Samples are batched by quickly pouring suitable volumes of homogenized sample into 2oz (32ml) sample cups that are placed in the 104 position sample tray.
Samples do not require accurate dispensing as the volume of the sample in each cup is measured automatically by the system to an accuracy of ±2% prior to dilution.
The CINRG CS-APC-3 particle counting system is a fully automated system that meets the requirements of ASTM D7647-10 in which oil samples are diluted with solvent prior to testing in order to eliminate interferences from ”soft” particles such as water, varnish and suspended liquid additives.
The system combines equipment from several leading equipment manufacturers with some innovative technology and sophisticated software that was developed by Wearcheck for use in their oil analysis laboratory. The system has a high degree of flexibility and can be customized to a large extent to suit local laboratory processing requirements.
A batch of samples can be quickly prepared by pouring suitable volumes of homogenized sample into 2oz (32ml) sample cups that are then placed in a 104 position sample tray. Samples do not have to be accurately dispensed into the sample cups as the volume of the sample in each cup is measured by the system to an accuracy of ±2% prior to dilution. Laboratory technicians can easily control sample dilution by controlling the amount of sample that is poured into the cup as all samples are diluted to a final volume of 30ml.
If a higher degree of accuracy than ± 2% is desired for the volume measurement samples may be pipetted or weighed into the cups and the sample volume or sample weight and sample density included in the systems batch file.
As samples are diluted prior to testing and dilution ratios can be varied between 1:0 (no dilution) and 1:9 (one part oil and 9 part solvent) it is possible to process samples having a wide range in viscosities. A 1:4 dilution for example, is more than adequate to process an oil sample with a viscosity of 1,000 cSt @ 40°C.
Samples can be processed without dilution if required but viscosity of these samples should be ≤46 Cst.
A batch file containing both sample information and processing parameters is required by the application software in order to process samples and this can be created within the software itself or imported from an external file in csv format. The sample information part of the batch file contains the sample ID, the sample position within the tray and if applicable, a sample volume or sample weight and density. If the sample volume and weight fields are blank the system will measure the volume of oil in the sample cup prior to sample dilution.
The process parameters control how the sample is processed prior to testing. The parameter settings determine how fast and for how long a sample is stirred and determine how a sample is degassed if this process is required. The report format can also be specified in the batch file (ISO 4406 or AS4059).
The parameters are typically in the range of 1 to 4 with the actual value of each setting being determined by system parameters that can be modified by the end user. E.g. Sample stirring times of 1,2 and 3 in the batch file could be defined as 15,20 and 30 seconds in the system parameters.
Before any testing is conducted the cleanliness of the batch of dilution solvent has to be determined to obtain the count data that is subsequently used to correct the particle count results for the effects of dilution. When selected in the application software a solvent verification is carried out automatically. Solvent is initially loaded into the sample cup in position 1 for use as a system flush and then into the sample cup in position 2 for actual measurement. Several measurements are conducted on the solvent and the suitability of the solvent is established by comparing the counts from each measurement against a set of system parameters that again can be modified by the end user to meet specific needs.
When sufficient data has been collected average count values are calculated from valid measurements and stored as the solvent background counts for subsequent calculations.
The sample batch file remains accessible even after processing has started and may be edited at any time to add to or remove samples from a batch or to set a priority flag within the batch to allow a sample to be processed out of sequence. It is not possible to edit samples that have already been processed or edit the sample that is in process at the time of editing.
A customizeable suffix identifies process control samples for which count data is compared against upper and lower user defined limits in the 4µm, 6µm and 14µm range to confirm acceptable system performance. A system parameter controls how the system proceeds following an unsatisfactory result on a process control standard.
The output format is defined in the sample batch file and the data exported can be easily customized using system parameters. With the system parameters it is possible to include such information as solvent background counts, sample volume, sample dilution ratio, and all raw count data in the output file.
| Parameter | Specification |
|---|---|
| Sample Through-put | 3.5 min/sample (6 hrs for complete 102 sample tray)* Throughput 130-140 samples per 8-hour shift* |
| Solvent Usage | 35 ml/sample** |
| Sample Batch Size | 102 samples (tray has 104 positions, pos 1 = cleaning beaker, pos 2 = verification solvent) |
* Sample through-put rate is directly dependent on the settings of the processing parameters. Specification stated is using default parameters.
** Solvent usage depends directly upon the dilution ratios and processing parameters. Specification stated is for 1:1 dilution using the default parameters.
| Parameter | Specification |
|---|---|
| Model | KLOTZ LDS 45/50 Laser Sensor |
| Measuring Range | 4µm to 70µm (3µm to 200µm) oil calibration range |
| 4µm co-incidence threshold | 25,000 particles/ml (undiluted sample) 50,000 particles/ml (1:1 dilution) |
| Cell Dimensions | 450µm x 500µm |
| Flow Rate | 10 to 50 ml/min (CS-APC-3 instrument is calibrated at 30 ml/min) |
| Parameter | Specification |
|---|---|
| Model | KLOTZ USB Counter |
| Number of Channels | 4,096 |
| Parameter | Specification |
|---|---|
| Model | Baumer UNKC 09 |
| Accuracy | ±0.1 mm from 3mm to 150mm |
| Parameter | Specification |
|---|---|
| Dimensions | 35" (W) x 30" (H) x 38" (D) (89cm x 76cm x 97cm) |
| Weight | 150 lbs (68 kg) |
| Voltage Requirement | 100-120-230/240VAC selectable, 50/60 Hz. |
| Input Current | 6.0A @100V, 5.0A @ 120V, 2.6A @ 230V, 2.5A @ 240V |
Protected by patents US9164019, US8689651, CA2791003, CA2809251, UE2912473. Other patents pending.
