1. HIAC Portable Oil Diagnostic System (PODS) Overview

2. PODS Applications Military fluid power Industrial fluid power
Construction and mining
Aerospace

3. 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

4. Results of Contamination Damage
Power loss
Loss of surface lubrication
Degradation of operation
Intermittent operation
Catastrophic failure
Costly repairs
Costly downtime
Costly rework

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 standards, the PODS performs in harsh environments, accurately monitoring hydraulic and lubricating fluids.
The Portable Oil Diagnostic System (PODS) is an intelligent, portable and durable analysis instrument for measuring, storing, and reporting oil contamination levels important for maintaining reliable hydraulic systems operation.
Additionally, PODS provides the means to analyze fluids and lubricants in an online or bottle sampling mode without interrupting operation of the machine. Maximum on line fluid pressure is 420 bar

6. PODS Features 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 calibration capability
Languages supported include: French, Italian, Spanish, German

7. 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
After sampling the required purge volume, the instrument begins the particle count
Flow is regulated automatically
No propulsion or mechanical interference required; system utilizes hydraulic system pressure
Upon completing specified number of runs, flow stops and instrument prints out results
So, there are two sampling modes, on-line or bottle sampling. On line requires a minimum pressure of 7 bar. The reason for this is that we believe that by sampling at this minimum pressure, there are no aeration issues. Incidentally, the bottle sample facility is pressure assisted, and drives the fluid through the sensor at a minimum of 4.2 bar for the same reason. This is why the PODS does not have a degas facility – as it is unnecessary.

8. 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
So, there are two sampling modes, on-line or bottle sampling. On line requires a minimum pressure of 7 bar. The reason for this is that we believe that by sampling at this minimum pressure, there are no aeration issues. Incidentally, the bottle sample facility is pressure assisted, and drives the fluid through the sensor at a minimum of 4.2 bar for the same reason. This is why the PODS does not have a degas facility – as it is unnecessary.

9. 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
Sample fluid temperature: Up to 90C (194F)
Read from slide

10. Sampling Modes Online Samples
The Online Sample Adaptor allows online sampling of fluids of pressures between 7 bar (90 psi) and 420 bar (6000 psi)
During online operation, the air/CO2 supply is not used
Flow rate is regulated automatically
The On line adaptor fits in place of the Bottle sample adaptor that we have just seen, and the hydraulic connection is made to the minimess type port that we can see here.
PODS Online
Adaptor

11. 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
Read from slide

12. Pressure Sources PODS requires an external pressure source.
This can be either:
Attachable CO2 bottle
Shop air

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

14. 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)

15. Bottle Sample Operation
Sample Chamber
Pressure Regulator – 90 PSI/7 bar
Sensor
Regulator
Flow Controller
To Waste
Atmosphere
Air/CO2
Supply

16. Pressure Regulator – 90 PSI/7 bar
Online Operation
Online Adaptor
Pressure Regulator – 90 PSI/7 bar
Sensor
Regulator
Flow Controller
7 to 420 bar
PSI
To Waste

17. 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

18. Keypad Features

19. Typical Setup Menu Page
Parameters
SAMPLE LABEL: Up to 10 characters
MODE: BOTTLE or ONLINE
STD: ISOMTD, ISOACF, NAS, MIL, NAVAIR
VOL: 5, 10, 20, 50 or 100 mL
FLOW: Between 15 and 50 ml/min or AUTO
PRINT: ENBL, DSBL or SETUP
Sample Name: Selecting this option will bring up a second menu, which allows the user to input a sample name of up to 10 characters. There is also a section for remarks, which become part of the sample record.
If BOTTLE mode is selected, a second page is activated to allow the purge volume to be entered ( 15 to 30 ml ). If ONLINE is selected, a second page will come up to allow programming of the following: number of samples (1 – 500); Hold time ( Hrs:Mins ); Purge volume (5-999ml).
STD: Determines the format that the results will be reported to.
VOL: Volume of fluid that will be sampled for each run. Bottle sampling is limited to 5, 10 or 20 ml per run.
FLOW: Can be selected between 15 and 50 ml/min or can be set to AUTO. When in AUTO mode, the PODS will automatically determine the optimum flow rate.
PRINT: Enables or disables the printer. SETUP prints the current PODS setup.

20. 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 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
Q. Everyone seems to claim adherence to ISO 11171, are they really doing ISO calibrations?
A. No, they are most certainly not performing ISO calibrations on their instruments.
ISO is a very comprehensive calibration procedure that calibrates an entire particle counting system. That is, it calibrates the counting electronics and sample delivery, as well as the sensor. There are a total of six (6) steps within the ISO calibration procedure; the calibration of a sensor using ISO MTD is only one of these steps.
So, when a competitor states that its calibration is “based on ISO 11171” or “compatible with ISO 11171” or “ISO MTD in accordance with ISO 11171” or other such language, it is NOT performing a full ISO calibration. The competitors are only performing one section (Section 6 in the ISO document) that covers the calibration of the sensor using ISO MTD dust.
The HIAC PODS can be calibrated to the full ISO standard and is the only instrument in its class that can make this claim.

21. Competitors Parker UCC—LCM20, PLC3000 Pall—PFC200, PFC400W, PCM 400
PAMAS—S40
Eaton Vickers—TargetPro
MP Filtri—LPA2
Hydac—FCU2100/2200
Internorman—CCS 2
Klotz—Abakus

22. What Parker Offers UCC LCM 20 portable particle counter
PLC3000 portable particle counter (manufactured by HU)
MCM 8000 online particle monitor (PM4000 OEM)
IQ200 online counter
MCM 20 online monitor based on the LCM20

23. What Pall Offers
PFC400W—laser particle counter manufactured by PAMAS with water content measurement
PCM pore blockage counters
PIM 400 online monitor

24. What PAMAS Offers
Pamas offers a range of particle counters for the laboratory and for field use.

25. Stoplight Analysis

26. Where We Win
PODS is the instrument of choice for the US Navy—not one of many but the only one
No one else offers ISO 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
SUPERIOR VALUE PROPOSITION

27. PODS Monetization
(Parker UCC LCM 20: $8,000 - $10,000)

28. PODS Benefits Proactive maintenance
Tracking and trending multiple system’s cleanliness
Certification to ISO, SAE and NAS requirements
On-site sampling
Reducing maintenance costs
Bottle samples
Roll-off cleanliness
Fluid analysis
System qualification
Read from slide

29. HIAC PODS Overview