PCM200 Operating Instructions

PALL PCM200 SERIES PORTABLE
FLUID CLEANLINESS MONITOR

Operating Instructions
Page 1 of 80
Preface
The ‘Pall’ PCM200 Fluid Cleanliness Monitor has been developed to provide
accurate and continuous information on the cleanliness of aqueous solutions,
hydraulic fluids and circulatory lubrication system fluids. Fluid cleanliness levels
monitored are then converted to one of the widely used cleanliness codes,
ISO4406, SAE AS4059 table 2 or SAE AS4059 table 1 (previously NAS1638).
This data can be downloaded from the main unit or from the optional handheld
readout to a PC via the RS232 communications ports, for subsequent trending of
stored data.
The self-contained unit is a fluid cleanliness monitor that can be used with a range
of fluids, including mineral oils, synthetic oils, and aqueous solutions.
These operating instructions should be read before attempting any aspects of

installation, operation or maintenance.
The product has been tested and quality-controlled in accordance with Pall
standard procedures. The customer should carefully inspect the product and
ensure it is not damaged and/or unsuitable for use. It is the user’s responsibility
to check actual operating conditions to ensure the PCM200 monitor is compatible
with the application and is operated within local safety codes.
NOTICE TO USERS
The PCM200 user manual is provided to assist users in maximising the benefits of
the PCM200 portable fluid cleanliness monitor.
As part of the continuous improvement process that Pall adopts in the

development of technology and satisfying customer requirements, this information
or procedure may be subject to change.
Pall welcomes feedback from users.
Please note the PCM200 is shipped to users filled with a protective fluid, Rust
veto NTP 32, which is miscible with both aqueous liquids and oils. Please ensure
the unit is flushed out before running tests. After flushing, the unit should be run
for at least three full test cycles on the system fluid before relying on the test
results.
MANUAL PART NUMBER ISSUE DATE

MA-PCM200 A Draft February2009
Page 2 of 80
PALL
PALL INDUSTRIAL
- A DIVISION OF PALL EUROPE LTD.
DECLARATION OF CONFORMITY
PRODUCT DESCRIPTION: Fixed Installation Cleanliness Monitor
PRODUCT PART NUMBER: PCM200, PCM200W, PCM200B,

PCM200WB
SERIAL NUMBER: SEE NAMEPLATE
On behalf of the Pall Machinery and Equipment division of Pall Europe Ltd, we
hereby declare that the above product complies with the following transposed
harmonised standards:
BSEN292-1 :1991 Safety of Machinery – Basic Concepts

BSEN60204-1 :1998 Safety of Machinery – Electrical Equipment of
machines
BSEN1050 :1997 Safety of Machinery – Risk Assessment
EN61000-6-3: 2001 Electromagnetic Compatibility – Generic Emissions
Standard Pt 1 Light Industrial
EN61000-6-2: 2001 Electromagnetic Compatibility – Generic Immunity
Standard Pt 2 Industrial Environment
EN61000-3-2 : 2001 Harmonic Current Emissions
EN61000-3-3 : 1995 Voltage Fluctuation and Flicker
BSEN60529 : 1992 Degrees of Protection Provided by Enclosures
This compliance is sufficient to meet the requirements of the EC Machinery

Directive 89/392/EEC (as amended by Directive 91/368/EEC), the Low Voltage
Directive 73/23/EEC and the EMC Directive 89/336/EEC (as amended by
Directive 92/31/EEC).
This product must be regularly serviced by Pall and /or their approved agent for
the declaration to remain effective after shipment.
J.Collard, Engineering ‘Projects’ Manager

For and on behalf of: Pall Industrial
Europa House
Havant Street
Portsmouth
Hampshire
England
PO1 3PD
Page 3 of 80
WARNINGS, CAUTIONS AND NOTES
Care must be taken in referring to this manual to ensure adherence with all
warnings, cautions and important notes. These carry information related to the
safety of personnel and the integrity and satisfactory operation of plant.
WARNINGS: THESE ARE INSTRUCTIONS THAT DRAW

ATTENTION TO THE RISK OF INJURY OR DEATH.
Cautions: These are instructions that draw attention to the risk of

damage to the product, the process, the equipment or the
surroundings.
!
Important: These are instructions that draw attention to information that
will aid installation, operation or maintenance.
Trademarks and Intellectual Property

The design of this equipment, software and supporting documentation is the
intellectual property of Pall Europe Ltd and is subject to copyright.
NOTE: Pall and are trademarks of Pall Corporation.
 Indicates a trademark registered in the USA
Filtration. Separation. Solution. is a service mark of Pall Corporation
Page 4 of 80
Contents
Page
Preface 2
Declaration of Conformity 3
Warnings, Cautions and Notes 4
Trademarks and Intellectual Property 4
Section 1: PCM200 SERIES Specification and Requirements 7

1.1 General Description
1.2 Fluid Environment
1.3 Ambient Environment
1.4 Electrical Requirements
1.5 Fluid System Connections
1.6 Product Specification
Section 2: PCM200 SERIES Inspection and Packaging. 8
Section 3: PCM200 SERIES Description of Monitor. 9
Section 4: PCM200 SERIES Principles of Operation 10

4.1 General Principles
4.2 Control Panel
4.3 Test Sampling
4.4 Power Schematic
Section 5: PCM200 SERIES Connecting the Monitor 12

5.1 Connection Options
5.2 Operational Checklist
5.3 Installation Checklist
Section 6: PCM200 SERIES Getting Started 28

6.1 General
6.2 System Components
6.3 Key Descriptions
6.4 The Flow Chart
6.5 Example Screens
6.6 Start-up Sequence
6.7 Sampling
6.8 On Line Test/Tank Sampling Routine
6.9 Output Results Routine
6.10 Warm-up Routine
6.11 Fluid Set-up Routine
6.12 Fluid Name
6.13 Fluid Water Content
6.14 Test Point Set-up Routine
6.15 Test Point Name
6.16 Number of Tests / Continuous Test
6.17 Test Period
6.18 Warm-up Cycle Target Temperature
6.19 Test Point Alarms
6.20 Setting the Time and Date
6.21 Engineering Set-up
Page 5 of 80
Page
Section 7: PCM200 SERIES Interface Protocol Using PCM Port COM2 51
Section 8: PCM200 SERIES Fluid Change Procedure 56
Section 9: PCM200 SERIES Function Codes and Corrective Actions 57
Section 10: PCM200 SERIES Mesh change procedure 61
Section 11: PCM200 SERIES Spare parts list 64
Section 12: PCM200 SERIES Disposal of Equipment 65
Appendix A: Commissioning, Training, Calibration and Aftermarket Services 66
Appendix B: ISO 4406 and NAS1638 (SAE AS4059) contamination classes 68
Appendix C: PCM200 SERIES menu flow chart 72
Appendix D: Software – Pall PCM200 Display Downloader 73
Appendix E: Software – Pall PCM200 Display Emulator 78
Pall World-wide Warranty 80
Page 6 of 80
Section 1:Pall PCM200 SERIES Fluid
Cleanliness Monitors
Specification and Requirements
1.1 General Description
The Pall PCM200 Series Fluid Cleanliness Monitor is specifically developed as a diagnostic
monitoring device that provides an assessment of system fluid cleanliness. An optional detachable
hand-held display or the standard PCM200 Emulator Software allows for simple menu-driven
input of sample identification, monitor configuration and data output in ISO4406, SAE AS 4059
Table 1 (previously NAS 1638) or SAE AS 4059 Table 2 formats. The self-contained unit is a fluid
cleanliness monitor that can be used with a range of fluids, including mineral oils, synthetic oils,
and aqueous solutions. Note: The PCM200 fitted with the Pall Water Sensor option, i.e. a
PCM200W, should not be used with aqueous fluids.
Fluid change procedures are included in section 8 of the manual and these help to ensure the
PCM200 monitor is adequately flushed ready for an alternative fluid application. The full technical
specification is given below.
1.2 Fluid Environment

Operating Pressure range 0 to 2 bar (29 psi) maximum
Operating Viscosity range 1.5 to 450 cSt (30 to 2,200 SUS)
Operating System Mineral Oils 5ºC - 80ºC (41°F - 176°F)
Temperature Water Glycols 5ºC - 60ºC (41°F - 140°F)
Water Based Fluid 5ºC - 60ºC (41°F - 140°F)
Fuels 5ºC - 40ºC (41°F - 104°F)
Industrial Phosphate
Esters & Polyol Esters 5ºC - 80ºC (41°F - 176°F)
Fluid Compatibility Aqueous fluids having a pH <11.0, water glycols,
high water based fluids, petroleum based fluids,
industrial phosphate esters, mineral oils and most
synthetic lubricating fluids.
Seals Fluorocarbon
1.3 Ambient Environment

Operating Temperature range 5°C - 50°C (41°F - 122°F)
Storage Temperature range -20°C to 55°C ( -4°F to 131°F)
(Monitor drained of fluid)
Dust and water protection IP65 (NEMA 4)
1.4 Electrical
Power Supply Unit (PSU) 90 – 264 V AC (auto-ranging), 47 – 63 Hz
Single Phase or 18-24 V DC
Communications RS232
1.5 Fluid Connections

Inlet / Outlet Fluid Connections M10 x 1mm thread male fitted with 6mm OD
/ 4mm ID X 1 metre plastic hose
1.6 Product Specification

Weight 9.0 Kg (20 lb)
Dimensions 267 x 257 x 164 mm (10.5” x 10.1” x 6.5“)
Monitoring range ISO4406 -/9/7 to -/21/17
Monitoring range AS 4059 Table 1 1 to 10 at 5 to 15µm
(previously NAS1638)
AS 4059 Table 2 > 6um 1B to 10B / >14um 1C to 10C

Accuracy ± 1/2 ISO Code using NIST calibrated light
blockage automatic particle counter
Page 7 of 80
Section 2: Pall PCM200 Series Fluid Cleanliness
Monitors
Inspection and Packaging
2.1 Inspection and Packaging
The PCM200 monitor is shipped in protective packaging inside a box. To ensure total protection,
this packaging should always be used for transporting the monitor. Visually inspect the box for
signs of external damage that may have occurred during shipping and bring any damage to the
attention of the shipper.
Inspect the interior of the box for damage to the contents as listed below. Compare the contents of
the box to the shipping papers to assure all the content is present. If any items are missing,
contact Pall or an approved agent.
The PCM200 package comprises of:
• PCM200 series monitor

• Mains power lead
• PCM200 to PC communications cable
• PCM200 series Operating Instructions and Software on CD ROM
• PCM200 series Quick Reference Guide
• Certificate of Conformity
• Certificate of Calibration Verification
• Pall ‘Fluid Cleanliness Trender’ software on CD ROM
• Packing note checklist
Within an envelope is the instrument’s specific serial number and calibration/service record sheet.
It is important to keep this in a safe place and return it with the unit for future annual service
requirements.
Page 8 of 80
Monitors
Description of the Monitor
3.1 Description of the Monitor
The PCM200 is designed and built for light Industrial use while maintaining aesthetic and user-
friendly ergonomics. See section 1 for full specification. The materials are selected to meet the
various fluid and environmental conditions that the PCM200 is likely to be subject to during
operation.
As a self-contained unit, including sampling hoses, the user is able to connect the PCM200 on-line
or to sample fluid directly from a system reservoir without breaking lines, thereby avoiding
extraneous contamination.
The PCM200 cleanliness monitor provides numerous display functions to assist the user at all
stages of operation and provides function codes to warn of any problems with both the PCM200
and the system fluid.
The PCM200 can be permanently installed to monitor critical applications (including component
test facilities).
The front facia user interface comprises buttons for unit On/Off, and test Stop/Start. There are two
communications ports both RS232; communications port 1 (Com1) for the optional hand-held
display, PC running the PCM200 Emulator program for test configuration: communications port 2
(Com2) configured for optional printer or PLC interface using protocol already implemented in
PCM200 Series monitors. Port 1 (Com1) can also be used to set the function of Port 2 (Com2) to
either PLC communications or use with the optional printer.
There are four LED indicators for Power, Standby/Testing, Sampling issues and Hardware issues.
An optional hand-held touch screen display allows for simple menu-driven input of sample
identification, monitor configuration and data output. The hand-held touch screen display shows
real-time data and test results which are automatically stored for subsequent trending and
evaluation.
Data can be displayed on a remote PC or PLC using simple ASCII commands. Data can also be
printed using the optional thermal printer.
Page 9 of 80
Section 4: Pall PCM200 Series Fluid Cleanliness Monitor
Principles of Operation
4.1 General Principles
On the start of a test sequence the PCM200 will self-prime and perform internal checks on the test
fluid condition. After approximately one minute the PCM200 will then start the analysis. During
the analysis cycle the sample fluid is presented to the meshes that capture the contamination in a
specified sequence. Particle concentrations are measured and computed for each mesh.
PCM200 hydraulic schematic
P3
Pump
LCF = 105µm V2 WIO
14µm(c) 6µm(c)
V1
V3
Inlet Outlet
P2
Viscometer
P1
Temperature
Probe
! !
" !
During the sampling sequence data is constantly analysed to identify any excessive variation in
temperature, viscosity, and pressure to ensure results are not spurious. The PCM200 will advise
the user by function codes if any excessive variation occurs. A list of function codes can be found
in section 9.
4.2 Control Panel
There is one latching push-button, one momentary action push-button and four light-emitting
diodes (LED) to indicate PCM200 operational status.
BUTTON:
• Latching push-button: On /Off
• Momentary push-button: Start test
LEDs:
• Blue
• Green
• Yellow
• Red
Blue Green Amber Red Description

On On Flash On On
X PCM200 Power On
X X PCM200 On - Operational / Standby
X X Test in Progress
X X Sampling problem detected
X X Hardware problem detected
Page 10 of 80
4.3 Test sampling
The optional hand-held display or PC-based Display Emulator program is designed to provide
clear viewing of the menu, test data and any function codes. The test sample sequence is
conducted by use of function keys displayed on the hand-held display or PC monitor screen. In
edit mode a qwerty keyboard is available on the screen, which enables users to enter, or edit, data
including sample points and fluid types.
4.4 Power
The PCM200 is normally powered by an AC supply 90-264 V AC (auto ranging). Standard mains
connectors are supplied with the unit. Mains fuse is 2 Amp. Alternatively the unit can be powered
by a DC input of 18-24 Volts, 3 Amps. The connector for DC has color coded flying leads:
A B
A = DC Main Power Port

B = AC Main Power Port
C = DC power cable with flying leads

RED Wire = + VE
BLUE Wire = - VE
GREEN Wire = Ground
SILVER Wire = Shielding
D = AC power cable
C D
Important:
Do not connect both AC and DC power at the same time.
Page 11 of 80
Monitors
Connecting the PCM200 for sampling and data collection
5.1 Connection Options for Sampling
A general checklist for the user is given in section 5.3 and also on the ‘Useful information’ quick
reference card supplied with the PCM200 unit.
PCM200 is configured for two hose operation, inlet (blue hose) and return (clear hose). Fluid
entering the PCM200 is filtered for contaminant greater than 105µm by a mesh element (Last
Chance Filter) that is user-changeable. In the event of this filter blocking during testing, the fluid
flow entering the PCM will be restricted. An alarm condition with a warning message will be given
on the display or sent as part of the data string to a connected PC. The return line must be
unrestricted and allowed to drain into a waste container or back to the system reservoir.
The PCM200 is simply connected to a system via the appropriate integrated sampling hoses.
When not in use, the sampling hoses are stored within the PCM200 and are coiled around the
inside of the rear of the instrument.
The PCM200 can be connected in Low Pressure Mode, Reservoir Sampling Mode, or Bottle
Sampling Mode. Low pressure mode is considered to be the most appropriate to achieve
representative sampling.
Caution: Ensure the system operating pressure is within the

PCM200 monitor specified limit of 2 bar, 29 psi, maximum.
Low Pressure Mode (0 to 2 bar 0 to 29 psi)
Page 12 of 80
Reservoir Sampling Mode
Bottle Sampling Mode
Page 13 of 80
5.2 Powering and boot up of the PCM200
Connect AC or DC power to the PCM200 as required (review section 4.4 if necessary). Once
power is connected to the PCM200 the blue LED will illuminate and remain on (A). Switch on the
PCM200 by pressing the “Power On/Off” button (E). Within a few seconds the green, yellow and
red LEDs will begin to flash. A series of “clicks” will be heard (this is normal). After approximately
20 seconds the boot-up process will be completed and the green LED will blink on and off. The
PCM200 is now booted up. Prior to starting a test ensure the PCM200 is properly connected to a
system as outlined in section 5.1.
A = Main Power Indicator

B = Green LED
C = Yellow LED
D = Red LED
A E = Power ON/OFF switch
E
F = Start/Stop test
B G = COM 1 port
H = COM 2 port
F
C
G H
5.3 Communicating with the PCM200 (Overview)
COM 1 Port: The COM 1 port of the PCM200 is used to control, configure and download data.
There are two options for connecting to COM 1.
COM 1 Port Connect Option A: Using a PC
Communication with the following software programs can be made with a PC through COM 1:
PCM400 Emulator (see section 5.4 below)

PCM200 Printer PLC Utility Program (see section 5.6 below)
PC Connected to COM 1
Page 14 of 80
COM 1 Port Connection Option B: Using the optional hand held-display
The operator can choose to purchase the optional hand-held display to configure and control the
PCM200. See section 5.5 below for more details.
Optional Hand-Held Display Connected to COM 1
COM 2 Port: The COM 2 port of the PCM200 is used for PLC communications and for printing
with the optional thermal printer.
COM 2 Port Connection Option A: PLC communications
Connect a PLC to the COM 2 port, send & receive signals as shown in Section 7 of this manual
Run the “PCM200 PLC Demo” program from a PC, send and receive PLC signals on COM2 port.
PC Connected to COM 2
Page 15 of 80
COM 2 Port Connection Option B: Optional Thermal Printer
The optional thermal printer can be connected to COM 2 and real-time or test data from previously
run tests can be printed.
Printer Connected to COM 2
5.4 Communication via PCM400 Emulator Program
The PCM400 Emulator program is the preferred method to configure, start/stop and download
data from the PCM200. To effectively use the PCM400 Emulator the items pictured below will be
needed (NOTE: Newer generation PC’s not having 9-pin serial port will require a USB to Serial
converter cable) :
A = PCM200
B = COM1 cable p/n PCM200.239
D A C = USB to Serial converter cable
with driver (Option)
D = PC (not supplied by Pall)
B
C
5.4.1 Loading the PCM200 Display Emulator Program
From the PCM200 CD Rom load the PCM200 Display Emulator program. Use all default settings and
folder names and allow an ICON to be added to the desktop.
IMPORTANT: Reboot the PC after program is loaded regardless if the PC prompts to reboot or not.
Page 16 of 80
5.4.2 Installing USB to Serial Converter Cable if needed (Option supplied by Pall)
If using a USB to Serial converter cable connect the cable to an available USB port and install the driver as
per the instructions enclosed with the converter.
IMPORTANT: Reboot the PC after the driver is loaded regardless if the PC prompts to reboot or not.
After rebooting ensure the USB to Serial cable is installed. Using your PC’s “Device Manager” utility
determine the COM port number the converter cable is connected to.
IMPORTANT: The COM port number where the converter is connected must be know to properly use the
PCM400 Display Emulator Program
5.4.3 Connecting the PCM200 to the PC
With the PCM200 powered on (blue LED on) and booted up (green LED flashing) connect the PCM200 to
the PC as shown below. (Note: The configuration shown below incorporates a USB to Serial converter
cable which may not be needed by all users)
5.4.4 Launching the PCM200 Display Emulator Program
Load and launch the “PCM200 Display Emulator” program using the desktop icon or path shown below.
Page 17 of 80
When the program is launched the below screen should appear.
IMPORTANT: Select the proper COM port number using the drop-down menu. (Refer
to section 5.4.2 to determine which PC COM port is connected to the PCM200).
If the PC is not connected to the PCM200 the following screen will appear on the PC. Refer back
to 5.4.3 and ensure all cables are properly connected as shown in the photo.
When a successful communication has been established the following screen will appear on the
PC:
The user can now skip ahead to section 6 for guidance on navigation through the various
configuration and setup screens.
5.5 Communication via Optional Hand-Held Display
Communication with the PCM200 can also be accomplished using the optional hand-held display.
To effectively communicate with the PCM200 the hand-held display must be connected as shown
below. Ensure power is provided to the PCM200 (blue LED will be illuminated), switch on the
PCM200 using the ON/OFF switch.
Page 18 of 80
A = PCM200
C A B = Optional Hand-Held Display
with cable p/n: PCM200-DISP
C = Power ON/OFF switch
Cautions: The PCM200 optional hand-held display touch

sensitive screen must not be pressed with a sharp or
pointed implement. Finger contact is sufficient to operate
the display menu icons and keyboard.
When properly connected the optional hand-held display will show the following screen.
The user can now skip ahead to section 6 for guidance on navigation through the various
configuration and setup screens.
Page 19 of 80
5.6 Toggling the PCM200 COM2 Port for PLC or Printer Communication
The PCM200’s COM2 port is factory-configured to communicate with a PLC. However the COM2
port can easily be configured to communicate with an optional thermal printer. To effectively
toggle the COM2 port configuration the items listed below are needed:
A = PCM200
D B = COM1 cable p/n PCM200.239
A
C = USB to Serial converter cable
with driver (not supplied by Pall)
C B
5.6.1 Loading the PCM200 Printer PLC Utility
From the PCM200 CD Rom load the PCM200 Printer PLC Utility program. Use all default settings and
folder names and allow an ICON to be added to the desktop.
5.6.2 Installing USB to Serial Converter Cable if needed (not supplied by Pall)
If using a USB-to-Serial converter cable connect the cable to an available USB port and install the driver as
IMPORTANT: The COM port number where the converter is connected must be known to properly use
the PCM400 Display Emulator Program
Page 20 of 80
With the PCM200 powered on and booted up connect the PCM200 to the PC as shown below. (Note: The
configuration shown below incorporates a USB to Serial converter cable which may not be needed by all
users)
5.6.4 Launching the PCM200 Printer PLC Utility Program
Launch the “PCM200 Printer PLC Utility” program using the path shown below or icon (if available).
When the program is launched, the below screen should appear.
IMPORTANT: Select the proper COM port number using the drop-down menu. (Refer to section 5.4.2 to
determine which PC COM port is connected to the PCM200).
Do not adjust any other items on this page.
Page 21 of 80
After pressing “OK” communications will begin immediately (see photo below left). After a short
time the screen shown below right will appear. The user can now toggle the PCM200’s COM2
port between PLC use and optional printer use.
To lock in the new settings click the “Update Printer / PLC Settings” button and the following
screens will appear.
IMPORTANT: If the PC is not connected to the PCM200, the following screen will appear on the
PC. Refer back to 5.4.3 and ensure the PCM200 is powered on and booted up and all cables are
properly connected as shown.
IMPORTANT: If connections are OK but communication continues to fail, close down all Pall
PCM200 programs, re-launch only the PCM200 Printer PLC Utility program, and try again.
Page 22 of 80
5.7 Communication via PLC commands
Note: Prior to starting this section ensure the COM 2 port is configured for PLC communication as
discussed in section 5.6.4.
The PCM200 COM2 port is factory-configured to accept commands from a PLC (protocol details
are discussed in depth within section 7 of this manual). Users may also simulate PLC
communications using a PC connected to the COM2 port of the PCM200. To effectively
communicate PLC commands between the PC and COM2 port of the PCM200 the items listed
below are needed:
A = PCM200
D B = COM2 cable p/n PCM100.217
C = USB-to-Serial converter cable
with driver (not supplied by Pall)
A
B
C
5.7.1 Loading the PLC Demo Program
From the PCM200 CD Rom load the “PCM200_PLC_demo setup” program. Use all default settings and
folder names and allow an ICON to be added to the desktop if prompted.
5.7.2 Installing USB-to-Serial Converter Cable if needed (not supplied by Pall)
If using a USB-to-Serial converter cable connect the cable to an available USB port and install the driver as
IMPORTANT: The PC’s COM port number where the converter is connected must be known to properly
use the PCM200 PLC demo program
Page 23 of 80
With the PCM200 powered on and booted up (section 5.2) connect the PCM200 to the PC as shown below.
(Note: The configuration shown below incorporates a USB-to-Serial converter cable which may not be
needed by all users)
5.7.4 Launching the PCM200 PLC demo program
Once the cable is connected, the power to the PCM200 should be cycled. If this is not
done the PC will not recognise the PCM200 is connected. Now launch the PCM200 PLC
demo program using the path shown below, or desktop icon (if available).
Page 24 of 80
When the program is launched, the below screen should appear.
IMPORTANT: Select the proper PC COM port number from the available options.
(Refer to section 5.4.2 to determine which PC COM port is connected to the PCM200).
Test the connection by clicking on the “Ping” button. The screen should then display the following:
IMPORTANT: If no results are returned, ensure the proper PC COM port number was selected
and also verify the PC is connected to the PCM200’s COM 2 port.
Detailed guidelines for PLC communication protocol are covered in section 7 of this manual.
Page 25 of 80
5.8 Using the Optional Thermal Printer
Data collected by the PCM200 can be printed using the optional thermal printer. The user should
obtain the printer kit corresponding to their geographical area (a listing of kit part numbers is listed
below). To effectively use the printer, the items pictured below will be needed:
Items Included in the Kit

A
A = PCM200 Printer Kit (part numbers)
E D PCM200-PRT (UK)
PCM200-PRTB (Europe)
PCM200-PRTC (USA)
PCM200-PRTD (Australia)
PCM200-PRTE (Japan)
B = 9 Pin gender changer (female both

sides)
F C = Printer to PCM200 cable
D = Thermal Printer
E = Mains power (UK cable shown)
F = Thermal Printer Paper (10 rolls)
C
G G = Instruction Manual
B
IMPORTANT: Printing should not be attempted unless the PCM200 COM 2 port has been
toggled to allow for printer communication on COM 2. To toggle the COM 2 port, follow the
instruction in section 5.6.
After toggling COM 2 port (to enable printer communication), connect the printer to the PCM200 as
shown below. Once connected, the printer may be powered up. Next, the power to the PCM200
should be cycled to enable the PCM200 to recognise the printer. The words “Printer Detected”
should appear on the printer to confirm the connection is established.
The user can now connect to the PCM200 through the COM 1 port and print data currently stored
on the PCM200.
Page 26 of 80
5.9.1 Installation Checks
At the installation to be sampled
1) Access the hoses at the rear of the PCM200.
2) Ensure the hose connectors are clean and free from any visible contaminants.
3) Ensure the installation to be sampled is in operation and has been running for a minimum
of 30 minutes prior to taking the samples, in order to distribute the contamination as evenly
as possible throughout the fluid. This is necessary to allow a representative fluid sample to
be taken.
4) Connect the clear return-line hose to the system reservoir or suitable capacity container.
Required container size is dependant on number of tests required and set sample size,
default test will require 800ml for a single test and one flush.
5) Connect the blue hose to the sampling point. Check for any leakage, rectify as required.
6) The PCM200 can now be switched on. The specific procedure for start-up is detailed in
section 6 ‘Getting started’.
Page 27 of 80
Monitors
Getting Started
6.1 General
Caution: Before proceeding ensure the PCM200 has been

properly connected for sampling as outlined in section 5 of
this manual.
Do not start a test sequence with the inlet and outlet hoses
capped. Doing so may damage the PCM200.
This section of the operator manual instructs the user how to set up and run fluid sampling tests
with the PCM200 Fluid Cleanliness Monitor. The icons and screen shots displayed within this
section will be seen by the operator while interfacing with the PCM200 in either of the following two
ways:
• PC running the “PCM400 Display Emulator” program and connected to COM1

• Optional hand-held touch screen display connected to COM1
(review section 5 for more details about connections to COM 1)
This section does not instruct the user in fluid sampling techniques. The user should consult Pall
for guidance on recommended sampling points and their positions in the systems under test.
6.2 Scope of Supply
• PCM200 Fluid Cleanliness Monitor

• COM 1 cable (part number: PCM200.239)
• COM 2 cable (part number PCM100.217)
• AC mains power cable
• DC mains power cable (part number: PCM210.489)
• Software CD Rom
• Calibration certificate
• Quick reference guide
• (Optional) PCM200 Handheld Display (part number: PCM200-DISP)
• (Optional) Thermal Printer (see section 5.8 for part numbers)
Page 28 of 80
6.3 Key Descriptions (displayed on optional hand-held display or PC emulator
software).
Returns the user to the main menu Time setting

Steps to the previous screen Date setting
Advances to the next screen View Test Report
Displays the edit keyboard Save test result
Select/edit specific fluid property View Data Manager
Select/edit test point properties Open button
Start a new test Scroll Up
Accept edited parameters and exit screen Scroll Down
Disregard edited parameter and exit screen Trash (bin) Delete data
Warm-up routine Create New file
Repeat a test
Alarm key Engineering Set up
Select Language Password protection
Code Format
Print current test
6.4 Display Flow Chart
The display flow chart can be used to help the new user become familiar with the PCM200
optional touch screen display / display emulator operating sequence; refer to appendix C of this
manual. The flow chart consists of a number of views, each of which summarises a screen
displayed by the PCM200.The flow chart also gives the user an overview of the operating system,
showing the position of screens relative to each other and the path that the system follows. These
will help the user to quickly become familiar and comfortable with the system.
Page 29 of 80
6.5 Example Screen ( optional hand-held display or PC emulator)
The screen below is an example of those that will be seen when using the PCM200. Explanations
of the most common key uses are given here:
The key will always return the user to the main menu.
The key will cause a keyboard to appear, enabling both text and numbers to be entered
directly.
The key will move the user back to the previous screen.
The key will advance the user to the next screen.
A sample screen shot of the PCM200 main menu:
6.6 Start-up Sequence
The PCM200 is powered up by pressing the power on/off button. The green light will flash for
several seconds. More details regarding the PCM200 boot-up sequence are given in section 5.2.
Whilst the unit powers up, the display will activate and the following screen will appear:
The user must either press to proceed directly to the main menu screen, or press key to
advance through the screens. The next screen displays information unique to that specific
PCM200. This information includes the PCM200 serial number, firmware version, and customer
details.
Page 30 of 80
!
Important: Pall recommends sending the monitor for calibration every
year or upon completion of up to a maximum of 3000 tests, whichever
occurs soonest.
If the PCM200 is out of calibration or requires an annual service or other intervention, a warning
screen will inform the user at start-up. This is to ensure the user keeps the PCM200 fully serviced
and helps ensure the integrity of the pressure parts of the instrument. Refer to section 8 Function
Codes, Possible Cause(s) and Corrective Actions. Pressing will advance to the next screen.
Page 31 of 80
The PCM200 next displays the time and date screen, which enables the user to ensure the unit’s
time and date are correct. Pressing either the or the icon enables the time or date to be set,
respectively.
The final screen in the boot screen sequence is the main menu. From the main menu it is possible
to configure/start a test, perform a warm-up sequence, review previous results, or configure unit
settings.
6.7 Sampling
To achieve the most accurate results use Low Pressure Mode sampling. Alternatively sample from
a reservoir or bottled oil sources. Refer to section 1 ‘Specifications’ and section 5.1 ‘Connection
Options’.
Page 32 of 80
6.8 Sampling Routine
From the main menu, upon pressing the test button , the user will be presented with the ‘Perform
Test’ screen, from which the user can edit the fluid properties (section 6.11) or the test point
properties (section 6.14). The user can also return to the main menu . To perform a test,
pressing the right arrow will advance to the next screen.
The user must now select a label to identify the test(s) about to be performed. The edit button
will produce the keyboard screen and enable the user to edit the label. The left arrow button
moves back to the previous screen. The home button shortcuts back to the main menu. The
right arrow advances to the next screen.
Page 33 of 80
Press the key to continue.
The user can select to save, or as required, or press to return to the previous screen.
The new screen enables the user to start the test , move back to the previous screen , or jump
to the main menu .
To start a test press and the PCM200 will perform a test. The unit displays a percentage bar to
illustrate how far through the test the unit is. The test can be stopped at any time by pressing the
main menu button .
Page 34 of 80
If the icon is pressed the test sequence is aborted and the following screen displayed
Press to continue.
On completion of a test the PCM200 displays a summary of results. If multiple tests were
specified, the unit will display a test period countdown screen and then start testing again. For
more information on ‘number of tests’ and ‘test trigger periods’, see section 6.16 and 6.17
respectively.
Page 35 of 80
A more detailed explanation of test results, including any test warnings or alarms, can be seen by
pressing the report icon (Test Details) and icon on the test details screen (Test Warnings).
Press to perform another test(s).
6.9 Output Results Routine (Optional Hand-Held Display or PC Emulator)
Any results saved on the PCM200 can be viewed and managed using the data manager. To view
the data manager screen press the data manager button in the main menu.
The data manager displays the current result.
Page 36 of 80
Press followed by to save and upload (store) the test results to the PCM200 series hand-
held display or PC (if running the emulation program). See page 40 for further information on
download of data from the Emulator program.
To continue, select the icon
To delete the result, press the icon.
Page 37 of 80
Press and enter the password “DEL1” followed by and to delete all test results. Refer
to section 6.21 for additional information.
The user can view a set of results from a common test point in graphical form. This enables the
user to easily see any trends in the results. This is done by opening a set of results from the
desired test point, then selecting the trend button from the data manager screen. This will
display a simple time graph of the saved results. See below for information on opening previously
saved test results.
Page 38 of 80
A previously saved result can be opened by pressing the open icon . The open result screen
enables the user to scroll up and down through previously saved results.
The displayed result can be selected by pressing the Icon.
The user can view a detailed report on the test by pressing the report icon (Test Details). The
report displays all parameters measured by the PCM200 together with any function codes and test
warnings.
If using PC Emulator the results can be output to file as follows:

In Data Manager select File and Export Results
Page 39 of 80
Select destination folder in My Documents
Export of data will be confirmed.
The results will appear in chosen directory in both .XLS and .TXT formats.
Page 40 of 80
6.10 Warm-up routine
The warm-up routine can be accessed from the main menu by pressing the thermometer button
. The warm-up routine is used to raise the temperature of the PCM200 unit to that of the test
fluid. This helps to prevent spurious test results due to severe viscosity changes during the test
procedure. During warm-up the unit pumps the test fluid through the instrument, bypassing the
measurement meshes, and displays the current unit temperature on the screen. The warm-up
target temperature is that entered in the current test point.
Press the icon to start the warm-up cycle
Either abort using the icon, or continue until the current test point temperature is reached.
Refer to section 6.18 to reset the target temperature.
Page 41 of 80
6.11 Fluid set-up routine
To access the fluid set-up menu, select the test button from the main menu.
Now select the fluid button . From this screen, the button returns the user to the main menu
and the right arrow button advances to the next screen.
6.12 Fluid name
This screen displays the name of the current fluid type. From this screen the user can create a
new fluid name , edit the current fluid , open an existing fluid , delete a fluid ,or return to
the main menu . Up to 250 individual test fluids can be created.
The open button presents users with a screen that enables them to scroll through existing
fluids, using the up and down buttons, followed by to select.
Page 42 of 80
If the edit button is pressed the user is presented with the fluid name, which can be edited by
pressing the edit button again.
6.13 Fluid water content (PCM400W with optional water sensor only)
Pressing the advance button from the fluid name screen enables the PCM200W to calculate the
absolute water content (PPM) of a test fluid. If PPM is set to NO then C1 and C2 will not be
requested and the results will be given in “% saturation” terms. Please contact Pall For the
availability of C1 and C2 values for your oil. If your oil is not in our Database we can run tests on
your oil to determine the values. Please contact Pall for further details.
Use to select, Yes or No and to continue. If Yes is selected then the following screens
apply.
Page 43 of 80
Use the edit button to enter these values when prompted, and the advance arrow to move to
the next screen. Note C1 is normally a negative value, but if a positive number is entered the
software will automatically correct for this.
Numerical values for C1 and C2 can be obtained by contacting your local Pall representative.
6.14 Test point set-up routine
The test point set-up routine can be accessed by pressing the test button from the main menu
and then pressing the test point button .
Page 44 of 80
The test point screen enables the user to create a new test point , edit an existing test point ,
open an existing test point , or return to the main menu . Up to 250 individual test points can
be created.
Press to delete a current test point.
Pressing the open button enables the user to scroll up and down through the existing test
points. Press to select required test point.
6.15 Test point name
The user can edit the test point name by selecting the edit button .
Press to continue.
Page 45 of 80
6.16 Number of Tests / Continuous Test
This screen enables the user to enter the number of times the PCM200 should repeat the test
procedure. Entering 0 in the number of tests will cause the PCM200 to continuously test the fluid.
Press to amend value, or press to advance.
Press to proceed.
6.17 Test trigger period
This screen enables the user to specify the time period between the start of consecutive tests. A
period of 0 will cause tests to immediately follow each other. Press to amend value, or press
to advance to the next screen (?).
!
Important
The trigger test period is between the start of a test and the start of the
following test. If the trigger period is shorter than the test time then
there will be no delay before the start of the following test. It is
suggested to set the minimum period to 10 minutes.
e.g. Trigger time=10 min. test time=6 min. time from end of test to the
beginning of the next test = 4 min.
Page 46 of 80
6.18 Warm-up cycle target temperature
This screen enables the user to specify the warm-up cycle target temperature. Press to amend
value.
Press to proceed.
6.19 Test point alarms
The alarms routine enables the user to advance through several screens using the edit or
advance icons and specifying alarm levels for different parameters. The parameters, in
sequence, are Water content % saturation or ppm, 6µm Code 14µm Code (or NAS / SAE AS
range if previously selected) and Temperature.
!
Important: The water content alarm is applicable to the PCM200W
monitor only.
The PCM200W monitor must not be used with water-containing fluids.
The PCM200 monitor does not include a water sensor.
Example of alarm setup screen.
Page 47 of 80
6.20 Setting the Time and Date
The Time and Date can be accessed during the start-up screen sequence.
6.21 Engineering set-up
From the main menu press the engineering set-up button and the PCM200 will display the
engineering set-up screen. From this screen the user can change the PCM200 time , date
and language settings.
Press to proceed to the next screen.
Page 48 of 80
Press to change the code format. Using select either ISO4406, SAE AS4059 Table 1
(previously NAS1638) or SAE AS4059 Table 2.
Press to change the temperature format.
Press to amend variables, including customer name and change result protection password.
Page 49 of 80
Press to enter password ENG1 and to accept.
The default variable is Customer. Press edit to change customer name.
The Delete Result password DEL1 can be changed. Press and type password, followed by
. The variable (password) and value (del1) are shown. Press edit and enter your preferred delete
result password _ _ _ _ , press . The new value is displayed.
Page 50 of 80
Monitors
Pall PCM200 Interface Protocol using PCM200 COM 2.

7.1 Hardware details
The RS232 settings are: 9600, 8, N, 1

Pin 2 TxD (Transmit Data)
Pin 3 RxD (Receive Data)
Pin 5 GnD (Ground)
Pin 2 and 3 must be crossed over when using a PC.
7.2 Protocol between PCM200 and PLC (or computer)
The commands available to the PLC or a computer start and end with a square bracket as follows:
[P] – “Ping” the unit to see the current status.

[L] – Request last result.
[S] – Start a test.
[A] – Abort a test.
Please note that the command letters are in UPPER CASE; it will not work with commands in
lower case.
[P] – Ping
The purpose of this command is to verify the PCM200’s current status.

When [P] is sent, the PCM200 responds with a comma-separated string, terminated by a carriage
return and a new line.
e.g.
PCM,P,0,00,00,00,00
PCM P 0 00 00 00 00
A B C D E F G
Where:
A - Label to identify that it is a valid transmission from the PCM200

B - The P signifies that the transmission doesn’t contain a result.
C – PCM200 status:
0: The unit is in standby.
1: The unit has ended a test and it is waiting to start a new test at the set time interval.
2: The unit is currently performing a test.
D,E,F,G – Latest error codes if any. See below for details.
Page 51 of 80
[L] – Request last result
The latest valid result is transmitted via communications port COM2. An example data string
appears like this:
PCM, R, 2005/11/20 20:28:00,1,2,00,00,00,00,NAS 11,50,22,10,Test1, 39648
PCM R 2005/11/20 20:28:00 1 2 00 00 00 00 NAS 11 50
A B C D E F G H I J K
22 10 Test1 39648
L M N O
Where:
A. Label sent by the PCM to signify start of transmission.

B. The transmitted string is a result. R=Result, A=Aborted test, P=Ping.
C. Date and time the test was performed.
D. Test number in the sequence.
E. Number of tests in the sequence.
F. Error codes (Hex) Byte 1. Hardware problems. (see below).
G. Error codes (Hex) Byte 2. Sampling problems. (see below).
H. Error codes (Hex) Byte 3. Sampling problems. (see below).
I. Error codes (Hex) Byte 4. User defined settings exceeded. (see below).
J. Result codes as selected on the unit (NAS, ISO or AS4059).
K. Viscosity.
L. Temperature.
M. Water In Oil (%SAT or PPM).
N. Test Label
O. Checksum.
Page 52 of 80
PCM200 Error codes
The codes are in hexadecimal format.
Byte Code Description
1 0x01 Very low battery

1 0x02 High pulse width modulation
1 0x04 Viscometer blocked
1 0x08 Low mesh differential pressure
1 0x10 Pressure transmitter failure
1 0x20 Temp transducer failure
1 0x40 Internal controller failure
1 0x80 Internal error
2 0x01 Low battery

2 0x02 High line pressure
2 0x04 Low line pressure
2 0x08 Unstable temperature
2 0x10 Unstable viscosity
2 0x20 Unstable sampling
2 0x40 High mesh differential pressure
2 0x80 Water in oil sensor failure
3 0x01 Water in oil

3 0x02 Memory full
3 0x04 6-micron mesh blocking
3 0x08 14-micron mesh blocking
3 0x10 Mesh test limit exceeded
3 0x20 Calibration period exceeded
3 0x40 Viscosity band mismatch
3 0x80 High viscosity differential pressure
4 0x01 Solid contamination alarm

4 0x02 Water content alarm
4 0x04 Temperature alarm
4 0x08 Too much contaminant
4 0x10 Test aborted
4 0x20 Test sequence aborted
4 0x40 RESERVED
4 0x80 RESERVED
[S] – Start a test.
The exact effect of this command depends on the status of the PCM200 unit.
1. The PCM200 is currently running a test: the command is ignored.

2. The PCM200 is in standby: the test series is initiated, with the maximum number of tests as
previously entered from the display.
3. The PCM200 is waiting between tests: a test is initiated and the scheduled test is then
started at the appropriate time. The total number of tests is decremented by one.
Once a test is started the results will be sent to the PLC on completion of the test.
Page 53 of 80
[A] – Abort test.
By sending [A], the entire test sequence is aborted and the result string would appear like this:
PCM, A, 2005/11/23 15:46:00,1,2,00,00,00,20,58695
The second string item is set to A (aborted), and error Byte number 4 contains the “Test sequence
aborted” message (0x20). The code field is NOT present.
Another example data-string is included here following an aborted test due to the PCM200 fluid
return-line being dead-ended:
PCM, A, 2005/11/23 16:15:00,0,2,04,02,30,20,51384
Byte1 = 04: Viscometer blocked

Byte2 = 02: High line pressure
Byte3 = 30: (10+20) Mesh test limit exceeded (10) and Calibration period exceeded (20)
Byte4 = 20: Aborted test sequence.
(Byte3 has been artificially generated for the benefit of the example.)
If the last test were requested then it would be a result with the latest valid code.
PCM, R, 2005/11/23 10:22:00,2,2,00,00,00,00,NAS 11,10323
If a ping were issued it would include the latest error codes.
PCM, P, 0,04,02,30,20
7.3 Modes of operation
a). – Test timing set on the PCM200

From the handheld, enter the number of tests to be performed in a test-cycle and also include any
delay between individual tests. A test sequence can be started from the PCM200 or from the PLC.
If an additional test is required whilst in a test-cycle delay period, the PLC can initiate this without
compromising the existing delay in the test-cycle setting.
Please be aware that the delay period entered will start from the beginning of a test.
b). – Test timing set by the PLC

From the handheld enter the number of tests to 1 (one) and enable the PLC to start a test at the
appropriate time. The time interval setting on the PCM200 will have no effect.
Page 54 of 80
7.4 Testing the PCM200 via a PC.
Power up the PCM200 and connect the 9-pin connector to an available COM port on the PC.
Please note that a USB-to-serial RS232 converter may be used if the computer does not have a
dedicated serial port. Run the HyperTerminal program and enter the settings as shown in the
following screens:
Procedure
1. Open Hyper Terminal

2. Enter a connection name (eg. PCM200 PLC Test).
3. Click OK.
4. Select a COM port. Click OK.
5. Set COM port properties as shown at left.
6. Click OK
By entering [P], the

PCM200 responds with a
short string.
Entering [S], the PCM200

starts a test. At the end it
sends out the result.
Page 55 of 80
Monitors
Fluid Change Procedure
!
Important: These instructions draw attention to information relating to
the correct fluid change procedure and subsequent continued
operation of the monitor. Mixing of incompatible fluids is likely to block
the PCM200 meshes.
When changing from mineral oil to water-based fluids or vice versa, a strict
fluid changeover procedure must be adhered to.
The changeover fluid is “Rust veto NTP 32”, which is miscible with both aqueous liquids and oils.
All changeover and flushing fluid should be drained into a suitable waste container and disposed
of in accordance with local Health and Safety legislation.
Mineral oil to water-based fluids:
Using Rust veto NTP 32, run at least 3 complete tests via the blue inlet hose. Then run at least
three tests with the new fluid.
Water-based fluids to mineral oil:
Using Rust veto NTP 32, run at least 3 complete tests via the blue inlet hose, or continue tests
until no traces of water/oil emulsion are visible in the return line hose. Then run at least three tests
with the new fluid.
!
Important: The PCM200W should not be used for water-based fluids.
If fluid changes are regular, the monitoring programme should be
modified so as to reduce the requirement for fluid changes. For
example, monitor mineral oil during a 4-week period, followed by 4
weeks monitoring water-based fluids.
Wet-to-dry oil or vice versa in quick succession:
When using PCM200W, stabilization times can effect the Water Sensor accuracy when sampling
fluids of vastly differing water content in quick succession. The related precautions, recommended
guidelines and test data related to this subject can be found in appendix E of this operating
manual.
!
Important: The PCM200W should never be used in applications whose
water content is known to be continuously at or above 100% saturation.
Page 56 of 80
Section 9: Pall PCM200 Series Fluid
Function Codes, Possible Cause(s)

and Corrective Actions
Function codes are flags which either make the user aware of a borderline test situation, or which
will curtail the test. An alarm will indicate registered function codes that can be cancelled by
pressing any key. A message will appear indicating the problem to the user.
There are several different function messages incorporated into the PCM200, a list of these
messages, their possible causes and corrective actions is given below.
Function PCM200
PCM200 Status Possible Cause Corrective Action
Code Condition
Unit halts the test and displays Blockage in hydraulic Ensure return hose is not
error message on screen circuit. blocked.
High Line
202 indicating high line pressure. Fluid viscosity too high. Decrease fluid viscosity.
Pressure
Amber LED on control panel Pressure transducer Contact Pall or an
illuminated. failure. approved agent.
Check fluid supply and inlet

Unit halts the test and displays No fluid. Last Chance
hose connection.
error message on screen Filter (LCF) blocked.
Low line Remove, clean, or replace
203 indicating low line pressure. Pump Malfunction.
pressure LCF.
Amber LED on control panel Pressure transducer
Contact Pall or an
illuminated . failure.
approved agent.
Unit halts the test and displays
High Pulse Fluid viscosity too high. Decrease fluid viscosity.
error message on screen.
102 Width Motor current over set Contact Pall or an
Amber LED on control panel
Modulation limit. Pump malfunction. approved agent.
illuminated.
Unit halts test and displays Operate Warm-up Cycle
Change >1°C / minute.
Unstable error message on screen. (refer to section 6.10.)
204 High oil temperature.
temperature Amber LED on control panel Allow system fluid
Low temperature.
illuminated. temperature to stabilise.
Unit halts test and displays Operate Warm-up Cycle
Fluid dilution. Large
Unstable error message on screen. (refer to section 6.10.)
205 temperature gradient
viscosity Amber LED on control panel Allow system fluid
across PCM200.
illuminated. temperature to stabilise.
Aeration problem.
Unit halts test and displays Ensure inlet hose is in
Pressure spikes in
Unstable error message on screen. contact with system fluid.
206 system sampled. Fluid
sampling Amber LED on control panel Ensure system return line
sample dilution/mixing.
illuminated. is full of fluid.
See Unstable viscosity.
Page 57 of 80
Function PCM200
Code Condition
Memory Full message will Upload test data to hand-

Internal store for test
302 Memory Full appear on screen at start-up held programmer, refer to
data full.
and when test store attempted. section 6.9.
Viscometer orifice
PCM200 will abort current blocked/blocking with Flush by testing with clean,
cycle and display warning contaminant causing low-viscosity oil.
Viscometer
103 message. differential viscometer Contact Pall or an
blocked
Amber LED. on control panel pressure and/or line approved agent.
activated on detection. pressure to exceed
operational limits.
Mesh element currently

PCM200 will abort current in the flow is
cycle and report error/warning blocked/blocking with Flush by testing with clean,
High mesh
message on the display contaminant causing low-viscosity oil.
207 differential
screen. differential mesh Contact Pall or an
pressure
Amber LED on control panel pressure and/or line approved agent.
illuminated. pressure to exceed
operational limits.
Differential pressure
PCM200 will abort current across mesh element is
test/cycle and report below set limit.
Low mesh
error/warning message on the Probable cause; hole in Contact Pall or an
104 differential
display screen. the mesh, incorrect approved agent.
pressure
Amber LED on control panel direction of flow,
illuminated. pressure transducer
failure.
Error/warning message will be
displayed on screen together Incorrect or no signal
Pressure with details of service/repair received from pressure
Contact Pall or an
105 transducer contact. No test functions will transducer during
approved agent.
failure be performed until the problem calibration / background
is rectified. Red LED will check.
illuminate.
PCM200W will display

Water in Oil
error/warning on successive Incorrect or no signal
(WIO) sensor Contact Pall or an
208 tests. received from the
failure approved agent.
Amber LED on control panel sensor.
(if applicable)
illuminated.
Page 58 of 80
Function PCM200
Code Condition
Internal
Error/warning message on
peripheral
screen (if possible). Alarm set. No communication with Contact Pall or an
107 micro-
Hold in this state. Red LED will main controller. approved agent.
controller
illuminate.
failure.
Limits of ratio between
dP (measured
differential pressure
Display warning message on
6-micron mesh across mesh) and dV Flush by testing with clean,
303 screen. Amber LED
blocking (differential pressure low-viscosity oil.
illuminated.
across viscosity sensor)
taken at the cycle start
have been exceeded.
Limits of ratio between
dP (measured
differential pressure
14-micron across mesh) and dV Flush by testing with clean,
304 screen. Amber LED
mesh blocking (differential pressure low-viscosity oil.
illuminated.
across viscosity sensor)
taken at the cycle start
have been exceeded.
Fatigue limit of mesh
exceeded based on Contact Pall or an
Mesh test limit screen at PCM200 start-up or
305 number of tests approved agent for service
exceeded at the end of current test
performed on the same details.
operation.
mesh set.
Calibration Contact Pall or an
Display warning message on 12-month calibration
306 period approved agent for service
screen at PCM200 start-up. interval expired.
exceeded details.
Unit halts test and displays

High viscosity Fluid viscosity out of Reduce fluid viscosity.
error message on screen.
308 differential specification, low fluid Increase fluid temperature
Amber LED on control panel
pressure temperature. at PCM200.
illuminated.
Possible hardware Contact Pall or an

108 Internal error Unit inoperative.
failure. approved agent.
Page 59 of 80
Function PCM200
Code Condition
Solid Display warning message on Pre-set solid

Repeat test to verify.
401 Contamination screen. Amber LED contamination level
Investigate process.
Alarm illuminated. exceeded.
Water Display warning message on Pre-set fluid water

Investigate cause of
402 Saturation screen. Amber LED saturation level
elevated water contents.
Alarm illuminated. exceeded.
High fluid Display warning message on

Pre-set fluid temperature Investigate process, reduce
403 Temperature screen. Amber LED
level exceeded. operating temperature.
Alarm illuminated.
Unit halts test and displays

Maximum solid Investigate process.
Contamination error message on screen.
404 contamination level Dilute the sample with
Too High Amber LED on control panel
exceeded. clean fluid.
illuminated.

Aborted Test Ensure Signal for Test
405 screen. Amber LED User Aborts Test.
Alarm Abort Is Not sent.
illuminated.
Display warning message on Ensure Signal for Test

Aborted Test User Aborts Test
406 screen. Amber LED Sequence Abort Is Not
Sequence Sequence.
illuminated. sent.
NOTE: Refer to section 6.19 to review and / or amend your selected alarm levels
Coding:- 1 High priority warning

2 Medium priority warning
3 Low priority warning
4 User defined alarm
Page 60 of 80
Monitors
Mesh Change Procedure

The PCM200 can perform 1000 to 3000 tests between mesh changes. The PCM200
automatically calculates the number of tests allowed based on viscosity and cleanliness of
fluids that have been tested. The PCM200 will inform the operator of the number of tests left
on the unit to enable the replacement to be planned. It is possible for the operator to
perform a mesh change using the PCM200 Mesh-Manifold Exchange Assembly. However it
should be noted that the unit should be returned annually to the supplier for service and
calibration and at this point new meshes will be fitted.
REQUIRED PARTS:
PCM210.550 PCM200 Mesh-Manifold Exchange Assembly
PCM200.239 Port 1 (Com1) Serial Cable as supplied with PCM200 and customers own
PC running Pall PCM200 Mesh Reset Count Software supplied with
replacement Mesh-Manifold Exchange Assembly.
TOOLS REQUIRED.
Adjustable Torque Driver/Wrench with 3Nm (26.5 inch pounds) setting.

2.5mm Hex Driver Bit
5mm Hex Driver Bit.
Lint-free wipes.
CHANGING THE MESH-MANIFOLD.
1: - Ensure the area for a mesh-manifold exchange is clean and dust free. Place the
PCM200 on a level surface and ensure any fluid spills can be contained. Remove both
supply and return hose end caps and put the return hose into a waste fluid container.
Power up the PCM and start a test run. Once air is being exhausted from the return line
stop the test and power-down the PCM.
DO NOT CONTINUE TO RUN THE PCM ONCE FLUID HAS BEEN REMOVED.
Reconnect the end caps to both hoses.
2: - Remove the rear cover by releasing the six M4 button-head fixing screws (2.5mm hex
driver)
Page 61 of 80
3: - With the 5mm hex driver remove the six off M6 Cap-Head bolts securing the mesh-block
assembly. The mesh-block is located on two stem fittings in the main manifold, so care is
advised when removing. Once removed place the mesh-block assembly complete with the
four O-ring seals in the return packaging for shipment to a Pall Service Centre or direct to
the manufacturer.
4: - Carefully remove the new mesh-manifold from its packaging and make sure it is free of
damage.
DO NOT FIT A DAMAGED MESH-MANIFOLD. CONTACT THE SUPPLIER FOR A
REPLACEMENT.
5: - With a lint-free wipe, clear the stem connectors in the base unit's manifold and the rest
of the face of any contaminant. Remove the protective strip covering the mesh-manifold
ports and ensure the four O-rings are in the port recesses. Carefully align the mesh-
manifold onto the two stem connectors. Move the mesh-manifold up to the main manifold
and secure in position by the two central M6 Cap-Head bolts.
6: - Fit the remaining four fixing bolts hand-tight and then follow the tightening sequence
indicated to no greater than 3Nm torque setting. Tightening to a higher setting may result in
permanent damage to the main manifold threads.
Page 62 of 80
7: - Power up the PCM and connect to a PC via COM1 RS232 Serial Cable
8: - Run the program “PCM200 Reset Mesh Count 1.0.0 Setup” and follow the instructions in the
PDF file “PCM200 Reset Mesh_Scores Guide”. The mesh test counter will now be zeroed.
9: - Reboot the PCM to view the DETAILS screen to confirm the number of available tests.
10: - Run a single test-cycle and check for leaks. Re-assemble the rear-cover and tighten each M4
securing screw to 1Nm torque.
Page 63 of 80
Monitors
Spare Parts List
Part Number Description
PCM200.235A Mains Cable UK
PCM200.235B Mains Cable Europe
PCM200.235C Mains Cable USA
PCM200.235D Mains Cable Australia
PCM200.235E Mains Cable Japan
PCM210.489 DC Power Cable
PCM200.DISP Hand-Held Display Assembly

PCM200.PRT+
Thermal Printer Kit and Accessories
(+ = Designate A,B,C,D or E as above)
PCM200.324 Thermal Printer Paper (pk. 10)
PCM200.239 COM 1 to PC Cable
PCM100.217 COM2 to PC Cable
PCM100.109KIT Last Chance Filter Kit
PCM200.550 Mesh Manifold Exchange Assembly

Operating Instructions -
UK60267
Cleanliness Trender CD ROM
Operating Instructions -
UK62981
PCM200 CD ROM
Operating Instructions
UK62982
PCM200 Quick Reference Card
PCM200.CASE Transit Case For Shipping PCM200
PCM200.USB RS232 To USB Converter
Page 64 of 80
Monitors
Disposal of Equipment
At the end of its life, the monitor should be dismantled and disposed of in accordance with all
applicable local waste disposal laws and bylaws. Where facilities exist, component parts of the unit
may be recycled. Details of the materials of construction are given on the product installation
drawing and, if required, more detailed information regarding specific items may be obtained from
Pall or an approved agent.
Under the Waste Electrical and Electronic Equipment (WEEE) Directive and implementing
regulations, when customers buy new electrical and electronic equipment from Pall they are
entitled to:
Send old equipment for recycling on a one-for-one, like-for-like basis (this varies depending on the
country) send the new equipment back for recycling when this ultimately becomes waste
Instructions to both customers and recyclers/treatment facilities wishing to obtain disassembly
information are provided by following the link below.
www.pall.com/weee
If component parts of the equipment were previously contaminated with the service fluid, an
appropriate Manufacturer’s Safety Data Sheet (MSDS) for the fluid should be obtained and read to
ensure that contaminated component parts are disposed of safely.
Page 65 of 80
Appendix A: Pall PCM200 Series Fluid Cleanliness
Monitors
Commissioning, Training, Calibration and

After Market Services
Commissioning and Training Packages
A valuable service encompassing guidance in the commissioning of the PCM200 monitor and
training in its use is available from Pall or its approved agent.
It is strongly recommended that this service be utilised in order to ensure correct installation and
operation of the equipment, as incorrect installation leading to incorrect or inefficient operation may
result in invalidation of warranty.
As with all condition monitoring equipment, regular servicing and maintenance will extend the life
of the equipment and lead to more effective operation.
Note: Pall or its approved agent will attempt to contact each customer in advance in order to
arrange commissioning and training. However, prior to attempting any installation work, it is
recommended that the customer should contact Pall in order to ensure that guidance and
involvement of a Pall technician has been arranged.
Note: The extent of involvement for Pall in this activity is an advisory role; no parts will be supplied.
The customer should ensure that all works requested by the Pall technician are completed prior to
his visit to the customer site.
Further Training Packages

In many cases the users of equipment such as the PCM200 series monitor will require more in-
depth training.
These training packages increase awareness of the function and benefit of the equipment, which
leads to more effective operation.
It is strongly recommended that further operator training be undertaken in order to ensure a full
appreciation of service limits, routine maintenance requirements, alarm conditions and corrections.
This can be offered by Pall Industrial and can be tailored to meet the requirements of the particular
user.
Arrangements for training packages may be made by contacting Pall or its approved agent.
Page 66 of 80
Calibration and Aftermarket Service
Pall PCM200 series fluid cleanliness monitors are designed to provide trouble-free operation for
many years. However, as for all condition monitoring equipment, optimum performance can only
be achieved through regular routine maintenance. To ensure your PCM200 receives the
maintenance necessary, Pall provides a maintenance service designed to increase the overall
effectiveness of the monitor. Pall recommends sending the unit for inspection and calibration
every 12 months, or when the screen indicates the need for service due to number of tests
performed, whichever happens sooner.
!
Important: Pall recommends sending the monitor for calibration every
year.
The annual service includes:

• Analysis of engineer’s diagnostic report and rectification of any faults found
• Power supply and clock check
• Performance evaluation on calibration fluid
• Software update to latest release level
• Check for oil leaks and rectification as necessary
• Last chance filter replacement
• Flush, strip and clean all internal components
• If appropriate, the incorporation of any design enhancements introduced since build
• Replace 6µm and 14µm meshes and flush housings
• Replace water sensor (PCM200W or PCM200WB only)
• Transducer calibration
• Perform production validation procedures
• Software menu checks
• Return carriage to customer
Any additional work required is subject to a separate written quotation.
Please contact Pall Industrial or its approved agent for additional information.
Page 67 of 80
Appendix B: ISO 4406, SAE AS4059 (previously
NAS1638) and Contamination Coding Systems
There have been several coding systems developed for reporting the solid contamination
levels in hydraulic and lubricating fluids, reducing particle count/size data down to a few
easily understood numbers. Of these systems, the two most commonly in use are described
in the standards NAS1638 and ISO4406, published by the Aerospace Industries Association
of America Inc. and the International Standards Organisation respectively. The former
standard has now been superseded by Society of Automotive Engineers standard SAE
AS4059. Each of these standards is periodically reviewed and recent changes have been
made to both standards; these changes are described here.
NAS1638
NAS1638 was the first coding system developed and was introduced in 1964 to assess the
quantity of solid contaminates that was being delivered in aircraft components. The basis of
this code was 14 codes (000 to 12) at 5 defined size ranges ("interval counts") i.e. 5 to
15µm, 15 to 25µm, 25 to 50µm, 50 to 100µm and greater than 100µm, all per 100 mL of
sample fluid. The interval between each class was a doubling of the numbers of particles.
As no coding system existed at the time for system fluid particulate levels, it was logical that
this system should the adopted for this purpose. Its use has diminished in favour of ISO
4406 (see below) but it is still widely used in the Aircraft and Offshore Industries and some
industrial sectors.
In May 2001 NAS1638 was withdrawn for use with newly designed systems because of the
impact of the change in the method of calibrating automatic particle counters (APC’s), and
was replaced by AS4059 (see below), again an aerospace standard. NAS1638 coding is no
longer selectable on the monitor and AS4059 table 1 should be used.
ISO4406
This was published by ISO in 1976 to define the particulate levels of systems and
overcome the drawbacks of applying NAS 1638 to systems where the presence of filters
modified the size distribution of the particulate. The Cleanliness Code developed was a
two-number code in which the first number indicates the particle concentration larger than
5µm in length (>5µm "cumulative counts") and the second the larger than 15µm particle
concentration. Codes at higher particle sizes were deliberately excluded to simplify the
code, as the numbers of these particles should be greatly reduced through filtration. Each
code number represents a concentration range of particles, given in particles per mL of fluid.
The numbers are defined according to the following table and the interval between each
code is a doubling of particle numbers:
Page 68 of 80
ISO 4406: 1987
No. of particles per mL Code/Scale
No.
More Up to and
Than including
6
>2.5 x 10 >28
6 6
1.3 x 10 2.5 x 10 28
3 6
640 x 10 1.3 x 10 27
3 3
320 x 10 640 x 10 26
3 3
160 x 10 320 x 10 25
3 3
80 x 10 160 x 10 24
3 3
40 x 10 80 x 10 23
3 3
20 x 10 40 x 10 22
3 3
10 x 10 20 x 10 21
3
5000 10 x 10 20
2500 5000 19
1300 2500 18
640 1300 17
320 640 16
160 320 15
80 160 14
40 80 13
20 40 12
10 20 11
5 10 10
2.5 5 9
1.3 2.5 8
0.64 1.3 7
0.32 0.64 6
0.16 0.32 5
0.08 0.16 4
0.04 0.08 3
0.02 0.04 2
0.01 0.02 1
0 0.01 <1
Thus a reported code of 14/12 would indicate that the fluid had a concentration of particles
larger than 5µm between 80 and 160 per mL and a concentration of particles larger than
15µm between 20 and 40 per mL
Changes to ISO Contamination & Filtration Standards
In 1992 the ISO committee dealing with contamination standards was advised of the
withdrawal of A.C. Fine Test Dust (ACFTD), which was used not only as the calibrant for
automatic particle counters (APCs) used in the analysis of oil samples from systems, but
also as a controlled contaminant in filter and component tests. The replacement (ISOMTD or
ISO 12103-A3 test dust) had its particle size distribution determined by the National Institute
of Science and Technology (NIST) to comply with modern traceability requirements. Thus
there was a potential for the results from APCs calibrated using NIST-certified dust being
different from those calibrated using ACFTD. To ensure that the change to reported
contamination codes was minimal, the size thresholds used by APCs were changed so that
an APC calibrated to the new standard would give very similar numerical results to the old
standard. In addition, these changes gave the opportunity to update the standard and
introduce a code to cover a smaller size. This resulted in new reported sizes of > 4µm (c),
>6µm (c) and > 14µm (c). These ' new'sizes were incorporated in the latest revision of ISO
4406:1999 and are for APCs only. They are differentiated by the use of “µm (c)”. Counting
at > 4µm (c) is not mandatory but the report must feature an entry, either “ – “ signifying that
counts are not required, or “ * ” denoting that the sample had too many >4µm particles to
count.
Page 69 of 80
The PCM200 monitor reports data at >6µm (c) and > 14µm (c), and "-/xx/yy" is displayed.
The calibration of the PCM200 is carried out in accordance with ISO 21018-Part 2 and is
traceable to an APC calibrated to ISO 11171 and 11943.
SAE AS4059
This was originally developed in 1988 to overcome the disadvantages of the NAS1638
system, especially the fact that it was designed for components not systems. It used the
same “maximum limit of contamination” but presented the data in the cumulative method of
presentation e.g > 5µm; > 15µm etc and introduced other improvements. In 1999 the
above changes to the calibration of APCs resulted in NAS 1638 being declared “inactive for
th
new designs after May 30 2001, see AS4059C " and "This standard should not be used
with automatic particle counters". Thus it was effectively replaced by AS 4059 Revision D.
In 2005 the Aircraft Industry reconsidered this decision and added what was effectively NAS
1638 to AS4059 Revision E.
SAE 4059 table 1 has replaced NAS 1638 for systems, and features the exact table of NAS
1638 (featuring "interval counts") and the corresponding APC sizes. To aid the user, the
monitor displays "SAE4059 table 1 (NAS1638)" thus still making reference to the older
standard.
SAE AS4059 Table 1

Cleanliness Classes for Differential Particle Counts
Particles/100 mL
Size, ISO 5-15µm 15-25µm 25-50µm 50-100µm >100µm
4402
Calibration,
or Optical
Microscope
Count*
Size, ISO 6-14µm(c) 14-21µm(c) 21-38µm(c) 38-70µm(c) >70µm(c)
11171
Calibration or
Electron
Microscope**
Cleanliness
class
00 125 22 4 1 0
0 250 44 8 2 0
1 500 89 16 3 1
2 1,000 178 32 6 1
3 2,000 356 64 11 2
4 4,000 712 128 22 4
5 8,000 1,425 253 45 8
6 16,000 2,850 506 90 16
7 32,000 5,700 1,012 180 32
8 64,000 11,400 2,025 360 64
9 128,000 22,800 4,050 720 128
10 256,000 45,600 8,100 1,440 256
11 512,000 91,200 16,200 2,880 512
12 1,024,000 182,400 32,400 5,760 1,024
* Particle size based on longest dimension

** Particle size based on projected area equivalent diameter
Note: Classes and contamination limits are identical to NAS1638
Page 70 of 80
SAE AS4059 table 2
AS4059, which has been adopted by a number of organisations, is included as Table 2.
Note that although the cumulative data in Table 2 was derived from the interval data in
Table 1, the data has been rounded up or down and very small differences exist. These will
only make a difference in the code obtained if the particle count data is adjacent to the code
boundary, where it may go into the next code.
SAE AS4059 Table 2

Cleanliness Classes for Cumulative Particle Counts
(particles/100 mL)
Size, ISO 4402 >1 >5 > 15 > 25 > 50 > 100
Calibration, or µm µm µm µm µm µm
Optical
Microscope
Count*
Size, ISO 11171 >4 >6 > 14 > 21 > 38 > 70
Calibration or µm(c) µm(c) µm(c) µm(c) µm(c) µm(c)
Electron
Microscope**
Size Code A B C D E F
000 195 76 14 3 1 0
00 390 152 27 5 1 0
0 780 304 54 10 2 0
1 1560 609 109 20 4 1
C
L 2 3120 1217 217 39 7 1
A 3 6250 2432 432 76 13 2
S 4 12,500 4864 864 152 26 4
S 5 25,000 9731 1731 306 53 8
E 6 50,000 19,462 3462 612 106 16
S 7 100,000 38,924 6924 1224 212 32
8 200,000 77.849 13,849 2449 424 64
9 400,000 155,698 27,698 4898 848 128
10 800,000 311,396 55,396 9796 1696 256
11 1,600,000 622,792 110,792 19,592 3392 512
12 3,200,000 1,245,584 221,584 39,184 6784 1024
Page 71 of 80
Appendix C: Pall PCM200 Series Fluid
Menu Flow Chart
MAIN MENU
PERFORM TEST
CURRENT ENTER TEST CURRENT

TEST POINT NAME FLUID
EDIT TEST SAVE TEST EDIT FLUID

POINT NAME RESULTS?
USE PPM?
NUMBER OF START
TESTS TEST?
ENTER PPM
C1 & C2
PCM200W only
TEST TESTING…
PERIOD
TEST
WARM-UP RESULTS
TEMPERATURE
% SAT ALARM
PPM ALARM
6µm ALARM
14µm ALARM
TEMPERATURE
Page 72 of 80
ALARM
Appendix D: Software
Pall PCM200 Display Downloader
Included on the PCM200 Series Pall Portable Fluid Cleanliness Monitor CD Rom is the PCM200
Download Software.
1.0 System Requirements
The recommended minimum specification computer for this software is a ‘Pentium’ 166MHz or
equivalent processor-based IBM-compatible PC running Microsoft Windows 98 or higher, NT4.0
operating system or higher with 32MB memory and 10MB hard disc space free. The computer’s
monitor should be set to a resolution of 800x600 or higher.
2.0 Pall PCM200 Display Downloader Software Installation
The following procedure details the installation of the PCM200 Display Downloader software onto
your computer’s hard disk.
2.1) Start Microsoft Windows operating system and insert the PCM200 Series Pall Portable Fluid
Cleanliness Monitor CD Rom into a suitable drive.
2.2)Select Run from the Start menu.
2.3) Select Browse X: (where X is the drive letter of your CD-ROM drive)
Page 73 of 80
2.4) Open PCM200 Operating Instructions and Software
2.5) Open PCM200 Display Download Software
2.6) Open p2disp-setup-x.x.x (where x.x.x is the version number).
2.7) Select OK to Run this set up program.
2.8) Follow the ‘on-screen’ instructions to complete the installation.
Page 74 of 80
3.0 Operation of Software
3.1) To operate the software, double-click the program from ‘Pall Diagnostics’ on the start menu:
3.2) Select the communications port you wish to use for connection to hand held display and click
“OK”.
The following screen will appear:
Page 75 of 80
Until the hand-held display is connected the ‘Download’ button on the toolbar is disabled and the
status bar reads ‘Disconnected’
3.3) Downloading test data from optional hand-held:

Connecting the hand-held display to the selected communication port will result in the ‘Download’
button on the toolbar becoming active and the status bar will change to ‘Connected’. (Note: the
COM port is also confirmed)
After the hand held display has been connected, selecting the download button on the toolbar will
result in confirmation of data stored. It will now be necessary to confirm your download request by
selecting Yes or No.
Important Note:
Before data may be transferred into the PC, it will first be necessary to upload test results from the
PCM200 into the hand-held display – refer to section 6.9 of this operators manual – 6.9 Output
Results Routine. Note that section 6.9 is written for both the optional display and emulator. This
section is only relevant to optional display.
Selecting “yes” will commence the data download process and the records will be seen to be
transferred into the computer ‘newest record first’, ‘oldest record last’.
Page 76 of 80
Uploaded data is saved by default within the folder where the user chose to install the program
software. The default file name is “pcm2data.txt”.
Important Note:
If the file name “pcm2data.txt” already exists the data is overwritten without warning.
3.4) Storage of Test Data:

It is strongly recommended that all test data is stored under a new name after each download
using the ‘Save’ button on the toolbar. The user may wish to save this test data to an archive
folder or for entry into a spreadsheet program such as Microsoft Excel for manipulation.
Page 77 of 80
Appendix E: Software
Pall PCM200 Display Emulator installation
Included on the PCM200 Series Pall Portable Fluid Cleanliness Monitor CD Rom is the
PCM200 Display Emulator Software.
1.0 System Requirements
The recommended minimum specification computer for this software is a ‘Pentium’ 166MHz
or equivalent processor-based IBM compatible PC running Microsoft Windows 98 or higher,
NT4.0 operating system or higher with 32MB memory and 10MB hard disc space free. The
computer’s monitor should be set to a resolution of 800x600 or higher.
2.0 Pall PCM200 Display Downloader Software Installation
The procedure is similar to the installation of the Display Downloader software except for the
addition of the below notes.
When the emulation is selected Windows Firewall may issue a warning. This is because the
program uses TCP/IP to communicate internally. If this happens, select “Unblock”.
Page 78 of 80
The PCM200 Emulator can be used instead of the standard display. To do this, connect the
computer to the display port (COM1) of the PCM200 using serial cable No. PCM200.239, and
run the Emulator program. On the first screen (shown above), select the computer serial port
number and press OK. The software uses the settings from the PCM200 and the results are
stored in the PCM200 unit.
To emulate the PCM200, select “Emulate PCM”. This will emulate the display without the
need for a PCM200 to be connected. This can be used to familiarise yourself with the display
navigation.
Page 79 of 80
Pall PCM200 Series Fluid
World-wide Warranty
Pall products are rigidly inspected during manufacture and on completion by a modern
Quality Control Department and are guaranteed for a period of one year from date of
commissioning against defective materials and workmanship when properly installed and
operated at design conditions.
All parts proven to be defective within this period will be replaced free of charge FOB England
or original FOB point as applicable. FOB (Freight On Board) specifies which party (buyer or
seller) pays for which shipment and loading costs, and/or where responsibility for the goods is
transferred.
However, claims for damage or labour will not be allowed; nor can the seller’s equipment be
warranted of failure where the operating conditions are beyond the control of the seller or
beyond monitor specification. All claims must be accompanied by full particulars including
system conditions if applicable.
Page 80 of 80

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PCM200 Operating Instructions

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PALL PCM200 SERIES PORTABLE

FLUID CLEANLINESS MONITOR

These operating instructions should be read before attempting any aspects of

As part of the continuous improvement process that Pall adopts in the

Pall welcomes feedback from users.

MANUAL PART NUMBER ISSUE DATE

PRODUCT DESCRIPTION: Fixed Installation Cleanliness Monitor

PRODUCT PART NUMBER: PCM200, PCM200W, PCM200B,

SERIAL NUMBER: SEE NAMEPLATE

BSEN292-1 :1991 Safety of Machinery – Basic Concepts

This compliance is sufficient to meet the requirements of the EC Machinery

J.Collard, Engineering ‘Projects’ Manager

WARNINGS: THESE ARE INSTRUCTIONS THAT DRAW

Cautions: These are instructions that draw attention to the risk of

Trademarks and Intellectual Property

NOTE: Pall and are trademarks of Pall Corporation.

 Indicates a trademark registered in the USA

Filtration. Separation. Solution. is a service mark of Pall Corporation

Section 1: PCM200 SERIES Specification and Requirements 7

Section 2: PCM200 SERIES Inspection and Packaging. 8

Section 3: PCM200 SERIES Description of Monitor. 9

Section 4: PCM200 SERIES Principles of Operation 10

Section 5: PCM200 SERIES Connecting the Monitor 12

Section 6: PCM200 SERIES Getting Started 28

Section 8: PCM200 SERIES Fluid Change Procedure 56

Section 9: PCM200 SERIES Function Codes and Corrective Actions 57

Section 10: PCM200 SERIES Mesh change procedure 61

Section 11: PCM200 SERIES Spare parts list 64

Section 12: PCM200 SERIES Disposal of Equipment 65

Appendix A: Commissioning, Training, Calibration and Aftermarket Services 66

Appendix B: ISO 4406 and NAS1638 (SAE AS4059) contamination classes 68

Appendix C: PCM200 SERIES menu flow chart 72

Appendix D: Software – Pall PCM200 Display Downloader 73

Appendix E: Software – Pall PCM200 Display Emulator 78

Pall World-wide Warranty 80

1.2 Fluid Environment

1.3 Ambient Environment

1.5 Fluid Connections

1.6 Product Specification

AS 4059 Table 2 > 6um 1B to 10B / >14um 1C to 10C

Inspection and Packaging

2.1 Inspection and Packaging

The PCM200 package comprises of:

• PCM200 series monitor

Description of the Monitor

3.1 Description of the Monitor

PCM200 hydraulic schematic

4.2 Control Panel

Blue Green Amber Red Description

A = DC Main Power Port

C = DC power cable with flying leads

Connecting the PCM200 for sampling and data collection

5.1 Connection Options for Sampling

Caution: Ensure the system operating pressure is within the

Low Pressure Mode (0 to 2 bar 0 to 29 psi)

Bottle Sampling Mode

A = Main Power Indicator

5.3 Communicating with the PCM200 (Overview)

COM 1 Port Connect Option A: Using a PC

PCM400 Emulator (see section 5.4 below)

Optional Hand-Held Display Connected to COM 1

COM 2 Port Connection Option A: PLC communications

Printer Connected to COM 2

5.4 Communication via PCM400 Emulator Program