Spectro 5200 Trivector Analyzer & OilView Manual - Rev A
Spectro 5200 Trivector Analyzer & OilView Manual - Rev A
2
fulfillment of its warranty obligation. A
replacement product or part, including a user-
installable part that has been installed in
accordance with instructions provided by
Spectro Inc, assumes the remaining warranty
of the original product.
For Authorized Service Locations, please
contact Spectro Inc. Technical Support, +1-
978-431-1130 or [email protected].
IMPORTANT!
Register Your Product.
Register your product online at http://
www.spectroinc.com/register.htm.
Filling out the online form completes your
product registration. Completing the one-page
form is quick and enables Spectro to:
• Contact you with important product
alerts.
• Inform you about any product updates.
• Send special product-based
applications as they become available.
• Obtain needed information for processing
a warranty claim.
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4
Contents
Chapter 1 • Introduction
How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
OilView Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electrostatic Discharge or Other Harsh Environments. . . . . . . . . . . . . . . . . . . . . . 1-3
On-Line Help System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
OilView System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Trivector Laboratory Data Import. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
License Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
OilView Software Menu Structure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Drop down menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Toolbar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-10
Database Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-11
Change Marks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-13
Right Mouse Click Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-14
Setup Menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
Communication Ports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-28
System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-30
Translations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-33
Severity Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-34
File Locations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-35
Licenses . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-36
DB Level Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-37
Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-38
Lab Labels. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-39
Reports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-40
E-mail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-41
Text Shortcuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .1-42
5
Reference Info. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4
Adding a Reference Oil. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-13
Database Queries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-15
Measurement Point Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-17
Schedule. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-20
Test and Display Filter. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-21
Internal Working Environment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-22
Internal Process Material. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-24
External Working Environment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-25
Oil Wetted Bearing Parts (P1) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-26
Analysis Parameter Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
Database Tree. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
AP Sets and AL Sets (Folder icon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-29
CSI Default Oil AP Set (AP Set icon) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-31
AP Sets Secondary Tabs and Information Window. . . . . . . . . . . . . . . . . . . . . . . 2-32
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-37
Current Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .2-39
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Chapter 4 • Importing Data From the Laboratory
Import Lab E-mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Laboratory Imports. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Database Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Statistics Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
7
Plot ASTM . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-12
Using the Digital Viscometer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13
Viscosity . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-15
8
Chapter 9 • Wear Debris Analysis
Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Sample/Atlas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Atlas Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-10
Analyst tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-11
The OilView Analyzers And Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-13
Using the Model 51WD Wear Debris Patch Maker. . . . . . . . . . . . . . . . . . . . . . .9-17
Using the Model 51SM Shop Microscope. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .9-21
9
Test 2 Calibration & Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-59
Procedure. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-59
Preparation for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60
Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-62
Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-65
Test 3 Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-67
Test 3 Particle Counter Calibration Overview. . . . . . . . . . . . . . . . . . . . . . . . . . .10-67
Test 3 Preliminary Instrument Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-73
Test 3 Sizing Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-76
Test 3 Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-79
Test 3 Diluent/Clean Fluid Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-83
Test 3 Coincidence Error Limit Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-86
Test 3 Flow Rate Limits . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-91
Test 3 Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-94
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-98
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Chapter 12 • OilviewLite
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-1
Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2
Databases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-2
Adding a Sample and Running a Test . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-3
Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-4
Alarm Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-5
Reference Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-6
Data. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .12-7
11
OilView Instrument Directory Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-4
Setting up OilView File Locations for Terminal Server or Citrix AMS Machinery Manager
ClientsD-6
Setting up OilView File Locations for Workstation A using AMS Machinery Manager Local
Client AD-7
Setting up OilView File Locations for Workstation B using AMS Machinery Manager Local
Client BD-8
Setting up OilView for Terminal Server or Citrix. . . . . . . . . . . . . . . . . . . . . . . . . D-9
Setting up OilView Local Client . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Summary. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Appendix F • Addendum
Models 5100-1 and 5100-2 OilView Analyzer CE Addendum . . . . . . . . . . . . F-1
Explanation of Symbols:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Electrical Specifications:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . F-2
Environmental Specifications:. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .F-2
Index
12
Chapter 1
Introduction
Note
This manual covers the OilView Analyzer Model 5100-1 and
Model 5100-2; however, some described functions and features are
applicable only to the particular model.
1-1
Manual Conventions
These conventions are used throughout this manual to call attention to the adjacent text:
Note
The Note paragraph indicates special comments or instructions.
Caution!
The Caution paragraph alerts you to actions that could have an
effect on the equipment or the collected data.
Warning!
The Warning paragraph warns you of actions that could cause
serious injury or death.
1-2 Introduction
OilView Disclaimer
The OilView instrumentation and software aids the user in diagnosing oil lubricating and
machine wear problems. Because of the complexities of real-world problems, there are no
claims or guarantees that OilView will correctly solve all of the problems encountered.
Questionable results should be sent to a reputable oil analysis laboratory for a more com-
prehensive analysis than OilView is able to perform.
All results must be considered as advisory information only and should be weighted care-
fully by the personnel who are responsible for maintenance actions which are taken.
Spectro does not accept any liability with regard to the actions performed or omitted by
those using this package.
The user is responsible for the safety of personnel and machinery. The user should consult
their safety department for the recommended methods of handling, storing, and ventilating
volatile and lubricating materials.
1-3
On-Line Help System
OilView and the AMS Machinery Manager software uses an HTML Help program to pro-
vide you with context sensitive Help as you navigate through the programs.
Pressing F1 on the keyboard launches a special CSI version of Microsoft Explorer.
Explorer displays the same information as is found in the AMS™ Suite: Machinery
Health™ Manager program user’s manuals in HTML format. These HTML (.chm) files
are stored within their own directory.
An on-line tutorial is also available from the Help drop down menu. See the OilView Soft-
ware Menu Structure section of this manual for more information.
1-4 Introduction
OilView System
The OilView system includes oil analysis software used in conjunction with an oil labora-
tory, a minilab, or both. This manual describes the operation of the OilView software, lab
communications devices, and OilView minilab instruments.
There are three license/configurations of the OilView system. Depending on which soft-
ware license you purchased, you may have one or more of the following configurations
enabled.
• Minilab instruments
• Laboratory Information Management System (LIMS) and Data I/O
• Wear Debris Analysis
License Configurations
The Minilab Instruments and Data Edit/Entry configuration is used to operate any of the
OilView products including any or all of the following:
• 5200 Trivector Analyzer
• OilView Analyzer (Models 5100, 5100-1, and 5100-2)
• Digital Viscometer (Models 51DV or 52DV)
• Particle Counter (Model 51PC)
• Ferrous Wear Monitor (Model 51FW)
These instruments are designed for use in industrial maintenance departments. They are all
portable, bench-top operated devices operated off of 110 to 230 V A/C power.
1-6 Introduction
The following table shows which tabs are activated by the three license categories. The Tri-
vector Lab Import does not require a license.
Activated categories
OilView Users
Software Manual
Trivector Minilab LIMS &
Tabs Chapter WDA
Lab Import Instruments Data I/O
1®
The primary tabs are used to select the group of functions that you wish to perform, and
then the secondary tabs are used to select options within the selected function
The front row of the primary tabs is the active row. If you click on the tabs on the back row,
the back row will be brought to the front and become the active row.
1-8 Introduction
Drop down menus
1-10 Introduction
Database Tree
The OilView database is a part of the hierarchical database system used in all modules of
the AMS Machinery Manager system as shown in the following illustration.
Clicking on the + symbol to the left of a Database branch allows you to expand it. Similarly,
clicking on the - collapses the branch. The color of the Oil Sample icon in the database tree
indicates the sample’s alarm status. A red icon indicates that at least one of the parameters
in the associated sample is in an extreme alarm state.
Severity – The level of severity at each branch of the DB tree reflects the highest severity
below that branch.
Customer Level – The RBM database can have an additional customer level that groups
areas under a particular customer. The feature is activated under setup.
The Reference database has a similar structure to the User database.
1-12 Introduction
Note
Although other types of data may be visible on the database tree,
OilView will only display oil points.
Change Marks
Whenever an oil sample has been updated, the database tree places change marks on the
left side of the window beside the sample and the associated measurement point, piece of
equipment, and area.
Add Customer – Allows addition of a customer level. Areas can be dragged and dropped
for one customer to another. Initially all areas fall under the “Unknown Customer.”
Find Sample # – A search facility to find a specific sample.
Recalculate Alarms – Should one change alarm limits then you have the ability to re-cal-
culate
Update Point Baseline – Alarms can have a baseline relative to the median at each point.
This option updates the point baseline for all points in the database.
Clear Mark - clears the change marks for each piece of equipment, measurement point,
and oil sample under all Areas.
Schedule – Schedule sampling for every point in the database. See scheduling, chapter 2.
Clear Marks - clears all of the change marks for each piece of equipment, measurement
point, and oil sample under all Areas.
Print/Preview
Point Labels – Create sample bottle labels for the entire database.
Sample Summary – Sample summary report for entire database.
1-14 Introduction
Parameter Exception – A report similar to the parameter exception report created using
the software’s reporting module. This report has been customized for oil data giving more
detailed information.
Point Configuration Summary – This report checks for inaccurate or incomplete Point
Setup information.
Alarm Setup Exception – Once the Point has been correctly setup then this report is used
to check that the alarms have been correctly applied to the sample data.
Oil Usage – A report showing oil consumption per point and by oil type.
Schedule Summary – A report showing the sampling schedule calendar for one year.
The summary reports are important management tools.
Print/Preview
Point Labels – Create sample bottle labels for the entire database.
Sample Summary – Sample summary report for entire database.
Parameter Exception – A report similar to the parameter exception report created using
the AMS Machinery Manager reporting module. This report has been customized for oil
data giving more detailed information.
Point Configuration Summary – This report checks for inaccurate or incomplete Point
Setup information.
Alarm Setup Exception – Once the Point has been correctly setup then this report is used
to check that the alarms have been correctly applied to the sample data.
Oil Usage – A report showing oil consumption per point and by oil type.
Schedule Summary – A report showing the sampling schedule calendar for one year.
The summary reports are important management tools.
Customer Details
The customer details are described in the “Laboratory Information Management System
(LIMS)” on page 11-1.
1-16 Introduction
Click On the Area Icon
10
Add Equipment - allows you to add a new piece of equipment to the current area.
Edit Area - allows you to change the ID and/or the name of the clicked on area.
Delete Area - allows you to delete an area provided there is only oil points under the area.
If there are any other technology points under the area then the only way to delete the area
is using the database utility program.
Recalculate Alarms – Should one change alarm limits then you have the ability to re-cal-
culate
Alarm Details – This options shows the severity of all technologies as show below.
Set Report Language – This options sets the languages for reporting for all points.
Clear Marks - clears all of the change marks for each piece of equipment, measurement
point, and oil sample under the selected Area.
Recalculate Alarms – Should one change alarm limits then you have the ability to re-cal-
culate
Update Point Baseline – Alarms can have a baseline relative to the median at each point.
This option updates the point baseline for all points in the database.
Clear Mark - clears the change marks for each piece of equipment, measurement point,
and oil sample under all Areas.
Schedule – Schedule sampling for every point in the database. See scheduling, chapter 2.
Print/Preview
Point Labels – Create sample bottle labels for the entire database.
Sample Summary – Sample summary report for entire database.
Parameter Exception – A report similar to the parameter exception report created using
the AMS Machinery Manager reporting module. This report has been customized for oil
data giving more detailed information.
Point Configuration Summary – This report checks for inaccurate or incomplete Point
Setup information.
Alarm Setup Exception – Once the Point has been correctly setup then this report is used
to check that the alarms have been correctly applied to the sample data.
Oil Usage – A report showing oil consumption per point and by oil type.
Schedule Summary – A report showing the sampling schedule calendar for one year.
The summary reports are important management tools.
1-18 Introduction
Alarm Details
11
12
Note
The icons on the database tree are only available if you have pur-
chased RBMview Full.
13
1-20 Introduction
This box displays the different technologies. Those technologies with check marks in the
boxes beside them will be the ones with active Alarm Tree Filters. You can turn on the fil-
ters for an entire technology category by checking in the box beside the category head of a
technology. For example, you can check Periodic Vibration and it will turn on all the anal-
ysis types under that Technology category. Or you can check those individual analysis
types you want filtered.
By default, the tree will show the status for all technologies that the user has purchased.
However, applications may set a filter to limit the number of technologies for which status
is displayed. For example, OilView may choose to set a filter to only display Oil Tech-
nology statuses.
You can also click on the box beside “Use these filters for all programs” to turn on the filters
for all the technologies. Doing so changes the dialog box heading to “Global Alarm Tree
Filters.”
14
Add Point - allows you to add a new measurement point to the current piece of equipment.
(See “Measurement Point Information” on page 2-17.)
Edit Equipment -allows you to change the ID and/or the name of the clicked on equip-
ment.
Print/Preview
Point Labels – Create sample bottle labels for the entire database.
Sample Labels – Print Sample labels.
Sample Summary – Sample summary report for entire database.
Parameter Exception – A report similar to the parameter exception report created using
the software’s reporting module. This report has been customized for oil data giving more
detailed information.
Point Configuration Summary – This report checks for inaccurate or incomplete Point
Setup information.
Alarm Setup Exception – Once the Point has been correctly setup then this report is used
to check that the alarms have been correctly applied to the sample data.
Oil Usage – A report showing oil consumption per point and by oil type.
Schedule Summary – A report showing the sampling schedule calendar for one year.
The summary reports are important management tools.
1-22 Introduction
Click On the Measurement Point Icon
15
Add Sample - allows you to add a new sample to the current measurement point.
Edit Point – allows you to edit the clicked on measurement point.
Delete Point - deletes the clicked on measurement point.
Copy Point - allows you to copy the current measurement point so that it can be pasted
(duplicated) into another piece of equipment.
Recalculate Alarms – Should one change alarm limits then you have the ability to re-cal-
culate
Update Point Baseline – Alarms can have a baseline relative to the median at each point.
This option updates the point baseline for all points in the database.
Clear Marks - clears all of the change marks for every oil sample under the selected piece
measurement point.
Update Point Baseline – Alarms can have a baseline relative to the median at each point.
This option updates the point baseline for all points in the database.
Clear Mark - clears the change marks for each piece of equipment, measurement point,
and oil sample under all Areas.
Print/Preview
Point Labels – Create sample bottle labels for the entire database.
Sample Summary – Sample summary report for entire database.
Parameter Exception – A report similar to the parameter exception report created using
the software’s reporting module. This report has been customized for oil data giving more
detailed information.
Point Configuration Summary – This report checks for inaccurate or incomplete Point
Setup information.
Alarm Setup Exception – Once the Point has been correctly setup then this report is used
to check that the alarms have been correctly applied to the sample data.
Oil Usage – A report showing oil consumption per point and by oil type.
Schedule Summary – A report showing the sampling schedule calendar for one year.
The summary reports are important management tools.
1-24 Introduction
The Add Sample option pops up a form in which you enter the sample data and number.
You also have the opportunity to record the observations that have been recorded when the
sample was collected.
16
17
Print/Preview
Point Labels – Create sample bottle labels for the entire database.
Sample Summary – Sample summary report for entire database.
Parameter Exception – A report similar to the parameter exception report created using
the software’s reporting module. This report has been customized for oil data giving more
detailed information.
Point Configuration Summary – This report checks for inaccurate or incomplete Point
Setup information.
Alarm Setup Exception – Once the Point has been correctly setup then this report is used
to check that the alarms have been correctly applied to the sample data.
Oil Usage – A report showing oil consumption per point and by oil type.
Schedule Summary – A report showing the sampling schedule calendar for one year.
The summary reports are important management tools.
Sample Labels – create a sample label.
Note
If the sample is dropped on a point, then the sample will be added
to the point. However, if the sample is dropped on another sample,
then the data will be merged.
1-26 Introduction
Copy for Ref DB
This enables one to copy an oil sample from the User database into the Oil Reference data-
base. Select the sample, then right click on the mouse, and then go to the Ref(erence) Data-
base where you will be able to paste it into the correct location.
Communication Ports
This function specifies the OilView and LIMS accessories that will be used with this soft-
ware, and to assign the OilView Analyzer and computer ports for these accessories.
18
The PC Comm Ports area grid has space for 8 RS232 comm port selections. The comm
ports available on your computer are in white while the rest are greyed out. For each avail-
able comm port use the drop down list box to select the appropriate piece of equipment to
be connected. For example, if the OilView Analyzer (5100 or 5200) is connected to the
Comm 1 port on the computer, select the OilView Analyzer from the list as shown below.
1-28 Introduction
You will observe that there are several other general purpose laboratory instruments in the
list. These instruments can be connected to the LIMS system for automatic data import.
You are limited first off to the number of comm ports available on your computer (up to a
maximum of 8) and secondly to the number of LIMS instrument link licenses you have
purchased.
19
The OilView Analyzer Type area is used to specify which Model 5100 or 5200 is to be used
with this software. Click the appropriate box beside the Model 5100 version or 5200 you
will be using. You cannot connect both a 5100 and a 5200 simultaneously to your com-
puter.
The OilView Analyzer port area is also used to specify which OilView equipment is con-
nected to the Model 5100 or 5200 ports. For example, if the Model 5XDV is connected to
port 4 on the Model 5100, check the box beside 5XDV under the Port 4 column.
Note
Comm 1 is the serial port number “1” (or letter A) on the computer;
Comm 2 is the serial port number “2” (or letter B) on the computer.
The Port numbers refer to the ports on the Model 5100-1 or Model
5100-2. See “System Setup” on page 5-21 for OilView Analyzer
port assignments.
20
Error Tracing
These options are for use only when working with Customer Support and you are resolving
a problem.
Test Modes
Diagnostics – Enable Minilab instrument diagnostics. These features are used for diag-
nosing problems in conjunction with customer support.
Add Sample With Start - When a new test is started with any of the Minilab instruments,
you are automatically prompted to enter a new sample number. When this box is checked,
if the sample already exists then it is used; otherwise, a new sample is added.
1-30 Introduction
Verbose – More detailed errors and warnings.
Data Collection Mode – Used in a WAN installation (see Appendix D).
Data Analysis Mode – Used in a WAN installation (see Appendix D).
Diagnostics and Verbose are only used when working with Customer Support and you are
resolving a problem.
Data Edit/Entry
This function is used to change the security level in the OilView software located on the
current computer.
Read Only - When this box is checked, the software is in the “Read Only” user mode. The
user is allowed to download data into the OilView database, and the ability to view and print
plots and reports. However, changing information and/or data in the OilView database is
not permitted.
Advanced User - This option places the software in the “Advanced user mode” and
allows the administrator of the OilView software to set up or edit areas and equipment,
measurement points, and other technical information. When this option is selected, the
“grayed out” primary tabs that are not available to the “read only” user are now accessible.
Miscellaneous
Pause on Daily Tip – If you do not have time to read the daily tip this option will pause
the software for you.
Mini-Lab Demo Mode – Switches the software into demo mode whereby the running
of the MiniLab instruments can be simulated without actually having them connect to the
computer.
Display ISO 11171 counts – By default particle counts are displayed with ISO 4406
standard. This option enables the new ISO 11171 standard. If selected, old data is automat-
ically converted to the this standard. The 5200 Trivector Analyzer can be calibrated in either
standard.
Let lab alarm levels override user alarms on import – By default when importing lab
data the lab severity is stored with the user severity, which is calculated based on alarm
limits. This option disables the calculation of user severity based on stored alarm limits and
instead sets the user severity equal to the severity imported from the lab. This is essential if
the alarm limits have not been correctly set up.
LIMS
Lab Options – Reserved for the Trivector lab.
Display Customer Level – The customer level in the RBM database groups areas under
a given customer. This option is activated here.
1-32 Introduction
Print lab label @ login – This option activates the automatic printing of lab labels one at
a time as samples are logged into the LIMS batch system. You need a label printer to use
this option.
Export 0-5 Severities – Used to export the old 0-5 severities to be compatible with Oil-
View 4.60 and earlier. This is a global setting and therefore applies to all data exported. The
new 1-100 severities used in OilView 4.70 are only compatible with OilView 4.61 (latest
patch) and OilView 4.70.
Trend Plots
All Data – plot all data on trend plots.
Last – plot the last “N” samples on trend plots. You select the number of samples.
Start Date –Plot all sample data after the start date on trend plots.
Translations
21
Severity Codes
During the diagnosis process there are five levels of severity ranging from normal to
extreme. Default terms for these levels are provided; however, you may use this window to
specify your own terminology. You may also select to use only 3 severity levels.
22
Note
When renaming the severity codes with this option, the actual
levels are not changed, only the name associated with the partic-
ular severity code.
1-34 Introduction
File Locations
This window shows the hard drive location of the calibration files for the instruments that
make up the OilView MiniLab system. The displayed default locations are set up during
the original software installation. However, this window can be used to change the file loca-
tions if desired.
23
You may type in the file location manually, or you may use the browse button (on the right
side of the field next to the appropriate instrument) to search through the hard drive direc-
tories and select a location. After you have finished making the changes, click on the Save
button, or click the Cancel button to revert to the original settings.
Note
These file locations should be adequate unless multiple users at a
site will share mini-lab instruments. Contact Customer Support for
information in this case.
PC Configuration
This file location is used to store setup configuration information such as which RS232
ports are being used by the various instruments. It is important to set this location to your
local drive in a multi-user network installation as this information is specific to a particular
PC.
Licenses
The Activate/Release buttons allow you to use a license and then release it to another user,
if required. The default check box marks those licenses that are automatically activated
when the OilView program is started.
24
1-36 Introduction
DB Level Names
The Database Level Names options enable you to globally substitute other descriptive
names used in the hierarchical database structure and the reference oil database.
Caution!
Spectro recommends that you do not use a keyword to replace
another keyword. For example, Equipment should not be substi-
tuted for Area.
25
If you decide not to keep the new names you have selected, click on the Restore Default
Level Names button to restore the names to factory setting.
26
Label Fields
Select the required fields to be printed on the sample label.
Label Printer
Select the appropriate printer. Labels can either be printed form sheets or single labels
depending on the printer selected. This enables printing labels on a specific printer rather
than the system default printer.
Default labels
Select a default label size.
1-38 Introduction
Lab Labels
The lab labels identify the sample and are used during the testing phase in the laboratory.
27
Label Fields
The test matrix lists the tests to be performed based on the Point Setup.
Label printer
Select the appropriate printer. Labels can either be printed form sheets or single labels
depending on the printer selected. This enables printing labels on a specific printer rather
than the system default printer.
Default Labels
Select a default label size.
28
Report Colors - This sliding color level is used to tone down the colors on trend plots or
on printed reports.
1-40 Introduction
E-mail
29
30
When typing an observation or action message, you can use shortcuts that automatically
enter phrases into your message. This is done by first setting up the shortcuts. You do this
by selecting the Text Shortcuts secondary tab at the bottom of the screen. Next, click on the
first box under the Shortcut column and type in your shortcut letter, number, symbol or
combination of letter, number, and symbol. The shortcut can be from one to six characters
long.
Now, when typing in an observation or action, type the “/” key, then the shortcut character
or characters, and then press the Enter key. The observation or action text associated with
that shortcut appears in the observation or action dialog area.
1-42 Introduction
Chapter 2
Reference Database
Many of the minilab measurements result from comparing new or reference oil tests with
similar tests on used oil samples. The OilView Analyzer, Digital Viscometer, and Particle
Counter all use Reference Oil test data. The OilView Analyzer’s Chemical Index readings
are given relative to a reference sample. So are the Particle Counter’s Dielectric and Color
Index readings. The Digital Viscometer requires lab measured 40 degrees C and 100
degrees C viscosities for reference information.
Many of the laboratory measurements are also most useful when reference oil data are pro-
vided for comparison. For example, the zinc and calcium (Zn and Ca) levels are additive
elements that can be compared between reference and used oils to detect additive depletion.
Spectro recommends that the reference oil sample be a new oil of the same type and from
the same source as the used test oil. If for any reason a known reference oil is not available,
it is probably best to conduct your used oil tests without a reference oil or against a previous
test from the same machine. In selecting a reference oil, remember that oil suppliers may
change additive packages, refineries, and oil sources without notice. Therefore, there is no
assurance that a reference sample taken after the fact from a new oil drum can be applied to
a test oil that originated from a previous drum—even though the oil is of the same type and
from the same supplier.
2-1
Assign Reference
The Assign Ref and Ref Info tabs are used to add and edit reference oil information. The
“Assign Ref” title is applied to this tab when the user is in the User Database because the
primary purpose is to assign references to points and samples on the User Database. The
assign reference function is disabled when switching to the Reference Database.
1® ˜
When using the Assign Ref tab in the User Database, a Reference Database tree is dis-
played in the middle of the screen alongside the User Database. The focus automatically
appears on the oil sample from the Reference Database tree in the display center which is
assigned, if any, to the Measurement Point or Sample highlighted on the User Database tree
in the display on the left.
2-3
Superseding References at the Point and Sample Levels
A somewhat different situation arises when the user has merged old oil databases and has
duplicate reference samples. In this case, the user wishes to supersede not only the refer-
ences assigned at the point level for future samples, but also the references assigned at the
sample level. This allows only one of the duplicate references to be assigned and the other
duplicate references may be deleted. In order to perform this operation, the user must first
right-mouse click at the top level of the reference database tree on the Assign Ref tab, and
then choose the Enable Global Supersede and Lock DB menu item. After this, dragging
and dropping a reference oil sample will assign the dragged reference oil to all samples and
points where the old reference was previously assigned. After completing the global super-
sede function, the user must right-mouse click at the top level again to Enable Default
Supersede and Unlock DB.
Reference Info
The Data Available tab is a display of the instruments and tests for which reference oil infor-
mation has been stored on a specific reference oil sample. These displays are for informa-
tion only and cannot be edited.
2-5
Data
The Data tab is a single column of reference oil parameters and associated measurement
values. This tab is only available when you are on the sample level of the Reference Data-
base tree. This list is similar to the data tabs under “Trend Info” on the User Database with
these key differences: only one sample is displayed – no trend information, and there are no
alarms applied to reference oil data. An Advanced user can edit any of the fields in this list.
The Oil Type tab is only available when viewing the oil designator (e.g., measurement
point) level of the Reference Oil Database (Advanced user mode). Check off the one base
stock field that describes the reference oil. If “synthetic” is selected as the base stock, then
select the type of synthetic oil base stock from the lower list. This lower list is grayed out
unless “synthetic” is checked in the upper list.
2-7
Properties
The Properties tab is only available when viewing the oil designator (e.g., measurement
point) level of the Reference Oil database (Advanced user mode). Select one or more prop-
erties for the reference oil. This information typically is included with specification infor-
mation from the oil supplier.
The Purpose tab is only available when viewing the oil designator (e.g., measurement
point) level of the Reference Oil Database (Advanced user mode). Select one or more func-
tional purposes for the reference oil. This information typically is included with specifica-
tion information from the oil supplier.
2-9
5x00/51PC
The upper selection of this section is only available when viewing the oil designator (e.g.,
measurement point) level of the Reference Oil Database (Advanced user mode). It is used
to identify the relative additive concentration for mineral oil base oils tested using the
Model 5100, 5100-1, 5100-2, or 5200. This information is used by the OilView software
in calculation of estimated water contamination.
The lower section is only available when viewing the reference oil sample level at the Ref-
erence Oil Database and is used to identify the default settings used when testing samples
on the Model 51PC. Typical default settings are 50 ml/min flow rate, 25 ml flush volume,
and 5 ml test volume.
This plot shows the reference value relative to all samples that use this reference. This is
used for verifying that the reference value is appropriate for the samples that it is being
applied to. This feature can also be used to set a reference value by either dragging the ver-
tical line to the appropriate value of by pressing the Set Ref Value button, which would set
it at the median value of 50%. The new value must then be saved. One can also automati-
cally net all reference parameters using the Set/Save All button. This feature can also be
used for establishing reference values when no reference oils is available.
2-11
Statistic Data
This displays the data used to create the histogram plot and is used to identify these data
points that appear to be incorrectly assigned.
ˆ®ˆ ˆ® 8
2-13
Note
Any data also may be entered manually by typing it into the
Sample Info/Data Spreadsheet. For example, Digital Viscometer
reference data such as the viscosities at 40ºC and 100ºC, and the
specific gravity are easily entered this way.
Note
This option requires a license to the LIMS module.
® 10
To query the database, select the “Q” Database Queries tab. Right mouse click on the Cus-
tomer Query option and select either Customer Sample Query or Generate Schedule.
2-15
Customer Query
® 11
Select the Cust ID (Customer Identification) or Cust Desc (Customer Description) from the
drop down menus. You may also select various reporting conditions as show and a start and
an end date. Press the Start button to run the query.
The results of a query are shown as a list similar to the LIMS (Laboratory Information Man-
agement System) Batch Info display. You have full access to all the reporting options for
the list as detailed in the LIMS module.
Generate Schedule
® 12
This menu option generates a list of samples that are due based on the current date and Look
Ahead date. The Start button will generate the list.
The list of points due for sampling can be manually edited. Sample bottle labels and a report
listing all the samples can also be printed.
13
General Information
Point ID - The Point ID is a three-character designator you select to tell the difference
between all of the points on a piece of equipment (the Point ID designation must be
unique for each point within the current machine). Normally you will want to use a con-
sistent method for numbering points so that the ID designator will be meaningful.
For example you may use “DR1” for an oil sample taken from the drain port or “OP3” for
the third oil sample in line taken from the oil line leading away from the oil lubricated
machinery or “OC1” for an oil sample taken from the oil compartment (e.g., oil sump).
Description - This field of up to 28 alphanumeric characters describes the current point
and should be as descriptive and unique as possible.
14
Alarm Limit Set - Click on this field to assign an alarm limit set to the current measure-
ment point (from the pop-up window containing a list of predefined sets).
The Alarm Limit (AL) Set is the list of alarms for the measurement point. If you have
selected the CSI Default Analysis Parameter set, the Alarm Limit set will automatically be
generated when you select an Equipment Type. See “Alarms” on page 2-37 for more infor-
mation.
Note
When specifying a new piece of equipment, you will probably
want to begin using a pre-defined Analysis Parameter and Alarm
Limit set for the first three months. Then after getting some expe-
rience with alarming in your plant, you can increase or decrease
alarm limits so that approximately 10% of your equipment is in the
highest alarm level and another 10% is in the second alarm level.
15
Setup sampling schedule by right mouse click on appropriate date. You should setup the
schedule for at least one year in advance, although you can setup for as far in the future as
you want.
Note
Printing of sample labels for due samples is done on the Q (Data-
base Queries) tab.
Criticality - is the relative impact of a failure of this equipment on overall plant opera-
tion. This function enables you to specify one of five levels of criticalness for this piece of
equipment.
16
Criticality - is the relative impact of a failure of this equipment on overall plant opera-
tion. This function enables you to specify one of five levels of criticalness for this piece of
equipment.
Many of the more than 90 parameters in the Analysis Parameter set are used for reference
and are not important in every report. By using this filter, you can limit the number of
parameters displayed to those of greatest interest. If at any time you want to view the data,
simply check the box or clear the check.
The filter is organized by measurement device. This way you can turn off the display of
blank information when you are not conducting particular tests on a point. Later, if you
begin collecting these data, simply turn the display back on.
17
Filter
Category - Select either “filtered” or “not filtered” category.
Oil Capacity
Estimate - Enter the approximate oil capacity of the system.
Actual - If known, enter the actual oil capacity of the system.
Breather - Indicate if there is a breather on the oil compartment.
Usage Units
These units are used to specify the volume of the oil compartment as well as the units used
when entering the amount of oil added when a new sample is taken.
18
General - If it is possible for process contamination of the oil, identify if this can cause the
oil to become chemically neutral, acidic, caustic, or unknown.
Gas - If the processed material is a gas, enter the kind.
Liquid - If the processed material is a liquid, enter the kind.
Solid - If the processed material is a solid, enter the kind.
Transformer - If the piece of equipment is a transformer, indicate the rated features.
19
20
21
22
Database Tree
The analysis parameter (AP) sets that are available for the database are represented as icons
at the bottom of the database tree. To expand and view the sets, click the plus box beside
the folder AP Sets and AL Sets.
23
Add AP Set
To add a new analysis parameter set, right mouse click on the folder icon and select Add
AP Set from the pop-up menu. You can then edit the current view and profile setup as
required for the new set.
24
Update Statistics
Exports all the parameter data for generating statistical information. You must first set both
the correct alarm type and which are to be alarmed. Also, you must update the Point Base-
line.
Edit AP Desc
First, right mouse click on an individual AP Set icon from the list under a folder icon to
bring up the option box with Edit AP Desc in it. Then from the list, select Edit AP Desc.
25
Use this option to edit the AP Set Description and to add/edit the AP Set ID code. This ID
is used to export AP Sets and then import them to the correct location within a database.
This is the same principal as the Area, Equipment, and Point ID.
The other options are explained under “Alarms” on page 2-37.
Current Views
The analysis parameter set current views include a table with eight columns. The first
column is the list of all the Analysis Parameters in the set. Spectro strongly recommends
that you use the CSI default Analysis Parameter set if at all possible to help you manage the
defined Alarm Limit (AL) sets for different equipment types.
26
The second column is the units associated with each analysis parameter set. The third,
fourth, and fifth columns are the primary functional category for each of these parameters.
Those listed under “Wear,” “Chemistry,” and “Contamination” directly contribute to the
respective dimension of the Trivector and show up on the respective tabs within Trend Info.
The “minilab” and “lab” columns indicate which parameters are associated with OilView
minilab instruments and which come from oil laboratories.
Profile Setup
Profile Setup is a list of all the parameters in the analysis parameter set. Editing of this list
will permanently change the analysis parameter set and is not recommended except when
absolutely necessary. The Update Changes button must be clicked in order to actually save
the new parameters.
27
Update Changes – This writes any changes made to an AP Set back into the database.
Highlight Used Parameters – The Drag and Drop feature enables the merging of AP
Sets. This may result in more than 96 parameters in which case it is presented. This feature
enables you to see which parameters in an AP Set actually have data. Those parameters that
do not have data can be removed (deleted) from the AP Set making room for additional
parameters that can be merged from another AP Set.
A Few Words about Drag and Drop. – Drag and drop enables more than the merging
of two AP Sets. In addition, the AL Sets from the AP Set being dragged and dropped are
also added to the AL Sets of the target AP Sets. Also, an AL Set may also be dragged and
dropped or copied from one AP Set to another. In the process all data is automatically
updated. This can be a slow process and there is a progress bar showing status of the merge
operation.
The user can also drag one parameter on top of another thereby superseding one with the
other. This is essential to replace the “Special Test” parameters with actual parameters or if
a parameter has been incorrectly used.
28
29
This shows the coverage weeks between an alert severity happening (i.e.,
severity of 1) where 0 implies normal. This can be referred to as Mean Time
Between Alerts (MTBA). Best results depend on alarm limits being correct and
uniformly applied to the statistics. The Recalculate option is useful in achieving
this. Once this has been done, it is also necessary to Update Statistics.
The MTB can be used to establish sampling intervals, which should be more fre-
quent than the MTBA to ensure alert situations are not missed due to infrequent
sampling.
The breakdown into Wear, Contamination, and Chemistry MTBA’s will give an
indication of the most frequent type of problems. This is very useful manage-
ment type information.
30
Delete AP
Delete an AP Set and all its associated AL Sets. The software first checks to ensure that nei-
ther the AP set nor any of the AL sets are currently being used. If they are the user cannot
delete the AP Set.
Alarms 2-37
Generate Default Alarm Sets
Generate a complete set of CSI default AL Sets. This function (also accessed with a right
mouse click on the folder icon) will create ALL the default alarm sets for each of the equip-
ment categories listed in the Point Setup. Spectro recommends that you do not use this func-
tion but rather only create those you require using the previous option.
31
32
Base Type - This column specifies if the alarm values are relative to zero or to the oil ref-
erence value. A good example of this is viscosity where one is interested in how much the
viscosity has changed relative to the reference oil viscosity.
The baseline can also be relative to the AL Set Baseline, Point Baseline, or Point Baseline
if here is no reference value (Ref or Pnt).
Delta Type - This column specifies whether the alarm value is an absolute value or in per-
cent of the reference value.
Alarm Type - This column specifies whether the alarm value is up (greater than), down
(Less than) or both Up and Down relative to the base type.
Alarms 2-39
Base Type Delta Type Alarm Type
Zero Value Up
ABS Value
Oil Ref. Value Up
AL Base Percent Down
Pnt Base Up and Down
Ref or Pnt
Disabled
AL Base
This column shows the AL Set baseline value.
Statistics
The statistical information must be created by first exporting all the data into a special data-
base using the Data I/O tab as shown below.
33
34
The annual average values for each parameter as calculated based on a simple average, or
on the 80%, 90%, 95%, or 98% percentile values. This information is used to establish
whether the oil analysis program is having a beneficial impact on the equipment, and is
based on a steady decline in contamination and wear.
Alarms 2-41
Right mouse button click on a particular parameter to display a histogram over time.
Histogram Plot
This is an extremely useful statistical plot for setting alarm limits. The x-axis plots the
parameter values and the y-axis the percentage of samples for each parameter value. The
basic concept in establishing alarm limits is that a maintenance department can only handle
a certain percentage of problems at any one time. Therefore, one typically assigns the
extreme alarm limit at 95% (i.e. put only those samples whose parameter values fall in the
top 5% into this category). Similarly the next alarm limit down is set at 90% (top 10%), then
at 80% (top 20%) and the lowest alarm limit at 70% (top 30%).
The vertical bars representing the alarm limit values can be dragged with the mouse to the
desired value. Once all the alarm limit positions have been set then press the “Save
Changes” button and the alarm limit value will be automatically written back to the AL Set.
Using this method one can easily and reliably set the alarm limits for all the parameters.
There should be at least 100 samples in the statistics before one can reliably use this method
to set the alarm limits. The more samples the better. Remember to update the statistics at
regular intervals to ensure you are using the latest samples collected.
35
Note
Sometimes the plot has several “bumps” that are difficult to inter-
pret. This is most often when a Reference baseline is being applied.
Alarms 2-43
Raw Data Plot
36
The raw data plot ignores any reference or other baseline and only plots the raw data. This
is useful for diagnosing the source of obscure plots. Most often these plots with “bumps”
are due to incorrect references being applied.
The solid vertical line shows the mean value and the dashed vertical line one standard devi-
ation from the mean value.
37
To further diagnose obscure plots the raw data itself can be viewed here to find the specific
data that is causing inconsistent plots. Using this information you can then usually correct
the problem much as fixing an incorrect oil reference.
One way of minimizing these sorts of issues is to run the Point Configuration Summary
report, which is designed to find incorrect oil reference and other Point Setup issues.
Alarms 2-45
Scatter Plot
38
The scatter plot is used to see if there is a correlation between any two parameters. Simply
select the appropriate two parameters from the X and Y drop down lists and then press the
Plot button.
If the two parameters correlate well, they will fall on a relatively straight line unlike the one
shown here. The slope and intercept of the best fit line are shown on the display together
with the correlation coefficient. A correlation coefficient of 1 represents a perfect correla-
tion.
This feature is extremely useful for developing rules for the expert system when it is
released. The scatter plot can either use linear or log axis depending on the scale of the
parameters.
39
The standard alarms have been established from a large base of data from many customers.
Alarm limits can be copied into an existencing AL Set by selecting the AL Set, the appro-
priate standard AL Sets, the appropriate standard AL Set and then pressing the <<< button.
Alarms 2-47
Alarm Analysis
40
The LIMS license is required in order to access the Alarm Analysis tab. This data is used
to assist with analysis of alarms. For the case shown, 15 samples use this alarm set with 6
samples in alarm. There is 1 sample with a severe alarm caused by only 1 parameter. That
parameter is Manganese.
41
Alarms 2-49
The LIMS license is required in order to access the Alarm List tab. This tab is useful for
quickly checking and changing configuration information. Lines can be sorted by clicking
a caption at the top of the column. Additional sort criteria may be entered in the text boxes
at the top. Columns can be hidden and made visible by clicking the buttons at the top. The
Type ID, AL Set, RefID, TCL’s, and Report Group (Grp) can all be modified from this
screen.
42
43
You may also select Ref oils from a drop down list on the Ref Oil Desc field.
Alarms 2-51
2-52 OilView Database Options
Chapter 3
OilView Reporting
Trend Information
The Trend Info tab is used to view and edit historical data and alarm status for all samples
stored on a given point.
3-1
Note
You can limit the number of parameters displayed using the Test
and Display Filter option on the Point Info tab.
The second column includes reference oil data or statistical data for the sample. Click on
the top of the second column to toggle through the options which include Mean, Standard
Deviation, Median, Point Baseline, and Oil Reference. The number of samples included in
the running statistical calculations selected on the Point Info tab, Equip minor tab.
The remaining columns display sample data for the point with the most recent sample on
the left. The first two entries on these columns are the sample date, sample number.
Alarming measurement status is reflected in the color shading behind the numerical values.
The color corresponds to the severity criteria of the Setup Tab as well as to the Trivector
Plot. Many of the analysis parameters may not be suitable for alarming and the alarm option
for these can be toggled on and off using the alarm flag which is part of the AP Sets tab.
You can add or limit the number of trend plots displayed using the “Plots? Yes/No” feature
under AP Sets, Current Views. Similarly, only those parameters that have the alarm flag
turned on will show the horizontal alarm limit lines.
The number of samples show on a trend plot can be limited to either a fixed number or for
a given time limit. This is set up on the Setup – System tab.
3-3
Detailed Parameter Plots
Right Mouse click on a parameter description in the grid or on a trend plot and you will get
a detailed trend plot for that parameter. You can select what additional information to dis-
play on this plot by using the check boxes. These include showing the alarm levels as illus-
trated below, the reference value, local median, mean and standard deviations and symbols
to indicate what observation are applicable.
Each condition level in the TriVector plot is a particular color starting from “Normal” green
and proceeding to “Extreme” red. A key to the color code is located directly to the left of
the trivector plot.
Reviewed
This button is used in conjunction with the LIMS.
Schedule
Once a sample has been diagnosed and if another sample is required, then you can go
directly to the schedule for the Point and schedule another sample.
ABC
The Spell check button checks the spelling in the Diagnostic message.
The shape of the TriVector plot is also helpful because it lets you quickly identify areas of
concern. For example, a sample with normal wear and contamination readings but very bad
lube chemistry would appear as below.
Observations Block
The Observations block provides the opportunity to annotate the sample with noteworthy
observations. To add an observation, use a right mouse click on the intended row and select
the appropriate observation from the pull-down list.
Observations
This list of selectable observations serves as a sample record for non-trendable information.
10
11
12
00 125 22 4 1 0
0 250 44 8 2 0
1 500 88 16 3 1
2 1000 178 32 6 1
3 2000 356 63 11 2
4 4000 712 126 22 4
5 8000 1425 253 45 8
6 16000 2800 506 90 16
7 32000 5700 1012 180 32
8 64000 11400 2000 360 64
9 128000 22800 4100 720 128
10 256000 45600 8100 1440 256
11 512000 91200 16200 2800 512
12 1000000 182000 32400 5800 1024
PPM Plot
14
Note
The particle PPM is calculated by volume whereas the typical PPM
is PPM by weight. To convert PPM by volume to PPM by weight,
you must multiply by density. If one assumes that all the particles
were the same size then one would multiply the PPM by volume
by 7 to get the PPM by weight of all the particles in the oil sample.
Because it is difficult t know what type of particles are being
counted we report the PPM by volume which is an accurate mea-
sure.
15
16
The shapes of these curves are used to determine the contamination and ferrous indices as
well as the presence of large ferrous and non-ferrous particles. The water content is also esti-
mated from these curves.
17
18
This is the most typical report generated. The parameters in the grid (spread sheet) and e
parameters plotted are selected in the Report Groups setup in the AP Set module. This gives
the user the flexibility to customize this report for different types of equipment such as
hydraulics, gearboxes, etc. Each point has its run report group assigned to it.
The logo and address can be customized on this report.
19
This report is used to give more detailed sample information including alarm limits and
diagnostics comments for each sample. It is typically used for reporting on historical exam-
ples.
Reports 3-19
Sample Trend – Vib Analyst
20
Parameters and graphs have been selected to highlight wear problems. The contents can be
customized on the Report Group sub tab of the AP Set tab. A summary of the wear debris
analysis is included if available.
21
This report is linked to the report groups in the same way as the Sample Trend report. It only
shows the data from a single sample but also lists the observations and actions. The report
also has a detailed lot such as the ISO plot shown above. Other versions of the report show
the NAS plot, particle count PPM plot, WDA image, and the 5100 / 5200 data plots.
Reports 3-21
Summary Report Options
22
The range of summary reports is controlled by the position on the database tree, e.g., Data-
base, Customer, Area Equipment, and Point and by the above selections.
23
This report shows the Area, Equipment, Point, Sample Date, Sample ID, and then the
Wear, Contamination, and Chemistry severities.
24
This report is a customized version for oil analysis of the exception report created by the
AMS Machinery Manager reporting module. It details the Area, Equipment, Point, Sample
Date, and Sample ID together with the parameter in alarm, color coded for severity, along
with the actual alarm limits.
Reports 3-23
Point Configuration Summary Report
25
This report checks to see if each Point in the database has been correctly set up. For each
point it shows the Equipment Type, AP Set, AL Set, Reference Oil, and the number of sam-
ples under each point. If there are any inconsistencies in the information, such as no refer-
ence oil, that cell in the report is highlighted in yellow.
This report also checks the median value of the dielectric and HOC viscosity against the ref-
erence oil values and if they differ by more than 30% this is also highlighted. If this happens,
it probably means the wrong reference oil has been assigned to the point. You must update
the Point baseline value before running this report. You can do the update from the Data-
base tree popup menu when you right click on the point in the tree.
26
This report does a detailed check on the alarm limit used at each point, looking specifically
for inconsistencies in the alarm limits. Examples would be all of the alarm limits set to zero,
or that they do not progress from small to high values for higher severity.
Use the alarm limit statistical options to correctly set alarm limits. This will give the most
consistent and reliable results.
Reports 3-25
Oil Usage Report
27
This report shows the oil added per year for each point. It then summarizes the oil used per
year for each oil type.
28
Reports 3-27
Print Preview
The Print Preview window is controlled with the following buttons:
29
Graphics save - adds the current image to the problem area in RBMview.
View case history - launches the RBMview program.
Save to File - Save the current report to a .pdf file.
Logon - Press this button to log onto your E-mail system. You must setup your E-mail con-
nection in the Setup – E-mail Tab before you can connect. Once you have logged onto the
E-mail then this button will change to “Logoff” so that you can disconnect once you have
completed importing data.
Import - Once logged-on the system will search for all E-mail messages whose “subject”
contains the phrase “Lab Data.” This enables the system to distinguish E-mail messages
containing lab data file attachments from other E-mail messages. A list of these E-mail
messages is then displayed. To import the data from each E-mail simply click on the E-mail
message to select it and then press the “Import” button.
4-1
Once the data has been imported the attached file containing the data is automatically
archived in the “Lab Export/Import” directory which is setup under File Locations on the
Setup tab. The E-mail message is then automatically deleted. If for some reason you need
to re-import that data then use the “Import Lab File” tab to import the data from the file in
this location.
Delete - Use this button to manually delete an E-mail message.
Cancel - This button stops an import before it is complete. There may be a short delay
before the import stops.
Lab File Type - See next section for details.
Import Into - See next section for details.
Lab Type - These are the currently supported download formats. If your oil laboratory is
not represented, CSI can provide them with a specification for the “Generic” file format.
When importing the data from the CSI Trivector lab the CSI Trivector lab format must be
selected.
Data File - allows you to “browse” the computer’s storage media (hard drives, floppy disk,
etc.) to find the file that is to be imported.
Import Into - This option either selects the current database (fastest) or all the databases in
the RBMadmin group.
Start - Click on the Start button to begin the import process.
4-3
Database Export
This tab is used to export data from the CSI AMS Machinery Manager database to a file
that can be imported into a spreadsheet or relational database. The data exported will
depend on the current position in the database tree. For example, to export the entire data-
base the database level would be selected. To export just one sample, that sample would be
selected.
Save As - The name of the file that will contain the exported data.
Export Format
• CSI Generic (.zip) using the Lab Unit ID as the key for data import
• Area, Equipment, Point (.zip) codes as keys for import. This option auto-
matically creates the Area, Equipment or Point in the target database if
they do not exist.
• Comma Delimited output file.
• Entek IRD format.
Note
When exporting sample data using the A/E/P option, the reference
oil and AP &AL Set ID’s are included in the generic file. this
enables the correct assignment of reference oils and AP and AL
Sets on import. It does depend on the target database have the same
ID’s.
4-5
Statistics Export
This tab is used to export data for the Alarm Limit statistics option.
5-1
The OilView Analyzer test is an immediate, on-site test that will detect abnormal condi-
tions. If the OilView Analyzer test indicates a problem, you may choose to send a sample
to an industrial fluid analysis lab for a more detailed analysis and for expert advice. When
using the CSI Trivector Laboratory for additional in-depth testing, please provide a copy of
the OilView Analyzer results along with the sample.
Test
This menu is used to test used oil samples with the Model 5100 and to test reference oil
samples. Select either the user database or the reference database tab; select or create the
sample point on the corresponding database tree; clean the sensor grid and begin testing.
A principle difference when Model 5100 tests are done on the user database is the auto-
matic application of assigned references. See “Assign Reference” on page 2-2 to learn how
a previously tested reference sample can be assigned to either a user database point or
sample.
Each day, before testing with the Model 5100, you need to either recalibrate each sensor
(see “Calibrate” on page 5-14) or verify (see “Verify” on page 5-13) each sensor that is
going to be used that day.
5100
Incoming lubes R O R 3
Pump oils R R R O R R 10
Compressor R R R O R R 10
oils
Engine oils R R O R O 8
turbine oils R R O R R O 10
Gear oils R R R R R 10
Hydraulic R R R R O 10
fluids
Transformer R R 11
oils
Greases R R R R 8
R = recommended
O = optional
* = typical time in minutes
The Undiluted Testing For All Parameters option is good for oils less than 46 cSt. The full
test time for oils less than 46 cSt will be either 250 or 500 seconds. Although not recom-
mended, this option can be used for oils greater than 46 cSt. Using the full test with high
viscosity oils may take up to 1200 seconds and the results will not be as sensitive as they
would if the same samples were tested using the preferred diluted testing option which
would take much less time.
The Diluted Testing For All Parameters option is good for all oils in any viscosity range (see
“Dilution Of Viscous Samples (OilView Analyzer)” on page 5-31). The dilution effectively
allows all of the measurable wear particles to get to the sensor during the 250 second test
interval, while only a small portion of the particles have enough time to get to the sensor
without dilution—even though the test interval is much longer.
Dilute
5100 Grid
5100 test Calibration Dedicated with
Oil Type Type
method Fluids grid? kerosene
(Gasket)
?
Since the sensor grid has no sensitivity above a dielectric value of 16, high dielectric fluids
cannot be tested. For reference, most mineral oils have a dielectric of 2 to 3, most synthetics
have a dielectric of 2 to 7, water has a dielectric of 78, and conductive materials like metals
have infinite dielectric.
The Model 5100 sensor grid gasket can be either buna-n rubber, this is a red gasket; or it
can be ethylene propylene rubber, this is a black rubber gasket. The red rubber is not com-
patible with phosphate ester oils. The black rubber gasket is not compatible with mineral
oils.
Cross-contamination of one test sample affecting the results of a subsequent test is a signif-
icant problem when testing oils of widely differing dielectric values; especially when the
oils are not soluble with each other. For this reason, it is best to dedicate sensor grids to
testing classes of oil having similar dielectric within +/- 0.2 dielectric units.
Most mineral and synthetic oils can be diluted with K1 kerosene (see “Dilution Of Viscous
Samples (OilView Analyzer)” on page 5-31). Some users prefer to use other hydrocarbon
solvents such as hexane or heptane.
Warning!
Consult your industrial hygiene department, be aware of flamma-
bility characteristics and skin contact restrictions for solvents and
oils.
Long Test
The Long Test is a full-length test performed by the OilView Analyzer. This test will take
from 250 to 1200 seconds depending on the viscosity of the oil and the test option. A long
test consists of 500 cycles through a three-step measurement sequence:
• measure dielectric with electromagnet off,
• measure dielectric with electomagnet north, and
• measure dielectric with electromagnet south.
Altogether, a full test consists of 1500 dielectric measurements and two temperature mea-
surements (at the beginning and end of each test). The OilView software uses these raw
data to calculate dielectric and index values.
Start
The Start button begins a test sequence.
Cancel
The Cancel button aborts a test sequence in process.
Ref
Reference oil information appears in the “Ref” window. Included in this window are the
date that the reference oil was tested, its viscosity, and the dielectric for the reference oil.
Date
This is the date of the reference oil test.
Viscosity
The viscosity value is obtained from the reference oil database and is used to determine the
time period for either “Enhanced Particle Sensitivity” or “Reduced Particle Sensitivity” test
options. If this value is missing or incorrect, it can be edited in the reference oil database.
Critical
Sometimes the results show “Critical.” The OilView analyzer measures dielectric values
between 1 and 16. Many fluids such as water and coolant have dielectric constants much
higher than 16. Also, metal particles can short the capacitance of the sensor grid causing the
sensor to report a value exceeding 16. If the dielectric value is greater than 16 at the end of
an OilView Analyzer test, the display will report “Critical.” The Contaminant and Ferrous
indexes will not be displayed for a Critical sample because the extreme contamination has
overwhelmed the sensitivity of the sensor at the end of the test.
Note
Never dilute the reference oil. Chemical comparisons between the
reference and the used oil must both be measured on unmixed,
undiluted oils.
The first application—deciding the length of time a sensor grid’s calibration will remain
valid before a warning message informs you that the calibration has expired—will depend
on environmental factors. For example, if you calibrate your grids on Monday and they
pass a Verification Test on Tuesday and Wednesday but fail Thursday, you may want to set
the calibration period to three days. The conditions at each user’s site will determine the
number of days selected. (Ambient temperature and relative humidity changes will be the
largest factors in grid calibration changes.)
If, at any time, you run a test and the results seem unreasonable or they suggest a strong
action such as changing 500 gallons of oil, for example, run a verification test to confirm
the operation of the OilView Analyzer.
The procedure for performing verification is the same as that used for the Calibrate proce-
dure which is described in the next section.
You should calibrate each sensor once each day using two Spectro supplied-calibration
fluids. See “Oil Compatibility Chart” on page 5-8 to determine whether a sensor should be
calibrated with Fluids A and B or with Fluids B and C. The software will automatically
prompt you for the correct fluid based on the configuration of the Model 5100’s Calibration
Settings tab.
Cleaning Process
Clean the sensor by carefully wiping the sensing grid dry using a soft tissue paper and a cir-
cular (twisting) motion. The grid has been wiped clean when it no longer stains or wets suc-
cessive clean pieces of tissue. Do not use a water-based cleaner or an abrasive material to
clean the grid. Do not allow water-contaminated oil to stand on the grid after a test.
Grids
The first software step in calibration or verification testing is to select the grid color from the
selection list. This menu does not default to the last color used which addresses a common
error when calibrating—inadvertently selecting the wrong grid color. You must select the
grid color before doing anything else on this menu tab.
Special Notice
It is especially important to thoroughly clean the sensor before calibrating or verifying. The
effects of cross contamination during calibration will affect all of the measurements made
until the next calibration. Be sure to clean the grid at least two times using the same calibra-
tion fluid that is to be tested. You must wipe the sensor surface completely dry using tissue
paper during each cleaning operation.
Keep in mind that Fluids A, B, and C are very different in dielectric; each one must be com-
pletely removed before continuing with the next measurement. (You may want to test your-
self on raw data repeatability results as you double-clean and test fluids A and B, or B and
C.)
Continue.. cancel
Continue through the sequence, following the instructions in the dialog box. You will be
asked to clean the sensor grid and then fill the sensor well with two calibration fluids
sequentially. Calibration Fluids A and B are used for normal oils and Fluids B and C are
used for higher dielectric oils.
Calibration Settings
Test Information
Three test options are available to the OilView Analyzer user. These settings remain in
effect constantly until they are changed.
Calibration Information
Before calibrating or verifying sensor grids, the grid type and calibration oil properties must
be selected. These properties are reported on the labels of Spectro-supplied calibration
fluids.
Grid Type
There are two calibration ranges: normal and high. Normal calibration is done using
Spectro supplied Fluids A and B for oils in the range of 2.1 to 3.2 dielectric. High calibration
is done using Spectro supplied Fluids B and C for oils having dielectric values above 4.0.
Be aware also that there are two grid types: Phosphate Ester and non-Phosphate Ester types.
Most people do not require Phosphate Ester type grids (which have a black rubber seal
material that the oil sensor plugs into). Select the grid type that matches the sensor. While
Phosphate Ester grids are always in the high range requiring calibration with Fluids B and
C, the non-phosphate ester grids may be either: normal requiring fluids A and B, or high
requiring fluids B and C. (See “Oil Compatibility Chart” on page 5-8.)
Diagnostics
The diagnostics tab is only to be used under the direction of CSI Customer Support when
troubleshooting potential problems.
System Setup
To set up the OilView Analyzer system, place the OilView Analyzer and the computer with
which it is to be used on a flat, horizontal surface. Using the provided interface cable, con-
nect the OilView Analyzer’s Port 1 to the computer's COM1 or COM2 serial communica-
tion (RS232) port.
Note
Ports 2, 3, and 4 are available only on the Model 5100-1 and 5100-
2. The earlier Model 5100 does not contain these ports.
Note
If port 2 of the Model 5100-1 or 5100-2 is not being used by either
the Digital Viscometer or the Ferrous Wear Monitor, then the Aux-
iliary Port connector key should be plugged into port 2.
After connecting the interface cable, plug the 110/220 volt power cable into the OilView
Analyzer unit and into a 110/220 volt outlet, and then turn the unit on. The analyzer should
give a three-tone output and display the OilView copyright message on its LCD screen.
Access the OilView software program. The system is now ready for use. Configuring the
software is described in “Software Setup” on page 5-3 and a typical testing session is
described in “An Example Testing Session” on page 5-25.
Caution!
The sensing grid should never be exposed directly to water.
Note
Because the OilView Analyzer is extremely sensitive to moisture,
it should be used indoors where humidity and temperature are rel-
atively constant. For best results, the humidity should be low and
the temperature should be nearly constant.
Note
OilView initializes the serial port where the analyzer is defined. If
the computer mouse is connected to that port, the mouse will not
work.
Note
If necessary, the fuse (next to the power connector) can be replaced
with a standard 2-amp fuse.
Caution!
Never expose a new sensor to water or water contaminated oil
before it is “cured.”
Phosphate Ester
When testing phosphate ester oils on the OilView Analyzer, you must use a special phos-
phate ester sensor grid. (You can recognize this type of sensor grid because the threaded
rubber material is black.) In addition, you must cure the sensor by applying a bottle of clean
phosphate ester oil to the sensor for 24 hours. Failure to follow this procedure will result in
an unstable chemical index as the grid reaches equilibrium with the phosphate ester.
Caution!
Do not use kerosene, mineral oil or CSI-supplied Calibration
Fluid A on the phosphate ester sensor grid—the black seal mate-
rial on the grid is not compatible.
Caution!
Do not use phosphate ester oil or CSI-supplied Calibration Fluid
C on normal sensors that have the red rubber seal. These fluids are
not compatible with the seal*.
*Phosphate ester oil and the CSI-supplied Calibration Fluid C are corrosive type fluids and
if used on the normal sensor grids (which have a red rubber seal) they would damage the seal.
CSI has special grids to use with the Phosphate ester oil and the CSI-supplied Calibration
Fluid C.
10
3····Once the sample has been shaken, screw the sensor to the bottle.
11
4····Plug the sensor into the OilView Analyzer. Take care to ensure that each
of the plugs on the sensor body is fully inserted in the jacks on the face
plate of the analyzer.
5 ··· Make sure the correct sample point is selected so the correct reference
will be used. A typical test will take approximately eight minutes to
complete. After conducting the test, save the test results.
6····As soon as the test is completed and the results are saved, unplug the
sensing grid and shake the bottle. This action stirs the debris that settled
onto the grid during the test back into the oil. Then place the bottle bottom
down and allow the oil to drain from the sensing grid back into the bottle
for a few seconds. After removing the sensing grid from the bottle,
replace the bottle cap.
7····The grid should be double cleaned after each test. Carefully wipe the
sensing grid clean and dry with a soft tissue paper inserted into the bottle
opening using a circular (twisting) motion. The grid has been wiped clean
and dry when it no longer stains or wets successive clean pieces of tissue.
Do not use a water-based cleaner or an abrasive material to clean the grid.
Do not allow water-contaminated oil to stand on the grid after a test. Be
sure to apply a few drops of the next lubricant to be tested on the grid and
wipe clean and dry before testing (see “Cleaning the sensor grid.” on page
5-15).
Caution!
The sensing grid should never be directly exposed to water.
Caution!
Prolonged exposure to salt water or acid may damage the sensor
grid.
Model 5100
When testing with the Model 5100, do not attempt to use the computer for any other task
while the test is running—data may become corrupted or lost.
The viscosity of the undiluted sample should be determined with the optional Model 51DV
Digital Viscometer. If this test shows a viscosity of less than 48 centistokes (cSt), dilution is
not necessary. If the viscosity is greater than 48 cSt, the oil should be diluted by adding ker-
osene to the oil sample. This can be done by filling the sample bottle slightly over 1/3 full
with oil, adding an equal amount of kerosene, and leaving the rest empty to allow for easy
mixing when shaking the sample.
When an oil is diluted prior to a test, it is wise to record that fact in the test comment line.
Note
For information on diluting samples to be used with the OilView
Particle Counter, see “Dilution Of Viscous Samples (OilView Ana-
lyzer)” on page 5-31.
Warning!
Consult your industrial hygiene department, be aware of flamma-
bility characteristics and skin contact restrictions for solvents and
oils.
Synthetic Oils
The OilView Analyzer can be used to test most synthetic lubricants. Extra care should be
taken in cleaning the grid when changing between mineral oils and synthetic lubricants. See
“Oil Compatibility Chart” on page 5-8 for additional information regarding testing syn-
thetics with OilView instrumentation.
Verify Calibration
After initially calibrating your grids using CSI-supplied calibration fluids, regularly verify
the calibration using the 5100 Verification Test. This quick test will indicate whether or not
a grid needs to be recalibrated.
Synthetic Oils
Since synthetic lubricants such as phosphate ester, polyol ester, or diester have vastly dif-
ferent properties from typical mineral oils, extra precautions are necessary to clean away
any residual of the synthetic before resuming tests with mineral oils, or vice versa. You must
dedicate a sensor grid for the sole purpose of testing each generic class of synthetic lubri-
cants that you use. Once again it is important to do final cleaning using the “next” oil to
wipe away any residual surface film on the grid surface and to wipe the sensor dry using
tissue paper between cleaning steps.
Start-Up Support
Start-up support is a good way to get off on the right foot. Allow CSI Reliability Services
(423-675-2110) to come to your plant to set up your initial databases and collect the first
samples. In many cases, the results of this first round of tests detect problems and achieve
significant cost savings.
The Model 51DV and 52DV Digital Viscometers (referred to in this manual as the Model
5xDV) can be used to rapidly measure the viscosity of lubricants and other fluids that have
a 40°C viscosity of from 20 cSt to 680 cSt.
Warning!
For safety reasons, the OilView Digital Viscometer should never
be applied to a highly flammable hydrocarbon liquid such as gas-
oline.
6-1
Note
The well must be cleaned of previously tested fluid before each
new measurement. Old fluid can be poured out of the unit by tilting
it and allowing the fluid to flow into a disposable receptacle. Take
care to ensure that the steel ball does not fall out of the well and be
accidentally discarded. Alternatively, you may place a paper towel
into the well and allow it to absorb the old fluid, or use the syringe
to remove the fluid.
Caution!
Exercise care when inserting the Digital Viscometer’s 15-pin con-
nector into the OilView Analyzer’s port 2—it is possible to force the
connector upside down.
1. ISO 14, 32, 68, 100, 137, 220, 460, and 680
Note
Make sure your Digital Viscometer is plugged in and warmed up
for one hour prior to starting a calibration. When calibrating, start
with the highest viscosity oil and progress to the lowest viscosity
oil.
Enter the Name, 40°C and 100°C viscosity, specific gravity, and viscosity index (VI) for the
calibration oil you are about to test. This information can be found on the label of the
Spectro-supplied Digital Viscometer calibration fluids. If you are using your own oils for
calibration, these numbers will have to be provided by an oil analysis laboratory.
Note
The viscosity index value is for reference only. If this field is left
blank, it will not affect your measurements.
Calibration Oil Description - Enter a unique name or title to identify the fluid being used
for calibration.
Auto-Calc - Check this box to instruct the program to automatically calculate the specific
gravity for non-synthetic oils based on the 40°C viscosity and temperature.
Viscosity Index - is an empirical number indicating the rate of change of an oil within a
given temperature range. A low viscosity index indicates large change, and a high viscosity
index indicates a relatively small change. As you remove unsaturates from the oil during
the refining process, you increase the thermal stability as well as the viscosity index.
If two oils had the same viscosity at room temperature, as the temperature increased the
high viscosity index oil would thin out less and have a higher viscosity at elevated temper-
ature.
Start Calibration
This function button starts the calibration for the highlighted oil entry.
Delete Calibration
This function can be used to delete the highlighted calibration oil.
Default Calibration
The Default Calibration function can be used to identify the highlighted oil (with an
asterisk) as the typical viscosity/temperature profile that will be used to compute the 40°C
viscosity value when tests are performed on unknown oils or when the 100°C value has not
been entered.
Cancel Calibration
This function aborts a calibration run in progress. Any new fluid data entered will be lost
after aborting and leaving the Calibration tab.
Note
When calibrating, start with the highest viscosity oil and progress
to the lowest viscosity oil.
After clicking on the Start button, a window will follow asking you to prepare the viscosity
standard for testing. Make sure that the sample well and steel ball are clean, and place
enough of the fluid into the well to fill it to the vertical rim as shown below. Then, place the
steel ball into the well (if it is not already there). Click the OK button to begin the calibration
procedure.
A progress bar will be displayed showing the test progress as the ball rotates. The progress
will display “Finished” at the end of the run. You may then save the results by clicking on
the Save button, or discard the results by clicking on the Cancel button.
Remove the ball from the cup using the magnetic ball retriever. Then remove the ball from
the retriever to prevent the ball from becoming magnetized. Discard the oil and clean the
cup and ball bearing before the next test.
To test the next calibration oil, enter the data and select the Start button to repeat the same
process described above. When you are finished with the last calibration oil, your calibra-
tion table will display the oils you tested from highest to lowest viscosity.
Highlight one of the oils in the calibration table and choose the Default (*) button to select
it as the default reference. This default will be used if no reference oil is chosen for a point
or if the chosen reference oil doesn’t include a 100°C viscosity.
Note
Spectro strongly recommends that the default reference be
changed as needed to match, as closely as possible, the viscosity
index of the oil being tested to the viscosity index of the calibration
oil. The viscosity index is printed on the labels of Spectro-supplied
calibration oils and should be available from your oil supplier for
the oils used at your site. This practice will ensure the most reliable
results from your Digital Viscometer.
Plot Cal
The Plot Cal tab displays the calibration curve of the full viscosity range tested. Each oil
used in your calibration is identified by a marker on the graph.
Verify
Use the Verify tab function to verify the measurement accuracy of the Model 5xDV. Select
the calibration oil you are using from the list, and then click on the Start button. The results
and percent deviation are displayed at the end of the test.
10
Note
The Settings, Diagnostics, and Raw Data tabs are normally grayed
out and not accessible. They may be used by Spectro Customer
Support to help diagnose problems.
11
Whenever possible, assign a reference oil to the displayed point prior to running the Digital
Viscometer test. Best results will be achieved if you provide both the 40°C and the 100°C
viscosity data for this reference (see “Assign Reference” on page 2-2 and “Data Available”
on page 2-5).
These 40°C and 100°C values will allow the Digital Viscometer to give the most accurate
measurements. There are three cases where the default calibration in the calibration file will
be used:
• if the 40°C viscosity is defined on the reference on the point, but the 100
C viscosity is not,
Note
If a reference oil is not specified for a point, it is very important to
choose a default calibration with a viscosity index similar to the oil
you will be testing.
Note
If both the 40°C and 100°C values are not specified on the point,
the Digital Viscometer will use the viscosity/temperature profile
from the default calibration file.
As in the calibration procedure, make sure that the sample well and steel ball are clean, and
place enough of the fluid into the well to fill it to the vertical rim. Then, place the steel ball
into the well (if it is not already there). Click the Start button to begin the test procedure.
After the test has completed, the window will display the calculated viscosity in cSt at 40°C
and the percent viscosity change from the reference value.
Viscosity 6-15
6-16 Digital Viscometer Model 51DV and Model 52DV
Chapter 7
The CSI Model 51PC Particle Counter is a laser-based optical particle counter enabling
direct particle measurements and size distribution from 2 microns upwards. The particle
counter is an essential tool for monitoring clean oil systems such as turbines, hydraulics,
high-speed compressors, or where life extension of equipment is an important consider-
ation.
The particle counter features ISO and NAS cleanliness outputs, in-line sensors for lube con-
dition, full integration with the OilView and AMS Machinery Manager software product
family, and industry recognized standard outputs. These outputs are readily trended using
the OilView software with automatic, knowledge-based expert system interpretation and
recommendations.
The Model 51PC Particle Counter includes:
• Laser Particle Counter with color and dielectric sensors
• OilView software
• Communications and power cables
• External universal power supply
• CO2 cartridge
• Plant air adapter
• Sensor cleaning brush
7-1
OilView Particle Counter Setup
Connect the provided interface cable to the 9-pin connector located on the right side of the
particle counter and connect the other end of the interface cable into port 3 or 4 on the Oil-
View Analyzer. Alternatively, the particle counter’s interface cable can be plugged directly
into the computer's COM1 or COM2 serial communication (RS232) port.
Connect the power supply’s output cable into the power connector located on the right side
of the particle counter. Plug the power supply’s AC cable into a standard 110/220 VAC
outlet.
• Make sure that all cables are connected properly (see “OilView Particle
Counter Setup” on page 7-2), then turn on the Particle Counter’s power
switch.
• Ensure that the communication port configuration is properly set up (see
“Setup Menus” on page 1-28).
Caution!
CSI highly recommends using an ultrasonic bath to prepare sam-
ples for the particle counter. If reducing sample preparation time
is an important consideration, a vacuum chamber may also be
used to speed up removal of entrained air. See “Sample Prepara-
tion” on page 7-22 for detailed procedures and vendor informa-
tion.
2····Unscrew the sample cup from the bottom of the particle counter. Place the
sample bottle upright in the cup (without lid). (Instructions for preparing
the sample are located at “Sample Preparation” on page 7-22.)
3····Turn the sample cup clockwise back onto the particle counter, tightening
until a hard stop is felt.
4····Ensure that the current sample point has been specified for the particle
counter (see “Database Tree” on page 1-11). Click on the Test tab at the
bottom of the window. Then in the Test Control area, verify the flow rate,
test volume, flush volume, diluent amount, and sample amount. (To
change these settings see “Settings” on page 7-21.)
Note
The default values for flow rate, test volume, and flush volume are
taken from the PC reference oil (see “Assign Reference” on page
2-2).
5 ··· At this point you have the option of specifying whether dilution is being
used. Check on the Diluted Sample box of the Test Control area if dilution
is to be used. Leave the box unchecked if dilution is not being used.
50 25 5 50 ml
6····Make sure that a drain container is positioned beneath the drain tube.
10
7····Select Start from the 51PC Test tab. When the test begins, turn the drain/
fill valve knob when requested to do so.
Inadequate pressure
• Flow rate is too high for viscosity of sample. Try diluting the sample.
• The CO2 cartridge is almost empty. Check the pressure regulator indi-
cator and ensure that the reading is greater than 2 kgf/cm2.
• Pressure regulator is not opened to the “HI” position. Adjust regulator.
• Plant air pressure is too low. You may need to increase air pressure to 100
psi or more.
• The sensor is dirty and needs to be cleaned (see “Sensor Cleaning” on
page 7-33).
On Power Up
When the particle counter is powered up, two short beeps should be heard and the LED
next to the power supply connector should turn green. If the LED remains red, some fluid
may be in the cylinder from a previous test and must be drained by starting a test and turning
the Drain/Fill valve knob to the “drain” position. If there is no audible beep and/or the LED
does not come on, check all power supply connections.
1-90 cSt 50 25 5 50 ml
91-160 cSt 20 25 5 50 ml
160-300 cSt 10 25 5 50 ml
12
Minimum Maximum
ISO Code
(Included) (Excluded)
1 0.01 0.02
2 0.02 0.04
3 0.04 0.08
4 0.08 0.16
5 0.16 0.32
6 0.32 0.64
7 0.64 1.3
8 1.3 2.5
9 2.5 5.0
Minimum Maximum
ISO Code
(Included) (Excluded)
10 5.0 10
11 10 20
12 20 40
13 40 80
14 80 160
15 160 320
16 320 640
17 640 1300
18 1300 2500
19 2500 5000
20 5000 10000
21 10000 20000
22 20000 40000
23 40000 80000
24 80000 160000
25 160000 320000
26 320000 640000
27 640000 1300000
28 1300000 2500000
00 125 22 4 1 0
0 250 44 8 2 0
1 500 88 16 3 1
2 1000 178 32 6 1
3 2000 356 63 11 2
4 4000 712 126 22 4
5 8000 1425 253 45 8
6 16000 2800 506 90 16
7 32000 5700 1012 180 32
8 64000 11400 2000 360 64
9 128000 22800 4100 720 128
10 256000 45600 8100 1440 256
11 512000 91200 16200 2800 512
12 1000000 182000 32400 5800 1024
Lube Quality - This is a measure of fluid degradation as detected by the colorimetric and
dielectric sensors. This measurement correlates with the analyzer Chemical index.
Dielectric Constant - A measure of the dielectric permittivity of the fluid (i.e., the insu-
lating quality). This will increase as the lubricant becomes degraded by oxidation or acidity.
Fluid classification
Component type
ISO code
13
14
Settings
Use these fields to adjust the flow rate, flush volume, and test volume for the Model 51PC
regular test.
CSI recommends always using the 50 ml/minute flow rate as this is the rate used to calibrate
the sensor. Normally, you will want to select 25 ml flush volume and 5 ml test volume.
Keep in mind that the total sample consumed equals the flush volume plus three times the
test volume.
Note
Do not put shaken samples of undiluted oil directly into a vacuum
chamber or foaming may occur.
When this process is complete, tighten the lids to the sample bottles and place them back
into the ultrasonic bath. The ultrasonic bath will keep the particles suspended until you are
ready to perform the test. Be sure to dry the water off the outside of the bottle before opening
and inserting it into the sample cup for particle counter testing.
Note
An appropriate amount of the sample can be anywhere between
one to twenty grams of sample depending upon contamination.
Note
The mixed solvent is proven to be effective on samples with up to
17% water content.
The diluent that is used should be one which is completely soluble with the oil sample.
After mixing the two, there should be no evidence of haziness or layers floating in fluid—
this would indicate a mixture as opposed to a solution.
Kerosene makes a very good diluent for mineral-oil-base stocks and nearly all synthetic
lubricants. For typical industrial applications, commercial K1 kerosene will suffice for
flushing to clean the sensor. You can filter commercial K1 kerosene yourself to use for dilu-
tion or final cleaning by passing it through a 0.8 micron filter.
For very clean systems, you will want to purchase laboratory reagent grade kerosene, or
you may even opt for “superclean” diluent which is certified to meet specified particle
count levels. In any case you will need to test a representative sample of the diluent to be
used, verify acceptable cleanliness, and store the results as diluent reference.
15
2 ··· Place the empty bottle on the scale, then select the “tare” option on the
scale. Effectively, now the empty bottle weights 0.0 gram.
16
3····Place the sample bottle on the scale to measure the weight of the sample
(in grams). Write the sample weight on the bottle label.
18
19
5 ··· Add an approximate amount of the diluent. For a 1:1 dilution ratio, add
about the same weight of diluent as the sample. For a 10:1 dilution ratio,
add ten times as much diluent as the sample.
6····Write the weight of the diluent on the label along with the weight of the
sample.
21 7
22
8 ··· Then enter the diluent weight and the sample weight in the cells in the Test
Control table.
Measuring By Volume
To measure the amounts by volume, fill with sample to a pre-measured line on the bottle
and then add diluent to a second pre-measured line on the same bottle. The actual particle
counts for the diluent (already stored in memory) will be used by applying the “rule of mix-
tures” for the most accurate calculation of particle counts on diluted samples.
Sample Types
Certain types of oil samples should not be tested on the OilView Particle Counter. Do not
test an oil unless it readily dissolves in the flushing solvent being used. This is critical
because you will need to flush 100% of this oil out of the system before introducing a dif-
ferent oil type into the particle counter. For instance, if kerosene is used to flush the sensor
clean between batches, then PAO (poly alpha olefin) is likely to be the only synthetic lubri-
cant that can be tested, since other synthetics will not dissolve in kerosene.
Caution!
Do not test per fluorinated ethers (for example, Krytox or Fom-
blin) since there is no solvent that chemically dissolves this PTFE-
based synthetic material.
To prevent excessive flushing time, do not test used diesel engine oils that are black from
soot. Note that all of these types of samples are able to be tested on the OilView Analyzer—
even though they cannot be tested using the OilView Particle Counter.
Finally, although it will not damage the particle counter, water/oil emulsions cannot be ade-
quately tested because the water droplets may give false particle counts.
Note
If you intend to screen the sample as described, you should split the
oil sample so that the Model 5100 test does not contaminate the
Model 51PC sample.
If high contamination or ferrous wear is indicated with the OilView Analyzer, then it will
be extreme when tested with the OilView Particle Counter which has 100 times greater sen-
sitivity. If the OilView Analyzer gives any marginal, bad, or extreme readings, then it is not
necessary to test the sample with the OilView Particle Counter.
In addition to using the OilView Analyzer to screen obviously bad samples before intro-
ducing them to the particle counter, look at the sample in the bottle. If the following visual
conditions exist, a laser particle count is probably not needed:
• Obvious visual sediment in bottle,
• Obvious visual indication of water or milky appearance.
Sensor Cleaning
When the sensor does not come clean with multiple kerosene flushing, use the wire brush
supplied with the particle counter to clean the sensor (see “Sensor Cleaning” on page 7-33).
The wire brush is able to clean contamination from the sapphire windows of the laser par-
ticle counter. After using the wire brush, it may take up to 300 ml of kerosene to flush debris
out of the sensor. Repeat this process as needed to attain acceptable cleanliness.
Kerosene
Clean kerosene can be purchased from Fisher Scientific5 or other laboratory supply com-
panies. CSI recommends the “odorless” kerosene (catalog number K10-4 from Fisher)
which has very little odor and consistently has very low particle counts. This is very good
for dilution and for final cleaning. “Gas station” variety K1 kerosene is fine for general
flushing to clean the sensor. Filtering K1 kerosene through a 0.8 micron filter allows you to
use it for dilution and final cleaning.
Introduction
The Model 51FW Ferrous Wear Monitor is a single-purpose analyzer that rapidly tests
lubricants and greases for ferrous wear particles.
The Model 51FW uses a magnetometer to sense (through the plastic of an unopened
sample bottle) the change in permeability due to the presence of a lubricant or grease con-
taminated with ferromagnetic particles. Because viscosity does not affect the measurement,
the Ferrous Wear Monitor is ideally suited for measuring viscous oils, such as gear lubes
and greases, without dilution.
Also, because the Model 51FW does not depend on optical properties, it can easily be used
on opaque and/or soot loaded oils without any special preparation.
8-1
Note
The Model 51FW does not detect lube degradation. Sufficient
quantities of non-ferrous particles can be detected and will gen-
erate a “non-ferrous particles” message in the status area.
Standard Equipment
The Model 51FW is available for stand-alone operation or as an accessory to either the
Model 5100-1, 5100-2, or 5200.
The stand-alone system consists of:
• The Ferrous Wear Monitor instrument
• Power supply and cable
• 15-pin to 9-pin female cable
• Reference standard
• Software
• User’s manual
The accessory system consists of:
• The Ferrous Wear Monitor instrument
• 15-pin to 15-pin female cable
• Reference standard
Caution!
The cables provided with the Model 51FW are custom engineered
and cannot be substituted with a standard serial cable.
Power Switch
The Ferrous Wear Monitor uses a three-way power switch. Operation is shown in the fol-
lowing illustration.
Caution!
The 51FW uses an internally generated magnetic field and sense
coil. External fields from some electronic devices or computer
monitors may interfere with the 51FW and cause erratic readings.
Large metal objects may have a similar effect. Move the 51FW
away from these objects.
Empty/Clean Calibration
When testing with the Model51FW, it is possible for a clean, empty sample bottle to cause
a slight reading by itself. This is due to the composition of the plastic used to make the
sample bottles. To account for this, a clean, empty sample bottle should be tested. The bottle
should be the same type as those used for collecting routine samples. If you change the type
of bottle you use, simply use the new bottle the next time you calibrate your unit.
When a standard calibration test is run, the result of the empty bottle test is automatically
subtracted from the standard calibration test results. This “zeros-out” the reading from the
empty bottle.
Select the 51FW tab on the top of the main menu, then click the Calibrate Empty tab. (Note
the date of the last calibration in the upper-right corner of the window.)
Click the Start button to begin the calibration procedure, the 51FW Message box should
read “Initializing.” After a moment, the status box will display “Ready,” and the User
Action box should display “Place Sample on 51FW.” In this case, place a clean, empty
sample bottle on the Model 51FW.
The Results area displays the results of the individual tests. The 51FW Message box dis-
plays the current status of the analyzer. Choose save to store the empty bottle result after
three good readings.
Standard Calibration
After completing the Empty/Clean calibration, select the 51FW Standard Calibration
option located under the Calibrations option of the Setup menu. Repeat the same test pro-
cedures using the CSI-supplied calibration standard.
The following section, “Taking Calibration Readings,” provides greater detail on testing
and the prompts given in the User Action box.
Note
Bad readings are commonly caused by slow placement of the
sample or movement of the sample before the measurement has
been completed.
Note
An “excessive range” message indicates an inconsistency between
the three bottle placement readings. This is most commonly caused
by the standard being placed off-center from the red sensing area.
Note
Although not required, CSI recommends that the Model 51FW be
calibrated daily. The 51FW index value for tests run using the cal-
ibration standard should equal 100 (±5). Any fluctuations in the
electromagnetic readings will be zeroed out when the 51FW is cal-
ibrated.
Note
Although not required, CSI recommends that the Model 51FW be
calibrated daily. During calibration, the raw results for the calibra-
tion standard typically will be in the 300 to 400 range. Then, when
the calibration standard is re-tested under the 51FW Test tab, the
software scales the raw results so the 51FW index value should
equal 100 (±5). The number on the calibration standard bottle is
simply a reference index as compared against a “gold standard” at
CSI. Any fluctuations in the electromagnetic readings will be
zeroed out when the 51FW is calibrated.
Click on the Start button and when the User Action box displays “Place Sample on 51FW,”
place the sample bottle inside the ring located on the top panel of the analyzer. The status
box will then display either Good Reading or Bad Reading. If a good reading has been
taken, the Readings box will display a number; if a bad reading, no number will be dis-
played. In either case, the User Action box will then display “Remove Sample from
51FW.”
You will be asked to place and remove the sample until the software records three good
readings. When the third good reading is recorded, you must remove the sample and click
the Save button to store the results.
Note
Data taken from a regular Ferrous Wear Monitor test may not be
stored to a reference file.
Screening
The sample screening tab is used to screen samples without saving the results to the data-
base. This is also a good place to verify your calibration. Three readings are averaged per
sample. Pressing he Next button starts a new set of readings.
The Wear Debris Analysis (WDA) tab is used to assist in analysis and documentation of
visual microscopic observations of wear debris and contamination extracted from oil sam-
ples. Wear debris analysis is implemented using a glass slide, a filter, Model 5100 sensor
grid, Model 51WD or 5200 patch maker, or other surface to collect debris which are then
viewed under a microscope.
“The OilView Analyzers And Wear” on page 9-13, discusses wear mechanisms and how
the OilView analyzers and microscopes assess wear.
Although you do not have to capture images to do wear debris analysis, it is helpful to use
a CCD camera with video capture to bring live images into the image window. The Oil-
View 4.0 Software provides image capture capabilities using a video camera and video
frame grabber card. Various video cameras and frame grabbers may be used, but the key to
the software interface is that the video frame grabber must provide an industry standard
TWAIN software interface. That is to say, the frame grabber manufacturer must supply a
TWAIN driver dynamic link library (.dll) along with the card. Note that the software can
import JPEG image files regardless of their source. The recommended camera and frame
grabber card specifications and requirements are listed in the following tables.
9-1
Video Camera
The CSI Model 51CV Wear Debris Image Capture Kit includes a camera and video frame
grabber card. Refer to the camera and capture card manuals for installation and setup
instructions.
9-3
In effect wear debris analysis introduces another level below the sample level on the User
Database tree—the image level.
Sample
The Sample tab is used to analyze and document this analysis for each individual image as
well as the overall oil sample. These features on the screen pertain to the image and to the
sample.
9-5
Sizes range from “Fine <6u,” to “Small 6-14u,” to “Med 14-40u,” to “Large 40-100u,” to
“Huge >100u.”
The photograph taken through the microscope is captured using the Capture button. Other-
wise, photographs are imported using the Add File button.
Note
When capturing an image with the 51CV Image Capture Kit,
verify the “Input Type” setting is SVideo. Save this setting.
Once the image is captured or added to the sample, additional images are sequentially
appended and can be scrolled through using the left and right arrow buttons.
Each image can be given a caption and note. These notes and captions remain associated
with the image and are not passed on to the sample record.
Notes added to the wear debris analysis Sample Diagnosis field are copied to the sample
record under the Sample Info tab. These notes apply to any or all images for a given sample.
The wear debris analysis grid includes five pages. Each page represents an analysis of a dif-
ferent group of particles. To do this analysis you can select one item from each column for
each group which most closely describes the group.
9-7
Measuring Image Size and Particle Density
Before you can measure the size of particles in the captured image, you must calibrate the
microscope capture system.
Note
You must enter the magnification and zoom settings on he micro-
scope when the image is captured.
To measure the particle size, first click on the Measure (particle size and set rectangle for
counting particles) button. Next, position the cursor near the particle, press the left mouse
button, and then draw a rectangle around the particle. The size of the particle is shown in
the popup dialog box.
Counting Particles
To measure the particle density (particles per square millimeter), first press the Measure
button and then draw a rectangle around the region containing the particles. Next, press the
Count (particles with mouse click) button. Now, you can visually count the particles,
pointing the mouse cursor to each particle and clicking. this automatically counts the parti-
cles. Or you can count the particles and manually enter the number to get the particle diver-
sity.
When finished, this information can be used to fill in the WDA matrix.
The left photograph is functionally the same as it is on the Sample screen, except that you
cannot edit the caption, notes, or select through the wear debris analysis grid.
The right photograph is one from the atlas. If no atlas image is present then you may scroll
through the tree on the lower right to select and view until you see one that looks like the
sample image.
The Show Analysis button displays the WDA matrix settings for the selected atlas image.
Once you have found an image that has features you want ported over to the wear debris
analysis, select one of the five groups on the lower left and then select the <<< button. This
automatically replaces entries in that analysis group with those from the atlas image.
Go back to the Sample tab to edit these entries to exactly fit your analysis of the sample.
9-9
Atlas Setup
The Atlas tab is much like the Sample tab except that it is used to add or edit the wear debris
analysis Atlas. You must be an advanced user to edit the atlas.
The tree on the upper left is used to select the image to be viewed, and the note field below
the tree contains information relevant to this image.
The wear debris analysis grid below the image represents the most obvious group of parti-
cles in the atlas image. There is only one group of particles represented in this grid.
To add images to the atlas, first use a right mouse click on a tree folder and select the Add
Child Folder option. Then use either the Add file or Capture buttons below the photograph
to add an image to the folder. These work the same as they do for the Sample images.
9-11
Calibration
To be able to measure the size of particles on the screen, you must calibrate the image cap-
ture characteristics. To do this you place the standard graticule (supplied with the micro-
scope or available from CSI), which has calibrated marking in microns as shown above.
Each small mark is 1 micron. Adjust the microscope magnification and zoom settings so
that you see most of the graticale
You must now enter the magnification and zoom settings in the text boxes in the software
as well as the length in microns of the graticale you are going to measure with the cursor.
Press the Measurement button and drag the cursor between the graticale lines that represent
the distance to be measured. When you release the mouse button the pixels /micron calibra-
tion factor is recorded. Now, save these settings by pressing the Save button.
Fatigue Wear
Fatigue wear is caused by cyclic loading of metal surfaces. This wear eventually results in
micro-cracks in the surface which causes separation of metal from the surface as the cracks
spread. Metal surfaces exposed to cyclic loading often fail from fatigue. The time to failure
decreases with increasing load and increasing cyclic load frequency. This implies that high
loads from sharp surfaces can cause both abrasive and fatigue wear in rolling elements.
Common machine parts subject to fatigue failure include gear teeth, roller element bear-
ings, cams, drive chains, and sprockets. In many cases fatigue wear can be the beginning of
the end of a component’s useful service life.
Fatigue wear can be accelerated through surface corrosion and inadequate lubricant film
thickness. In general, the size of fatigue wear particles increase with increasing rates of
wear. The particles produced are often too large to be detected with atomic spectroscopy.
These relatively large particles are easily detected by the OilView Analyzers, Ferrous Wear
Monitor and Particle Counter.
9-13
In many cases, fatigue wear will not have a solution other than planning to replace the worn
part. In the short term, corrosion influences and secondary abrasive wear from fatigue wear
particles should be minimized by changing the oil and filter. In addition, vibration analysis
should be performed on the machine to determine if the system is being subjected to abnor-
mally high levels of vibration. In terminal cases, the use of a more viscous oil can some-
times delay catastrophic surface failure at the cost of increased friction and higher operating
temperatures.
Adhesive Wear
Adhesive wear is caused by metal to metal contact in the absence of an oxide or lubricant
film. The mechanism involves bonding at the atomic level between clean opposing metal
surfaces. Wear debris produced by adhesion is often referred to as rubbing or sliding wear.
The size of the wear particles produced is generally dependent on the roughness of the
opposing surfaces. Finely finished metal surfaces produce very fine wear debris particles.
Mild adhesive (rubbing or sliding) wear is normal in many machine types.
Sliding wear particle sizes may decrease over time as opposing surfaces polish one another.
This is the case during “break-in” of newly aligned or machined bearing surfaces.
Abnormal adhesive wear is usually a result of an inadequate oil film, or increased surface
roughness. The OilView Analyzer sensor grids and Ferrous Wear Monitor are only sensi-
tive to severe adhesive wear. They will generally not detect normal rubbing wear due to the
very fine particle sizes. However, the OilView Particle Counter and 5200 tests are very sen-
sitive to all particles larger than 2 µm.
Typical solutions to abnormal adhesive wear are to minimize “cold” start-ups, ensure ade-
quate oil viscosity and flow, check for and eliminate abnormal vibration, and maintain a
clean oil in order to prevent abrasive wear from roughening opposing surfaces and causing
subsequent adhesive wear.
9-15
Allow the oil to drain into the bottle and remove the bottle from the grid. Place the grid back
on the analyzer and attach the microscope. Initiate an OilView Analyzer test to cycle the
analyzer’s electromagnet. You can then observe ferrous particles as they are rotated through
three distinct angular positions each second.
Note
To classify particles, see the CSI “Wear Particle Atlas.”
If the residue moves with the magnet, the material is ferromagnetic. If individual particles
can be resolved with the naked eye under a bright light, they are probably 40 microns or
larger along their smallest dimension and are evidence of abnormal wear of a ferrous sur-
face. If the particles are “chunky” or plate-like, fatigue wear is likely. If the particles appear
to be long narrow strips or have a spiral appearance, cutting (severe abrasive) wear is likely.
An alternative method is to submerge a white magnet in the oil, lightly rinse it with solvent,
and look for magnetic particles adhering to the magnet. The magnetic particles will tend to
follow the lines of magnetic flux and will concentrate on the corners of the magnet.
Preparation
Select the pore size(s) for the filter patch(es) based upon the estimated or measured particle
size range. Standard filter patch pore sizes are 3 micron and 8 micron. Other pore sizes
ranging from 0.8 micron to 30 micron are readily available and may be used. A few tests
will quickly reveal what pore sizes tend to plug and which ones yield meaningful speci-
mens. The goal is to produce wear debris analysis patches with particles distributed so they
can be easily viewed with a microscope.
Assemble the filter into the patch maker including all O-rings and screens according to the
diagram.
9-17
Patch Making
All samples must be diluted before they are put into the patch maker. A very small amount
of actual sample is required. About 2 ml of sample should be used consistently, unless a
sample is extremely clean or extremely dirty. Shake the sample thoroughly and then extract
2 ml using a clean pipette. Add this to a clean mixing bottle or beaker, and then add 10 to
20 ml of solvent (lamp oil will suffice). The diluted sample will filter and clean-up more
easily as well.
Shake the diluted sample and then pour it into the patch maker chamber. Press the vacuum
pump foot pedal to run the pump and suck the sample through the patch. Pour additional
solvent into the chamber while vacuuming to wash the particles through the plumbing and
to clean the oil residue off of the filter patch. Continue running the pump and suck air
through the patch to help dry it.
Remove the filter patch(es) from the holder and allow them to dry. After they have dried,
glue them onto the backing in the filter storage container so they will stay flat for micro-
scopic viewing.
10
9-19
11
9-21
Through-lens lighting can be used when viewing particles where the oil film has been
removed; however, oblique lighting is best when viewing particles in an oil film. (An oil
film clouds the image when using through-lens lighting.)
Keep in mind that the process of removing the oil film with solvents will also remove most
of the non-ferrous particles. Therefore, oblique lighting can be used first to view both fer-
rous and non-ferrous wear debris with an oil film present. Then, if desired, the oil film can
be washed away with solvent (while a permanent magnet retains ferrous particles) and
through-lens lighting can then be used to view the remaining ferrous particles.
In addition to photomicrographs wear particle identification, CSI’s “Wear Particle Atlas”
(included with the Model 51SM shop microscope) provides hints and recommendations
on particle extraction and examination.
12
9-23
9-24 Wear Debris Analysis
Chapter 10
Introduction
The Model 5200 Trivector Analyzer is a complete “minilab-in-a-box.” It combines the
Model 5100 type system with a particle counter and wear debris analysis system in a single
unit, giving enhanced performance. The scale can be used for accurately measuring the
dilution of oil samples.
The right-hand chamber (Test 1) is used to measure the dielectric of the neat oil and, with
the aid of a reference oil, produce the chemical index. The center chamber (Test 2) is used
to measure the contamination and ferrous indices of a diluted oil sample, and the tower
arrangement (Test 3) is the particle counter. The mechanical assembly on the front panel is
a filter patch maker that works in conjunction with the diluted oil in the Test 2 chamber.
10-1
Instrument Overview
The front panel of the instrument is replicated in the software interface, and the instrument
can largely be operated from either interface aside from certain mechanical operations.
The interface is divided into three tests. Test 1 measures the dielectric of the neat oil, Test 2
the contamination and ferrous indices, and Test 3 the particle counts. In addition, the diluted
oil from the Test 2 chamber can be filtered through the patch maker to create wear debris
filter patches.
The front panel has a series of colored LEDs that are used to indicate the status of each test.
In general, a flashing LED indicates the next action that you should take. The four push but-
tons are used to control the tests and weighing sequence of the scale. Associated with these
buttons are four check boxes that are used to turn on (checked) the test or scale. This enables
you to only use those tests required for a particular oil sample.
The Trivector status of the oil sample is also displayed on the front panel using red, yellow,
and green LEDs.
Initial Setup
The 5200 must be connected to a computer for starting and controlling the test sequences
and for collecting the test results. Also, the analyzer comes complete with a waste container
system including a vacuum pump. The communications cables and plumbing must be con-
nected before the instrument can be operated.
Caution!
Before making any cable or power connections, turn off the power
to the unit by toggling the power switch on the rear panel to the off
position.
Caution!
The 5xDV communications port is a 15-pin, high-density sub-D
connector which provides both power and serial communications.
Use caution when inserting the 15-pin cable into this port as it is
possible to force the connector upside down – damaging the cable
and the port connector. Always make sure the power is off before
connecting this cable.
Note
The power supply cable connector is keyed and labeled on the top
position.
Software Setup
After verifying the cable connections, go to the Setup/Comm Ports software screen and
configure the ports as described in Chapter 1.
Electronic Scale
The analyzer system includes an electronic scale which is used for accurately weighing
dilution ratios. The scale comes with its own DC power supply which is unique and should
not be used on any other instrument. The scale also uses batteries, but its power supply
should be used to keep it out of power saver mode.
Connect the scale to its port on the back of the 5200 using a 9-pin, RS232 cable.
Caution!
Do not apply excessive force to the weighing surface of the scale.
Doing so will overload and damage the weighing mechanism. If
the scale must be packaged or stored, then remove the plastic and
metal trays, and store them separately. Also, protect the weighing
posts that protrude from the top of the scale.
Note
There are two different scale models with slightly different keypad
interfaces. The keys for the newer, VIC-511 VICON model (CSI
P/N 93030) are described below with the older, VIR-400 model
(CSI P/N 93035) keys listed in parentheses.
1. ·· To gain access to the balance internal menu system, start with balance
turned off.
2 ··· Now briefly press the ON/OFF (ON/MEMORY) key and immediately
(and briefly) press the ZERO (TARE/PRINT) key on the scales keypad.
You should see a “1” toward the left side of the LCD display. This is the
“left” segment value.
3. ·· There are three segment values on the display: left, center and right. Four
categories need to be set-up for the scales, the Baud Rate, Parity, Stop
Bits, and Handshake. Use the F (TARE/PRINT) key repeatedly to
increment the segment values. Use the ENTER (CAL/MODE) key to
switch from one segment position to another.
4. ·· Once a category has been set up with correct values, PRESS & HOLD
the ENTER (CAL/MODE) key until “o” or “>” is displayed in the lower
right of the right-segment display. This indicates the category values have
been stored.
5. ·· Now repeat Steps 3 and 4 for the remaining set-up categories in the table.
6. ·· To finalize and save ALL revised parameter settings, press and hold the
ZERO (TARE/PRINT) key until the balance resets (balance displays all
zeros). Now all of your new settings will be balance defaults at startup.
Error Codes
The following error codes may be displayed during scale operation of the VIR-400 model.
Warning!
The vacuum pump is not explosion-proof. It must not be used in
the presence of flammable liquids or gases. Adequate ventilation
of its exhaust is required.
Hardware/Software Startup
Turn on the power to the analyzer using the switch in the rear. On power-up, the analyzer
should sound one initial beep, pause, and then sound two more beeps. It is best to power-
up the unit before accessing the 5200 tab in the software, because the software must read
the calibration data and the configuration settings from the hardware. The software will dis-
play an “Initializing…” message for approximately 25 seconds while the data is being read.
If any errors occur during the initialization, then check the power to the analyzer and verify
the communications cable connection to the computer is correct before re-trying in the soft-
ware. The software will periodically re-try while the 5200 Test tab is active until the cali-
bration data has been successfully read.
Note
Any communications errors must be resolved before using the
instrument.
Side view.
Test 1, chemistry. Fill 10 ml syringe with “neat,” undiluted oil. Insert syringe tip and
inject into hole at bottom, run test, and then flush/clean with solvent.
Sampling
When collecting used oil samples, collect approximately 2/3 of a sample bottle of oil. This
will be sufficient for running the digital viscometer test and all 5200 tests. Do not fill the
bottle to the top. Full bottles are not easily mixed by hand shaking. If you need more oil for
other tests, consider collecting a second sample bottle.
Viscosity
Use the OilView Digital Viscometer to measure the viscosity of the undiluted oil sample.
You may want to test viscosity on all samples in the batch before beginning 5200 tests.
Always run the viscosity test on the undiluted oil before the 5200 tests.
Solvent Selection
Before testing any oil samples, test that the cleaning solvent easily dissolves with that oil
type. To test this, add equal amounts of oil and solvent to a clear bottle, shake, and watch.
If the fluid comes clear in 10 or 15 seconds then you are okay to begin testing. If the mixture
stays milky, cloudy, or separated into layers, STOP. Find another solvent that easily dis-
solves in that oil before testing it in the Trivector Analyzer. The table below provides a gen-
eral guideline of solubility for different oil types.
Warning!
Both Toluene and Isopropyl Alcohol have flash points below room
temperature. They require an explosion proof vacuum pump.
4 ··· Press the button next to the flashing Test 1 LED. The test will take
approximately 5 seconds. The LED will change to solid red after the
results have been automatically read and saved to the database.
5 ··· When the LED changes to a flashing yellow color, this means that it is
time to clean Test 1. This may occur immediately after Test 1, if it is the
only test in the sequence, or at some later time if other tests are being run.
6 ··· Flush Test 1. Remove and discard the syringe. Use the foot pedal to run
the vacuum pump to evacuate the oil from the Test 1 chamber. You may
push thick oils out of the sensor using a syringe filled with solvent.
7 ··· Clean Test 1. Pour lamp oil or other solvent into the chamber to flush out
the oil. Do this for 5 to 10 seconds, and then, without pouring any
additional solvent, just vacuum air through the chamber to dry it.
8 ··· Perform a clean check. Press the Test 1 button next to the flashing yellow
LED, and the software will take a reading. If not sufficiently clean, you
may try vacuuming more air and pressing the button again. If this fails,
then clean by flushing with more solvent and vacuuming air, then repeat
the clean check.
9 ··· When the chamber is sufficiently clean, you will be directed to the next
test to clean, or to wait for Test 2 to complete.
Note
If testing a new reference oil sample, refer to the section on refer-
ence oil tests.
After completing any required, undiluted oil tests (for example, viscosity and Test 1 chem-
istry tests), follow these Test 2 procedures:
1····Determine which dilution method will be used, either the volumetric or
weighing method as described later. If weighing, then enable the scale and
the software will guide you through the process. Otherwise, disable the
scale and enter the volumes into the software.
2····Dilute the sample approximately 1:1 in its original sample bottle, using
the appropriate solvent (see Solvent Selection information above).
3····Replace the lid on the sample bottle and shake vigorously until the Test 2
LED flashes green indicating the sample may be added.
4····Open the bottle and pour the diluted oil sample into the Test 2 chamber up
to the top of the tapered cone – this takes approximately 20 ml. The sensor
will automatically detect the fluid, start the test by itself, and stop flashing
the LED.
5 ··· This test will take approximately four minutes to complete. If you are also
running Test 3, then you will be directed on to start that test while Test 2
is running. After Test 3 finishes, you will be prompted to clean Test 1 if
necessary.
6 ··· When the LED changes to a flashing yellow color, this means that Test 2
is finished and it is time to clean. Before cleaning, examine the Test 2 and
Test 3 results to see if wear debris analysis filter patches should be made.
7 ··· If you wish to prepare filter patches, make them at this time, following the
procedure outlined later in this chapter for making WDA filter patches.
8 ··· Clean Test 2. Pour lamp oil or other solvent into the chamber to flush out
the sample. Do this for 5 to 10 seconds, and then, without pouring any
additional solvent, just vacuum air through the chamber to dry it. Use a
cotton-tipped swab to gently wipe the surface of the grid to dry off most
of the solvent.
Caution!
Never touch the Test 2 sensor grid with a hard object! Doing so
may permanently damage the sensor.
9 ··· Perform a clean check. Press the Test 2 button next to the flashing yellow
LED, and the software will take a reading. If not sufficiently clean, you
may try further drying and press the button again. If this fails, then clean
by flushing with more solvent and vacuuming air, then repeat the clean
check.
Warning!
Both Toluene and Isopropyl Alcohol have flash points below room
temperature. They require an explosion proof vacuum pump.
Dowanol Statement
Dowanol® DPnB is a clear colorless solvent produced by the Dow Chemical Company. It
is soluble in hydrocarbon oils as well as water, which explains how it works as a water mask
solvent for lubrication oils. For the purpose of water masking, handle the Dowanol® as if
it were kerosene. However Dowanol® has a higher flash point 212 F than kerosene 148 F
which makes it safer to use. This solvent is one of a series of glycol ether solvents made by
Dow Chemical, and was chosen because of its relatively low toxicity as based on the
MSDS. The user should follow all precautions as stated on the MSDS as well as following
all applicable regulations. Use this URL for DOWANOL® DPnB technical information:
http://www.dow.com/dowanol/nam/products/dpnb.htm
The sharp-eyed observer may have noted that there are two CAS numbers for Dowanol®
DPnB. Inquiries to Dow Chemical gave the following response, “Actually, both registry
numbers can be used to describe DOWANOL DPnB. The registry number 35884-42-5
describes the mixture of all 4 structural isomers, whereas 29911-28-2 describes the sec-
ondary, secondary isomer, which is the major isomer in our product, though we don’t rou-
tinely measure and cannot control isomer content. The way to ensure that you are getting
DOWANOL material is to use the Aldrich product code 48,423-7.”
Note
Test 3 itself is not cleaned because the initial 10 ml of the diluted
sample is used to flush the laser detector. Additional cleaning
should be performed at the end of the day by manually squirting a
syringe full of solvent into the Test 3 input port. Manual cleaning
should also be used after testing a very dirty sample or between
dissimilar fluid batches.
14 ··Remove and discard the used syringe. The syringe has been contaminated
on both the inside and outside and will contaminate the next sample if re-
used.
Note
The scale checkbox must be cleared to use this method.
Spectro recommends that for Test 2, you dilute 1 to 1; in other words, equal parts of oil and
solvent (usually lamp oil). Using a clean, empty sample bottle, place two equally spaced
marks on the bottle using a marker pen. After thoroughly shaking the oil sample, pour in
the used oil up to the first mark and then add solvent up to the second mark. Thoroughly
shake to mix the oil and solvent.
The on-screen text boxes next to the sample bottle icons are automatically filled with 10 for
the icon representing a bottle with only oil in it, and 20 for the icon representing oil and sol-
vent. This gives a dilution of 1:1. The second entry being the total fluid present (i.e. oil plus
solvent).
If further dilution is required for Test 3 because the sample is particularly dirty, you must
click on the check box next to the bottom sample bottle icon to indicate that further dilution
is required. You have a choice between diluents for the Test 3 additional dilution step.
Double-click on the bottom sample bottle icon to toggle between diluent types. The water
masking bottle icon will display half blue. Then enter 40 into the bottom text box to estab-
lish an additional 1 to 1 dilution. After pouring off the required 20ml into the Test 2
chamber, pour off more of the diluted oil into the waste beaker until you reach the first mark
and then add additional solvent up to the second mark. This will give a final 1 to 3 dilution.
Note
The scale checkbox must be checked for the scale to be activated.
If an empty bottle has not been previously weighed, you will be prompted to place an
empty bottle on the scale. Once the empty bottle is on the scale, press the button on the front
panel next to the scale icon to automatically record the weight of the empty bottle. (Do not
use the buttons on the scale.) If you must re-weigh an empty bottle, double click on the
empty bottle icon to set the empty bottle weight to zero.
Spectro recommends that you dilute 1 to 1; in other words, equal parts of oil and solvent
(usually lamp oil) for Test 2. Using a clean, empty sample bottle, place two equally spaced
marks on the bottle using a marker pen. After thoroughly shaking the oil sample, pour in
the used oil up to the first mark, and then place the half-filled sample on the scale and press
the weigh button. Now add solvent up to the second mark and re-weigh the bottle con-
taining oil and solvent. Thoroughly shake the bottle to mix the oil and solvent before
pouring it into the Test 2 chamber.
The on-screen text boxes next to the sample bottle icons are automatically filled with
weights of the empty bottle, bottle with oil only, and bottle plus oil and solvent.
If further dilution is required for Test 3 because the sample is particularly dirty, you must
click on the check box next to the bottom sample bottle icon to indicate that further dilution
is required. Double click the bottle icon to choose which additional diluent will be used.
Move the mouse pointer to the bottle for a second to see which diluent is currently selected.
After pouring off the required 20ml into the Test 2 chamber, pour off more of the diluted oil
into the waste beaker until you reach the first mark and re-weigh the sample as directed by
the flashing LED. Now add additional solvent up to the second mark and re-weigh as
directed. The dilution ratio is automatically calculated from the recorded weights.
The 5200 results are broken down by the three tests. The main results from the three tests
are also summarized on the main test screen.
Test 1 – Chemistry
Dielectric – The dielectric of the oil is a basic property and changes with oxidation, nitra-
tion, and moisture content. Different oil types have different dielectrics as well. The Test 1
sensor measures the dielectric of a small volume of the sample between two electrical
plates.
Chemical Index – The chemical index is a measure of the change in dielectric of the used
oil sample relative to the reference oil. This indicates a chemical change in the oil, water in
the oil, or a mixture of different oil types. The chemical index is scaled such that a 0.10
dielectric change produces a chemical index value of 10 which is an alarm status for most
oils. A reference oil with known dielectric must be assigned in order to calculate the chem-
ical index.
Results 10-37
Test 2 – Wear / Contamination
The Test 2 sensor measures dielectric properties of contaminants in the oil. The Test 2
sensor uses gravity and an electromagnetic field to concentrate and move particles on the
surface of the sensor grid during the test. See the Test 2 Plot example later to better illustrate
the following indices.
Contamination Index – This index is based upon the change in apparent dielectric
resulting from non-ferrous contaminants settling onto the sensor grid over the test time.
Water has the largest affect on the contamination index, but other non-ferrous metals affect
it as well. The contamination index is calculated by scaling the total dielectric change
during the test.
Non-Ferrous Index – This index is the same as the Contamination Index.
Ferrous 1 Index – This index is a measure of the delta dielectric resulting from the ferrous
particles standing up and lying down on the sensor grid. An internal electromagnet changes
states during the first part of Test 2 to produce this effect.
Ferrous 2 Index – During the second part of Test 2, a different electromagnetic field
sequence is used to sweep the settled iron outside of the sensing area. The resulting change
in dielectric is scaled to give the Ferrous 2 Index.
Large Ferrous – As the particles settle onto the grid and the electromagnet changes states,
large ferrous particles or ferrous chains of particles will sometimes cause abrupt spikes in
the data plot. The Large Ferrous indicator is a count of these spikes.
Large Non-Ferrous – Spikes which occur while the ferrous particles are standing up are
treated as Large Non-Ferrous indicators.
Water Droplets – As water droplets settle onto the sensing grid, they cause abrupt changes
in dielectric too. However, these changes last for at least a few test cycles, and are thus dis-
tinguishable from other contaminant spikes.
Estimated % Water – As mentioned before, water has the largest effect on the contami-
nant index. Water will settle onto the sensor grid differently for different oil types and addi-
tive levels. Water also affects the Test 1 Chemical Index.
Test 3 – Contamination
Test 3 uses a laser-based particle counter to simultaneously count and size particles in eight
different size ranges as the fluid is forced through the sensor at a constant flow rate.
Results 10-39
Plots
Test 2 Plot
The Test 2 plot shows a time resolved plot of dielectric as particles settle on the detector
grid. The first part of the plot shows two curves that are produced by alternating a magnet
sequence that alternately stands up and lays down ferrous particles. If there are no ferrous
particles present then these two curves fall on top of each other. The second part of the plot
shows a decrease in dielectric as the ferrous particles are swept off the grid. If there are no
ferrous particles present, then the curve becomes a continuation of the first part. If there are
large particles present, then spikes appear on these curves.
10
Plots 10-41
Test 3 ISO Plot
The ISO 4406 plot is a representation of size distribution and concentration for particles in
oil. The graph has two lines. One line is for the sample data, and the other is for the target
cleanliness level (as set on the Point Information, Equipment tab). Cumulative counts are
displayed on the left vertical axis whereas ISO codes are displayed on the right vertical axis.
The size axis displays either the old or new particle sizes based upon the current ISO 11171
display mode.
11
Up to and
ISO Code More than
including
1 0.01 0.02
2 0.02 0.04
3 0.04 0.08
4 0.08 0.16
5 0.16 0.32
6 0.32 0.64
7 0.64 1.3
8 1.3 2.5
9 2.5 5.0
10 5.0 10
Plots 10-43
Particle Count Range (per ml)
Up to and
ISO Code More than
including
11 10 20
12 20 40
13 40 80
14 80 160
15 160 320
16 320 640
17 640 1300
18 1300 2500
19 2500 5000
20 5000 10000
21 10000 20000
22 20000 40000
23 40000 80000
24 80000 160000
25 160000 320000
26 320000 640000
27 640000 1300000
28 1300000 2500000
>28 2500000
00 125 22 4 1 0
0 250 44 8 2 0
1 500 88 16 3 1
2 1000 178 32 6 1
3 2000 356 63 11 2
4 4000 712 126 22 4
5 8000 1425 253 45 8
6 16000 2800 506 90 16
7 32000 5700 1012 180 32
8 64000 11400 2000 360 64
9 128000 22800 4100 720 128
10 256000 45600 8100 1440 256
11 512000 91200 16200 2800 512
12 1000000 182000 32400 5800 1024
Plots 10-45
12
The NAS plot shows the number of particles in each of the six specified size ranges. It also
shows the resulting NAS code profile. You will notice from this example that the >100 µ
particle size category is closest to the NAS profile. So this category is the one that actually
determines the NAS value.
Restore Latest
Each calibration screen contains a “Restore Latest” button which is used to restore the most
recently saved calibration data for that test. This function may be used to restore the latest
calibration data after viewing an older, historical calibration. Also, if the user starts a re-cal-
ibration and then decides to discard the data before saving it, then he should click the
Restore Latest button to restore the previously saved data.
Save Changes
Each calibration screen also contains a “Save Changes” button which saves changes to the
hardware and to the calibration database. This button is initially grayed out and becomes
active after changes have been made to the data. In order to save time, the user should wait
until all fluid samples for a particular test have been tested before clicking the Save button.
If you forget to save the changes, the software will prompt you to save when you try to
switch tabs.
Historical Calibrations
The historical calibration data table lists all past and present calibrations that have been
saved in the calibration database. The calibrations are sorted in the table by serial number,
test type, and date. This table serves as a log of all calibration activity for the unit. Also, if it
ever becomes necessary to restore a previous calibration, then this is the place to do it.
The current calibration database path name is displayed above the table. The “…” button
may be used to browse for and switch calibration databases. However, normally only the
default A5200cal.mdb calibration database should be used.
Read Test(s) – This command button is used to restore previous calibrations. First high-
light the test(s) to be restored by clicking and dragging the mouse pointer over the rows in
the table. Then click the Read Test(s) button to restore the test data. The restored data may
then be viewed by going to the individual test calibration tabs. Note that the restored data
will only be active during the current software session.
Read Final Cal – This command button is used to restore all of the latest calibration data
for the highlighted serial number in the table. This function may be used after viewing older
data to restore the latest calibration data for all tests.
Procedure
Perform the calibration procedure and clean check procedure with fluid A and fluid B in
the following sequence, A – B – A – B.
1. On the Calibration screen, enter fluid A information in the first and third
rows. See the figure below for example.
2. Enter fluid B information in the second and fourth rows.
3. Calibrate with fluid A. Flush and perform clean check.
4. Calibrate with fluid B. Flush and perform clean check.
5. Calibrate with fluid A. Flush and perform clean check.
6. Calibrate with fluid B. Flush and perform clean check.
7. Save the results.
13
Caution!
Never use the wrong syringe with the wrong calibration fluid
bottle.
Note
During re-calibration, the calculated dielectric will not always be
available or accurate because it is derived from the calibration
itself. The frequency value, however, should stay relatively the
same for the clean sensor, and the software uses the stored clean
frequency to determine when the sensor is sufficiently clean.
12 ·If the software determines that the three tests of the same fluid are
consistent, then follow the software's prompt and clean the sensor by
proceeding with Step 13.
13 ·· Using the solvent syringe, squirt 10ml of solvent into the Test 1 chamber.
14 ·Follow this with some additional solvent (~ 10-20ml), using the squirt
bottle while running the vacuum pump. Make sure you continue to run the
pump after all fluid has been pulled out of the sensor. This will flush any
remaining neat oil from the sensor and at the same time help wash any oil
from the walls of the sensor. It will also help dry the walls of the sensor.
15 ·· Push the button beside the flashing Test 1 LED. The software will check
whether the Test 1 sensor is clean. You may need to use more solvent or
you may just need to pull more air through the sensor for drying purposes.
Repeat this step until the sensor passes “Clean” test.
Note
If this is the first calibration fluid of a new calibration then the
dielectric calculation will not be available, only the clean fre-
quency will be displayed.
Repeat steps 2 to 15 for the remaining calibration fluids. The software will average the
results each time and then plot the average on the graph.
As each fluid is tested, the software will display the Fit % Error for each fluid. The plot is a
best-fit line through all points. Therefore the percent error is a calculation of the deviation
of each fluid point (Avg F) from the best-fit line. If the software pops up a warning message
that the error is outside the limits, then you will need to repeat one or more fluid calibrations.
Start with the fluid which has the most variation between its Freq 1 to 3 values.
If all calibration data looks good, you must select the Save Changes button to save the cal-
ibration data. It takes several seconds for the data to be written to the analyzer.
14
Procedure
Perform the calibration procedure and clean check procedure with fluid A and fluid B in
the following sequence, A – B – A – B.
1. On the Calibration screen, enter fluid A information in the first and third
rows. See the figure below for example.
2. Enter fluid B information in the second and fourth rows.
3. Calibrate with fluid A. Flush and perform clean check.
4. Calibrate with fluid B. Flush and perform clean check.
5. Calibrate with fluid A. Flush and perform clean check.
6. Calibrate with fluid B. Flush and perform clean check.
7. Save the results.
15
Calibration of the Test 2 Grid will follow a procedure very similar to the Test 1 process
except that more cleaning is involved. When you test your used oils, they will all be diluted
with a solvent. However, for the purpose of a calibration and/or a verification we use “Neat”
oil (undiluted) on the flat sensor surface with the grid traces. The sensor circuit board has
pores in it which allow fluid to collect in them and this can vary the capacitance of the
sensor. Thorough cleaning becomes very important to avoid cross contamination during
this process. Please take every effort to follow this procedure as thoroughly as possible.
Note
During re-calibration, the calculated dielectric will not always be
available or accurate because it is derived from the calibration
itself. The frequency value, however, should stay relatively the
same for the clean sensor.
12 ·If the software determines that the three tests of the same fluid are
consistent, then follow the software's prompt and clean the sensor by
proceeding with Step 13.
13 ·Squirt some solvent into the test chamber or onto the test sensor (~ 20ml),
using the squirt bottle while running the vacuum pump. After draining,
gently wipe the surface of the grid with a cotton-tipped swab. Follow this
with another flush of solvent. Make sure you continue to run the pump
after all fluid has been pulled off of the sensor. This will flush any
remaining calibration fluid from the sensor and at the same time help
wash any fluid from the walls of the sensor. It will also help dry the
surface of the sensor. Gently wipe the grid with a clean and dry cotton-
tipped swab for final drying.
14 ·· Push the button beside the flashing yellow Test 2 LED. The software will
check whether the Test 2 sensor is clean. You may need to use more
solvent or you may just need to pull more air through the sensor for drying
purposes. Repeat this step until the sensor passes “Clean” test.
Note
If this is the first calibration fluid of a new calibration then the
dielectric calculation will not be available and only the clean fre-
quency will be displayed.
Repeat steps 2 to 14 for the remaining calibration fluids. The software will average the
results each time and then plot the average on the graph.
As each fluid is tested, the software will display the Fit % Error for each fluid. The plot is a
best-fit line through all points. Therefore the percent error is a calculation of the deviation
of each fluid point (Avg F) from the best-fit line. If the software pops up a warning message
that the error is outside the limits, then you will need to repeat one or more fluid calibrations.
Start with the fluid which has the most variation between its Freq 1 to 3 values.
If all calibration data looks good, you must select the Save Changes button to save the cal-
ibration data.It takes several seconds for the data to be written to the analyzer.
16
17
0.8 4
1 4.2
2 4.6
4.3 6
5 6.4
10.25 10
15 13.6
15.5 14
23.4 20
25 21.2
40 31.7
50 38
52 - 55 40
70 - 75 48
100 54
*Note that the newer ISO 11171 particle sizes are always designated as m(c).
Fluid Requirements
Each part of the calibration procedure has its own fluid requirements. The factory standard
calibration uses about 400 ml total of Partistan™ 2806 fluid, which contains NIST Medium
Test Dust (MTD), for both calibration and verification. In addition, super clean fluid is used.
Refer to the individual test sections below for exact fluid requirements. As mentioned
above, additional tests and fluid volumes are required for full compliance with the ISO
11171 standard. Contact Spectro for more information on this special calibration service.
Cleanliness Guidelines
The majority of particle sizes being counted are not visible to the naked eye. Thus the user
must take proper precautions to make sure extraneous contamination does not get into the
containers or calibration samples:
• All calibrations must be performed in a dust-free environment.
• Sample bottles and lids should be certified clean or cleaned in accordance
with ISO 3722. Keep the bottles tightly sealed until ready for use.
• The syringes must be kept sealed in the original factory packaging until
ready to use. Do not handle the outside of the syringe or lay the syringe
down on a contaminated surface prior to use.
• If dust has accumulated on the outside of the calibration fluid bottles
during storage, then clean it off with a lint-free cloth before use.
• Never re-use bottles or syringes, or recycle calibration fluids. Any con-
tamination tends to accumulate from prior use.
18
The Test 3 calibration, Preliminary Check tab contains the first set of tests run as part of the
factory standard calibration. These tests consist of a noise level check, volume calibration,
and verification. These tests only need to be repeated following repair or readjustment of
the particle counter. If a new batch of syringes is received, then the volume calibration may
need to be repeated.
Noise Level
The laser sensor outputs a signal proportional to particle size each time a particle flows by
the sensor. The bigger the particle, the higher the signal output is. The signal also contains
some background noise. The smallest particle size of interest must create a signal that is at
least 1.5 times the noise level.
Volume Calibration
The volume calibration is used to enter the dimensions of the syringe, and to verify the
sample volume and count repeatability with flow.
First use a metric ruler to measure the dimensions of the syringe as illustrated on the display.
These dimensions are necessary to get the correct flow rate and volume through the particle
counter. Enter the dimensions in the three boxes as shown.
Next, a standard fluid must be used to run a volume verification test. The fluid should have
between 2000 and 8000 particles/ml at the smallest size of interest. The ISO 11171 standard
uses a concentration of Ultrafine Test Dust (UFTD). Concentrations between 0.5 and 1.0
mg/l will work. However, either ACFTD, MTD, or UFTD may be used to verify volume
accuracy. Select the appropriate fluid from the drop-down list in the software. Enter the
manufacturer and lot number in the boxes below the fluid type.
19
The Test 3 sizing calibration is performed as part of the factory standard calibration. The
purpose of this calibration is to establish calibration curve data which correlates sensor
output signal levels to particle sizes. The sizing calibration needs to be repeated following
repair or readjustment of the particle counter, or at least on an annual basis.
The sensor’s signal response is measured using a known calibration fluid standard with
known particle size distribution. This fluid may be either the older Air Cleaner Fine Test
Dust (ACFTD) used by ISO 4402, or the newer NIST Medium Test Dust (MTD) called
out by ISO 11171. The software sets initial default channel voltages for the eight particle
sizes dictated by the fluid type selected by the user. Three samples of the same fluid are
tested. After each sample test, the software re-calculates the channel voltage settings to try
to match the standard sizes more closely and produce the correct particle counts. The three
samples multiplied by eight channel settings produces a calibration curve of 24 points. This
curve is then used to compute final channel settings for the particle sizes of interest.
20
The Test 3 verification is performed as part of the factory standard calibration. The purpose
of verification is to verify particle counting accuracy using size channel voltage settings cal-
culated from the calibration data curve. Verification should be performed whenever the
accuracy of the particle counter is in question or after repair or adjustments have been made
to instrument.
21
After the Test 3 laser sensor has been calibrated and its calibration verified, it is necessary
to verify the sensor’s ability to measure low contaminant levels in a “super clean” fluid.
This is performed as part of the factory standard calibration, and the initial factory results
are stored in the unit. These results will be overwritten by the user’s diluent test.
The user needs to regularly test and store counts for the diluent used to dilute samples. This
allows the software to subtract the diluent counts from the diluted sample results and report
the counts per milliliter of the original undiluted sample. The 5200 / Calibrate / Test 3 /
Diluent / Clean Fluid screen allows a standard diluent and an optional water masking
diluent to be tested and stored for diluted sample calculations.
Note
Clean fluid tests are very sensitive to any contamination. Thus, the
procedures below must be followed as closely as possible to get
accurate, repeatable results.
Begin by preparing the samples. Always keep clean lids on the bottles to prevent dust from
getting into them. Do not open each syringe until right before use. If not using a solvent fil-
tration device, then shake the larger clean fluid / diluent bottle thoroughly to re-suspend any
particles. Fill one certified clean bottle with 100 ml of clean fluid to be used as an initial
flush. Then prepare three identical samples of the clean fluid / diluent by pouring 40 ml into
each of three clean sample bottles.
Use the left half of the table for a super clean fluid test or a standard diluent test, and use the
right side for a masking diluent test.
22
The Test 3 Coincidence Error Limit test establishes what concentration of particles causes
the sensor to start undercounting particles. The error is a result of the physical dimensions
of the sensing volume as well as the fluid’s particle size distribution, including particles too
small to be counted. If there are too many particles in the sample, then some particles may
overlap each other in the sensing volume and be counted as a single bigger particle instead
of multiple smaller particles. CSI specifies a coincidence error limit for the instrument
based upon the design of the sensor. Thus, this test is not part of the factory standard cali-
bration procedure, but may be ordered as a special calibration service. Alternatively, the
user may use the software along with the proper calibration fluids to run this test.
The procedure described here and implemented in the software is based upon the ISO
11171 calibration standard. Multiple dilutions of ISO Ultrafine Test Dust (UFTD) fluid are
used to establish the error limit.
23
where
Ct ··is the theoretical concentration limit as specified by CSI, in particles per
ml, or in mg/l of dust;
Vs··is the final volume of the diluted sample, in ml;
L ···is the dilution percentage of the concentration limit, i.e. 10%, 20%, etc.;
Ca··is the concentration of the concentrate, in particles per ml, or in mg/l of
dust.
The average particles per ml greater than 4 m(c) in 1 mg/l of ISO UFTD is 6,750. Using
a default dust concentration of 2.5 mg/l gives 2.5 times 6,750, or 16,875 particles/ml as a
theoretical concentration limit for the sensor. This value should be in the right ballpark for
the test. The dilution volumes will come out even if a beginning concentrate is chosen
which is an even multiple of the theoretical concentration limit of the sensor. For example,
if 2.5 mg/l of UFTD is the theoretical concentration limit of the sensor, then an initial con-
centrate of 5.0 mg/l could be used. Each diluted sample should be 80 ml total volume. Thus,
for a 10% concentration using these values in the above equation gives the concentrate
volume as
24
The following results are displayed in the coincidence limit data table:
Count n/ml – Each syringe sample is counted as three sub-samples. These are the indi-
vidual counts per sub-sample.
Avg/ml – Average counts per ml of the three sub-counts.
Rng% – percent range of the sub-sample count data within a given sample. The software
checks the percent range for count repeatability within the sample.
Xt/ml – Theoretical counts per ml based upon a best-fit line through the 0% to 40%
average sample counts.
%Err – Percent error of average count versus theoretical count.
25
The Test 3 Flow Rate Limits test establishes the flow rate limits of the instrument. The par-
ticle counter calibration is sensitive to flow rate. At low flow rates or high flow rates, the
electronics may filter out signals which are too wide or too narrow due to particles being in
the sensing volume too long or not long enough. CSI specifies flow rate limits for the instru-
ment based upon the design of the sensor and actual test results from representative instru-
ments. Thus, this test is not part of the factory standard calibration procedure, but may be
ordered as a special calibration service. Alternatively, the user may use the software to run
this test on-site.
The procedure described here and implemented in the software is based upon the ISO
11171 calibration standard. ISO Ultrafine Test Dust (UFTD) fluid is used to establish the
upper and lower flow rate limits. Identical samples are prepared and tested at flow rates
ranging from 10 ml/min up to 80 ml/min in 10 ml/min increments.
First prepare nine identical samples of 1.00 mg/l of ISO UFTD fluid. Make sure the UFTD
fluid bottle is well shaken before pouring 40 ml into each of the nine clean sample bottles.
Cap each bottle with a clean lid.
26
The Test 3 Resolution test measures the ability of the instrument to distinguish between par-
ticles of different sizes. This is largely governed by the optics and electronic design. This
test is not part of the factory standard calibration procedure, but may be ordered as a special
calibration service. Alternatively, the user may use the software to run this test on-site.
The procedure described here and implemented in the software is based upon the ISO
11171 calibration standard. This test requires the use of a certified suspension of 10 micron
latex spheres at a concentration that is approximately 25% of the concentration limit of the
sensor. A super clean dilution fluid will also be used for flushing the sensor.
During the test, the software uses the calibration curve data to set the channel voltage set-
tings for five channels to center around the 10 micron sphere size. The software also con-
verts the cumulative counts from the hardware into differential counts for each size range
to the left and right of the sphere size. Because latex spheres do not always respond the
same as test dust, the test must be repeated until the channel settings are centered around the
actual sphere size. The channel settings as computed by the software and shown in the data
table are as follows:
27
Diagnostics 10-99
10-100 The Model 5200 Trivector Analyzer
Chapter 11
Introduction
Keeping track of oil samples as they are processed can be difficult. Normally, only a subset
of machines in an oil analysis program are sampled at one time. The oil analysis technician
must search the database for the machines and sampling points before each test is per-
formed. Depending on the size and complexity of the database, this can be time consuming
and a potential source of errors. A similar problem occurs when the analyst reviews the new
data to make diagnoses and distribute reports to the appropriate recipients.
11-1
The LIMS (Lab Information Management System) solves the problem by allowing sam-
ples to be grouped into batches for testing, analysis, and reporting. Samples remain linked
to the master database so that data, analysis, and diagnostic comments are automatically
stored in the proper location in the database.
Each of the required activities–tests, analyses, and reports–is checked off for each sample
in the batch as it is performed. This makes it easy to keep track of the work that remains to
be done. LIMS facilitates reporting by allowing you to establish a directory of report recip-
ients. With a click of the mouse, the appropriate data and reports are emailed, faxed, or
printed according to preferences that you have established.
Right mouse click on the top-most item in the left-hand batch tree to add a new batch. The
date will default to the current day, but may be changed if needed.
Batches can also be deleted using the menu options. When a batch is deleted, the samples
and their data are not deleted from your database, they are only removed from the batch list.
Database Level
Customer Level
For this option to be visible, the “Display Customer Level” must be enabled. If not enabled,
you will not see this dialog box. To have the Customer Level option, you must first enable
the “Display Customer Level.”
• To do so, click on Setup button at the top of the OilView screen. The main
viewing window changes.
• Next, click on the Systems secondary tab at the bottom of the screen.
• Now, locate the LIMS category and click to place a check mark in the box
beside the “Display Customer Level” selection.
• Finally, click on the LIMS button at the top of the screen to return to the
LIMS window.
Equipment Level
The options available in this dialog box will be the same whether or not the “Display Cus-
tomer Level” option is enabled.
10
Point Level
The options available in this dialog box will be the same whether or not the “Display Cus-
tomer Level” option is enabled.
11
Sample Level
The options available in this dialog box will be the same whether or not the “Display Cus-
tomer Level” option is enabled.
12
13
14
On the extreme right of the grid are date columns reflecting the date on which each process
was completed. The analyst and reviewer user IDs are also recorded with each sample.
15
Depending on which of the flags are set on the options specified for reporting, you can then
generate a variety of reports for printing and automatic E-mailing. You can also export the
data for importing at a remote site using the report results menu option shown below.
16
Before any reports can be generated, each Area and/or Equipment level in your database
must have at least one customer assigned to it. Each customer has an address that is printed
on the report, and a profile specifying the kinds of reports that customer requires. These
details are described later in this section of the manual.
17
The section “Report Override Options” is used to generate ad hoc reports that will ignore
or override the specific setup for each customer assigned to the sample. The options here
are the same as those in the customer report profile that will be described in the next section.
18
To generate a specific report, the severity level at which that report will be created must be
set. The lowest severity level is “Normal” implying that the report will always be generated.
If the severity level is set higher, then reports will only be created if the severity for the
sample is greater than or equal to that level.
The Fax reports operate in the same manner. You must setup a fax printer to enable auto-
matic faxing of reports. (See E-mail/Fax tab in ten Setup tab.)
Contacts 11-15
The check boxes are used to specify which form the reports are to be sent. To automatically
E-mail a report directly to a contact, check the “E-mail” box and the “Format pdf (Adobe
Acrobat)” box.
In a network environment, it may be more convenient to place the reports in a directory that
the contact can access. To use this method, check the “Directory” box instead of the “E-
mail” box. The directory is specified in the “Contact Sub-directory” text box.
Each customer is required to have a unique sub-directory that is used as a working directory
by the software.
19
To assign a contact to either of these levels, select the relevant node on the database tree and
then select the contact from the bottom list. Use the Add button to assign the contact.
Note
CSI makes the following distinction between customers and con-
tacts. “Customers” own the data in a database and only they can
import the data, whereas “contacts” receive reports either by e-
mail or in printed form. There can be only one customer assigned
at the area level, but there can be many contacts at either the area
or equipment level.
For those customers that require the sample data to be sent directly to them, the “Data
Export” section must be completed. This information is completely independent of the con-
tacts assigned to either the Customer, Area, or Equipment levels.
At the customer level you must specify the sub-directory into which temporary information
is stored prior to the data being sent. Each customer must have their own unique sub-direc-
tory to avoid data being sent to the wrong customer. You must also specify the e-mail
address to which the data is sent. If you do not select the e-mail option then the data remains
in the sub-directory and can be accessed directly from a WAN. The data format defaults to
the Area, Equipment, Point (AEP) format. The alternative uses the Unit ID format.
The data export setup only applies to the Area level. You must specify the customers data-
base name where the data is to be imported, as well as the temporary subdirectory on the
local system where the data is written.
There must be a different sub-directory for each customer database. In general, the local lab
database level structure may be different from the customers at the top (Area) level. If this
is the case, then the next field “Cust Area ID” must be filled in with the customers ID.
To automatically E-mail the data to the customer, the E-mail checkbox must be checked
and an E-mail address entered. For the export process as a whole to be activated, the export
flag must be checked.
20
At each Area level of the database you must enter the database name to which the data is
being sent (In general this will be different from the current database.) as well as the equiv-
alent Area ID to which the data is being sent. This too may be different from the current
Area ID. This feature enables a single LIMS/RBM database to store data from multiple
user databases. To export data the Export check box must be selected.
21
22
Once the instruments are connected through the RS232 port, then their data will be auto-
matically loaded into the LIMS as the tests are run. Samples must be identified by their Lab
ID in the testing device. The Batch Info screen will automatically display the status of these
tests.
Certain problems may be corrected without having to re-run a test. For example, an invalid
Lab ID could be edited and re-processed.
23
From the drop down menu, select either Contact Statistics or Lab Statistics.
24
OilviewLite
Introduction
The OilviewLite software package is designed to operate the new Model 5200 Trivector
Analyzer, Model 52DV Digital Viscometer, and the Model 51FW Ferrous Wear Monitor.
This software is completely independent of AMS Machinery Manager and has a simple
Microsoft Access database for storing the sample data. This data can be exported into either
the CSI generic file (for import into OilView when you upgrade to the full-featured
system), or into a comma separated value (csv) file for import into spreadsheets such as
Excel.
12-1
The software is divided into two main areas. On the left-hand side is a list of the samples in
the database. The right-hand side has a series of tabs that allow access to Setup, Alarm Sets,
Reference Oils, Data, Model 51FW, Model 52DV, and the Model 5200 Analyzer. The top
of the screen displays the current reference oil and alarm set.
Setup
The first step in using the software is to configure the communication port for the Model
5200 Analyzer and then the ports for the Model 51FW and Model 52DV. These latter two
instruments can either be plugged into the auxiliary ports on the Model 5200 or directly into
serial COM ports on the computer.
Each instrument requires a path to their calibration and configuration files that are typically
in the same directory as the OilviewLite application.
Databases
By default the last-used database will be automatically opened when you start the Oilview-
Lite program. To create a new database, or to open another database, use the File menu
option.
This menu option is also used to export the selected (highlighted) samples to either a
comma separated file (csv) or the CSI generic file format for import into the OilView soft-
ware. The generic file requires you to enter an Equipment ID for each sample that matches
the Lab Unit ID setup in the OilView software. This is the key that matches the two systems
together.
12-2 OilviewLite
Adding a Sample and Running a Test
To add a new sample, press the Add New Sample button above the sample list. You then
assign an Alarm Set and Reference Oil to the sample. The next step is to select the test to
be run (Models 5200, 52DV, 51FW) and proceed as described elsewhere in this manual for
each instrument.
12-4 OilviewLite
Alarm Sets
The alarm limits are categorized into Alarm Sets. You can add new alarm sets using the
Add Alarm Set menu option under the Setup Menu option. Alarm sets can be deleted from
the Edit Menu. The alarms for each of the parameters are divided into five levels (4 values),
each of which you can set.
To connect an alarm set to a sample, first select the sample with a mouse click, select the
required alarm set, and then make a right-button mouse click. The message box shown
below will prompt you to either click the OK button if this is correct, or click the Cancel
button to select a different alarm set.
The selected alarm set for each sample is displayed at the top of the screen.
12-6 OilviewLite
Data
The Data tab shows the test results for each sample in a spreadsheet. As each instrument is
run, the data is automatically entered into the database and displayed in this spreadsheet.
Scroll horizontally to see all of the data.
Data 12-7
12-8 OilviewLite
Appendix A
A-1
Gear Oils
The OilView Analyzer is an excellent tool for monitoring the condition of gear oils. It will
detect water and ferrous wear debris. Large “chips” resulting from fatigue wear of gear
teeth are very easily detected.
Hydraulic Oils
The OilView Analyzer can also be used to screen for water and ferrous debris in noncon-
ductive hydraulic fluids. However, OilView Analyzer testing of fluids used in precise
hydraulic systems should always be accompanied by subsequent laser particle counter
tests.
Compressor Oils
Mineral and synthetic oils used in compressors can be tested for moisture contamination,
oil breakdown, and mechanical wear. It is normally important to degas the used oil samples
taken from refrigerant compressors prior to testing them regardless of what instrumentation
is being used. Most often it is normal for the used lubricant to contain significant amounts
of refrigerant such as ammonia, CFC, or R134A. The ammonia in particular has a signifi-
cant effect on the OilView Analyzer sensor since ammonia has a high dielectric just like
water.
A-2 -
Electrical Insulating Oils
A special test option can be selected (see “Oil Compatibility Chart” on page 5-8) to test
transformer oils using the OilView Analyzer. This screening test evaluates the oil quality
and moisture contamination for electrical insulating oils commonly used in transformers
and oil filled circuit breakers (OCBs). The OilView screening test does not replace the need
for dissolved gas analysis to detect partial discharge in high voltage transformers.
Fuel Testing
The OilView Analyzer can be used to test fuel oils such as #2 diesel for water—a common
problem that destroys fuel injection pumps.
For safety reasons, the OilView Analyzer should never be applied to a highly flammable
hydrocarbon liquid such as gasoline.
A-3
Collecting Oil Samples
The key factor in any oil and machine condition monitoring program is consistency in col-
lecting samples. Any oil monitoring program will probably fail if careful attention is not
paid to your sampling technique. Therefore, you must always sample from the same loca-
tion, in the same manner, and under the same machine conditions.
The location from which the oil is sampled should always be from the same plug, valve, or
port. In general, oil should be sampled from a location where the oil is well agitated or
flowing. Samples should normally be taken from the return line to the oil compartment
upstream of any filter. If the oil is sampled on the downstream (outlet side) of a filter, wear
debris and particulate contaminants will have been removed by the filter. Keep in mind that
the oil compartment or sump will act as a sedimentation “filter.”
The manner of collection should always involve a gradual, uniform flow of oil into a clean
bottle. Care should always be taken not to take the dregs or the initial spurt of oil when
filling from a drain or pressurized line.
Oil should be sampled either just after a machine has been shutdown or (if safe) while the
machine is still running. The “when” of sampling is most critical in the cases of lubrication
systems with relatively low operating viscosities.
Because the OilView tests are relatively inexpensive and under your direct control and
interpretation, do not hesitate to tailor unconventional sampling techniques to your specific
needs. Just remember to apply common sense in correlating your sampling technique and
test results to your application.
Warning!
Hot oil may cause severe burns, and used oil should never be allowed to
remain on your skin or clothing. Consequently, be extremely cautious when
sampling oil from a hot or pressurized system.
Never handle very hot oil with a plastic bottle, as the bottle may melt or
deform. Use an intermediate, clean metal container to cool the oil, if neces-
sary. If a metal container is used, remember to shake it vigorously before
transferring the oil to a plastic bottle.
The OilView Analyzer and its accessories are designed to work with room-
temperature oils.
A-4 -
Warning!
Follow standard practice procedures for health and safety as established by
your safety department when collecting oil samples or handling new and
used lube oils, hydraulic fluid, and transformer oils.
A-6 -
• Take samples just after the equipment has been shut down or, when it is safe, while
the equipment is operating. This is most important with less viscous oils as large
particles and water will settle out of the oil rapidly. It is extremely important to be
consistent with respect to when as well as where you sample.
• Carefully label each sample bottle. The label should minimally identify the oil type,
the machine from the which the oil was taken, and the date on which the sample
was taken. If a sample is diluted prior to testing, the label should reflect that fact. A
sample taken from an unknown source has little value. Mislabeling of samples may
lead to unnecessary maintenance actions.
• Over time, some contaminants will agglomerate and cling to the bottle walls, mois-
ture may evaporate, and small ferromagnetic particles may be chemically altered to
a non-magnetic form which will not be detected by ferrographic means. Therefore,
tests should be conducted within a reasonable time frame.
All OilView tests should be conducted with the oil at room temperature and with the
sample vigorously shaken just before the test.
B-1
OilView Analyzer Model 5100 Detection Limits
Propert Indexe
Lubricant Type Minimum Detectable Limit
y s
Lube Degradation
Water OL, Chl, Heavy Duty Diesel <0.2% (OL, Chl, Cont)
Cont, LC 1% to 5% (LC Droplets; Water droplet formation
begins when lubricant plus additive is saturated.
Water OL, Chl, Stern Tube Oil (used to lubricate the bearing at the <0.2% (OL, Chl, Cont)
Cont, LC aft end of a marine drive shaft.) >15% (LC-Droplets)
Water OL, Chl Polyol Alkaline Glycol (synthetic lubricant used in <0.04% (OL, Chl)
R-134a refrigerant compressors)
Water OL, Chl, Polyol Ester (synthetic lubricant used in R134a 0.04% (Cont)
Cont, LC refrigerant compressors.) 0.08% (OL
0.32% (Chl)
0.64% (LC-Droplets)
Water OL, Chl Perfluorinated Ether (synthetic lubricant used in <0.02% (Chl)
hard vacuum pumps) 0.05% (OL)
Mechanical Wear
B-2 -
Propert Indexe
Lubricant Type Minimum Detectable Limit
y s
Legend:
“OL” the OilLife™ index. “Cont” the contaminant index. “Fe” the ferrous index.
“Chl” the chemical index. “LC” qualitative “large ferrous” or “large non-ferrous” or “droplets.”
Results Display
The OilView results display is a time plot that represents the change in dielectric properties
caused by contaminants forced onto the sensor during the time of the test. The Y axis rep-
resents changes in the dielectric properties of the oil while the X axis represents 500 test
magnetic oscillations during the test.*
Note
It is important to note that a thorough understanding of the OilView Ana-
lyzer data plots is not necessary to receive the full benefits of the OilView
software. The View and More View functions interpret the test data and
supply results and recommendations in a text format.
*. For more technical information on this subject, refer to “Portable Oil Analyzer for Predictive
and Proactive Maintenance,” by Kirkpatrick, J. F., Nov. 1992 (available as an Industry Report
from CSI).
B-3
If a reference file is available for the current data, the bottom line on the plot will display the
magnet “off” state from the reference oil measurement. The three remaining lines on the
plot show the measurements for the oil being tested: a “magnet off” state, and two “magnet
on” states.
1
Plot Examples
In an oil with no ferromagnetic debris and without insoluble contaminants, these lines
should overlay one another and be nearly horizontal. The figure below is an OilView Ana-
lyzer plot taken from a clean, fresh turbine oil.
B-4 -
The figure below is an OilView Analyzer plot of a used pump oil containing ferrous debris.
Note the divergence of the two upper “magnetic” lines from the lower “nonmagnetic” or
base line. This indicates ferromagnetic particles in the oil.
B-5
The figure below was taken with a fresh turbine oil containing 0.13% water. Note that all
three lines overlay indicating no significant ferromagnetic content. However, all lines have
a steep upward slope, rising more than half a point in 500 seconds. This indicates a signifi-
cant non-ferromagnetic contaminant content. In this case there was also at least one small
droplet of free water as indicated by the small spike which occurred at about 260 seconds
into the test.
The figure below is a data plot from a test sample contaminated with large copper particles.
Note the shape of this plot as compared to the two previous plots; the presence of upward
spikes with all three magnet lines running together.
B-6 -
These spikes are caused by the large copper particles settling on the grid.
In an extreme case involving free water or large metal chips, you may see a sudden upward
jump of the plot with no return to a lower value. This will be accompanied by the display
of the word “Critical” on the results screen. Shake the bottle and repeat the test. If the pattern
is repeated, you have a serious lubrication problem involving either severe wear or free
water in the oil. In this case, Fe and large Fe values cannot be reported. However, if the plot
reveals a divergence of the magnet-off line and the magnet-on lines, ferrous debris is prob-
ably present.
B-7
Test Results
More information can be obtained from oil testing when test results are trended over time.
Lubricant degradation is rarely linear over time. Typically, a petroleum-based lubricating
oil contains additives which protect and enhance the lubricating qualities of the base oil.
The oil will degrade slowly over time until one or more components of the additive
package are exhausted. After that point, the oil will rapidly degrade.
The time to additive exhaustion varies with oil type, the machine type, and changes in the
operating environment. In well-sealed, low-temperature applications, a lubricating oil may
last for years. In extreme reciprocating engine applications, an oil will degrade after only a
few hundred hours of use. Consequently, once you have a knowledge of the “normal” trend
of oil degradation in a specific case, abnormal conditions can be detected.
The OilView Analyzer test results are quantitatively reported in three numerical indexes
and two indicators which are discussed in the following sections.
B-8 -
OilLife Index
The OilLife Index reports on the overall condition of the lubricant, considering both lube
degradation and system contamination.
When the OilLife index is near zero, the lubricant is in good shape. An increase in the Oil-
Life index indicates performance of the lubricant is getting worse. Oil degradation, such as
oxidation, affects both the OilLife and Chemical index. Oil contamination, such as water in
mineral oil, affects both the OilLife and Contaminant indexes.
Because of the way in which the OilLife index is computed from OilView Analyzer raw
data, it has greater sensitivity than either the Chemical or Contaminant indexes. This can be
valuable when testing very clean oils such as transformer, hydraulic, and new lubricants.
Note
The OilLife, Chemical and Contaminant Indexes are a direct measure of the
difference in dielectric permittivity between new and used oils when the
measurements are made at the end of the respective tests. A 0.10 increase in
ending dielectric yields an index of 10.0.
Note
Remember that a reference sample must be assigned to the sample in order
to obtain a chemical index. If a reference is not available, the chemical index
will not be given.
B-10 -
Contaminant Index
This index is a measure of the level of oil-insoluble contaminants in the oil as opposed to
changes in the bulk oil chemistry. Some common contaminants include water, glycol cool-
ants, metallic wear debris, and road dust. This index may also increase if solid additives
have been added to the oil.
This index should normally read near zero. Any positive increase in this value over time
indicates increasing levels of contaminants and a laboratory oil test is recommended. The
graphics plot on the results screen will slope more sharply up with increasing levels of con-
taminants. If the plot shows that the magnet “on” and magnet “off” lines overlay but are
rough and jagged, it is an indication of relatively large semi-conductive bodies such as
water droplets. If the plot shows very sharp upward spikes, conductive metal particles may
be present.
The following conditions will cause an increase in the contaminant index:
• the presence of insoluble water in the oil. Very high values will be seen if corrosive
compounds (such as salts) are present in the water,
• the presence of conductive metal particles in the oil. If the particles are large and
highly conductive, very sharp upward spikes will be seen,
• the presence of dirt, grit, or polar hydrocarbons in the oil.
This index will be influenced by a reference. If a reference has been made, the contamina-
tion value will be given with reference to the reference oil. If a reference is not used, an
allowance for noise will be included in the analysis. Consequently, small, near-zero values
may be seen when a reference has been used that will not be present if the same test is made
without a reference.
B-12 -
Large Contaminant Indicator
There are four text outputs for the qualitative assessment reported as “Large Contaminant
Indicator.”
No Large Indications - indicates that the analyzer did not detect excessively large metal
particles or water droplets.
Large Ferrous - indicates that large iron particles, probably much larger than 60 µm were
detected. The magnet north/south plots should show upward spikes for tests reporting
“Large Ferrous” or “LF.”
Large Non-Ferrous - indicates that large (usually much larger than 60 µm) non-ferrous
particles, such as copper, aluminum, tin, lead, or chrome, were detected. The magnet off
plots should show upward spikes for tests reporting “Large Non-Ferrous” or “NF.”
Droplets - indicates that water droplets or similar fluid droplets were detected. All three
plots (magnet off/north/south) should show spikes or sharp changes in slope for tests
reporting “Droplets” or “D.”
Note
Any Large Contaminant Indication other than “No Large Indications” may
indicate a serious problem.
Dielectric Number
This field reports the permittivity or dielectric constant, which, like boiling point, melting
point, viscosity, and refractive index, is a fundamental property of a material. Simply put,
dielectric constant measures the resistive, or nonconductive properties of the oil. Contami-
nants (liquids or solids) settling onto the surface of the sensor grid cause a change in dielec-
tric constant at the oil/grid interface. When oils are oxidized or the water concentration
increases, it is reflected in the dielectric number.
This Appendix has outlined the primary differences in the original frequency units test
method and the new dielectric units test method. The dielectric units method is recom-
mended and the original frequency units method is no longer supported. Older data that has
been stored in the user database is viewable.
*. For more technical information on this subject, refer to “Portable Oil Analyzer for Predictive
and Proactive Maintenance,” by Kirkpatrick, J. F., Nov. 1992 (available as an Industry Report
from CSI).
C-1
Original Frequency Units Data Plot Examples
In an oil with no ferromagnetic debris and without insoluble contaminants, these lines
should overlay one another and be nearly horizontal. The figure below is an OilView Ana-
lyzer plot taken from a clean, fresh turbine oil.
C-2 -
The figure below is an OilView Analyzer plot of a used pump oil containing ferrous debris.
Note the divergence of the two lower “magnetic” lines from the upper “nonmagnetic” or
base line. This indicates ferromagnetic particles in the oil. Also note the jagged appearance
of the magnetic lines relative to the base line. This indicates relatively large ferromagnetic
debris being attracted to the sensing grid.
C-3
The figure below was taken with a fresh turbine oil containing 0.13% water. Note that all
three lines overlay indicating no significant ferromagnetic content. However, all lines have
a steep downward slope, dropping more than five percent in 500 seconds. This indicates a
significant non-ferromagnetic contaminant content. In this case there was also at least one
small droplet of free water as indicated by the small spike which occurred at about 260 sec-
onds into the test.
C-4 -
The figure below is a data plot from a test sample contaminated with large copper particles.
Note the shape of this plot as compared to the two previous plots; the presence of down-
ward spikes with all three magnet lines running together.
C-5
In an extreme case involving free water or large metal chips, you may see a sudden down-
ward jump of the plot with no return to a higher value. This will be accompanied by the dis-
play of the word “Critical” on the results screen. Shake the bottle and repeat the test. If the
pattern is repeated, you have a serious lubrication problem involving either severe wear or
free water in the oil. In this case, Fe and large Fe values cannot be reported. However, if the
plot reveals a divergence of the magnet-off line and the magnet-on lines, ferrous debris is
probably present.
“Critical” oil sample with free water droplets and large metal chips.
C-6 -
Appendix D
Communications
The main issue when installing OilView software and minilab instruments in a WAN envi-
ronment is the RS232 communication between the software and hardware. Unlike the
2120 type instruments where data is simply dumped back to the RBM database after the
instruments have been run, the OilView software and Minilab hardware should be regarded
as a single unit, as the software controls the operation of the hardware while the test is in
progress. This means that it is not possible to operate the minilab instruments using Thin
Path, as time delays over the WAN make this totally unreliable. Furthermore, the wear
debris image capture can only work with a direct connection between the PC image capture
card and video camera attached to the microscope.
D-1
The other issue with a WAN installation is the slowness of the MS Access databases. One
way to overcome this issue is to use terminal server or Citrix in which case AMS
Machinery Manager is running over a LAN (between The AMS Machinery Manager
server and the AMS Machinery Manager client installed on the computer running Terminal
Server or Citrix) and only display information and mouse and keyboard entries are trans-
mitted over the WAN with no data access being sent. This works well for analyzing data
using the OilView software as hardware connections are not required for this process.
The most convenient setup for running the minilab instruments is to install an AMS
Machinery Manager client directly on the PC workstation to which the minilab instruments
are connected. This overcomes the RS232 communication issues. In order to limit the
slowness of the MS Access databases, OilView has features to disable the slowest of these,
namely the RBMview connection (see below). Furthermore, to avoid confusion between
the two types of installations there are several setup options that need to be set as described
below.
D-2 -
The basic mode of operation is therefore to use the AMS Machinery Manager Local Client
on each workstation to run the minilab instruments and capture the data. Analysis features
will be disabled in this case. The user then swaps to terminal server or Citrix to run the other
version of OilView which allows analysis but disables access to the minilab instruments.
D-3
OilView Instrument Directory Setup
This directory appears under the Custdata directory and is used to store calibration and
setup information for the minilab instruments. There must be a separate directory for each
set of instruments connect to a particular PC workstation. If we assume that we have two
workstations A and B using minilab instruments then we require the following directory
structure, containing the files listed below.
The only exception to this is the 5200 which uses a common calibration file, a5200cal.mdb.
This is so because the 5200 hardware has a readable serial number that is used to identify
the correct calibration data in the a5200cal.mdb database. Furthermore, this database is
only accessed when the 5200 is being calibrated; under normal operation the calibration
data is read directly from the hardware.
…\Custdata\Instrmnt\
a52caldm.def
a52calHW.def
a5200cal.mdb
example.zip
olv5200.cfg
olvcfg.cfg
parms.mdb
Wdatlas.mdb
…\Custdata\Instrmnt\A\
anDemoR0.cfg
anDemoR1.cfg
anDemoT0.cfg
anDemoT1.cfg
dvcal_d.def
D-4 -
dvcal_demo.def
dvcal_dm.def
dvcal_h.def
olv51dv.cfg
olv51fw.cfg
olv51pc.cfg
olv5100.cfg
olvcfg.cfg
olvwda.cfg
WDACalLM.jpg
WDACalZM.jpg
…\Custdata\Instrmnt\B\
anDemoR0.cfg
anDemoR1.cfg
anDemoT0.cfg
anDemoT1.cfg
dvcal_d.def
dvcal_demo.def
dvcal_dm.def
dvcal_h.def
olv51dv.cfg
olv51fw.cfg
olv51pc.cfg
olv5100.cfg
olvcfg.cfg
olvwda.cfg
All instances of OilView running under terminal server or Citrix use the same Instrmnt
directory.
Example
\\FPServer\RBMnet\RBMSuite\Custdata\Instrmnt\
D-6 -
Setting up OilView File Locations for Workstation A using AMS Machinery
Manager Local Client A
Example
\\FPServer\RBMnet\RBMSuite\Custdata\Instrmnt\A\
Example
\\FPServer\RBMnet\RBMSuite\Custdata\Instrmnt\A\
D-8 -
Setting up OilView for Terminal Server or Citrix
Check the “Data Analysis Mode” as shown below. This will disable access to the minilab
instruments. Wear Debris is enabled, but image capture is disabled.
Summary
The AMS Machinery Manager local based client will be used for data collection only and
the RBMview communications will be disabled.
The AMS Machinery Manager terminal server or Citrix client will be used for data anal-
ysis. RBMview communications will be enabled.
D-10 -
Appendix E
The NAS 1638 standard ends at 12. CSI has extended this table to better serve industrial
applications.
E-1
E-2 -
Appendix F
Addendum
Usage Notes:
Warning!
If the analyzer is not used in the manner specified either here or in the
accompanying users manual, then the safety protection provided by the
equipment may be impaired.
1···· The analyzer must be connected to a safety ground by means of the safety ground
pin in the power plug.
2···· Do not cover or block the ventilation slots on the analyzer
3···· The power disconnect device for the analyzer is the power cord. When installing the
unit, be sure that the power cord is accessible for easy disconnection.
4···· The analyzer is designed such that oil normally will not enter the unit in the case of
a spill. However, all spills should be wiped up as soon as possible. If it is suspected
that oil has entered the unit, then the unit should be returned to the factory for de-
greasing of internal wiring insulation.
F-1
Explanation of Symbols:
Protective Conductor Terminal
Alternating Current
Electrical Specifications:
Input Line Voltage Range: 100-240 VAC +/- 10%
Frequency Range: 47-63 Hz
Environmental Specifications:
Environment:Indoor use only
Operating Temperature: 0 degrees C to 5o degrees C
Storage Temperature: -25 degrees C to +85 degrees C
Relative Humidity: 5% to 80% non-condensing
Over Voltage (IEC 1010-1): Category II
Pollution (IEC 1010-1):Degree 2
P/N 97379 Rev. A
F-2 -
Index
I-1
contaminants B-4, C-2 E
large B-13 E-mail 1-41
minimum B-1 Import Lab 4-1
corrosion B-10 Laboratory Information Management System
Customer Details 1-16 1-41
engines A-1
D enhanced particle sensitivity 5-31
Data Export 11-18
Database Export 4-4 F
database tree fatigue wear 9-13
change marks 1-13 ferromagnetic B-4, B-5, C-2, C-3
expand entire tree 2-4 ferromagnetic index B-12
Right Mouse Click Functions 1-14 ferrous wear 9-14
definition Ferrous Wear Monitor 8-1
contacts 11-18 Cables And Connections 8-5
customers 11-18 calibrating 8-8
diesel A-1 Empty/Clean Calibration 8-8
digital viscometer Software Setup 8-3
calibration 6-6 to 6-12 Standard Calibration 8-9
connections 6-3 to 6-5 Standard Equipment 8-2
Digital Viscometer Setup 6-3 Taking Calibration Readings 8-9
Alternate OilView Analyzer Port 6-4 Testing Samples 8-11
Using the Digital Viscometer 6-3 ferrous wear monitor
Using the Digital Viscometer With a Computer calibration 8-8 to 8-10
6-5 filter 9-13, A-4, A-6
dilution 5-31 free water A-1, B-6, C-4
particle counter 7-11, 7-25 frequency units test method
Dilution Of Viscous Samples 5-31 data plot C-1 to C-6
dilution ratio 7-27 fuel A-3
dilution samples fuse 5-23
dilution ratios 7-27
Disclaimers G
electrostatic discharge 1-3
gear A-2
harsh environments 1-3
results 1-3
double cleaning H
sensor grids 5-33 hardware setup
drain plug A-6 ferrous wear monitor 8-5 to 8-7
oilview analyzer 5-21
I-2
particle counter 7-2 to 7-3 Filter 2-22
humidity 5-22 General 2-17
Internal Process Material 2-24
I Internal Working Environment 2-22
If Duplicate File Name 11-14 Lab Unit ID 2-18
Import Lab E-mail 4-1 Lubrication System, Units 2-18
ISO Code 7-15 Oil Capacity 2-23
Oil Wetted Bearing Parts (P1) 2-26
Oil Wetted Parts (P2) 2-27
K Oil Wetted Parts (P3) 2-28
kerosene 7-38 Point ID 2-17
Report Group 2-18
L Report Language 2-18
labels Schedule 2-20
lab label 1-39 Target Cleanliness 2-18
sample bottle label 1-38 Test and Disply Filter 2-21
Laboratory Imports 4-3 Usage Units 2-18, 2-23
Laboratory Information Management System 11-1 microscope 9-14 to 9-22
assign customers 11-17 model 51SM 9-21
Assign Samples 11-3
Batch information 11-10 N
contact address book 11-15 NAS 7-18
Manual Entry 11-20 nitration 5-2
Result Options 11-13
Serial Communications 11-21
left mouse button function O
Drag and Drop 2-3 oil
Drag and Drop Sample 1-26 bearing A-2
License Configurations 1-5 collecting samples A-4 to A-7
lighting, microscope 9-22 crankcase A-1
gears A-2
hydraulic A-2
M pump A-1
Measurement Point Information turbine A-1
Alarm Limit Set 2-19 Oil Tests
Analysis Parameter Set 2-18 reference 10-32
Description 2-17 OilLife index B-9
Equipment Type 2-19 OilView Analyzer
External Working Environment 2-25 usage tips 5-33
I-3
OilView Analyzer - Initial Setup 5-21 R
sensor curing 5-24 Ref Samples used in Database 2-4
system setup 5-21 reference
OilView Analyzer Usage Tips 5-33 file B-11
Double-Clean the Grid 5-33 Reference Oil
Verify Calibration 5-33 adding 2-13
OilView Particle Counter Setup 7-2 Reports 3-18
OilviewLite 12-1 Result Options 11-13
Adding a Sample and Running a Test 12-3 right mouse button function
Alarm Sets 12-5 Area Icon 1-17
Data 12-7 Database Icon 1-14
Databases 12-2 Equipment Icon 1-21
Reference Oils 12-6 Measurement Point Icon 1-23
Reporting 12-4 Sample Icon 1-25
Setup 12-2 RS232 port 5-21, 5-25, 7-2
On-Line Running a Test 7-5
help 1-4 Alternative Testing Method 7-14
tutorial 1-4 Particle Counter Test Procedure 7-7
Overview Problems 7-13
Calibration 10-47
oxidation 5-2, A-1 S
sample 1-38
P sample bottle 5-26, A-6, A-7
particle counter label A-7
sample dilution 7-25 Sample Information
sensor cleaning 7-33, 7-38 5100 Data Plot 3-15
setup 7-2 5200 Plot 3-16
phosphate ester 5-24 Data tab 3-10
plant air adapter 7-6 ISO 4406 plot 3-11
plot B-3 to B-7 NAS Count 3-12
lines B-4 Notes 3-9
Plot Cal 6-10 Observations 3-8
plots TriVector Plot 3-5
trivector 3-5 Viscosity Plot 3-17
pressure regulator 7-5 Sample Preparation 7-22
pumps A-1 Schedule 2-20
sensor curing 5-24
sensor grid
I-4
cleaning 5-16 T
curing 5-24 tare weight 7-28 to 7-32
double cleaning 5-33 test 5-25 to 5-29
phosphate ester 5-24 results B-8 to B-13
using 5-26 to 5-29 Test esults 7-15
setup, operating characteristics 1-28 to 1-38 test options
shop microscope 9-21 high viscosity oils 5-32
Software Menu Structure 1-8 Test Results 7-15
Software Setup 5-3 Diluent Test 7-21
Calibrate Tab 5-14 ISO 4406 Cleanliness Code Levels 7-16
Calibration Information 5-19 ISO Recommended Cleanliness Levels 7-19
Calibration Settings 5-18 NAS Code 7-18
Diagnostics 5-20 Settings 7-21
Test 5-3 Test ISO Plot and Test NAS Plot 7-20
Test Data Plot tab 5-18 Tests
Test Time Options 5-19 Reference Oil 10-32
verification testing 5-13 Text Shortcuts 1-42
specific gravity 6-8 Toolbar 1-10
spectroscopy 9-13 Trend Information 3-1
Statistics Export 4-6 Data, Minilab Data, and Lab Data Tabs 3-1
Summary Report Options 3-22 Detailed Parameter Plots 3-4
Alarm Setup Exception Report 3-25 Wear, Contamination, and Chemical Plots 3-3
Oil Usage Report 3-26 Trivector Analyzer 10-1
Parameter Exception Report 3-23 Dilution By Weight For Test 2 and Test 3 10-29
Point Configuration Summary Report 3-24 Initial Setup 10-3
Sample Summary Report 3-22 Instrument Overview 10-2
Schedule Summary Report 3-26 Making WDA Filter Patches 10-29
sump A-6 Plots 10-40
Superseding References 2-3 Test 2 Plot 10-40
Supplemental OilView Particle Counter Procedures Test 3 ISO Plot 10-42
7-36 Test 3 NAS Plot 10-45
Batching Similar Oil Samples 7-37 Results 10-37
Flush Till Clean 7-36 Test 2 – Wear / Contamination 10-38
Test 3 – Contamination 10-38
Intelligent Software 7-38
Test 1 Calibration & Verification 10-51
Kerosene 7-38
Calibration 10-54
Sample Types 7-36 Initial Clean Check 10-53
Screening Samples 7-37 Verification 10-57
sensor cleaning 7-38 Test 2 Calibration & Verification 10-59
synthetic lubricants 5-32, 5-33, 7-36 Calibration 10-62
I-5
Preparation for Calibration 10-60 sampling location A-6
Verification 10-65 WDA Filter Patch 10-29
Test 3 Calibration 10-67 wear 9-13 to 9-17
Test 3 Coincidence Error Limit Test 10-86 Wear Debris Analysis 9-1
Test 3 Diluent/Clean Fluid Calibration 10-83 Analyst tab 9-11
Test 3 Particle Counter Calibration Overview Atlas Setup 9-10
10-67 Model 51SM Microscope 9-21
Test 3 Sizing Calibration 10-76 Model 52LM Lab Microscope 9-22
Test 3 Verification 10-79 Model 52ZM Stereoscopic Zoom Microscope
Test Procedure 10-16 9-23
Volumetric Dilution For Test 2 and Test 3 10-28 OilView Analyzers And Wear 9-13
trivector plot 3-5 Sample 9-5
turbines A-1 Sample/Atlas 9-9
Using the Model 51WD Wear Debris Patch
U Maker 9-17
ultrasonic bath 7-7, 7-22 Video Camera 9-2
Using the Digital Viscometer 6-13 Video Frame Grabber 9-2
wear particles 5-2, B-12
V
vacuum chamber 7-22
verification test
OilView Analyzer 5-13
viscometer 5-31
Viscosity 6-15
viscosity
adhesive wear 9-14
dilution 5-31
fuel dilution A-1
viscosity index 6-8
viscosity index value 6-7
W
water 9-17, A-1
contaminant index B-11
corrosion index B-10
droplets B-13
example plot B-6, B-7, C-4, C-6
hydraulic oil 5-2
I-6