HIAC Portable Oil Diagnostic System (PODS)
Customer Name
Date
Presenter
Presenter Title
PODS Applications
• Proactive maintenance
• Tracking and trending
multiple system’s cleanliness
• Certification to ISO, SAE &
NAS requirements
• On-site sampling
• Reducing maintenance costs
• Bottle samples
• Roll-off cleanliness
• Fluid analysis
• System qualification
Copyright 2007 Hach Ultra Analytics, Inc. – Page 2
Introduction to PODS
• Measures, stores and reports oil condition parameters
essential for reliable hydraulic systems operation
• Analyzes fluids and lubricants in online or bottle sampling
modes to determine the machine’s operating condition
immediately.
• Instant analysis is as accurate and precise as traditional
laboratory analysis that normally takes weeks.
• Real-time assessment of the oil under operating conditions
Copyright 2007 Hach Ultra Analytics, Inc. – Page 3
PODS Features
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8-channel display
Bottle and online sampling
Viscosity and temperature measurement
500 sample memory
High speed thermal printer buffer
Flash programmable
Aluminum alloy sheet metal casing
Built-in bottle sampler pressure chamber
Compact power supply
Refillable CO2 bottle or shop air operation
Multiple language capabilities
Full ISO 11171 calibration capability
Copyright 2007 Hach Ultra Analytics, Inc. – Page 4
Results of Contamination Damage
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Power loss
Loss of surface lubrication
Degradation of operation
Intermittent operation
Catastrophic failure
Costly repairs
Costly downtime
Costly rework
Copyright 2007 Hach Ultra Analytics, Inc. – Page 5
PODS “Elevator/Lift Description”
• Offers flexibility in sampling with an online or
lab/bottle mode for multi-variant analysis of particle
counts, viscosity and temperature
• Capable of calibration to full ISO 11171 standards,
the PODS performs in harsh environments,
accurately monitoring hydraulic and lubricating
fluids
Copyright 2007 Hach Ultra Analytics, Inc. – Page 6
Method of Operation
Online mode
Sample fluid directly from the hydraulic system using the online
sample adaptor
After pressing the start key:
• Fluid flows through the particle counter, purging the fluid
path
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After sampling the required purge volume, the instrument
begins the particle count
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Flow is regulated automatically
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No propulsion or mechanical interference required; system
utilizes hydraulic system pressure
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Upon completing specified number of runs, flow stops and
instrument prints out results
Copyright 2007 Hach Ultra Analytics, Inc. – Page 7
Method of Operation
Bottle Mode
Place bottle of fluid for analysis into the bottle sampler adaptor, which is
then fitted to the PODS
Press the start key
• Air or gas flows into the bottle sample adaptor, and pressurizes it to
7 bar (90 psi)
• Fluid begins to flow through the instrument
• After sampling the required purge volume, the instrument begins the
particle count
• Flow is regulated automatically
• No mechanical interference to the sample
• Upon completing specified number of runs, instrument stops,
releases pressure and prints results
Copyright 2007 Hach Ultra Analytics, Inc. – Page 8
Performance
Fluid Compatibility
• Phosphate ester based fluids AND petroleum and synthetic
based fluids
• Online sampling at pressures of 7 to 420 bar
(9 to 6000 psi)
• Maximum fluid viscosity of 434 cSt
• Concentration limit: 30,000 particles/mL @10%
• Sample fluid temperature: Up to 90C (194F)
Copyright 2007 Hach Ultra Analytics, Inc. – Page 9
Sampling Modes
Bottle Samples
• PODS can analyze bottle samples by using the
Sample Bottle Adaptor
• Bottles hold approximately 120 ml of fluid
• Flow is regulated automatically.
Copyright 2007 Hach Ultra Analytics, Inc. – Page 10
Sampling Modes
Online Samples
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The Online Sample Adaptor allows
online sampling of fluids of
pressures between 7 bar (90 psi)
and 420 bar (6000 psi)
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During online operation, the
air/CO2 supply is not used
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Flow rate is regulated automatically
Copyright 2007 Hach Ultra Analytics, Inc. – Page 11
Pressure Sources
PODS requires an external pressure source
This can be either:
• Attachable CO2 bottle
• Shop air
Copyright 2007 Hach Ultra Analytics, Inc. – Page 12
Shop Air
Connect PODS only to known
CLEAN and DRY air source
Ensure the air pressure is
between 6.2 and 7.6 bar (90 to
110 psi)
Copyright 2007 Hach Ultra Analytics, Inc. – Page 13
CO2 Bottles
• Fill CO2 bottle prior to use (ensure the
CO2 bottle is fully discharged prior to
shipping)
• Inspect threads for damage and apply
clean lubricant to O-ring
• Thread the bottle clockwise into the
CO2 port, continue ¼ turn after
pressurization
• Turn bottle counterclockwise to
disengage the CO2 bottle
• Each bottle will holds enough gas for
approximately 60 runs
Copyright 2007 Hach Ultra Analytics, Inc. – Page 14
Bottle Sample Operation
Pressure
Regulator –
90 PSI/7 bar
Atmosphere
Regulator
Air/CO2
Supply
Sensor
Sample
Chamber
Flow
Controller
To Waste
Online Operation
Pressure
Regulator –
90 PSI/7 bar
Regulator
Sensor
Online
Adaptor
Flow
Controller
90-6000 PSI
To Waste
7 to 420 bar
Flow Control
• Sophisticated flow control system
• True volumetric flow
• Pressure transducer reduces purge volume
to 15mL minimum
• Flow is controlled by a stepper motor driven needle valve
opening or closing as required
• Flow regulation is automatic or manual depending on the
counter setup
Copyright 2007 Hach Ultra Analytics, Inc. – Page 17
Keypad Features
Copyright 2007 Hach Ultra Analytics, Inc. – Page 18
Typical Setup Menu Page
Parameters
1. SAMPLE LABEL: Up to 10
characters
2. MODE: BOTTLE or ONLINE
3. STD: ISOMTD, ISOACF, NAS, MIL,
NAVAIR
4. VOL: 5, 10, 20, 50 or 100 mL
5. FLOW: Between 15 and 50 ml/min or
AUTO
6. PRINT: ENBL, DSBL or SETUP
Copyright 2007 Hach Ultra Analytics, Inc. – Page 19
Calibration
• ISO MTD and Latex Spheres in
MIL-H-5606 as per procedures
based on ISO 11171
• ACFTD in MIL-H5606 as per
procedures based on ISO 4402
without the need to change
software or hardware
• Calibration is performed using
NIST traceable ISO Medium Test
Dust (MTD)
• The only portable that can be
calibrated FULLY to ISO 11171
Copyright 2007 Hach Ultra Analytics, Inc. – Page 20
Superior Value
• PODS is the instrument of choice for the US Navy—not
one of many - but the only one
• No one else offers ISO 11171 calibration for a portable
particle counter
• No other portable particle counter currently on the
market measures viscosity and temperature
• HIAC name continues to carry great weight in the
hydraulics industry
• Only on-line and bottle mode liquid particle counter
Copyright 2007 Hach Ultra Analytics, Inc. – Page 21