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  • Manual

    PODSWare 2.3

    ARGO-HYTOS GmbH

    1

  • Table of Contents

    PODSWARE INFORMATION...............................................................................6

    Welcome to PODSWare ................................................................................................... 7 Introduction................................................................................................................................... 7 Note to New PODSWare Users ................................................................................................... 7

    PODSWare Features ........................................................................................................ 7 System Requirements....................................................................................................... 8

    Hardware and Operating System ................................................................................................. 8 Minimum System Requirements .................................................................................................. 8

    The First Run of PODSWare ............................................................................................ 8 Uninstalling PODSWare.................................................................................................... 8 PODSWare Support.......................................................................................................... 8

    PODSWare Technical Support..................................................................................................... 9

    THE PROGRAM WINDOW...................................................................................9

    The PODSWare Window ................................................................................................ 10 The Menu Bar ................................................................................................................. 10

    About the Menu Bar.................................................................................................................... 11 Using the Menus ....................................................................................................................................11

    File .............................................................................................................................................. 11 Edit.............................................................................................................................................. 11 View............................................................................................................................................ 12 Data ............................................................................................................................................ 13 Instrument................................................................................................................................... 13 Extras.......................................................................................................................................... 14

    Language ...............................................................................................................................................14 Options...................................................................................................................................................14

    Help ? ......................................................................................................................................... 14 The Toolbar..................................................................................................................... 15

    About the Toolbar ....................................................................................................................... 16 Displaying/Hiding the Toolbar ................................................................................................................16 Moving the Toolbar ................................................................................................................................16 The Toolbar Buttons...............................................................................................................................16

    The Treeview Window .................................................................................................... 16 About the Treeview Window....................................................................................................... 18

    Folders ...................................................................................................................................................18 Folder (Category) Properties Dialog........................................................................................... 18

    The Data Grid ................................................................................................................. 19 About the Data Grid.................................................................................................................... 20

    General Section .....................................................................................................................................20 Remarks.......................................................................................................................... 20 Section Standards and Particle Distribution.................................................................... 20

    Standards ................................................................................................................................... 20

    2

  • Particle Distribution..................................................................................................................... 21 User defined ranges ................................................................................................................... 21

    Section Physical Data ..................................................................................................... 21 Selecting records ............................................................................................................ 21 Selection of more than one record.................................................................................. 21 Select all records ............................................................................................................ 21 Move/Copy selected records to other folders ................................................................. 21

    Edit Remarks .............................................................................................................................. 22 The Data Plot .................................................................................................................. 22

    Particle Concentration Plot ......................................................................................................... 23 Standards Plot ............................................................................................................................ 23 Plot Commands .......................................................................................................................... 24

    The Control Panel ........................................................................................................... 25 About the Control Panel ............................................................................................................. 26

    The Status Bar ................................................................................................................ 26 About the Status Bar .................................................................................................................. 27

    PODS Status Display .............................................................................................................................27

    THE CHARTS .....................................................................................................27

    The ISO 4406 Chart........................................................................................................ 28 The SAE AS4059 Chart .................................................................................................. 28 The Time Chart ............................................................................................................... 29

    Display a Time Chart: ................................................................................................................. 29 The Viscosity Chart......................................................................................................... 30

    Display a Viscosity Chart:........................................................................................................... 30 The Chart Window .......................................................................................................... 31

    The Toolbars in the Charts......................................................................................................... 31 The Toolbar ................................................................................................................................ 31 Z-Ordered View .......................................................................................................................... 31 The Annotation Bar..................................................................................................................... 32 The Palette Bar........................................................................................................................... 32

    Change the current Palette ....................................................................................................................32 Change the colors of series....................................................................................................................32

    The Pattern Bar .......................................................................................................................... 32

    THE REPORTS...................................................................................................32

    Report Basics.................................................................................................................. 33 Printing Reports.......................................................................................................................... 33 Fixed Reports: Report ISO 4409, SAE AS4059 and NAS 1638 ................................................ 33 The Report Viewer...................................................................................................................... 33

    The Report ISO 4406...................................................................................................... 33 The Report SAE AS4059 ................................................................................................ 34 The Report NAS 1638..................................................................................................... 35 User Defined Report ....................................................................................................... 36

    3

  • ALARMS.............................................................................................................36

    Alarm Handling ............................................................................................................... 37

    PERSONALIZING PODSWARE.........................................................................38

    General Options.............................................................................................................. 39 General Settings......................................................................................................................... 39 Date ............................................................................................................................................ 39 Time............................................................................................................................................ 39 Units Selection............................................................................................................................ 39 Oil Data Settings......................................................................................................................... 40

    Options Data Grid ........................................................................................................... 40 Visible Grid Columns: ................................................................................................................. 40 Grid Appearance ........................................................................................................................ 40

    Options Charts ................................................................................................................ 40 Chart ISO 4406........................................................................................................................... 41 Time Chart.................................................................................................................................. 41 Viscosity Chart............................................................................................................................ 41

    Options Reports .............................................................................................................. 41 General Settings......................................................................................................................... 42 Size and Alignment..................................................................................................................... 42

    Options Instrument.......................................................................................................... 42 Device Connection ..................................................................................................................... 43 Download Data Selection ........................................................................................................... 43

    Options Alarm ................................................................................................................. 43 Acoustic Alarm............................................................................................................................ 44 Visual Alarm ............................................................................................................................... 44

    HOW DO I... ........................................................................................................44

    Manage Database Files .................................................................................................. 45 Open an existing Database File ................................................................................................. 46 Create a new Database File....................................................................................................... 46 Create a new folder in a Database............................................................................................. 46 Rename a Folder........................................................................................................................ 46 Copy Records into other Folders................................................................................................ 46 Select Records ........................................................................................................................... 47 Delete Records........................................................................................................................... 47 Delete Folders ............................................................................................................................ 47 Export Data................................................................................................................................. 48 Print Data.................................................................................................................................... 49 Save the Data............................................................................................................................. 49 Copy Records to Clipboard ........................................................................................................ 49 Create an oil data table as MS-Excel Sheet............................................................................... 49

    Download Data from PODS ............................................................................................ 50 Download Data ........................................................................................................................... 51

    Generate a Chart ............................................................................................................ 51 Display Data as a Chart.............................................................................................................. 52

    4

  • Generate a Report .......................................................................................................... 52 Printing Data as a Report ........................................................................................................... 53 Select a MS-Word Template ...................................................................................................... 53 Create a new MS-Word Template.............................................................................................. 54

    General Informations:.............................................................................................................................54 Measurement Identification............................................................................................. 54 Date and Time ................................................................................................................ 55 Physical Data .................................................................................................................. 55 Particle Distribution per mL............................................................................................. 55 Particle Distribution per Liter........................................................................................... 56 Particle Concentration per 100 mL ................................................................................. 56 Chart ............................................................................................................................... 56 Output Format................................................................................................................. 56

    PODS ENZYCLOPEDIA .....................................................................................57

    PODS Encyclopedia ....................................................................................................... 58

    TECHNICAL SUPPORT AND LICENSING ........................................................64

    License Agreement ......................................................................................................... 65 Feedback ........................................................................................................................ 65

    5

  • PODSWare Information

    6

  • Welcome to PODSWare

    Introduction

    PODSWare is a user friendly powerful program for saving, managing, displaying and deploying data from PODS, the Portable Oil Diagnosis System by ARTI. Oil analysis data are displayed in a data grid, as graphical distribution charts using several international cleanliness standards as well as in printed oil sample reports. Download data generated by PODS and document the particle contamination as well as temperature and viscosity of your oil. PODSWare is the window to the oil condition of your machine!

    PODSWare Features

    Note to New PODSWare Users

    If this is the first time you are using PODSWare, browse through the help topics to get an idea of what the program can do and familiarize yourself with the program. You can learn more about using this help system and the other help resources in Using PODSWare Help. Current Revision: PODSWare Version 2.3 (Oktober 2009)

    PODSWare Features

    y Store, display and handling data from PODS y Display data in a data grid, customizable display and column selection y Display data as time plot, display as particle concentration or standard selectable y New: SAE AS4059 Standard y Manage data in a tree-like, easy to use structure y New: Individual Input of Remark Text for each Sample y Display graphical distribution for various standards y Display and Print oil analysis reports y Controlling of PODS and setting of parameters via software y Performing measurements under software control (bottle or online) y Comprehensive PODS status display y Alarm handling, alarms selectable for particle concentration or available standards y User entry for additional data (notes)

    7

  • y Export to selectable formats (Excel, Text, HTML, PDF, XML) y Export graphical data to bitmaps y Intuitive Microsoft Office Look-and-Feel

    System Requirements

    Hardware and Operating System

    PODSWare is a 32-bit Windows application. It requires one of the following Windows operating systems on your PC: y Windows 98 / ME y Windows NT 4.0 with SP5 and Internet Explorer 4.01 or higher installed y Windows 2000 y Windows XP Minimum System Requirements

    y Pentium 120 MHz y 40 MB of free disk space y 16 MB RAM, 32 MB recommended y VGA Graphic, min. 256 colors y A CD-ROM y A free serial port and an appropriate serial cable for data input from the PODS device To get a reasonable data display screen resolution should be set to 1024 by 768 or higher. Color resolution should be 32768 (15 Bit) or higher. 256 colors will definitely not provide satisfying results when displaying charts.

    The First Run of PODSWare

    PODSWare will ask for a new database on first startup:

    Select Create New Database and click OK. Follow the on-screen prompts.

    Uninstalling PODSWare

    y Click Start and select Settings -> Control Panel y Click Add/Remove Programs, select PODSWare y Click the Add/Remove button y Follow the on-screen prompts.

    PODSWare Support

    If you have any questions about using PODSWare, first have a lock to your manual and to this help file. If the problem is not fixed, please contact FSP Technical Support. y You can find the PODSWare manual on the CD-ROM. y Accessing and using the help file y General information on using Microsoft Windows Help

    8

  • y The " How Do I . . . " topics in the help system,

    PODSWare Technical Support

    If you have a question and cannot find a solution in the help system or manual, please e-mail to: [email protected]

    The Program Window

    9

  • The PODSWare Window

    The Menu Bar

    10

  • About the Menu Bar

    Click a menu heading to open the menu and choose a command. The commands you use frequently are also displayed on the Toolbar.

    Note: Menu items that appear in gray either do not apply or are unavailable.

    Using the Menus

    You can display menu commands using the following methods: y Clicking the desired menu in the Menu Bar, or y Pressing the key plus the underlined letter in the menus title. For example, to display the File Menu, press + . Select or execute a menu command: y Clicking the item in the menu, y Pressing the key plus the underlined letter in the menus title, and then pressing the underlined letter of the menu item. For

    example, to select the menu item File Open, press + + , or y Using the cursor or the , and keys to highlight a menu item, and then pressing the Enter key; or y Use an appropriate Toolbar button. File

    y New: Create a new Database File

    y Open: Open an existing Database File

    y Save As ...: Save the data y Export Data: Export your data to an Excel Worksheet, to a text, HTML or XML file (Click File-Export Data and select the

    desired format. Follow the on-screen prompts) Note: If you export your data to an Excel Worksheet, the unit of the temperature will be C and the unit of the viscosity cSt.

    You can convert them in MS-Excel y Print Data: Starts the Printer dialog(Click File-Print Data and follow the on-screen prompts.) y MRU List (most-recently-used): This menu item displays the names of files that have previously been opened. To re-open one of

    these databases, click its name in the list. The maximum number of files listed in the menu is limited to 4. Note: If you have just installed PODSWare and no files have been opened before, this list will be empty.

    y Exit: Terminates PODSWare Edit

    11

  • y Cut: Not implemented yet.

    y Copy: Click to copy selected records to the Windows clipboard. y Paste: Not implemented yet. y New Category: Creates a New Folder. Follow the dialog instructions. y Rename Category: Rename current category (folder). y Delete Category: Delete current category including all sub-categories. A confirmation dialog is displayed first to avoid accidental

    deletion.

    y Delete Records: Click to delete selected records. y Select All: Click to select all records in the Data Grid. y Edit Remarks: Create or edit remark text of currently selected samples. y Properties: Displays the properties dialog for the currently selected database folder (category).

    View

    To check/uncheck an item, click the item or press the underlined letter on the keyboard. y Toolbar: Shows/Hides the toolbar y Status Bar: Shows/Hides the status bar

    y Treeview: Shows/Hides the treeview window ( ).

    y Instrumentpanel: Shows/Hides the control panel ( ).

    12

  • y Grid Window: Shows/Hides the data grid ( ).

    y Plot Window: Shows/Hides the data plot ( ). y Select Category: Select a database folder (category) via dialog. This function is equivalent to clicking a folder in the treeview

    window but works even with the treeview window hidden.. y ISO 4406, NAS 1638, SAE AS4059 or NAVAIR 01: Select the standard displayed in the Data Grid. y Show ACFTD Sizes: When checked displays the measured particle distribution according to the Air-Cleaner-Fine-Test-Dust

    (ACFTD) in the Data Grid and in the ISO Report By default the measured particle distribution is shown according to the test dust ISO MTD.

    y Refresh: Refresh the data grid display. This function can be useful, when data was written to the current database by another application but is not displayed yet.

    Data

    y Distribution ISO 4406: Particle distribution according to ISO 4406 standard.( )

    y Distribution SAE AS4059: Particle distribution according to SAE AS4059 standard.( )

    y Time Chart: Particle distribution over time.( )

    y Viscosity Chart: Display normalized viscosity over time ( ).

    y Report ISO 4406: Report using ISO 4406 standard.( )

    y Report SAE AS4059: Report using SAE AS4059 standard.( )

    y Report NAS 1638: Report using NAS 1638 standard.( )

    y User Defined Reports: Your own reports defined by a Word template ( )

    Note: You must first select one or more records to display a Chart or a Report!

    Instrument

    y Connect Instrument: Switch on PODS and select this menu item to connect PODS to the computer. The checked item signals

    an active connection. Errors during connection will be flagged in the status display. y Readout Data: Download buffered samples from PODS. A dialog allows setting of selection parameters. y Start Measurement: Start a measurement. This item is enabled only if PODS has been successfully connected. Measurement

    parameters can be set in the Control Panel.

    13

  • y Device Setup: Set connection port and download parameters via Option dialog. Gertedaten lesen: Klicken Sie auf Gertedaten lesen, um den Dialog 'Daten auslesen' zu ffnen. Dort wird Ihnen die Schnittstelle angezeigt an, die Sie momentan eingestellt haben. Klicken Sie auf Setup, wenn der richtige COM Port noch nicht eingestellt ist und korrigieren Sie die Einstellung. Status Bar Display:

    The color of the image in the status bar shows information about the connection status of PODS.

    No connection to the PODS

    Successful connection to the PODS

    PODS error ( an appropriate message is shown next to the image)

    Extras

    Language

    Click and select the desired language. Possible selections depend on the language available in your PODSWare installation.

    Options

    Use this dialog to set application parameters of PODSWare. Click Options to start the dialog.

    Help ?

    y Click Menu Item -> ? , or y Press

    Choose Contents to display this help file. Click About PODSWARE to see version and system info.

    14

  • The Toolbar

    15

  • About the Toolbar

    The Toolbar allows you to use menu commands quickly. You can close and open the Toolbar as needed, and drag it around the screen.

    Place the mouse pointer over a toolbar button. A pop-up hint referred to as a ToolTip appears.

    The Toolbar can be incorporated into the edges of the workspace (docked) or pulled away and floated (undocked).

    Displaying/Hiding the Toolbar

    Choose Menu Bar - View and select/unselect the Toolbar.

    Moving the Toolbar

    Move you mouse pointer on the Toolbar. Keep the left mouse button pressed drag the Toolbar to a new location drop the Toolbar.

    The Toolbar Buttons

    New Database

    Open a Database

    Save the Data

    Copy records to the Windows Clipboard

    Delete records

    Display the ISO 4406 Distribution Chart

    Display the SAE AS4059 Distribution Chart

    Display a Time Chart

    Print a Report according to the ISO 4406 standard

    Print a Report according to the SAE AS4059 standard

    Print a Report according to the NAS 1638 standard

    Print a user defined report

    Select the standard displayed in the Data Grid

    Oil selection

    Viscosity Chart

    Display/Hide treeview window

    Display/Hide control panel

    Display/Hide data grid window

    Display/Hide data plot window

    The Treeview Window

    16

  • 17

  • About the Treeview Window

    The Treeview lets you navigate easily within a current database. Click the + sign to open folders and to display the affiliate subfolders. Click a folder to select it. A selected folder has a blue background.

    Folders

    The folders treeview is supposed to reflect the organization of your oil analysis (like company divisions, sites, machines, tested devices or simply different tests taken). There is a (virtually) unlimited number of different folders and levels of subfolders. Feel free to use them intensively for documentation and organization of your data. Data can be transferred (moved or copied) between folders easily via Drag&Drop. You can enter new, rename or delete folders or subfolders in the tree view pane. Additional properties can be adapted in the properties dialog. The Treeview implements the Look&Feel of MS Office, especially MS Outlook, for easy adaptation of a novice user.

    Folder (Category) Properties Dialog

    Open this dialog via menu command Edit -> Properties or by right-clicking the desired folder in the treeview and selecting "Properties".

    18

  • y Category Name: Name of category (database folder). y Category Notes: Additional notes for measurements in this category. This user selected text is stored in the database. y Flags: Info flag in database. Currently not used. y Date Created: Creation date and time of this category (folder), read-only. y Oil Selection: Selection of an oil type used for calculation of a normalized viscosity for this category's measurements. The

    available selections are read from a parameter file on application startup. y Oil Description: Additional information on the selected oil, read-only.

    The Data Grid

    19

  • About the Data Grid

    The Data Grid displays all samples within the selected folder of the database and is divided into four sections, which cant be shown complete in the Data Grid window. Use the scrollbar at the bottom of the Data Grid to see one or more sections.

    General Section

    The column General shows individual settings of the single records, like the name of records and the date and time of the measurement. You can set your Date/Time format via the Menu Bar Extras - Options in the general tab.

    PODS Mode Display Text

    Bottle BOT

    Filter FIL

    Online ONL

    Unknown (older PODS-Versions) -X-

    Remarks

    Remarks are user-defined text entries in the PODS device and may contain up to 30 characters (3 lines of 10 chars.). Remarks may be created or edited by the user.

    Section Standards and Particle Distribution

    Standards

    This section shows the selected standard. Possible selections are: y ISO 4406 y NAS 1638 y SAE AS4059 y NAVAIR 01 To change the standard displayed in the Data Grid you may either: y Right click the header of the Data Grid and select the desired standard in the pop up menu. y Choose View in the Menu Bar.

    20

  • y Choose Extras-Options-Data Grid y Use the appropriate Toolbar button.

    Particle Distribution

    Here you can see the measured number of particles sorted by size ranges. The unit is Particles/mL. To show the measured particle distribution according to the Air-Cleaner-Fine-Test-Dust (ACFTD), right click the header of the Data Grid and check "Show ACFTD Sizes". If "Show ACFTD Sizes" is unchecked, the measured particle distribution is shown according to the new test dust ISO MTD.

    User defined ranges

    If measurements are taken with user defined channel sizes, particle concentrations cannot be properly classified. Standards are thus invalid and will be displayed as "---". The particle concentration data will be displayed in blue followed by the channel size in brackets.

    Section Physical Data

    This section displays the physical data of the single records. The standard viscosity depends on a reference temperature and an oil. Reference temperature and oil can be set via options Oil Data , and the units for temperature, viscosity, standard viscosity via options General. The selected reference temperature is shown in brackets after the header (Viscosity ( 40 C)). The standard viscosity is only shown, if an oil is selected, else will be printed. Volume and Flow rate are defined by the PODS.

    Selecting records

    Select the desired record(s) by clicking the grey field on the very left. Selected rows will be displayed with a blue background.

    Selection of more than one record

    Select the first record. To select a range of records, select the last record with -Click (hold down the Shift key on the keyboard while clicking). To freely select any number of records, use -Click.

    Select all records

    Use the menu command: Edit-Select All

    Move/Copy selected records to other folders

    21

  • y Move the mouse pointer into the blue background of the selected records. y Press the right mouse button (the pointer changes to a hand). y Keep the right mouse button pressed and drag the records to the desired folder in the Treeview Window. y Drop the records into the desired folder. Make your choice in the Popup menu. Edit Remarks

    PODS measurements can be annotated with a 30 character remarks text. This text has to be manually entered in the PODS device before each measurement. PODSWare offers the ability to create or edit remarks for existing measurements. This allows the user to easily document conducted measurements afterwards. Warning: Existing remark texts will be deleted - there is no possibility for retrieving accidentally overwritten data!

    A warning is displayed if multiple records are selected to avoid accidental overwriting of data:

    The Data Plot

    22

  • Particle Concentration Plot

    This plot shows the distribution of particle concentration in a sequence of samples. The range will be set to a reasonable value when loading the data and can be adjusted by the user thereafter. Sample data can be loaded from the data grid by a toolbar command or directly via Drag&Drop.

    Standards Plot

    23

  • This plot shows the distribution of the selected classification in a sequence of samples. The desired standard may be re-selected at any time by the buttons in the right upper corner of the plot.

    Plot Commands

    Plot Toolbar Commands:

    Move axis range. If this mode is selected (button pressed) the visible range an axis can be moved with the mouse. Left-click an axis and drag the mouse to get the desired visible range.

    Scaling of axis. If this mode is selected (button pressed) the scaling of an axis can be zoomed with the mouse. Left-click an axis and drag the mouse to get the desired scaling.

    Show/Hide data cursor.

    Copy an image of the plot to the clipboard.

    24

  • Save the plot as meta file (EMF) to disk.

    Print the plot.

    Scale the X axis (time axis) to a preselected value.

    Load data from table to the plot. Selected records will be loaded into the plot. If no records are currently selected, all table data will be loaded.

    Clear plot.

    Note: Selecting an interval will reset any manually adjusted scaling of the X axis to the selected value.

    The Control Panel

    25

  • About the Control Panel

    The control panel allows direct access to the PODS. Available parameters can be entered or selected by the user. The progress bar at the bottom allows a quick check of the current operation status.

    The Status Bar

    26

  • About the Status Bar

    The Status Bar is the horizontal area in PODSWare below the Data Grid and provides information about actions performed as well as the the current state of the PODS in the very right pane.

    To connect a PODS to your PC, check Connect Instrument in the Menu - Instrument.

    PODS Status Display

    No PODS device connected.

    PODS connected.

    PODS Error (An error description is displayed next to the icon).

    The Charts

    27

  • The ISO 4406 Chart

    The Chart ISO 4406 displays the cumulative particle distribution with the ISO 4406 cleanliness code overlaid on the right ordinate. In the background of the chart area the correspondent ISO classes are shown as white and gray sections. The ISO codes are printed at the right side of the chart area.

    Tip: Right click the chart area to start the options dialog. Display an ISO 4406 Chart: y Select one or more records y Choose Menu Bar-Data-Distribution ISO 4406, or

    y Click the Toolbar button

    The SAE AS4059 Chart

    The Chart SAE AS4059 displays the differential particle distribution as a bar graph according to the standard SAE. Tip: Right click the chart area to start the options dialog.

    Display SAE AS4059 Chart: y Select one or more records y Choose Menu Bar-Data-Distribution SAE AS4059, or

    y Click the Toolbar button

    28

  • The Time Chart

    The Time Chart displays the temporal trend of your measurements with the ISO 4406 cleanliness code overlaid on the right ordinate. In the background of the chart area the correspondent ISO classes are shown as white and gray sections. The ISO codes are printed at the right side of the chart area.

    Display a Time Chart:

    y Select one or more records y Choose Menu Bar-Data-Distribution-Time Chart, or

    y Click the Toolbar button

    29

  • The Viscosity Chart

    The viscosity chart displays the temporal trend of your measured oils. A standard viscosity is calculated from the measured viscosity and temperature. You can change the reference temperature via Options-Oil Data. The viscosity chart can only be shown, if there are data about the viscosity distribution, i.e. if you selected an oil (Options Oil Data) The printed time axis (X-Axis) is equal to the time axis in the time chart.

    Tip: Right click the chart area to start the options dialog.

    Display a Viscosity Chart:

    y Select one or more records y Choose Menu Bar-Data-Distribution-Viscosity Chart, or

    y Click the Toolbar button

    30

  • The Chart Window

    The Toolbars in the Charts

    The following bars are available in the Charts: y The Toolbar y The Annotation Bar y The Palette Bar y The Pattern Bar

    You can close and open the bars as needed, and drag them around the screen. The bars can be incorporated into the edges of the workspace (docked) or pulled away and floated (undocked). To hide the Toolbar in the Charts, double click the Toolbar, then click the Close button in the upper right of the new window. To show the Toolbar again, restart the Chart.

    To show or hide another bar click the Tool button in the Toolbar of the Charts and check or uncheck an item. Tip: Right click the chart area to start the options dialog.

    The Toolbar

    Hints are provided by the ToolTips

    Z-Ordered View

    31

  • Selecting the Z-Ordered View draws all data series (lines or bars) behind each other. You might not be able to see some of the data, when covered by foreground objects (e.g. higher bars).

    This selection is most useful in 3D perspective and for changing the Color or Pattern of series.

    The Annotation Bar

    With the help of the Annotation Bar you can write notes into the chart, mark important sample data and more. Feel free to try out the features of the Annotation Bar. A complete help documentation is beyond the scope of this product but useful hints are provided by the Tooltips. The annotation objects (selected via the Annotation Bar) are provided as a means to improve special printouts (like drawing an explanatory text or a dart pointing to an important fact) and will not be preserved (stored) when the chart is closed.

    The Palette Bar

    With the help of the Palette Bar you can assign colors and color schemes to series.

    Change the current Palette

    Click the Palette image on the right side of the Palette Bar and select a new Palette.

    Change the colors of series

    Click a color in the Palette Bar (keep the left mouse button pressed) and drag it to the desired series and drop the color.

    Tip: To change the color of series use the Z-Clustered-3D View of your chart and assign your colors to the series.

    The Pattern Bar

    The Pattern Bar allows you to assign different pattern to the series. (See: Change the color of series)

    The Reports

    32

  • Report Basics

    Use a Report to generate a compact and informative result of your oil analysis data.

    Printing Reports

    y Select one ore more records in the Data Grid. y Use Menu Bar -Data - Report or click the appropriate Toolbar button,

    Fixed Reports: Report ISO 4409, SAE AS4059 and NAS 1638

    These reports show a set of records, either in the ISO 4409, SAE AS4059 or NAS 1638 format. The layout is fixed and cant be changed, but you can use your own logo. The selection is done via Options Reports . Reports are shown in the Report Viewer.

    The Report Viewer

    The Report Viewer displays one record (one sample) per page. Move between the pages with the "Next" and "Previous" buttons. Reports can be saved to file in portable document format (PDF) via the toolbar button "Save". These files can be distributed and displayed with Acrobat Reader.

    The Report ISO 4406

    Use this report to get a compact and informative result about your oil analysis data according to the standard ISO 4409. Note: You must select one or more records before printing a Report!

    33

  • The Report SAE AS4059

    Use this report to get a compact and informative result about your oil analysis data according to the standard SAE AS4059. Note: You must select one or more records before printing a Report!

    34

  • The Report NAS 1638

    Use this report to get a compact and informative result about your oil analysis data according to the standard NAS 1638. Note: You must select one or more records before printing a Report!

    35

  • User Defined Report

    Use this report to print your data and charts in a MS-Word document, designed to your layout request. Requirement: You must have MS-Word installed on your system and you must have selected a template. The standard selection is the template last used. Select a template Create a new template

    Alarms

    36

  • Alarm Handling

    Open Alarm property dialog via menu Edit -> Properties or right-click to a category in the treeview window and select "Properties".

    y Alarm enabled: Activate alarms for this category. y Alarm Direction: Select alarm on values exceeding or below the selected limit. y Alarm Acknowledge: Select the desired acknowledge of an alarm by the operator. y Alarm Selection: Select the type of alarm. Limits selection is depending on this selection. y Alarm Limits: Setting of the alarm limit values depending on the alarm type. Channels can be selected individually for alarm

    handling on alarm types offering more than one limit value (e.g. ISO, particles/mL).

    Note: Alarm parameters are stored in the database and are valid for all measurements in a category (folder).

    The action taken on alarm is selectable in the Options. Alarm Limits for Alarm Type "Particles/mL":

    37

  • Alarm Limit values are selectable as ISO standard codes.

    Personalizing PODSWare

    38

  • General Options

    Use this dialog to set general settings of PODSWare. y Choose Menu Bar - Extras - Options, General Settings

    In the General Tab you can set your favored date and time format, displayed in the Data Grid and the Reports.

    Date

    System Settings (Long Date): Use system setting Long Date System Settings (Short Date): Use system setting Short Date User Format: Select a predefined format from the Drop-Down.

    Time

    Use System Settings: Use system setting Time User Format: Select a predefined format from the Drop-Down.

    Units Selection

    Select units used for data display of temperature and viscosity in datagrid, charts and reports.

    39

  • Oil Data Settings

    Selection of viscosity data table. This data is read during application startup and is used to calculate a normalized viscosity at a reference temperature. Selection of a certain type of oil is on a per-category basis (i.e. a selected oil is used for all measurements stored in a database folder). The Reference Temperature for Viscosity is used to calculate a normalized viscosity based on the oil data given. Standard value is 40C.

    Note: Your selections will be stored, when exiting PODSWare.

    Options Data Grid

    Visible Grid Columns:

    Selection of columns displayed in the datagrid.

    Grid Appearance

    Selection of visual parameters for datagrid (background color, text color on error or non-standard channel sizes). Clicking "Reset standard values" resets the default values.

    Options Charts

    40

  • Tip: Right click the chart area for a qiuck start of this option dialog.

    Chart ISO 4406

    Line Width: Line width setting Show ISO Labels in 3D View: Show labels normal or in 3D View.

    Time Chart

    Line Width: Line width setting. Max. Number of Time Marks: The number of time marks on the time axis (X-Axis). PODSWare automatically determines a reasonable division depending on the time values given in the sample data. Maximum number of tickmarks can be set between 2 and 12.

    Viscosity Chart

    Line Width: Line width setting

    Options Reports

    41

  • General Settings

    Use Default Logo: FSP logo Use Custom Logo: Printing your logo in the report. You can use one of the following files: y Bitmaps (*.bmp) y Gif Files (*.gif) y WMF Files (*.wmf) y JPG Files (*.jpg)

    Size and Alignment

    Your logo will be changed to a predefined size. The alignment will be centered. You will get good results with the following proportions: Height: 32 mm (about 150 pixels) Width: 160mm (about 750 pixels)

    Note: y The selected logo will be printed in all standard reports. y The logo file will not be saved within the PODS Database. If is is required to pass the logo with the data, you must pass your logo

    as file.

    Options Instrument

    42

  • Device Connection

    Select the serial port (COM port) used for communication to your PODS.aus. Only ports avaliable on this computer will be listed and selectable .

    Download Data Selection

    Select data records for download from POPDS. y All Samples: All records buffered in PODS will be downloaded (up to 500 records) y Date: Only records taken within the selected date will be downloaded y Sample ID: Only records with a certain name will be downloaded. Selection criterion is the beginning of a sample name i.e. input

    of "SAMP" will select all samples with a name starting with "Samp" for download (e.g. "Sample1", "Sample2" etc.). The selection is not case-sensitive!

    Options Alarm

    43

  • Acoustic Alarm

    Activate an acoustic signal on alarm (PC beep).

    Visual Alarm

    Activate a visual alarm indication by flashing the title bar of the application and the info bar (text bar below toolbar) in a selectable color.

    Hint: Choose a GREEN color for indication of reaching a certain level of cleanliness (alarm direction 'Low') and RED for exceeding critcal limits.

    How Do I...

    44

  • Manage Database Files

    45

  • Open an existing Database File

    y Choose Menu Bar - File - Open, or the y Most-Recently Used List, or

    y Click the Open button on the Toolbar. Follow the on-screen prompts. You can see the filename and the folder in the Treeview Window. If the database contains subfolders, you will see a + sign before the Database icon. Click it to expand the tree.

    Create a new Database File

    Before you create a new Database File, think about how you will use it. Basically you should use efficient filenames for your oil analysis data (e.g. company divisions, machines, tested devices or simply different tests taken). y Choose Menu Bar - File New, or

    y Click the New Database button on the Toolbar. Follow the on-screen prompts. Select the folder, where the new database should be created, use an efficient filename and click Save. The file extension (.pod) will be added automatically. You can see the new filename and the folder in the Treeview Window. A standard folder is automatically created.

    Tip: Move the mouse pointer in the Treeview Window to database name to see the full name and path of the file.

    Create a new folder in a Database

    First of all think about a useful structure of your database file.

    y Right click on the desired parent folder in the Treeview Window. In the pop-up menu click New Folder. y Use an efficient name in the next dialog and click . Rename a Folder

    y Right click a folder in the Treeview Window and select Rename Item in the pop-up menu y Rename the folder. y Save your changes.

    Copy Records into other Folders

    46

  • You can copy/move selected records to other folders in a database file using Drag&Drop.

    1. Click the folder with the source records to show them in the Treeview Window 2. Select the desired records 3. Move your mouse pointer to the blue background of the selected records 4. Right click the selection (the mouse pointer changes to a hand) 5. Drag the records to the destination folder in the Treeview Window 6. Drop the records into the new folder. Make your choice in the context menu.

    Select Records

    Select the desired record(s) by clicking the grey field on the very left of the Data Grid. Selected rows will be displayed with a blue background. Selection of more than one record Select the first record. To select a range of records, select the last record with -Click (hold down the Shift key on the keyboard while clicking). To freely select any number of records, use -Click. Select all records Use Select All in the menu Edit.

    Delete Records

    y Select one or more records y Choose Menu Bar - Edit - Delete,

    y Clicking the Delete button on the Toolbar.

    A warning message is issued to the user before the actual deletion to avoid accidental loss of data.

    Delete Folders

    y Right click a Folder in the Treeview Window. y Select Delete Item in the pop-up menu

    47

  • A warning message is issued to the user before the actual deletion to avoid accidental loss of data.

    Export Data

    Choose this command to export your data either to an Excel Worksheet, to a pure text or to a HTML formatted file. y File Export Data

    Click the desired item to start the Export Dialog.

    Export to:

    Enter the folder and the filename, or click to start the save dialog and follow the on-screen instructions. A user selection for exporting only the selected rows or all rows in the Data Grid is possible.

    48

  • To analyze your data in Microsoft Excel, use the feature export to Excel Worksheet. A suggestion for the name of the new Excel Worksheet is given in the dialog "Save As...". You may accept this name or enter a new one. It is recommended to avoid special characters and symbols for the worksheet name.

    Try especially exporting to HTML and view the exported data with Internet Explorer. There is no functionality yet to export a complete database including all folders and subfolders implemented yet. This is one of the planned features. The PODSWare database format is MS Jet 3.x so *.pod files can be opened and processed in Access97! Note: When exporting data to an Excel Worksheet, temperature values will be given C and viscosity in cSt. If required,

    convert values in MS-Excel.

    Print Data

    Print the raw grid data as displayed. Only the complete displayed Data Grid can be printed in the present version. y Menu Bar - File Print

    Save the Data

    y Click Menu Bar - File Save As, or

    y Click the Save button on the Toolbar. Follow the on-screen prompts.

    Copy Records to Clipboard

    y Select the records you want to copy to the clipboard. y Click Edit -> Copy in the menubar or ... y Enter Ctrl-C on the keyboard or ...

    y Click to in the toolbar. The selected records are copied to the clipboard as formatted text. You may then paste this test into any Windows application.

    Create an oil data table as MS-Excel Sheet

    By means of viscosity data given in a MS-Excel sheet PODSWare allows you to display a viscosity value normalized to a reference temperature for your samples. Basic oil data is distributed with PODSWare but can be adapted or extended at user's requirements. Create a new MS-Excel workbook and insert a worksheet for each type of oil. Enter your oil data into the worksheets using the following layout:

    49

  • Note: y Create a separate worksheet for each oil. Worksheet names are freely selectable and will not be used by PODSWare. y Four columns of data are required. The table headers (first row) are unimportant. y A (unique) name for the oil is required (in line 2), a description text can be entered at user's discretion. y Temperature values must be given C , viscosity values in cSt. If desired, convert data within the Excel sheets. y Oil viscosity data must be starting in the second row. A minimum of 2 lines of data (2 rows) is required to enable interpolation

    of data. y No special order of the data is required, sorting is done by PODSWare. y The temperature steps used between 2 pairs of data is freely selectable (e.g. every 10 C or 10 C, 15 C 25 C, 28 C, 84

    C). For important temperature ranges use smaller intervals (about every 2 C), so viscosity interpolation is more precise.

    Download Data from PODS

    50

  • Download Data

    Select Instrument-Readout Data to start the Readout Data Dialog.

    Click Setup if you want to change the COM port, where your PODS device is connected to. Click Start to download the data. A progress bar shows the download process in continuation. After a successful download the new data are displayed in the PODSWare Data Grid. If you select Start and the following message is shown:

    Please check: y The communication port used via menu command Extras Options. y The connection of your PODS device to the computer with a normal serial cable. y Make sure PODS is switched on. Generate a Chart

    51

  • Display Data as a Chart

    y Select one or more records in the Data Grid y Choose Menu Bar-Data, select either Distribution ISO 4406, Distribution SAE AS4059 or Time Chart y Or click an appropriate Toolbar button

    Generate a Report

    52

  • Printing Data as a Report

    y Select one ore more records in the Data Grid. y Use Menu Bar -Data - Report... or click an appropriate Toolbar button, The Report Viewer window is shown with a set of records, either in the ISO 4409, SAE AS4050 or NAS 1638 format. Each record is shown on a separate page.

    Select a MS-Word Template

    Click Menu Bar>Data>User Defined Reports and select a template. Standard templates can be found in the folder PODSWare/ReportTemplates. Create your own template The menu item Open Report Template you will display the 4 templates used last. When called for the first time, this menu item will be empty.

    53

  • The standard selection is the template last used.

    Create a new MS-Word Template

    A template is a MS-Word document defining the layout of a User Defined Report. This template will not be altered during generation of a report, i.e. the layout and standard elements will remain unchanged. The first step is to create a MS-Word document with the desired information. Place a token into your document whereever you want to prinout data from PODSWare. During report generation all tokens will be replaced by the appropriate data. Use the following tables for the tokens:

    Note: A token is a string embedded between two colons. It consists of two parts separated by _

    For example: ":P_TMC:" -> "P" stands for physical data, "TMC" for temperature in C

    General Informations:

    Token Data

    :G_DB: Name and folder of the current database file

    :G_CAT: Current category of the database file

    :G_ALS: Alias for Category (currently not used)

    :G_NOT: Notes for Category

    :G_EST: PODS Error Status

    :G_ETX: PODS Error Information (Text)

    Measurement Identification Token Data

    :I_ID: Measurement ID (Name String plus ID Number)

    :I_NAM: Measurement Name String

    :I_NUM: Measurement ID Number

    :I_MOD: PODS Mode

    :I_ALM: Alarm State (active, no alarm etc.)

    54

  • Classification

    Token Standard Class / Code

    :S_IS1: ISO Code Channel 1 (4 m)

    :S_IS2: ISO Code Channell 2 (4,6 m)

    :S_IS3: ISO Code Channel 3 (6 m)

    :S_IS4: ISO Code Channel 5 (14m)

    :S_NAS: NAS Class (00 - 12)

    :S_MIL: MIL Level (1 - 1000)

    :S_NAV: Navair Class (0 - 6)

    Additional Informations for Samples

    Token Data

    :N_INF: Additional Info (currently not used)

    :N_ANN: Annotations (currently not used)

    :N_RMK: Remarks from PODS PODS, 30 characters

    :N_RM1: Remarks 1

    :N_RM2: Remarks 2

    :N_RM3: Remarks 3

    Date and Time

    Token Data

    :D_DAT: Date of Measurement

    :D_TIM: Time of Measurement

    :D_DTM: Date and Time of Measurement

    Physical Data Token Data

    :P_TMC: Temperature value in C

    :P_TMF: Temperature value in F

    :P_VIC: Viscosity value in centiStokes

    :P_VIS: Viscosity value in SUS

    :P_VNC: Normalized viscosity in centiStokes

    :P_VNS: Normalized viscosity value in SUS

    :P_TVN: Reference temperature for normalized viscosity in C

    :P_FLW: Flowrate

    :P_VOL: Volume

    :P_TAN:

    :P_OCP:

    :P_DIE: Dielectrical constant

    :P_WTR: Water concentration in the sample

    Particle Distribution per mL Token Data

    :C_1: Number of Particles greater than 4m per mL

    :C_2: Number of Particles greater than 4,6m per mL

    :C_3: Number of Particles greater than 6 per mL

    :C_4: Number of Particles greater than 9,8m per mL

    55

  • :C_5: Number of Particles greater than 14m per mL

    :C_6: Number of Particles greater than 21,2m per mL

    :C_7: Number of Particles greater than 38m per mL

    :C_8: Number of Particles greater than 68m per mL

    Particle Distribution per Liter Token Data

    :L_1: Number of Particles greater than 4m per Liter

    :L_2: Number of Particles greater than 4,6m per Liter

    :L_3: Number of Particles greater than 6m per Liter

    :L_4: Number of Particles greater than 9,8m per Liter

    :L_5: Number of Particles greater than 14m per Liter

    :L_6: Number of Particles greater than 21,2m per Liter

    :L_7: Number of Particles greater than 38m per Liter

    :L_8: Number of Particles greater than 68m per Liter

    Particle Concentration per 100 mL Token Data

    :R_2_5: Particle Concentration between 2 and 5 m per 100 mL

    :R_5_10: Particle Concentration between 5 and 10 m per 100 mL

    :R_5_15: Particle Concentration between 5 and 15 m per 100 mL

    :R_10_25: Particle Concentration between 10 and 25 m per 100 mL

    :R_15_25: Particle Concentration between 15 and 25 m per 100 mL

    :R_25_50: Particle Concentration between 25 and 50 m per 100 mL

    :R_50_100: Particle Concentration between 50 and 100 m per 100 mL

    :R_100: Particle Concentration between 100 m pro 100 mL

    Chart Token Data (Chart)

    :X_ISO: Chart ISO 4406

    :X_NAS: Chart NAS 1638

    Note: Place the token for a chart into a MS-Word textbox to set a desired size for the chart. The dimensions of the chart will automatically be resized. Oil Data

    Token Data

    :O_NAM: Oil Type (Name)

    :O_DES: Oil Description

    :O_REF: Reference Temperatur for Viscosity Calculation

    Alarm Information

    Token Data

    :A_TYP: Type of Alarm (ISO, NAS etc.)

    :A_ENA: Alarm State (enabled/disabled)

    :A_DIR: Alarm Direction

    :A_ACK: Alarm Acknowledge

    Output Format

    Optionally the data display in a user report can be formatted at user's requirements. The format definition must be following the token and starts with a '#'.

    56

  • Remark: Actual formatted output depends on the local settings of the computer! Possible Format Definitions: y Numbers: y #0.0 Setting of decimal places, use zeros after the dot. y #,##0 Include a thousand separator with a komma. Example: :C_1#,##0.00: displays: "45.345,30" :R_2_5#0.0: displays: "3287,9" y Date/Time: y DD Day-of-Month (1 - 31) y MM Month (1 - 12) y MMM Month as short text (Feb., Apr.) y YY Year, 2 digits y YYYY Year, 4 digits y HH Time-of-day, Hours y MM Time-of-day, Minutes Example: :D_DTM#DD.MMM.YYYY - HH:MM: displays: "12.Apr.2000 - 13:44"

    PODS Enzyclopedia

    57

  • PODS Encyclopedia

    m: Denomination of the particle size dimension according to the former ACFTD calibration

    m(c) Denomination of the particle size dimension according to the new NIST/ISO 11171 calibration

    Accessories Rollerbox, Bottle-Adapter, Online-Adapter, Pressure tubing 1 meter long, Gas bottles (2), Plastic sample b

    120 mL (10), Power adapter, Printer paper rolls (2), Shoulder strap, Cleaning brushes (2), Wrench "

    ACFTD Filter test dust (Air-Cleaner-Fine-Test-Dust), which was used since 25 years in hydraulics for filter testing amanufactured by General Motors Company. 1992 its production was stopped. The new test dust ISO MTDinvestigated in lengthy tests by microscopy and particle counters

    ACFTD-Calibration ACFTD was used until recently for the calibration of particle counters. The particle number concentration (in oil) for a given dust addition (mg/L) was standardized in ISO 4402. During the years it became more andapparent that this distribution was wrong.With introduction of the new calibration standard ISO 11171 (199calibration standard ISO 4402 becomes invalid and ACFTD is no longer a valid calibration standard.Duringthe channel voltages (thresholds) of the individual size channels are varied and tests are repeated until thenumber distribution for an ACFTD-suspension in oil (typical 5 mg/L) matches the standardized distribution."count-calibration" achieves better number accuracy than the "voltage-calibration" used with other particle which uses Latex-spheres in water. Especially the use of oil as carrier fluid achieves a more realistic calibr

    ACFTD-Sizes PODS-users can choose between ISOMTD- and ISOACF-standard settings, even after the measurement.ISOMTD the results are printed along with the NIST-sizes, with ISOACF the results are printed with the ACPODS-users who have had ACFTD-calibrated particle counters are advised to use the ISOACF-setting firsmore familiar to them from former work than the ISO MTD-reporting scheme.

    Advantages of PODS versus other "online-batch" competitors

    1. High system pressure (420 bar) in the sensor, no pressure reduction before the sensor, therefore no buformation by outgasing 2. High concentration (ISO 24 or 90000 P/mL at 10% coincidence), which eliminates dilution (dilution is imthe field!) 3. High viscosity (up to 800 mm/s, at the current temperature), even in the bottle-mode, which eliminates d4. Automatic flow adjustment to the viscosity and pressure conditions 5. Calibration by the new test dust (ISOMTD) according to the new ISO 11171:1999. Comparability with ACmeasurements. 6. Compatibility with mineral oils and phosphate esters (like Skydrol), so both fluids can be measured witexchanging any O-rings in PODS 7. User friendly, very comfortable software (Podsware) 8. Option for a relative water sensor, refitable, near future 9. Fast measurement (usually 1 min, may longer at very high viscosity) 10. High memory capacity (500 samples) 11. High gas-bottle capacity (60 samples) 12. High battery capacity (360 samples at low viscosity, 160 at high viscosity) 13. Less battery memory effect by using Ni MH-battery 14. Laser life 70000 h @ 21C 15. Local calibration centers at ARTI, FSP and RION

    Air pressure connector For USA/Canada ARTI delivers PODS with an SAE-4 quick-connect fitting mounted into a female 1/8 inch For Europe FSP replaces this by a German connector

    Air quality PODS operates when the gas pressure is over 4 bar (internally regulated). The air should be particle free aotherwise the internal filter is contaminated. If this internal filter is clogged it has to be changed at the servi

    Backflushing the protection screen PODS has a screen of 15 m mesh width behind the sensor to protect the components after the sensor. Tbe cleaned by back flushing from time to time. For this purpose the sunken cleaning port on the left side ofto be opened by means of the " wrench. Then clean, filtered oil is pressed into the outlet port of PODS, wthrough the cleaning port. During this cleaning Pods has to be switched on and has to be in the purge mod

    Bottle analysis Bottle analysis is often the only method of particle monitoring, when an online-measurement is not possiblpressure (in tanks) or low fill volume (gearboxes). In order to prevent secondary contamination, only clean

    58

  • be used. One should use glass bottles at clean oils.

    Bottle-adapter The bottle-adapter is a cylindrical container, which takes up the sample bottle. It is screwed into the adapteand pressurized to 7 bar with CO2-gas or shop air.

    Calibration,Primary Reference particle counters for secondary calibration must have a primary calibration by the manufacturercalibration occurs with NIST-standards SRM 2806.

    Calibration, Secondary For recalibration at the service centers a secondary calibration may be used. This occurs with SRM 8231 swhich must be measured by a reference-sensor having a primary calibration.

    Calibration-Centers 1. Fluid-Systems-Partners GmbH, ARTI/RION-Service-Center, Industriestrae 9, D-76703 Kraichtal, Germ+49-7250-76-522, Fax. +49-7250-76-575 2. ART Instruments Inc., Service-Center, 1055 Redwood Ave, Grants Pass, OR 97527, USA, Tel +1-541-4Fax. +1-541-472-0196 3. RION Co. Ltd, Service-Center ARTI, 20-41 Higashimotomachi 3-chome, Kokubunji, Tokyo 185-8533, Ja+81-42-359-7878, Fax +81-42-359-8533

    Classification PODS classifies the cleanliness by 5 internal standard settings: ISO 4406:1999 for NIST/ISO 11171 sizes (m(c)), internally named ISOMTD ISO 4406:1999 for ACFTD/ISO 4402 sizes (m), internally named ISOACF SAE AS4059 Rev. D (2001) NAS 1638:1987 MIL-STD-1246C:1994 NAVAIR 01-1A-17:1998 The standard must be chosen in the set-up. The result is printed and stored in the memory. The standard cchanged after the measurement, too. No cleanliness standard except ISO 4406:1999 specifies a specific calibration method. Usually users workACFTD-calibrations in former times. Since now ACFTD is no valid calibration material any more and particmanufacturers must change to NIST-calibrations, the other standards also have to use the NIST-sizes if thcleanliness codes shall stay the same.

    Classification sizes The cleanliness standards use the following NIST sizes: m(c) 4 4.6 6 9.8 14 21.2 38 68 ISOMTD x x x ISOACF x x x SAE AS4059 x x x x x x NAS x x x x x MIL x x x x x x x x NAVAIR x x x x x x CO2-bottles CO2-bottles from FSP can be transported in the filled state in Europe.The bottle pressure of

    about 75 bars is internally reduced 7 bar for bottle sampling. The bottle is mounted vertical, so no liquid gas fills the tubing during transport.FSP sells sets of 10 each CO2-bottles, additional to the standard bottles (2) in the regular PODS accessories. Bottles returned by the customer, in sets of 10 each, will be exchanged by full bottles. The customer may also order his local filling service to refill the bottles.

    Computer-Interface PODS has a Sub-D serial connector (9 pin female) for RS 232C. A standard 9-pin-Sub-D male/female serial cable is required for data-dump or remote control by a PC.

    Concentration The display and the printer show the concentration in "Particles per Milliliter" (P/mL) as a running average. In the standard a display as (P/10 mL) may also be set.

    Dilution Dilution for particle counting is generally necessary to reduce the viscosity or the particle concentration, in order to achieve values below the sensor limit values. PODS with is high concentration and viscosity limits requires dilution very seldom compared with any other system.

    Dilution problems Some fluids, depending on the additives, may require dilution even with particle concentrations much below the concentration limit of PODS. If dilution is required is a matter of experience.

    59

  • Drain tubing The drain tubing may be of PVC or a similar soft material (6 mm O.D.). There may be no

    pressure on the outlet when draining into a bottle.

    Flow cell The PODS sensor flow cell is from Sapphire, a very hard optical material with extreme material strength, which can stand the high pressure forces when 420 bars are applied directly to the sensor. The cell is sealed to the inlet/outlet-fittings by AFLAS O-rings, that are compatible both with mineral oil and Skydrol.

    Flow meter The flow rate is measured by a gear-flow meter after the sensor.

    Flow regulation PODS uses a gear-flow-meter followed by a regulation valve to regulate the flow to values between 15 mL/min and 50 mL/min. The first 15 mL purge-run of each sample is used to measure and regulate the flow rate. The regulation accuracy is less than about 2%. Other units can operate at one flow rate only to which the sensor must be calibrated. PODS is the first system to adjust the flow rate automatically to the current viscosity and pressure conditions.

    Fluid aging Biodegradable fluids like triglycerides (Rape oil) and unsaturated synthetic esters discompose in presence of water into acid and alcohol. This increases the acidity and the viscosity of the fluid. Both quantities may be used to monitor the oil condition.

    Fluid properties measured Particle concentration (size distribution), fluid viscosity

    Fluid properties, meaning Particle concentration: Abrasion, blockage and failing of system components Viscosity: Increases with degradation (aging) of an oil, mixing with an oil of other viscosity

    Fluids, difficult to measure - Fluids with free water (AOT makes these fluids measurable) - Used engine oils, especially those from Diesel engine, need dilution (>100 times), due to the large soot content absorbing the light. - Glycol-water mixtures - Mixtures of chemically incompatible fluids like mineral oil and synthetic esters

    Fluids, easy to measure - Transparent, non-turbid fluids - Mineral oils - Environmental pressure fluids - Phosphate esters (like Skydrol). - Gear oils - Fresh engine oils - Biologically degradable fluids (synthetic esters must be treated before the measurement to remove water). - Glycols

    Flushing mode Before an online measurement is started PODS should be flushed in order to renew the dead volume in the tubing of Pods and the complete tubing to Pods to make sure that the status of the sampled fluid is identical with the fluid in the system. To get rid of "dirt" on the walls of the former oil one should flush 3-5 times of the complete dead volume. Even with highest purge volume one will never measure the system oil temperature, but the Minimess hose and the large thermal mass of Pods are cooling down the oil. During the flushing mode Pods has to be switched on and operating in the puring mode.

    Free water Biodegradable fluids like triglycerides (Rape oil) and unsaturated synthetic esters discompose in presence of water into acid and alcohol. Water in excess of the saturation limit is free water, suspended as water in oil droplets. Water contents above the saturation concentration are called "free water" and are water droplets in oil. Water droplets are counted like solid particles. Both mineral oils as well as synthetic esters should be excluded from the measurement, if water contamination is suspected.

    Functioning In the online-mode the system pressure drives the oil through the sensor. After the sensor a screen (15 m mesh) protects the following components, then the pressure is reduced by two pressure-regulators to 90 psi (6 bar) and 52 psi (3,5bar). Then the flow passes the sensors for

    60

  • temperature, pressure and the flow regulator, after which it is drained with no (atmospheric) pressure. With the sensors signals the viscosity is calculated. In the bottle-mode CO2-gas or shop air, internally reduced to 7 bar, drives the fluid through the sensor.

    I/O connector PODS has a round digital I/O connector to switch external devices such as a horn, a lamp or the circulation pump of the ECOLINE UM45P filter service cart, when the filter mode is used.

    ISO Cleanliness Codes ISO 4406 (1999) specifies the cleanliness code for the following sizes: 1.) 5/ 15 m for old instruments (with ACFTD-calibration) 2.) 4/ 6/ 14 m(c) for new instruments (with NIST-calibration)

    ISO MTD ISO MTD is the new filter-test dust and its number distribution in dependance of the mass concentration is standardized in ISO 12103-1(1997) for filter testing. It is available from PTI Inc. in USA or their European representative ELIS COMPONENT. One certified batch of ISO MTD is available from NIST as SRM 2806 for primary particle counter calibration. For secondary calibration NIST supplies dry dust (SRM 8231) to be dispersed in oil. .ISO MTD replaces ACFTD as calibration material and in the Multipass-Test.

    Light Extinction Light Extinction, in literature also called "Light Blockage" or "Light-Obscuration", is a "shadow measurement in the bright field": The Laser projects a thin light sheet across the sapphire cell, which hits directly on the detector (PIN-diode) on the other side of the cell. Without the presence of a particle in the beam the detector generates a maximum signal (10 Volt). A particle in the beam absorbs or scatters the light and the reduced light intensity is correlated with the particle size.

    Light Source in PODS PODS has a Laser diode with a life of ca 70000 h at 21C. The wave length is 780 nm. The Laser life depends on the temperature. Each 10 C temperature increase reduce the Laser life by a factor of 2. Continuous operation at high temperatures should therefore be prevented.

    Measuring error The counting error is the difference between the actual and the measured particle concentration. This error is mainly dependent on number statistics and thus increases with size. At particle counts higher than 1000 (class 17) this error is typically about 1-3 %; at particle counts less than 1 (class 7) this error may rise to about 10 % due to stochastically errors. Insufficient treatment (for example not enough purging) usually causes errors higher than 10 -20%, at smaller particle counts even at about 50 % or more. The viscosity error may be relatively high if there is no sufficient temperature exchange between oil and Pods; several measured quantities (Temperature, Pressure, Flow Rate) are affecting the viscosity accuracy. With reliable temperature exchange error is about 10%.

    Measuring principle of particle counting

    PODS measures the particle size with a Light-Extinction sensor. This method is suitable for particles >1 m. For smaller particles scattered light may be used.

    Multipass-Test This test is standardized in ISO 16889(1999) and used for filter testing. A suspension of ISO MTD is continuously added to the flow through the test filter and the Beta Ratio of the filter is measured in dependance of the total mass added and the differential pressure over the filter.

    NIST National Institute of Standards of the USA Address: SRM Sales Department, Building 202, Room 204, Gaithersburg, MD 208899, USA, Tel +1-301-975-6776, Fax. +1-301-948-3730

    NIST-Calibration NIST-calibration, for which most existing particle counters are not suitable, uses the new test dust SRM 2806, which is ISO MTD suspended in oil. Calibration of all particle counters with this standard guarantees small count differences world wide.

    NIST-Sizes The new ISO 4406 (1999) is unchanged with respect to the concentrations of the cleanliness codes. However, since ISO MTD has higher concentrations under 10 m and lower concentrations over 10 m than ACFTD and the ISO-Code shall not change, particle counters with ISO MTD-calibration must measure with the so-called "NIST-sizes", count-equivalent to the ACFTD-sizes. Thus a counter like PODS, calibrated with ISO MTD, measures the same counts and ISO-codes at 4/ 4,6/ 6,4/ 9,8/ 13,6/ 21,2/ 38/ 68 m(c) as an ACFTD-calibrated counter at 1/ 2/ 5/ 10/ 15/ 25/ 50/ 100 m.

    Online-Adapter The online-adapter is identical in its dimensions with the bottle-adapter and replaces the latter

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  • for online-measurements. It applies the high pressure to the lower end of the suspension tube. The upper part of the adapter is at ambient pressure and has an overflow. The pressure force (about 1200 N) is taken by the thread between the adapter-holder and the online-adapter. The online-adapter has a Minimess M16x2 fitting for the pressure tubing which is compatible with mineral oil and Skydrol.

    Online-Batch-Systems Portable particle counters, which allow online-samples (Online) and bottle samples (Batch).

    Online-Only-Systems Portable particle counters, which allow only online-samples (without separate units).

    Online-Sample-Ports Due to the balance between inertia forces of the particles and viscous forces of the flow the fluid should (theoretically, in order to achieve a size-independent sampling) be sampled isokinetically (against the flow direction, in the middle of the tube, with the local mean velocity). This normally requires sampling through a thin axial tube on a tube bend. The sample tube should reach at least 1 tube diameter over the knee in order to prevent secondary flows from influencing the sampling. Minimess-ports sample the oil near the wall and normal to the flow direction, which may lead to a separation of sizes. It would be better to lead a bent sample tube against the flow onto the axis of the tube and weld the Minimess-port to the outer end of this tube. For cases where customers do not have a Minimess sample port at the required location, some companies offer sample connectors, which may be mounted on the tube (without interrupting the system operation), press a hole into the wall and sample through this hole. This wall pearcing causes a bending of the tube wall to the inside, which has the advantage that the sample is taken from the turbulent core rather than the laminar sub-layer.

    Online-sampling Online-sampling, where the oil is pressed directly through the sensor, is the safest method of particle monitoring and prevents any secondary contamination of the oil due to dirty bottles.

    Operation modes of PODS 1. Online, under system pressure 2. Batch from sample bottles 3. Filter mode with ARGO-ECOTEC filter service unit UM45

    PODSWare PODSWare is a software package to control PODS and display, edit, download and store PODS data records. y Display data in user-adjustable tabular form. y Data display as time plot, selectable as particle concentration or oil standard y Administration of data in tree-like structure y Graphical charts using different oil standards y Printing of user-defineable cleanliness reports. y Remote control of PODS, data download from device. y Measurements in Bottle or Online mode. y Alarm functions. y Data export to various formats (Excel, Text, HTML, PDF, XML, Bitmaps) PODSWare runs on Win98, WinME, Windows NT 4.0, Windows 2000, Windows XP

    Power Adapter PODS is delivered with an automatic power adapter which adjusts to any AC-voltage from 90 to 240 VAC. For Europe a German power cord is delivered, which fits in most central-european states.

    Pressure tubing The pressure tubing (6 mm O.D., 1 m long, 630 bar rated pressure) is a standard accessory. It has Minimess M16x2 fittings on both sides, which are compatible with mineral oil. For phosphate esters a special tubing with EPR/EPDM-O-rings can be supplied.

    Printer PODS has a thermal printer (80 mm wide paper, 25 m long).

    Purpose of PODS Portable system to monitor the fluid cleanliness in the field under system conditions, in hydraulic or lubrication systems. Analysis of bottle samples in the laboratory.

    Rollerbox PODS is supplied with a water proof plastic case with rolls, which contains all accessories including 6 sample bottles. The case weighs about 20 kg. It serves especially for transport to

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  • the next Service-Center. For hand carry air trips an optional soft bag with the main accessories can be supplied.

    Run With each run the particles in 5, 10 or 20 mL (in online and filter mode also 50 or 100 ml) oil are counted. The 3 runs of each sample are measured after another without interrupting the flow.

    SAE AS4059 Cleanliness Classification for Hydraulic Fluids defined by Aerospace Standard.

    Sample Each sample consists a purge run (> 15 mL) and 3 consecutive runs of 10 mL (or 5, 20 ml and 50, 100 ml in online and filter mode) each taken after another. The purge run is necessary to measure and set the flow-rate, but also to purge PODS from the last sample, which may have had another contamination or viscosity. All runs are printed (optional) and internally stored or transferred to the computer (optional) in the remote mode.

    Sample bottles PODS is delivered with 10 PP-plastic bottles (120 mL). These are regularly used in USA/Canada, cheap and good for training the handling of PODS. For instance, PP-bottles may be used in order to flush the sample tubing of the sampling pimp with several bottle-fillings before taking the actual sample for analysis. The final sample then is taken in a 100 mL glass bottle. FSP recommends cleaned glass bottles (sealed in plastic bags) in order to prevent secondary contamination. Clean glass bottles are more expensive. FSP sells sets of 25 each glass bottles to its customers.

    Sample locations for PODS-Online Suitable sampling points for online-measurements with PODS: - Upstream of the high pressure filter (condition after pump) - Upstream of the return filter (condition after system) - Upstream of the bypass-filter (tank condition) If the pressure in the bypass-flow is not high enough or the viscosity of the oil to high to achieve the required flow rate through the particle sensor in Pods between 15 and 50 ml/min, then PODS shows a "Waiting for Pressure" message. In this case the pressure must be increased by a check valve in the filter line.

    Sensor cell The sensor cell of PODS is from Sapphire, a very hard optical material with extreme tension and scratch-resistance, which resists the high pressure forces at 420 bar in the sensor. The cell is sealed against the inlet/outlet fittings with O-rings, which are resistant to mineral oil as well as Skydrol.

    Sensor cleaning, brushes PODS is supplied with a set of 2 cleaning brushes. These are used to clean the sensor in case it is contaminated or blocked by particles. Normally this does not happen very often. The cleaning brushes are from plastic and fit into the flow cell with its small cross section. On the left side of PODS there is a sunken inch Swagelock-cleaning port which must be opened using the " wrench in the PODS accessory kit. Then the brush is turned and carefully pushed into the oily drain tube after the sensor until there is a sensible resistance. Then, the conic opening of the flow cell must be found while softly turning the brush, and the brush is carefully pushed into the cell (10 mm only) and back, which removes any objects blocking the cell.

    Sensor cleaning, back-flushing When particles block the cell one may try to back-flush the cell and thereby clear the cell passage. This is done by pumping clean, filtered oil from the outlet port through the sensor into a sample bottle, using a inch tubing connected to the outlet port behind the bottle adapter. It is recommended to back-flush the protection filter before this in order to remove any particles which might cause another blocking of the sensor cell. To back flush one has to switch on Pods and have it running in the flushing mode.

    Skydrol One phosphate ester used in the aerospace industry as a non-combustible hydraulic fluid. Skydrol dissolves elastomer seals which are compatible with mineral oils. Therefore, for measuring Skydrol, another pressure tubing must be used which either has EPM or EPDM O-rings in the Minimess-fitting or JIC-AN connectors on both sides.

    SRM 2806 This material is a certified NIST standard for Primary Calibration of particle counters, which consists of 2 bottles 400 mL Mil-H-5606 with 2,8 mg/L ISO MTD.

    SRM 8231 This material i