Fluid Condition

Handbook

Manual of analysis and

comparison photographs

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 Index Introduction
Pg’s
Introduction 2 In hydraulic fluid power systems, power is
transmitted and controlled through a liquid
General Information 3-6
under pressure within an enclosed circuit.
Sampling Procedures 7-9 The liquid is both a lubricant and a power-
transmitting medium.
Cleanliness Reporting
Formats 10-15 The presence of solid contaminant particles
in the liquid interferes with the ability of
Comparison
Photographs for the hydraulic fluid to lubricate and causes
Contamination wear to the components. The extent of
Classes 16-25
contamination in the fluid has a direct
Hydraulic Component bearing on the performance and reliability
Manufacturer’s of the system and it is necessary to control
Recommendations 26-27
solid contaminant particles to levels that
Hydraulic System are considered appropriate for the system
Target Cleanliness concerned.
Levels 28
A quantitative determination of particulate
Cleanliness Code contamination requires precision in obtaining
Comparison 29
the sample and in determining the extent
Measuring Water in of contamination. Liquid Automatic Particle
Hydraulic and Counters (APC) (MP Filtri Products), work
Lubricating fluids 30-31
on the light-extinction principle. This has
Contamination become an accepted means of determining
Monitoring
the extent of contamination. The accuracy
Products 32-33
of particle count data can be affected by the
techniques used to obtain such data.
IMPORTANT. For definitive and comprehensive guidance on condition monitoring and the content held within this
document, always refer to the relevant standard.
MP Filtri UK Ltd has created this document based on related current standards dated as such. The document is
intended as a guide only and MP Filtri UK Ltd reserves the right to alter content, specifications, artwork and related
information without prior written notice.
To ensure that you always have the latest revision of this document, please go to www.hydraulicparticlecounter.com

2 www.hydraulicparticlecounter.com
 General Information

The NAS 1638 reporting format was developed for use where the principle
means of counting particles was the optical microscope, with particles
sized by the longest dimension per ARP598. When APC’s came in to
use this provided a method of analysing a sample much faster than the
ARP598 method. A method of calibrating APC’s was developed, although
they measured area and not length, such that comparable results to that
of ARP598 could be obtained from the same sample. Now, APC’s are
the primary method used to count particles and the projected area of a
particle determines size. Because of the way particles are sized with the
two methods, APC’s and optical microscopes do not always provide the
same results. NAS 1638 has now been made inactive for new design
and has been revised to indicate it does not apply to use of APC’s.

Prior to ISO 11171, the previous APC calibration method most widely
utilised was ISO 4402, which used Air Cleaner Fine Test Dust (ACFTD)
as the reference calibration material. ACFTD is no longer manufactured
and the ISO 4402 method using this dust has been made obsolete. The
industry developed the method ISO 11171, which supersedes ISO 4402,
with a calibration standard based on NIST-certified samples of ISO 12103-
1 A3 medium test dust suspended in hydraulic oil. There is a difference
between the particle measurements by ISO 4402 and ISO 11171. To
retain the same cleanliness measure, calibrations using ISO 11171 are
conducted to a corrected particle count scale. For example, particles
reported as 5 um with the ISO 4402 method are reported as 6 um (c)
by the ISO 11171 method. In fact 5 um corresponds to 6.4 um (c), and
some round off was conducted for simplification.

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 Particle size analysis
Several methods and instruments based on different physical principles
are used to determine the size distribution of the particles suspended
in aeronautical fluids. The numbers of particles found in the different
size ranges characterize this distribution. A single particle therefore
has as many equivalent diameters as the number of counting methods
used.
Figure 1 shows the size given to the particle being analysed (shading)
by a microscope as its longest chord and an APC calibrated in
accordance with ISO 11171 using the Standard Reference Material
NIST SRM 2806 sized by the equivalent projected area.

Particle to be analyzed

Sized by APC calibrated as

per ISO 11171 (new NIST)
Sized by microscope
“diam. of equiv. proj.
“longest dimension”
surface”

13μm Area = 78.5 μm2

Equivalent size
Equivalent size
d = 10 μm
d = 13 μm

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Differences between NAS 1638 and AS4059E.
AS4059E was developed as a replacement/equivalent to the obsolete
NAS 1638 format, where table 2 relates to the old AS4059D standard
and table 1 is the equivalent NAS1638 standard. However, there are
differences. Particularly in Table 2, (Cumulative Particle Counts).
Counting of Smaller Particles.
AS4059E allows the analysis and reporting of smaller particle sizes
than NAS 1638.
Counting Large Particles and Fibres.
In some samples, it has been observed that many of the particles
larger than 100 micrometers are fibres. However, APC’s size particles
based on projected area rather than longest dimension and do not
differentiate between fibres and particles. Therefore, fibres will be
reported as particles with dimensions considerably less than the length
of the fibres. A problem with fibres is that they may not be present
in fluid in the system but rather have been introduced as the result of
poor sampling techniques or poor handling during analysis.
Determining AS4059E Class Using Differential Particle Counts:
This method is applicable to those currently using NAS 1638 classes
and desiring to maintain the methods/format, and results equivalent to
those specified in NAS 1638.
Table 1 applies to acceptance criteria based on differential particle
counts, and provides a definition of particulate limits for Classes 00
through 12. A class shall be determined for each particle size range.
The reported class of the sample is the highest class in any given
particle range size.
NOTE: T he classes and particle count limits in Table 1 are identical to NAS 1638.
Measurements of particle counts are allowed by use of an automatic
particle counter (calibrated per ISO 11171 or ISO 4402:1991), or an
optical or electron microscope. The size ranges measured and reported
should be determined from Table 1 based on the measurement method.

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 Determing AS4059E Class Using Cumulative Particle Counts:
This method is applicable to those using the methods of previous
revisions of ÅS4059 and/or cumulative particle counts. The
cleanliness levels for this method shall be specified by the appropriate
class from Table 2. To provide versatility, the applicable cleanliness
class can be identified in the following ways:
a. Basing the class on the highest class of multiple size ranges .
b. Total number of particles larger than a specific size.
c. Designating a class for each size range.

Designating a Class for Each Size Range:

APC’s can count the number of particles in several size ranges. Today,
a different class of cleanliness is often desired for each of several size
ranges. Requirements can be stated and cleanliness can easily be
reported for a number of size ranges. A class may be designated for
each size from A through F*. An example is provided below:

7B/6C/5D is a numeric-alpha representation in which the number

designates the cleanliness class and the alphabetical letter designates
the particle size range to which the class applies. It also indicates that
the number of particles for each size range do not exceed the following
maximum number of particles:

Size B: 38,924 per 100 ml

Size C: 3462 per 100 ml
Size D: 306 per 100 ml

*Please check standard for definition of size/classes

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 Sampling Procedures

Methods of
taking samples
from hydraulic
applications
using appropriate
recepticles
ENSURE THAT ALL DANGERS ARE
ASSESSED AND THE NECESSARY
PRECAUTIONS TAKEN DURING THE
SAMPLING PROCESS.
DISPOSAL OF FLUID SAMPLES
MUST FOLLOW PROCEDURES
RELATING TO COSHH.

Sampling procedures are defined in ISO4021. Extraction of fluid

samples from lines of an operating system.
Receptacles should be cleaned in accordance with DIN/1505884.
The degree of cleanliness should be verified to ISO3722.

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 Methods of taking sample from hydraulic
applications, using appropriate recepticles

Methods One & Two

Method One – Method Two –
Preferred method Preferred method
(Using a suitable sampling valve with (Using an unspecified
PTFE seating method) sampling valve)

Install sampling valve in pressure or Install valve in return line or an

return line (in closed condition) at an appropriate point where flow is
appropriate point under constant flow constant and does not exceed 14 bar
or turbulent conditions

Operate system for at least 30 Operate system for at least 30

minutes before taking a sample minutes before taking a sample

Clean outside of sampling valve Flush sampling valve by passing at

least 45 litres through valve back to
reservoir
Open the sampling valve to give app-
ropriate flow rate and flush at least
one litre of fluid through the valve Disconnect line from valve to
reservoir with valve open and fluid
Do Not Close Valve After Flushing
flowing

Remove cap from sampling bottle.

Ensure cap is retained in hand face
downwards

Place bottle under sampling valve.

Fill bottle to neck. Cap bottle & wipe.

Close the sampling valve

Label the bottle with the necessary

information for analysis e.g. Oil type,
running hours, system description etc.

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 Methods of taking sample from hydraulic
applications, using appropriate recepticles

Methods Three & Four

Method Three - Method Four –
Reservoir sampling Bottle Dipping
(Use only if methods One & (Least preferred method due to possible
Two cannot be used) high ingression of contamination

Operate system for at least one hour Operate system for at least one hour
before taking a sample before taking a sample

Thoroughly clean area around the Thoroughly clean area around the
point of entry to the reservoir point of entry to the reservoir where
sample bottle is to be inserted
Attach sample bottle to the sampling
device Clean outside of ultra clean sample
bottle using filtered solvent, allow to
Carefully insert sampling hose into evaporate dry
the midway point of the reservoir. Try
not to touch sides or baffles within Dip sample bottle into reservoir, cap
the reservoir and wipe

Extract sample using the vacuum

Re-seal reservoir access
pump and fill to approx 75% volume

Release vacuum, disconnect bottle Label the bottle with the necessary
and discard fluid information for analysis e.g. Oil type,
running hours, system description etc.
Repeat the above three steps three times
to ensure flushing of the equipment

Attach ultra cleaned sample bottle to

sampling device – collect final fluid sample

Remove bottle from sampling device &

cap - label with appropriate information

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 Cleanliness Reporting Formats

ISO 4406:1999 Cleanliness Code System

The International Standards

Organisation standard
ISO 4406:1999 is the preferred
method of quoting the number
of solid contaminant particles in
a sample.

The code is constructed from

the combination of three scale
numbers selected from the
following table.

The first scale number

represents the number of
particles in a millilitre sample of
the fluid that are larger than
4 μm(c).

The second number represents

the number of particles larger
than 6 μm(c).

The third number represents

the number of particles that are
larger than 14 μm(c).

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www.hydraulicparticlecounter.com 11
 Cleanliness Reporting Formats

Classes of Contamination According to NAS 1638

The NAS system was originally developed in 1964 to define
contamination classes for the contamination contained within aircraft
components. The application of this standard was extended to
industrial hydraulic systems simply because nothing else existed at the
time.

The coding system defines the maximum numbers permitted of 100ml

volume at various size intervals (differential counts) rather than using
cumulative counts as in ISO 4406:1999.

Although there is no guidance given in the standard on how to quote

the levels, most industrial users quote a single code which is the
highest recorded in all sizes and this convention is used on MP Filtri’s
APC’s.

CONTAMINATION LEVEL CLASSES according to NAS 1638

(January 1964)
The contamination classes are defined by a number (from 00 to 12)
which indicates the maximum number of particles per 100 ml, counted
on a differential basis, in a given size bracket.

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 13
Classes of Contamination

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According to NAS 1638
 Cleanliness Reporting Formats

SAE AS 4059 REV.E**

Cleanliness Classification for Hydraulic Fluids (SAE Aerospace Standard)

This SAE Aerospace Standard (AS) defines cleanliness levels for

particulate contamination of hydraulic fluids and includes methods of
reporting data relating to the contamination levels.
Tables 1 and 2 below provide differential and cumulative particle
counts respectively for counts obtained by an automatic particle
counter, e.g. LPA2.

TABLE 1 - Cleanliness Classes for Differential Particle Counts

MAXIMUM CONTAMINATION LIMITS (PARTICLES/100ml)

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 Cleanliness Reporting Formats

SAE AS 4059 REV.E**

Cleanliness Classification for Hydraulic Fluids (SAE Aerospace Standard)

TABLE 2 - Cleanliness Classes for Cumulative Particle Counts

MAXIMUM CONTAMINATION LIMITS (PARTICLES/100ml)

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 Comparison Photographs

ISO 4406:1999 Class 14/12/9

SAE AS4059E Table 1 Class 3
NAS 1638 Class 3
SAE AS4059E Table 2 Class 4A/3B/3C

1 graduation= 10 µm

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for Contamination Classes

ISO 4406:1999 Class 15/13/10

SAE AS4059E Table 1 Class 4
NAS 1638 Class 4
SAE AS4059E Table 2 Class 5A/4B/4C

1 graduation= 10 µm

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 Comparison Photograph’s

ISO 4406:1999 Class 16/14/11

SAE AS4059E Table 1 Class 5
NAS 1638 Class 5
SAE AS4059E Table 2 Class 6A/5B/5C

1 graduation= 10 µm

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for Contamination Classes

ISO 4406:1999 Class 17/15/12

SAE AS4059E Table 1 Class 6
NAS 1638 Class 6
SAE AS4059E Table 2 Class 7A/6B/6C

1 graduation= 10 µm

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 Comparison Photograph’s

ISO 4406:1999 Class 18/16/13

SAE AS4059E Table 1 Class 7
NAS 1638 Class 7
SAE AS4059E Table 2 Class 8A/7B/7C

1 graduation= 10 µm

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for Contamination Classes

ISO 4406:1999 Class 19/17/14

SAE AS4059E Table 1 Class 8
NAS 1638 Class 8
SAE AS4059E Table 2 Class 9A/8B/8C

1 graduation= 10 µm

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 Comparison Photograph’s

ISO 4406:1999 Class 20/18/15

SAE AS4059E Table 1 Class 9
NAS 1638 Class 9
SAE AS4059E Table 2 Class 10A/9B/9C

1 graduation= 10 µm

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for Contamination Classes

ISO 4406:1999 Class 21/19/16

SAE AS4059E Table 1 Class 10
NAS 1638 Class 10
SAE AS4059E Table 2 Class 11A/10B/10C

1 graduation= 10 µm

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 Comparison Photograph’s

ISO 4406:1999 Class 22/20/17

SAE AS4059E Table 1 Class 11
NAS 1638 Class 11
SAE AS4059E Table 2 Class 12A/11B/11C

1 graduation= 10 µm

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for Contamination Classes

ISO 4406:1999 Class 23/21/18

SAE AS4059E Table 1 Class 12
NAS 1638 Class 12
SAE AS4059E Table 2 Class 13A/12B/12C

1 graduation= 10 µm

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 Hydraulic Component Manufacturer’s***
Recommendations

Most component manufacturers know the proportionate effect that

increased dirt level has on the performance of their components and
issue maximum permissible contamination levels. They state that
operating components on fluids which are cleaner than those stated will
increase life.

However, the diversity of hydraulic systems in terms of pressure, duty

cycles, environments, lubrication required, contaminant types, etc,
makes it almost impossible to predict the components service life over
and above that which can be reasonably expected.

Furthermore, without the benefits of significant research material and

the existence of standard contaminant sensitivity tests, manufacturers
who publish recommendations that are cleaner than competitors may
be viewed as having a more sensitive product.

Hence there may be a possible source of conflicting information when

comparing cleanliness levels recommended from different sources.

The table opposite gives a selection of maximum contamination levels

that are typically issued by component manufacturers. These relate
to the use of the correct viscosity mineral fluid. An even cleaner level
may be needed if the operation is severe, such as high frequency
fluctuations in loading, high temperature or high failure risk.

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 Hydraulic Component Manufacturer’s***
Recommendations

***

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 Hydraulic System
Target Cleanliness Levels****

Where a hydraulic system user has been able to check cleanliness

levels over a considerable period, the acceptability, or otherwise, of
those levels can be verified. Thus if no failures have occurred, the
average level measured may well be one which could be made a bench
mark. However, such a level may have to be modified if the conditions
change, or if specific contaminant-sensitive components are added to
the system. The demand for greater reliability may also necessitate an
improved cleanliness level.

The level of acceptability depends on three features

•   the contamination sensitivity of the components
•   the operational conditions of the system
•   the required reliability and life expectancy

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 29
Cleanliness Code Comparison

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ISO 4406 SAE ASA059 Table 2 SAE ASA059 Table 1 NAS 1638
>4μm(c)/>6μm(c)/14μm(c) >4μm(c)/>6μm(c)/14μm(c) 4-6, 6-14, 14-21, 5-15, 15-25, 25-50,
21-38, 38-70, >70 50-100, >100
23/21/18 13A/12B/12C 12 12
22/20/17 12A/11B/11C 11 11
21/19/16 11A/10B/10C 10 10
20/18/15 10A/9B/9C 9 9
19/17/14 9A/8B/8C 8 8
18/16/13 8A/7B/7C 7 7
17/15/12 7A/6B/6C 6 6
16/14/11 6A/5B/5C 5 5
15/13/10 5A/4B/4C 4 4
14/12/09 4A/3B/3C 3 3

Standards
**** Although ISO 4406 standard is being used extensively within the hydraulics industry other standards
are occasionally required and a comparison may be requested. The table above gives a very general
comparison but often no direct comparison is possible due to the different classes and sizes involved.
 Measuring WATER in hydraulic
and lubricating fluids

In mineral oils and non-aqueous fire resistant fluids water is undesirable.

Mineral oil usually has a water content of 50-300ppm which it can
support without adverse consequences. Once the water content exceeds
about 500ppm the oil starts to appear hazy.
Above this level there is a danger of free water accumulating in the
system in areas of low flow. This can lead to corrosion and accelerated
wear. Similarly, fire resistant fluids have a natural water content which
may be different to mineral oil. (From North Notts Fluid Power Centre)

Saturation Levels
Since the effects of free
(also emulsified) water is
more harmful than those of
dissolved water, water levels
should remain well below the
saturation point. However,
even water in solution can
cause damage and therefore
every reasonable effort
should be made to keep
saturation levels as low as
possible.
There is no such thing as too
little water. As a guideline,
we recommend maintaining
saturation levels below 50%
in all equipment.

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Typical Water Saturation Levels
- For new oils

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 Contamination Monitoring Products

VPAF – 100
A simple way to check
the fluid used in hydraulic
applications is to verify
the contamination of
solid particles ; the KIT
“VPAF – 100” is suitable
for checking these
contaminants.

LPA2 – Twin Laser Particle Analyser

The LPA2 is a highly precise, lightweight & fully
portable instrument suitable for on-site and
laboratory applications. It can automatically
measure and display particulate contamination,
moisture and temperature levels in various
hydraulic fluids.

CML2 – Compact Laser Particle Analyser

The CML2 is a compact, super lightweight
mains operated unit for on-site and laboratory
applications. It can automatically measure and
display particulate contamination, moisture and
temperature levels in various hydraulic fluids.

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 Contamination Monitoring Products

BS110 & BS250 – Bottle Samplers

The BS110 & BS250 bottle samplers are suitable for off line and
laboratory applications where fluid sampling at point of use is in-
accessible or impractical. A fluid de-aeration facility comes as standard.

PML2 – Permanently Mounted Laser

Particle Analyser
The PML2 is a pressure dependant in-line product
intended for on-site and industrial applications. It
can automatically measure and display particulate
contamination, moisture and temperature levels in
various hydraulic fluids.

ICM - Inline Contamination Monitor

The ICM automatically measures and displays
particulate contamination, moisture and temperature
levels in various hydraulic fluids. It is designed
specifically to be mounted directly to systems, where
ongoing measurement or analysis is required, and
where space and costs are limited.

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 The complete range of
Contamination
Monitoring Products

When contamination is
the problem,
we have the solution.
34 www.hydraulicparticlecounter.com
Don’t let Contamination
Create a Crisis!
70–80% of all failures on hydraulic systems + up
to 45% of all bearing failures are due to
contaminants in the hydraulic fluid.

The Complete Hydraulic

Filtration & Accessory Range
When contamination is
the problem,
we have the solution.
www.hydraulicparticlecounter.com 35
 Fluid Condition
Handbook

ITALY (Head Quar ters) FR ANCE

MP FILTRI S.p. A . MP FILTRI FR ANCE
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