by the size of the opening created when the poppet or ball is displaced by the probe. Continue screwing down the hose end until the desired flow rate is achieved. 2. Pass a minimum of 200 ml of fluid through the Schroeder Check test point before collecting the fluid into a waste container. 3. Place the sampling bottle in position to collect the fluid. Use a sampling bottle having a contaminant level of at least two decades lower than the expected sample as qualified per the American National Standard Procedure for Qualifying and Controlling Cleaning Methods for Hydraulic Fluid Power Fluid Sample Containers, ANSI/B (NFPA/T , ISO ). 4. After removing the cap and plastic film from sample bottle, direct the fluid stream through the microflex hose into the bottle mouth. 5. Take a sample of not more than 80% nor less than 50% of the sampling bottle volume. 6. To terminate the sampling process, simply back off the hose gland nut at the Schroeder Check test point, keeping in mind that this operation should be performed before the container is completely filled. 7. Recap the sample bottle immediately. 8. Prior to taking additional samples, flush the microflex hose with a suitable solvent or fluid. Equipment Available from Schroeder Industries: Schroeder Check Test Point/Sampling Valves: Part Number SP1215NPT14P ¼ NPT Part Number SP1215UN716P 7/16 UNF Part Number SP1215UN916P 9/16 UNF Microflex Hose Assembly for Schroeder Check Test Points Shown Above: Part Number SM feet Page 9 of 12

10 Sampling Procedures -Appendix B: Recommended Practices For Taking Oil Samples From a Hydraulic Reservoir Equipment and Supplies: NOTE: Use only materials compatible with the fluid sample. 1. Use sample bottles having a contaminant level at least two decades lower than the expected sample as qualified per the American National Standard Procedure for Qualifying and Controlling Cleaning Methods for Hydraulic Fluid Power Fluid Sample Containers, ANSI/B See below for availability. (NFPA/T , ISO ) 2. Use lint-free cloths, free of visible dirt. 3. Use a device to permit withdrawal of a sample. (See figure below) 4. Provide lengths of tubing. Sampling Procedure: 1. Find a convenient opening above the fluid level in the reservoir through which the sampling tube can enter. 2. Determine the approximate distance D/2 as shown to establish the depth of the reservoir sampling tube. 3. Place a reference mark on the sampling tube at a point corresponding to the length of the tubing needed to reach D/2 from the opening through which the sampling tube will enter. 4. Use lint-free cloth to clean all surfaces which could contribute contaminant to the fluid sample. 5. Operate the hydraulic circuits to help diffuse particulate contaminant as evenly as possible throughout the reservoir. NOTE: When a procedure to diffuse particulate contaminant has been established for a particular system, maintain that procedure for all similar systems. If a sample representing normal operating conditions is desired, do not operate the hydraulic circuits for prolonged periods in an artificially clean environment. 9. Remove sample bottle and recap immediately. 6. Insert the sampling tube into the reservoir to the reference mark immediately after the contaminant in the reservoir has been diffused per point 5. NOTE: It may be necessary to weight the end of the tubing to help it to be positioned at the desired level. 7. Flush sampling tube with reservoir fluid equal to approximately five times the internal volume of the sampling line. Do not use flushing fluid or flushing bottle to obtain fluid sample per point Withdraw a fluid sample from the reservoir into a clean sample bottle. Fill sample bottle to not more than 75 percent nor less than 50 percent of the sample bottle volume. NOTE: Hours of operation immediately prior to sampling is vehicle or system running time per point. Page 10 of 12

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