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ii
License Agreement Transfer
IMPORTANT: CAREFULLY READ ALL THE TERMS AND CONDITIONS OF THIS You may transfer the software and license to another party only with the
AGREEMENT BEFORE OPENING THE PACKAGE OR PROCEEDING WITH INSTAL- written consent of CSI and only if the other party agrees to accept the
LATION. OPENING THE PACKAGE OR COMPLETING THE INSTALLATION INDI- terms and conditions of this Agreement. If you transfer the program, you
CATES YOUR ACCEPTANCE OF THE TERMS AND CONDITIONS CONTAINED IN must transfer the documentation and any backup copies or transfer only
THIS AGREEMENT. the documentation and destroy any backup copies.
IF YOU DO NOT AGREE TO THE TERMS AND CONDITIONS CONTAINED IN Copyright
THIS AGREEMENT, CANCEL ANY INSTALLATION AND PROMPTLY RETURN THIS The software and documentation are copyrighted. All rights are reserved.
PRODUCT AND THE ASSOCIATED DOCUMENTATION TO CSI, AND YOUR Termination
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Definition of Software
Virus Disclaimer
As used herein, software refers to any computer program contained on
CSI uses the latest virus checking technologies to test all its software.
any medium. Software includes downloadable firmware for use in
However, since no anti-virus system is 100% reliable, we strongly advise
devices such as analyzers or MotorStatus units and it includes computer
that you use and anti-virus system in which have confidence to verify the
programs executable on computers or computer networks.
software is virus-free. CSI makes no representations or warranties to the
Software License effect that the licensed software is virus-free.
You have the non-exclusive right to use this software on only one device NO WARRANTY
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IN WORKMANSHIP OR MATERIAL IS EXPRESSLY LIMITED TO
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subject to restrictions set forth in the Federal Acquisition Regulations and
its Supplements.
iii
Hardware Technical Help Software Technical Help
1. Please have the number of the current version of 1. Please have the number of the current version of
your firmware ready when you call. The version your software ready when you call. The version
of the firmware in CSI’s Model 2100 series, Model number for software operating under MS-DOS®
2400, and other analyzers appears on the power- appears at the top of every menu screen. The
up screen that is displayed when the analyzer is version number for software operating under
turned on. Windows® is displayed by selecting “About” under
2. If you have a problem, explain the exact nature of the Help menu bar item.
your problem. For example, what are the error 2. If you have a problem, explain the exact nature of
messages? When do they occur? Know what you your problem. For example, what are the error
were doing when the problem occurred. For messages? (If possible, make a printout of the error
example, what mode were you in? What steps did message.) When do they occur? Know what you
you go through? Try to determine before you call were doing when the problem occurred. For
whether the problem is repeatable. example, what mode were you in? What steps did
you go through? Try to determine before you call
Hardware Repair whether the problem is repeatable.
CSI repairs and updates its hardware products free for 3. Please be at your computer when you call. We can
one year from the date of purchase. This service serve you better when we can work through the
warranty includes hardware improvement, modifica- problem together.
tion, correction, recalibration, update, and mainte-
nance for normal wear. This service warranty excludes Software Technical Support
repair of damage from misuse, abuse, neglect, care- CSI provides technical support through the following
lessness, or modification performed by anyone other for those under maintenance contract:
than CSI.
• Telephone assistance and communication via the
After the one year service warranty expires, each Internet.
return of a CSI hardware product is subject to a
• Mass updates that are released during that time.
minimum service fee. If the cost of repair exceeds this
minimum fee, we will call you with an estimate before • Interim updates upon request. Please contact CSI
performing any work. Contact CSI’s Product Support Customer Services for more information.
Department for information concerning the current
rates. Returning Items
1. Call Product Support (see page 2) to obtain a return
Obsolete Hardware authorization number. Please write it clearly and
Although CSI will honor all contractual agreements prominently on the outside of the shipping
and will make every effort to ensure that its software container.
packages are “backward compatible,” to take advan- 2. If returning for credit, return all accessories
tage of advances in newer hardware platforms and to originally shipped with the item(s). Include cables,
keep our programs reasonably small, CSI reserves the software diskettes, manuals, etc.
right to discontinue support for old or out-of-date 3. Enclose a note that describes the reason(s) you are
hardware items. returning the item(s).
4. Insure your package for return shipment. Shipping
costs and any losses during shipment are your
responsibility. COD packages cannot be accepted
and will be returned unopened.
iv
Contents
Chapter 1 • Introduction
How To Use This Manual · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-1
OilView Disclaimer · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-4
Electrostatic Discharge or Other Harsh Environments· · · · · · · · ·1-4
On-Line Help System · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-5
OilView System · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-6
Trivector Laboratory Data Import· · · · · · · · · · · · · · · · · · · · · · · · ·1-6
License Configurations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-6
OilView Software Menu Structure · · · · · · · · · · · · · · · · · · · · · · · · ·1-9
Drop down menus · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-10
Toolbar · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-11
Database Tree · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-12
Change Marks· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-14
Right Mouse Click Functions · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-15
Setup Menus · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-29
Communication Ports· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-29
System · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-32
Translations· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-36
Severity Codes · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-37
File Locations · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-38
Licenses · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-39
DB Level Names· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-40
Labels · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-41
Lab Labels· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-42
Reports · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-43
E-mail · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-44
Text Shortcuts · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·1-45
v
Reference Info · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-5
Adding a Reference Oil· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-13
Database Queries· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-15
Measurement Point Information · · · · · · · · · · · · · · · · · · · · · · · · · · 2-17
General Information · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-17
Schedule · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-21
Test and Display Filter· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-22
Internal Working Environment· · · · · · · · · · · · · · · · · · · · · · · · · · 2-23
Internal Process Material· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-25
External Working Environment · · · · · · · · · · · · · · · · · · · · · · · · · 2-26
Oil Wetted Bearing Parts (P1) · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-27
Analysis Parameter Sets · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-30
Database Tree · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-30
AP Sets and AL Sets (Folder icon) · · · · · · · · · · · · · · · · · · · · · · · 2-30
CSI Default Oil AP Set (AP Set icon) · · · · · · · · · · · · · · · · · · · · · 2-32
AP Sets Secondary Tabs and Information Window· · · · · · · · · · 2-34
Alarms· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-40
Current Alarms · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 2-42
vi
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
vii
Plot ASTM · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-13
Using the Digital Viscometer · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-14
Viscosity · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 6-16
viii
Chapter 9 • Wear Debris Analysis
Sample· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·9-5
Sample/Atlas· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·9-9
Atlas Setup · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·9-11
Analyst tab · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·9-12
The OilView Analyzers And Wear · · · · · · · · · · · · · · · · · · · · · · ·9-14
Using the Model 51WD Wear Debris Patch Maker · · · · · · · · · ·9-18
Using the Model 51SM Shop Microscope· · · · · · · · · · · · · · · · · ·9-22
ix
Test 3 Preliminary Instrument Check · · · · · · · · · · · · · · · · · · · · 10-66
Test 3 Sizing Calibration · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-69
Test 3 Verification· · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-72
Test 3 Diluent/Clean Fluid Calibration · · · · · · · · · · · · · · · · · · · 10-75
Test 3 Coincidence Error Limit Test · · · · · · · · · · · · · · · · · · · · · 10-78
Test 3 Flow Rate Limits · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-82
Test 3 Resolution · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-85
Diagnostics · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · 10-88
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
x
Data · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · · ·12-7
xi
Appendix E • Extended NAS Table
Index
xii
Chapter 1
Introduction
1-1
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.
1-2 Introduction
Manual Conventions
These conventions are used throughout this manual to call attention to the
adjacent text:
Note
The Note paragraph indicates special comments or instruc-
tions.
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.
1-3
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 comprehen-
sive analysis than OilView is able to perform.
All results must be considered as advisory information only and should be
weighted carefully by the personnel who are responsible for maintenance
actions which are taken. CSI 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.
1-4 Introduction
On-Line Help System
OilView and the RBMware 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 RBM-
ware 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 Software Menu Structure section of this manual for more infor-
mation.
License Configurations
The Minilab Instruments and Data Edit/Entry configuration is used to
operate any of the CSI OilView products including any or all of the fol-
lowing:
• 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)
1-6 Introduction
These instruments are designed for use in industrial maintenance depart-
ments. They are all portable, bench-top operated devices operated off of
110 to 230 V A/C power.
The LIMS and Data I/O configuration is used by the CSI lab customer
who wants to do more than just view CSI lab data. This configuration is
able to import data from CSI’s lab and from other leading industrial oil
analysis labs as well. It is fully integrated with RBMWare, and allows you
to add, edit, or perform further analysis on the data.
The Wear Debris Analysis configuration provides effective and efficient
means to perform detailed wear debris analysis (WDA), to capture images,
to store images, and to review an atlas of sample images. This tool is
designed to be used with any WDA or ferrography system such as any of
the following:
• Model 5200 Trivector Analyzer
• OilView Shop Microscope (Model 51SMC) used with the OilView
Analyzer (Model 5100)
• OilView 52LM Lab Microscope
• Analytical ferrography
• Rotary Particle Depositor
• Filter Patch Analysis
• OilView 52ZM Stereo Zoom Microscope
• OilView 51CV Camera and Video Card
Activated categories
OilView Users
Software Manual Trivector Minilab LIMS &
Tabs Chapter WDA
Lab Import Instruments Data I/O
Trend Info 3 yes yes yes yes
Sample 3 yes yes yes yes
Info
Assign Ref 2 yes yes yes yes
Point Info 2 yes yes yes yes
AP Sets 2 yes yes yes yes
AL Sets 2 yes yes yes yes
LIMS n/a no no yes no
Data I/O 4 Only CSI no All Labs no
5100 5 no yes no no
5xDV 6 no yes no no
51PC 7 no yes no no
51FW 8 no yes no no
5200 n/a no yes no no
WDA 9 no no no yes
Expert n/a n/a n/a n/a n/a
Setup 1 yes yes yes yes
1-8 Introduction
OilView Software Menu Structure
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.
1-10 Introduction
Toolbar
1-12 Introduction
To view oil sample data, click on the open/close boxes to expose the area,
equipment, measurement point, and then the desired sample.
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.
1-14 Introduction
Right Mouse Click Functions
The right mouse button can be used to perform the following functions
from within the database tree:
Print/Preview
Point Labels – Create sample bottle labels for the entire database.
Sample Summary – Sample summary report for entire database.
1-16 Introduction
Clear Mark - clears the change marks for each piece of equipment, mea-
surement point, and oil sample under all Areas.
Schedule – Schedule sampling for every point in the database. See sched-
uling, 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.
Parameter Exception – A report similar to the parameter exception
report created using the RBMware 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.
10
Add Equipment - allows you to add a new piece of equipment to the cur-
rent 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-calculate
1-18 Introduction
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-calculate
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, mea-
surement point, and oil sample under all Areas.
Schedule – Schedule sampling for every point in the database. See sched-
uling, 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.
Parameter Exception – A report similar to the parameter exception
report created using the RBMware 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.
11
12
1-20 Introduction
Display Color Scheme – Select either 3 or 5 levels for color/icon scheme.
The default is 5.
Show Alarm severity icons – Select to enable or disable icon display. The
default is enable.
Show an icon for no alarm or normal – Select to show or hide the “No
Alarm” icon. The default is hide.
Show an icon when no analysis has been performed – Select to show
or hide the “Not Set” icon. The default is hide.
Automatic repaint interval in minutes – This feature is most useful on
network installations. It controls the frequency with which the icons on the
database tree are automatically updated by reading the values from the
database. This will allow changes made by one user to be seen on another
user’s computer without the second user having to close and re-open RBM-
ware programs. The default is 0, which means that automatic repaint is dis-
abled.
Note
The icons on the database tree are only available if you have
purchased RBMview Full.
13
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 equipment.
1-22 Introduction
Delete Equipment - allows you to delete a piece of equipment provided
there are only oil points under the equipment. If there are any other tech-
nology points under the equipment then the only way to delete the equip-
ment is using the database utility program.
Paste Point - is used to paste in a point that was previously copied at the
point item.
Clear Marks - clears all of the change marks for each measurement point
and oil sample under the selected piece of equipment.
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, mea-
surement point, and oil sample under all Areas.
Schedule – Schedule sampling for every point in the database. See sched-
uling, 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 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 RBMware 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.
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-calculate
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.
1-24 Introduction
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, mea-
surement point, and oil sample under all Areas.
Schedule – Schedule sampling for every point in the database. See sched-
uling, 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.
Parameter Exception – A report similar to the parameter exception
report created using the RBMware 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.
16
1-26 Introduction
Click On the Sample Icon
17
Edit Sample – allows you to change the date and/or sample number of the
clicked on sample.
Delete Sample – deletes the clicked on sample.
Delete WDA – Delete all wear debris images and delete associated with
this sample.
Recalculate Alarms – instructs the program to recalculate the alarm status
of the current sample.
Set Mark – sets the change mark for this oil sample only.
Clear Mark – clears the change mark for this oil sample only.
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 RBMware 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.
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.
1-28 Introduction
Setup Menus
The Setup menus includes functions to specify operating characteristics of
the OilView hardware and software.
Communication Ports
This function specifies the OilView and LIMS accessories that will be used
with this software, and to assign the OilView Analyzer and computer ports
for these accessories.
18
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 computer.
The OilView Analyzer port area is also used to specify which OilView
equipment is connected 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 com-
puter; 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 5-23 for
OilView Analyzer port assignments.
1-30 Introduction
Refresh Comm Port Status
This button is used to check the computer’s Comm Port Status to see if the
ports are available. If a port’s status is “unavailable,” then either it is not
configured in the operating system or some other application program is
using it.
20
Error Tracing
These options are for use only when working with CSI’s Customer Support
and you are resolving a problem.
Test Modes
Diagnostics – Enable Minilab instrument diagnostics. These features are
used for diagnosing problems in conjunction with CSI customer support.
1-32 Introduction
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.
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 CSI’s 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 data-
base, 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 infor-
mation. 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 automatically converted to the this standard. The 5200
Trivector Analyzer can be calibrated in either standard.
1-34 Introduction
Rename Log File
This function allows you to rename the current log file. This feature can be
used, for example, to create multiple log files during a software trouble-
shooting session.
LIMS
Lab Options – Reserved for the CSI Trivector lab.
Display Customer Level – The customer level in the RBM database
groups areas under a given customer. This option is activated here.
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 com-
patible with OilView 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.
21
The Sample Trend report and the Minilab report can be printed in multiple
languages. The specific language is setup at each point. Different points can
have different languages assigned to them. These reports do require that the
diagnostic message be written in the appropriate language for each point.
1-36 Introduction
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 par-
ticular severity code.
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 directories 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 CSI’s Customer
Support for information in this case.
1-38 Introduction
Lab Export/Import
This file location is used to archive data import files when importing data
using the E-mail option. After the data has been imported from the E-mail
then it is automatically archived in this directory.
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 impor-
tant to set this location to your local drive in a multi-user network installa-
tion 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
Caution!
CSI recommends that you do not use a keyword to replace another key-
word. For example, Equipment should not be substituted 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.
1-40 Introduction
Labels
Use this function to set up the dimensions of the labels being used to label
sample bottles. The labels identify the sample and are used on sample bot-
tles.
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.
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.
1-42 Introduction
Reports
The Name and address appearing on several reports may be customized as
shown below. You may also use your own logo by specifying the location
of a bitmap of your logo.
28
Report Colors - This sliding color level is used to tone down the colors on
trend plots or on printed reports.
29
1-44 Introduction
Select Fax Printer
The LIMS enables the automatic faxing of reports. this is enabled by setting
up a fax printer.
Text Shortcuts
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 charac-
ters 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 obser-
vation or action text associated with that shortcut appears in the observa-
tion or action dialog area.
Reference Database
Many of the minilab measurements result from comparing new or refer-
ence 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 provided for comparison. For example, the zinc and calcium
(Zn and Ca) levels are additive elements that can be compared between ref-
erence and used oils to detect additive depletion.
CSI 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. There-
fore, 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 displayed 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 Measure-
ment Point or Sample highlighted on the User Database tree in the display
on the left.
2-3
Drag and Drop
New reference oil can be copied to another point on the Ref DB tree. First,
click and hold the left mouse button on the new reference oil. Next, move
the highlight data to another point. Finally, release the mouse button. You
will be prompted with a message to continue.
Data Available
The Data Available tab is a display of the instruments and tests for which
reference oil information has been stored on a specific reference oil sample.
These displays are for information 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 Database 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 “syn-
thetic” 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 properties for the reference oil. This information
typically is included with specification information 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 functional purposes for the reference oil. This
information typically is included with specification 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 concentra-
tion 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 Reference Oil Database and is used to identify the default set-
tings used when testing samples on the Model 51PC. Typical default set-
tings 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 ref-
erence. 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 vertical 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 fea-
ture 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 iden-
tify 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 Viscom-
eter 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 Customer Query option and select either Customer Sample
Query or Generate Schedule.
2-15
Customer Query
® 11
Generate Schedule
® 12
This menu option generates a list of samples that are due based on the cur-
rent 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 consistent method for num-
bering 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).
14
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 experience 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
Note
Printing of sample labels for due samples is done on the Q
(Database Queries) tab.
16
17
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
19
20
21
22
Database Tree
The analysis parameter (AP) sets that are available for the database are rep-
resented 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 Baseline.
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 cor-
rect 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 2-40.
Current Views
The analysis parameter set current views include a table with eight col-
umns. The first column is the list of all the Analysis Parameters in the set.
CSI strongly recommends that you use the CSI default Analysis Param-
eter 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.
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.
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 Sta-
tistics.
The MTB can be used to establish sampling intervals, which should be
more frequent 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
management type information.
30
Delete AP
Delete an AP Set and all its associated AL Sets. The software first checks to
ensure that neither the AP set nor any of the AL sets are currently being
used. If they are the user cannot delete the AP Set.
31
Alarms 2-41
Current Alarms
This table shows the current alarms assigned to the Alarm Limits (AL) set.
The alarm threshold value fields can be edited, if required.
32
Base Type - This column specifies if the alarm values are relative to zero
or to the oil reference 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 percent 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.
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.
Alarms 2-43
Statistics
The statistical information must be created by first exporting all the data
into a special database using the Data I/O tab as shown below.
33
This option is automatically activated from the AP and AL Set popup menu
button Update Statistics.
34
Alarms 2-45
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 prob-
lems 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.
35
Note
Sometimes the plot has several “bumps” that are difficult to
interpret. This is most often when a Reference baseline is being
applied.
Alarms 2-47
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 deviation 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 informa-
tion 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 Configura-
tion Summary report, which is designed to find incorrect oil reference and
other Point Setup issues.
Alarms 2-49
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 corre-
lation coefficient of 1 represents a perfect correlation.
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 appropriate standard AL Sets, the appropriate
standard AL Set and then pressing the <<< button.
Alarms 2-51
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
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. Addi-
tional 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.
Alarms 2-53
42
Sequential items may be changed by selecting the desired value and drag-
ging down the list.
You may also select Ref oils from a drop down list on the Ref Oil Desc field.
Alarms 2-55
2-56 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.
44
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 cal-
culations selected on the Point Info tab, Equip minor tab.
45
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.
46
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.
3-3
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.
47
48
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.
49
50
51
Observations
This list of selectable observations serves as a sample record for non-
trendable information.
52
53
54
55
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
57
The standard plot displays the cumulative counts versus size. This plot dis-
plays the actual counts versus size (dashed line) and total volume of the par-
ticles versus size. The total volume of all particles is also shown. This value
is only displayed if the PPM Vol(ume) parameter has been added to the AP
Set. To see this for historical data, you must run the Calculate PC Vol option
on the main File menu. Oil Capacity must be entered for point configura-
tion in order to calculate System Debris.
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 par-
ticles 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 measure.
58
59
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 par-
ticles. The water content is also estimated from these curves.
60
61
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.
62
Reports 3-19
Sample Trend – Vib Analyst
63
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.
64
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
65
66
This report shows the Area, Equipment, Point, Sample Date, Sample ID,
and then the Wear, Contamination, and Chemistry severities.
67
This report is a customized version for oil analysis of the exception report
created by the RBMware 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
68
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 samples under each point. If there are any inconsis-
tencies in the information, such as no reference oil, that cell in the report is
highlighted in yellow.
This report also checks the median value of the dielectric and HOC vis-
cosity against the reference oil values and if they differ by more than 30%
this is also highlighted. If this happens, it probably means the wrong refer-
ence 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 Database
tree popup menu when you right click on the point in the tree.
69
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
70
This report shows the oil added per year for each point. It then summarizes
the oil used per year for each oil type.
71
This report shows the sampling schedule for each point for an entire year.
If samples have already been collected, their status (severity) is shown.
This report is useful to see that sampling has been scheduled and to see that
samples have actually been processed in the past.
Reports 3-27
Print Preview
The Print Preview window is controlled with the following buttons:
72
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 vsp file that can be viewed using
the CSI report viewer.
73
Logon - Press this button to log onto your E-mail system. You must setup
your E-mail connection 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.
74
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 RBMware 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 database the database level would be
selected. To export just one sample, that sample would be selected.
75
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
automatically creates the Area, Equipment or Point in the target data-
base if they do not exist.
• Comma Delimited output file.
• Entek IRD format.
Note
When exporting sample data using the A/E/P option, the ref-
erence 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.
76
77
5-1
The OilView Analyzer test is an immediate, on-site test that will detect
abnormal conditions. 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 Lab-
oratory for additional in-depth testing, please provide a copy of the Oil-
View 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 data-
base tab; select or create the sample point on the corresponding database
tree; clean the sensor grid and begin testing.
78
A principle difference when Model 5100 tests are done on the user database
is the automatic 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 5-15) or verify (see “Verify” on page
5-13) each sensor that is going to be used that day.
5100
Test
Neat Diluted 51FW 51PC 5xDV 51SM
Short time*
Full Full
Test
Test Test
Incoming R O R 3
lubes
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 recommended, 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.
Dilute
5100 Grid
5100 test Calibration Dedicated with
Oil Type Type
method Fluids grid? kerosene
(Gasket)
?
Mineral oil Regular Most oils A&B No Yes
(Red)
Polyalphaolephin Regular Most oils A&B No Yes
(PAO) (Red)
Synthetic Regular Most oils A&B No Yes
hydrocarbon (Red)
(SHC)
Polyol ester (POE) Regular Most oils B&C Yes Yes
(Red)
Diester Regular Most oils B&C Yes Yes
(Red)
Polyalkalene Regular Most oils B&C Yes Yes
glycol (PAG) (Red)
Perfluorinated Regular Heavy B&C Yes No
ether (PFE) (Red) synthetic
Phosphate ester Special Heavy B&C Yes Yes
(PhE) (Black) synthetic
Transformer oils Regular Ultraclean A&B Yes n/a
(Red)
Liquid Regular Ultraclean A&B Yes n/a
hydrocarbon fuels (Red)
Bunker fuels Regular Most oils A&B Yes Yes
(Red)
Water/oil n/a None n/a n/a n/a
emulsions
Fluids with n/a None n/a n/a n/a
dielectric > 16.0
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 dielec-
tric.
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 compatible 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 significant 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 sim-
ilar dielectric within +/- 0.2 dielectric units.
Most mineral and synthetic oils can be diluted with K1 kerosene (see “Dilu-
tion Of Viscous Samples (OilView Analyzer)” on page 5-33). Some users
prefer to use other hydrocarbon solvents such as hexane or heptane.
Warning!
Consult your industrial hygiene department, be aware of
flammability characteristics and skin contact restrictions
for solvents and oils.
79
Short Test
The Short Test is a relatively fast test for a single dielectric value with the
electromagnet in the off position. This test option only measures the dielec-
tric and, if a reference is available, a Chemical Index for the sample. There
are three common reasons for using the short test:
• Determine the dielectric to assess the identity of an unknown oil.
• Determine the dielectric and Chemical Index of a used oil when
chemical changes are the only interest.
• Determine the dielectric and Chemical Index of a used oil prior to
diluting the sample for diluted sample testing. This shortens overall
test times and provides greater sensitivity to particulate debris.
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.
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 incor-
rect, 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 Oil-
View 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.
80
81
You should calibrate each sensor once each day using two CSI supplied-cal-
ibration fluids. See “Oil Compatibility Chart” on page 5-7 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 circular (twisting) motion. The grid has been wiped clean 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.
82
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—inadvert-
ently 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 calibration 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 completely removed before continuing with the next measure-
ment. (You may want to test yourself on raw data repeatability results as you
double-clean and test fluids A and B, or B and C.)
83
Test Information
Three test options are available to the OilView Analyzer user. These set-
tings 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
CSI-supplied calibration fluids.
Grid Type
There are two calibration ranges: normal and high. Normal calibration is
done using CSI supplied Fluids A and B for oils in the range of 2.1 to 3.2
dielectric. High calibration is done using CSI 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-Phos-
phate 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
5-7.)
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, connect the OilView Analyzer’s Port 1 to the
computer's COM1 or COM2 serial communication (RS232) port.
84
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 Auxiliary 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 Oil-
View copyright message on its LCD screen.
85
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 5-27.
Caution!
The sensing grid should never be exposed directly to water.
Note
Because the OilView Analyzer is extremely sensitive to mois-
ture, it should be used indoors where humidity and tempera-
ture are relatively 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 phosphate 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 material 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 com-
patible with the seal.
86
3 ···· Once the sample has been shaken, screw the sensor to the bottle.
87
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 5-16).
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.
Note
For information on diluting samples to be used with the Oil-
View Particle Counter, see “Dilution Of Viscous Samples (Oil-
View Analyzer)” on page 5-33.
Warning!
Consult your industrial hygiene department, be aware of
flammability 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 5-7 for
additional information regarding testing synthetics with OilView instru-
mentation.
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 different 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 lubricants 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 Reli-
ability 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.
89
6-1
Warning!
For safety reasons, the OilView Digital Viscometer
should never be applied to a highly flammable hydro-
carbon liquid such as gasoline.
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 recep-
tacle. 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.
90
Caution!
Exercise care when inserting the Digital Viscometer’s 15-pin connector
into the OilView Analyzer’s port 2—it is possible to force the connector
upside down.
91
92
*. ISO 14, 32, 68, 100, 137, 220, 460, and 680
93
Note
Make sure your Digital Viscometer is plugged in and warmed
up for one hour prior to starting a calibration. When cali-
brating, 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 CSI-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.
94
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.
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.
Calibration Continued
The digital viscometer should be calibrated with at least eight fluid samples
representing the range of viscosity of the fluids that will be tested. CSI rec-
ommends normal 40C viscosity values of 14, 32, 68, 100, 137, 220, 460, and
680. Keep in mind that the larger the number of calibration samples and
the more diverse these samples are within the viscosity range, the more
accurate the instrument will be in the actual testing of fluid samples.
Note
When calibrating, start with the highest viscosity oil and
progress to the lowest viscosity oil.
95
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 mag-
netized. Discard the oil and clean the cup and ball bearing before the next
test.
Note
Do not pour the calibration fluid back into the original bottle.
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 calibration table will display the oils you tested
from highest to lowest viscosity.
Note
CSI strongly recommends that the default reference be
changed as needed to match, as closely as possible, the vis-
cosity index of the oil being tested to the viscosity index of the
calibration oil. The viscosity index is printed on the labels of
CSI-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.
96
This plot shows the ball speed as a function of viscosity in cps at ambient
test temperature. These are the actual units the viscometer measures. You
can use the left mouse click feature to see which calibration oil each graph
marker represents.
The high power plot is the default plot and normally is the only one dis-
played.
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.
97
98
Note
The Settings, Diagnostics, and Raw Data tabs are normally
grayed out and not accessible. They may be used by CSI Cus-
tomer Support to help diagnose problems.
99
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/tempera-
ture 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 ver-
tical 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 vis-
cosity in cSt at 40˚C and the percent viscosity change from the reference
value.
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 OilView 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.
100
101
102
103
104
• Make sure that all cables are connected properly (see “OilView Par-
ticle 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 1-29).
105
Caution!
CSI highly recommends using an ultrasonic bath to prepare samples for
the particle counter. If reducing sample preparation time is an impor-
tant consideration, a vacuum chamber may also be used to speed up
removal of entrained air. See “Sample Preparation” on page 7-21 for
detailed procedures and vendor information.
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
7-21.)
106
3 ···· Turn the sample cup clockwise back onto the particle counter,
tightening until a hard stop is felt.
107
4 ···· Ensure that the current sample point has been specified for the
particle counter (see “Database Tree” on page 1-12). 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 7-20.)
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.
109
110
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
indicator and ensure that the reading is greater than 2 kgf/cm2.
• Pressure regulator is not opened to the “HI” position. Adjust regu-
lator.
• 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 7-32).
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
111
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
Fluid classification
Component type
ISO code
112
113
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.
‡. CSI (1-423-675-2110) Parent part number A5101A1.
**. Fisher Scientific (1-800-766-7000) Vacuum Desiccator, Fisher No. 08-642-7.
Vacuum Pump, Fisher No. 01-092-25 (115 V AC).
Note
An appropriate amount of the sample can be anywhere
between one to twenty grams of sample depending upon con-
tamination.
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 commer-
cial K1 kerosene yourself to use for dilution or final cleaning by passing it
through a 0.8 micron filter.
114
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.
115
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.
117
118
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.
120 7
121
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 mixtures” for the most accu-
rate calculation of particle counts on diluted samples.
Note
The laser windows in the Model 51PC are made of sapphire
and cannot normally be damaged with the bristles of the sup-
plied wire brush.
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 different 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 Fomblin)
since there is no solvent that chemically dissolves this PTFE-based syn-
thetic material.
Screening Samples
Screen certain samples with the OilView Analyzer prior to testing on the
OilView Particle Counter. You may want to use the OilView Analyzer first
before using the OilView Particle Counter to test certain samples. This can
minimize the time spent flushing the laser particle counter sensor.
Note
If you intend to screen the sample as described, you should
split the oil sample so that the Model 5100 test does not con-
taminate the Model 51PC sample.
Intelligent Software
The OilView software will evaluate the test results for indications of
common problems and provide messages as appropriate. These helpful
suggestions include automatic evaluation of dirty sensor, excessive contam-
ination requiring dilution, or excessive viscosity requiring dilution.
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 7-32). The wire brush is able to clean contami-
nation from the sapphire windows of the laser particle 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 Scientific†† or other labora-
tory supply companies. 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 contaminated with ferromagnetic particles. Because
viscosity does not affect the measurement, the Ferrous Wear Monitor is ide-
ally 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.
123
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.
124
125
126
127
Power Switch
The Ferrous Wear Monitor uses a three-way power switch. Operation is
shown in the following illustration.
128
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.)
129
Click the Start button to begin the calibration procedure, the 51FW Mes-
sage box should read “Initializing.” After a moment, the status box will dis-
play “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 Mes-
sage box displays 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 procedures 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.
You will be asked to place and remove the Calibration Standard until the
software records three good readings. Upon completion of the calibration
procedure, the test status will show finished and you should click the Save
button to store the results.
Note
An “excessive range” message indicates an inconsistency
between the three bottle placement readings. This is most com-
monly 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 calibration standard should equal 100 (±5). Any fluc-
tuations in the electromagnetic readings will be zeroed out
when the 51FW is calibrated.
Note
Although not required, CSI recommends that the Model
51FW be calibrated daily. During calibration, the raw results
for the calibration 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 com-
pared against a “gold standard” at CSI. Any fluctuations in the
electromagnetic readings will be zeroed out when the 51FW is
calibrated.
130
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 displayed.
In either case, the User Action box will then display “Remove Sample from
51FW.”
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 database. 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.
131
The Wear Debris Analysis (WDA) tab is used to assist in analysis and doc-
umentation of visual microscopic observations of wear debris and contam-
ination extracted from oil samples. 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 9-14, discusses wear mecha-
nisms 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 OilView 4.0 Software provides image capture capa-
bilities using a video camera and video frame grabber card. Various video
cameras and frame grabbers may be used, but the key to the software inter-
face 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 man-
uals 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.
132
Sample
133
The Sample tab is used to analyze and document this analysis for each indi-
vidual 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.”
134
The photograph taken through the microscope is captured using the Cap-
ture button. Otherwise, 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.
9-7
Instead of selecting individual items from the wear debris analysis grid,
many people choose to use the wear debris analysis Atlas to select an image
that most closely represents the one being analyzed. The analysis of the
image in the atlas can be copied over to any of the five groups automati-
cally. You are then free to edit the results to correct any differences between
the atlas image and your actual image. This is described on the following
sections.
135
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
microscope 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.
Sample/Atlas
This screen is used to compare images from the wear debris analysis Atlas
with sample images and to import analysis results accompanying the atlas
image over to a selected group in the sample image.
136
9-9
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 anal-
ysis 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.
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 particles 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
Analyst tab
The Analyst tab displays multiple sample images simultaneously for easier
classification and diagnosis.
137
138
To be able to measure the size of particles on the screen, you must calibrate
the image capture characteristics. To do this you place the standard grati-
cule (supplied with the microscope or available from CSI), which has cali-
brated 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 mea-
sured. When you release the mouse button the pixels /micron calibration
factor is recorded. Now, save these settings by pressing the Save button.
9-13
The OilView Analyzers And Wear
Wear is the (unwanted) removal of material from a surface. In lubricated
machinery, abnormal wear results from one or more of three general mech-
anisms: abrasion, fatigue, or adhesion.
Fatigue Wear
Fatigue wear is caused by cyclic loading of metal surfaces. This wear even-
tually 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 bearings, cams, drive chains, and sprockets. In many cases fatigue
wear can be the beginning of the end of a component’s useful service life.
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 par-
ticles. 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 Ana-
lyzer sensor grids and Ferrous Wear Monitor are only sensitive 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 sensitive to all particles larger than 2 µm.
Typical solutions to abnormal adhesive wear are to minimize “cold” start-
ups, ensure adequate 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
Testing For Ferrous Wear with the 5100
When the OilView Analyzers or Ferrous Wear Monitor are used to screen
for ferrous wear, the most important things to look for are increasing fer-
rous levels over time and a large ferrous indication. Remember that the fer-
rous reading will increase with particle size as well as particle
concentration. Consequently, any sudden increase in the ferrous index is
an indication that wear has accelerated in the lubricated system. If this
occurs, laboratory-based Analytical Ferrography is in order.
An on-site inspection technique may be employed using CSI’s Model
51SM 100x reflective microscope to help in the characterization of smaller
particles. A permanent magnet can be used to retain wear particles on the
sensor grid while the bottle is unscrewed from the grid.
One way of doing this is to invert the analyzer (as shown in the following
photograph) and use the analyzer’s permanent magnet, along with oil film
surface tension, to hold wear particles on the grid. Alternatively, remove
the sensor grid and bottle from the analyzer. With the bottle still upside
down, place a permanent magnet beneath the sensor and then invert the
bottle.
139
140
Note
To classify particles, see the CSI “Wear Particle Atlas.”
If the residue moves with the magnet, the material is ferromagnetic. If indi-
vidual 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 surface. 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.
9-17
When the OilView Analyzer shows a high contamination index with a non-
zero ferrous reading, a question arises as to the nature of the contaminant.
In this case, a study of the plot is invaluable. If the plot contains a series of
very sharp upward spikes, it is possible that the reading is a result of con-
ductive metal particles. If the plot has a steep, upward slope with only
minor upward spikes, the contaminant is probably water. In either case a
laboratory test is recommended.
Here again, there may be some benefit in visually examining the oil. Using
a pipette, draw a small amount of oil from the bottom of the bottle after it
has been standing upright. Then place a few drops of the oil on a clean
piece of paper under a bright light. If the contaminant is a solid with particle
sizes of 40 microns or more, they can be distinguished as discrete particles
on the paper surface after the oil has been absorbed. In many cases, it will
be possible to visually determine if the particles are metallic. Again, the
shape of the particles may give insight into the nature of their source and
the wear mode that produced them.
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 vacu-
uming to wash the particles through the plumbing and to clean the oil res-
idue 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 microscopic viewing.
9-19
Ferrous / Non-Ferrous Separation
If you wish to view ferrous and non-ferrous particles on separate patches,
then use the sheathed magnet to extract ferrous particles from the diluted
sample mixture before ever adding it to the patch maker chamber. After
removing the ferrous particles, you can pour the remaining diluted sample
into the chamber and prepare the non-ferrous patch. Remove the non-fer-
rous patch and insert a new patch for the ferrous particles. Then remove the
magnet from the sheath, and rinse the ferrous particles off of the sheath into
the chamber with solvent. Flushing this time will create the ferrous patch.
141
9-21
Using the Model 51SM Shop Microscope
The Model 51SM shop microscope can be set on the top of the OilView
Analyzer directly over the sensor grid as shown in the following photo-
graph. The light source can set up to be either oblique or through-lens, and
light intensity is controlled with the knob on top of the lamp power supply.
9-23
Model 52ZM Stereoscopic Zoom Microscope
The 52ZM Stereo Zoom Microscope provides three-dimensional viewing
of wear debris particles. Continuous zoom magnification allows samples to
be quickly searched at low power and then zoomed in to a higher magnific-
tion. See the illustration below and the microscope manual for setup and
operation.
143
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.
144
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 cer-
tain 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.
145
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 buttons 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.
Cable Connections
Refer to the illustration of the rear view of the analyzer for all cable connec-
tions. The 5200 communicates with a computer using a standard 9-pin,
RS232 serial communications cable which is included.
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 posi-
tion.
Caution!
The 5xDV communications port is a 15-pin, high-density sub-D con-
nector which provides both power and serial communications. Use cau-
tion 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 con-
nector. 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.
Note
The null modem communications adapter must be connected
in-line with the cable to the electronic scale.
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.
Scale Calibration – The scale is factory calibrated and ready to use. The
calibration may be verified by weighing the 200 gram standard which
comes with the scale. If the calibration standard weighs between 199.5
grams and 200.5 grams, then the scale should be accurate enough for dilu-
tion ratio calculations. If necessary, use the following procedure to re-cali-
brate the scale:
1. ··· Remove all objects from the scale tray top, power on the scale, and
allow it to warm up for 30 minutes. Place the scale in a stable
environment free from vibration and air currents.
2. ·· Press the TARE/PRINT key briefly to re-zero the scale. The scale
should display a stable “0.0” reading with the “units” arrow at the
lower right of the display pointing to the “g” gram mode.
3. ·· If the arrow points to a different unit display mode, then press the
CAL/MODE key repeatedly until the arrow moves to the gram
position.
Warning!
The vacuum pump is not explosion-proof. It must not be
used in the presence of flammable liquids or gases. Ade-
quate ventilation of its exhaust is required.
146
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 display an “Ini-
tializing…” 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 software. The software will periodically re-
try while the 5200 Test tab is active until the calibration data has been suc-
cessfully read.
Note
Any communications errors must be resolved before using the
instrument.
Side view.
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 col-
lecting a second sample bottle.
Viscosity
Use the OilView Digital Viscometer to measure the viscosity of the undi-
luted 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 dissolves in
that oil before testing it in the Trivector Analyzer. The table below provides
a general 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.
Test 1, Chemistry
Use this test to accurately measure the dielectric of the “neat,” undiluted oil
sample, and generate the chemical index. You may also use this test to
establish a reference dielectric for a new reference sample on the Ref DB
tree.
1 ···· Thoroughly shake the sample bottle to get a homogeneous mixture.
2 ···· Use a clean, 10 ml syringe, and extract 10 ml of the neat oil from the
sample bottle. Be careful to NOT pull air pockets into the syringe. Air
will cause a false, low measurement.
3 ···· Place the tip of the syringe into the hole at the bottom of the Test 1
chamber and squirt the sample into the instrument. Leave the syringe
in place for now. This will prevent any air bubbles from being sucked
into the sensor.
Note
To obtain more accurate results for high dielectric oils, first
prime the sensor with 5 to 10 ml of the undiluted sample.
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.
Note
If subsequent Test 3 particle counting is to be run on the
sample, then the representative particle count for the diluent
must be saved first using the Calibrate/Test 3 Diluent/Clean
Fluid Calibration procedure described later in this chapter.
Note
If testing a new reference oil sample, refer to the section on ref-
erence oil tests.
Note
High dielectric oils such as PAGs or Phosphate Esters require
priming of the sensor grid. The software will check the Test 1
dielectric and the reference dielectric. If either value is above
a threshold, the software will prompt the user to prime the Test
2 sensor grid with a few ml of the diluted sample. After evacu-
ating the priming fluid with the vacuum system, add 20 ml of
the diluted, shaken sample and push the button to start the test
manually.
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.
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.
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 manu-
ally 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.
CSI 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 solvent. 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
establish 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 acti-
vated.
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.
CSI 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
containing 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 automat-
ically calculated from the recorded weights.
148
Note
The optional Test 2 reference water test requires an additional
50 to 100 ml of the undiluted reference oil. Also, a variable
speed drill with a stirring paddle attachment, plus a lab stand,
is required for mixing water with the reference oil.
150
151
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, nitration, 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.
Results 10-33
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 pro-
duces 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 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.
The particle count table shows the individual particle counts per milliliter
for each of the size ranges. The displayed sizes are either the older ISO
4402 calibration-based sizes (i.e. 2, 5, 15 µm, etc.) or the newer ISO 11171
sizes (i.e. 4, 6, 14 µm(c), etc.). The size display mode is selectable under
Setup / System by checking or un-checking the “Display ISO 11171 counts”
box. A micron (µm) is one millionth of a meter. There are 25.4 µm per
thousandth of an inch (per mil). The “µm(c)” notation is used by the new
ISO 11171 standard to denote the new sizing method. For more information
on these two particle counting standards, refer to the Test 3 Calibration sec-
tion later in this chapter.
ISO Code – The ISO codes are reported based upon the older ISO
4406:1987 or the newer ISO 4406:1999 ISO code table where each incre-
ment of one ISO Code represents approximately a doubling of actual par-
ticle counts. The three reported ISO codes for the older ISO 4406:1987
standard are >2 µm / >5 µm / >15 µm. For the newer 1999 standard, the
three ISO codes are for >4 µm(c) / >6 µm(c) / >14 µm(c). The ISO codes
for >5 µm and >15 µm should be almost equivalent to the >6 µm(c) and
>14 µm(c) codes. The >4 µm(c) ISO code could be one or more higher
than the >2 µm code.
NAS Code – The NAS code is from the NAS 1638 standard for classifying
particle distributions. The NAS classification method looks at five size
ranges from 5 micron up to >100 micron. The worst case size range dictates
the resulting code.
Results 10-35
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 pro-
duced 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.
152
153
Plots 10-37
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 Informa-
tion, 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.
154
Plots 10-39
Test 3 NAS Plot
The NAS cleanliness code (NAS 1638) was developed by the Aerospace
Industries Association of America, and is similar to ISO 4406 in that it clas-
sifies cleanliness according to pre-defined particle counts of certain particle
sizes. The following table shows the particle sizes, counts, and corre-
sponding NAS “Class.” The NAS 1638 standard ends at 12. CSI has
extended this table to better serve industrial applications. See Appendix E
for more information. All particle size counts must be less than or equal to
the defined counts for a particular NAS class to be assigned to that class. Or
in other words, the highest NAS class for either of the five size ranges is
defined as the overall NAS class.
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
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 pro-
file. So this category is the one that actually determines the NAS value.
Plots 10-41
Calibration Overview
The 5200 is factory calibrated so it is ready to use out of the box. The cali-
bration procedure uses known fluids with known chemistry and contami-
nant levels in order to baseline the instrument. This allows the instrument
and software to compute the absolute dielectric and particle counts for
unknown oil samples.
The basic calibration factors are stored inside the instrument. These factors
are read by the software each time the software starts. These basic factors
are all that are needed to run tests with the instrument. Additional calibra-
tion data and historical calibration log data are stored in a calibration data-
base. The database provides more detailed calibration data for
informational purposes. Also, previous calibration results can be retrieved
and viewed from the calibration database.
The initial factory calibration database is shipped on a floppy disk with
each instrument. This database is named A52cal_(serialnumber).mdb, and
should be copied to the Custdata\Instrmnt folder before running the 5200
software. If you forget to copy the database or do not have it, the software
will prompt for it when you go to the 5200 Calibrate tab. You may browse
for the database or just cancel to work without it. If you choose to cancel,
then a template database will be used and the basic hardware calibration
factors will be stored in a new database named A5200cal.mdb. If you do
have the serialized factory calibration database, then its contents will be
copied into A5200cal.mdb. The calibration data for multiple 5200 serial
numbers may all be stored in the same database.
New Calibration
If a verification shows large percent errors, then first check to make sure the
procedure is being followed correctly and that the correct fluids are being
used. Repeat the verification on the fluid in question. If the fluid still fails
the verification test, then re-calibration is required.
Each calibration screen in the software contains a “New” button. This
button is used to erase all of the calibration data for the current test screen
in preparation for a new test. For example, if two or more fluids fail Test 1
Verification, then go to the Test 1 Calibration tab and click the New button
to start a completely new Test 1 Calibration. If only one fluid fails the veri-
fication, then do not use the “New” button. Simply re-calibrate with the
failing fluid as described under Test 1 Calibration below.
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, his-
torical calibration. Also, if the user starts a re-calibration 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 ini-
tially 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 nec-
essary 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 data-
bases. However, normally only the default A5200cal.mdb calibration data-
base should be used.
Read Test(s) – This command button is used to restore previous calibra-
tions. First highlight 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.
156
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 calibra-
tion itself. The frequency value, however, should stay rela-
tively the same for the clean sensor, and the software uses the
stored clean frequency to determine when the sensor is suffi-
ciently 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.
Note
You may want to wait and do the verification before repeating
any of the calibrations as it may give you a better idea of which
fluid is truly out of calibration range.
If all calibration data looks good, you must select the Save Changes button
to save the calibration data. It takes several seconds for the data to be
written to the analyzer.
157
158
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 calibra-
tion itself. The frequency value, however, should stay rela-
tively 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
frequency 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.
Note
You may want to wait and do the verification before repeating
any of the calibrations as it may give you a better idea of which
fluid is truly out of calibration range.
If all calibration data looks good, you must select the Save Changes button
to save the calibration data.It takes several seconds for the data to be
written to the analyzer.
159
160
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
µm(c).
ISO Codes
Since the particle sizes were re-defined, the ISO 4406 standard for coding
contamination levels was revised. The older ISO 4406:1987 standard used
a two-part code for contamination levels representing >5 µm / >15 µm.
Industry extended this standard to a three-part code of >2 µm / >5 µm /
>15 µm.
ISO 4406:1999(E) replaces the first edition, and defines a three-part code
for particle count contamination levels where the codes are for >4 µm(c) /
>6 µm(c) / >14 µm(c).
Fluid Requirements
Each part of the calibration procedure has its own fluid requirements. The
factory standard calibration uses about 400 ml total of ACFTD fluid 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 CSI for more informa-
tion 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 accor-
dance 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
contamination tends to accumulate from prior use.
161
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.
The Noise Level test automatically increments the channel voltage settings
for each particle size until all channels read zero counts with clean fluid
under no-flow conditions. Run the test as follows:
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 illus-
trated 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. How-
ever, either ACFTD, MTD, or UFTD may be used to verify volume accu-
racy. 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.
Finally, have a stopwatch ready and run the volume verification test as fol-
lows:
162
The Test 3 sizing calibration is performed as part of the factory standard cal-
ibration. 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 set-
tings to try to match the standard sizes more closely and produce the cor-
rect particle counts. The three samples multiplied by eight channel settings
produces a calibration curve of 24 points. This curve is then used to com-
pute final channel settings for the particle sizes of interest.
163
164
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 stan-
dard 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
Uncertified diluents should be filtered through a 0.8 micron or
smaller filter before being used for both the clean fluid test and
for normal diluted sample tests. The clean diluent particle
counts should be a small percentage of the used oil counts in
order to minimize errors when testing the diluted sample. The
OilView 51SF Solvent Filtration device may be used for this
purpose.
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 filtration 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.
Follow these steps to perform the test:
1. ··· Open a new syringe and draw up 30 ml of clean fluid from the 100
ml flush bottle. Insert the syringe into the Test 3 sample port and
manually squirt all of the fluid into the sensor. Repeat this with two
more 30 ml flushes to clean the sensor.
2. ··· Click on the appropriate side of the table on Count1 to select it as the
first sample to be tested.
3. ··· Click the Start button in the software to start the test.
165
166
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 µm(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 concentrate 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
167
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 individual 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.
As each sample is tested, the software updates the table and plots average
counts versus dust concentration. After the 0% to 40% samples have been
tested, the software computes a best-fit line equation for these sample
counts. The theoretical counts are calculated from this line equation, sub-
stituting each sample concentration up to 150% into the equation. After all
samples have been tested, the software computes another line equation
having a slope that is 95% of the theoretical line. Where the actual data line
crosses this 95% line is the coincidence error limit of the sensor. A coinci-
dence error limit report is available.
After all samples have been tested, click the Save Changes button to save
all results. The save operation will take several seconds as the data is written
back to the hardware.
168
The Test 3 Flow Rate Limits test establishes the flow rate limits of the instru-
ment. The particle 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 instrument based
upon the design of the sensor and actual test results from representative
instruments. Thus, this test is not part of the factory standard calibration
procedure, but may be ordered as a special calibration service. Alterna-
tively, 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 sam-
ples are prepared and tested at flow rates ranging from 10 ml/min up to 80
ml/min in 10 ml/min increments.
169
The Test 3 Resolution test measures the ability of the instrument to distin-
guish between particles of different sizes. This is largely governed by the
optics and electronic design. This test is not part of the factory standard cal-
ibration 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 cer-
tified 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.
170
Diagnostics 10-89
10-90 The Model 5200 Trivector Analyzer
Chapter 11
Introduction
Keeping track of oil samples as they are processed can be difficult. Nor-
mally, 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 performed. 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 appro-
priate recipients.
171
11-1
The LIMS (Lab Information Management System) solves the problem by
allowing samples to be grouped into batches for testing, analysis, and
reporting. Samples remain linked to the master database so that data, anal-
ysis, and diagnostic comments are automatically stored in the proper loca-
tion 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 recipients. With a click of the mouse,
the appropriate data and reports are emailed, faxed, or printed according
to preferences that you have established.
172
173
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.
174
175
176
You can print Lab sample labels for all samples in a batch, or for multiple
batches, depending on the level in the LIMS database tree (selected from
the right mouse button pop-up menu).
The lab labels are used internally with the lab as is the lab # printed on it,
as well as which tests are to be performed on the sample. This information
is derived the Point setup for the sample. (Set Lab Labels on the Setup tab.)
Database Level
177
178
179
Equipment Level
The options available in this dialog box will be the same whether or not the
“Display Customer Level” option is enabled.
180
Point Level
The options available in this dialog box will be the same whether or not the
“Display Customer Level” option is enabled.
181
Sample Level
The options available in this dialog box will be the same whether or not the
“Display Customer Level” option is enabled.
182
183
184
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.
185
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 auto-
matic E-mailing. You can also export the data for importing at a remote site
using the report results menu option shown below.
186
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 cus-
tomer 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.
187
188
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.
Contacts 11-17
Assign Contacts
Once the contact list has been created, the next step is to assign contacts to
the user databases so that contact-specific reports can be generated. Mul-
tiple contacts can be assigned at the Customer, Area, and Equipment levels
of the user database. This means that more than one contact can receive
reports and data for each sample. Once contacts have been assigned to the
user database, then each time reports are generated they will automatically
receive them.
189
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
contacts. “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 cus-
tomer assigned at the area level, but there can be many con-
tacts 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 com-
pletely independent of the contacts assigned to either the Customer, Area,
or Equipment levels.
At the customer level you must specify the sub-directory into which tempo-
rary information is stored prior to the data being sent. Each customer must
have their own unique sub-directory 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-direc-
tory 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 database 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 gen-
eral, the local lab database level structure may be different from the cus-
tomers 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.
190
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 cur-
rent database.) as well as the equivalent 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.
191
192
Once the instruments are connected through the RS232 port, then their
data will be automatically loaded into the LIMS as the tests are run. Sam-
ples 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.
193
From the drop down menu, select either Contact Statistics or Lab Statistics.
194
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
RBMware 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.
195
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 OilviewLite 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 software. 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.
196
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 pro-
ceed as described elsewhere in this manual for each instrument.
197
198
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.
199
200
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.
201
Data 12-7
12-8 OilviewLite
Appendix A
A-1
Turbine and Pump Oils
Oils used in steam turbines and water pumps are prone to contamination
with water. In these oils, the OilView Analyzer will detect water concentra-
tions below 100 ppm. In addition, the OilView Analyzer will indicate when
“free” water (droplets) are present in the oil. Avoiding free water is impor-
tant because water droplets can disrupt hydrodynamic and elastohydrody-
namic lubrication of load-bearing surfaces. The OilView Analyzer is also
sensitive to the corrosive potential of the water. For example, it will give a
much higher reading for saltwater contamination than contamination with
fresh water.
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 nonconductive hydraulic fluids. However, OilView Analyzer
testing of fluids used in precise hydraulic systems should always be accom-
panied by subsequent laser particle counter tests.
A-2
Compressor Oils
Mineral and synthetic oils used in compressors can be tested for moisture
contamination, oil breakdown, and mechanical wear. It is normally impor-
tant 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 refrig-
erant such as ammonia, CFC, or R134A. The ammonia in particular has a
significant effect on the OilView Analyzer sensor since ammonia has a high
dielectric just like water.
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-4
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.
Warning!
Follow standard practice procedures for health and
safety as established by your safety department when col-
lecting oil samples or handling new and used lube oils,
hydraulic fluid, and transformer oils.
A-6
• As a general practice, you would not want to initiate a maintenance
action on the basis of an oil sample taken directly from a used oil
filter. However, this is where you will find the highest concentration
of solid contaminants and large wear debris particles. If the filter is
free of metallic debris, it is unlikely that you have had extensive
abnormal system wear since the filter was last changed.
• 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 iden-
tify 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, moisture may evaporate, and small ferromagnetic parti-
cles 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
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 <0.2% (OL, Chl, Cont)
Cont, LC the aft end of a marine drive shaft.) >15% (LC-Droplets)
Water OL, Chl Polyol Alkaline Glycol (synthetic lubricant used <0.04% (OL, Chl)
in 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
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.”
B-2
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 represents changes in the dielectric proper-
ties 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 Analyzer 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 recom-
mendations in a text format.
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.
202
*. 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).
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 parti-
cles in the oil.
B-4
The figure below was taken with a fresh turbine oil containing 0.13% water.
Note that all three lines overlay indicating no significant ferromagnetic con-
tent. However, all lines have a steep upward slope, rising more than half a
point in 500 seconds. This indicates a significant non-ferromagnetic con-
taminant 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.
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 pre-
vious plots; the presence of upward spikes with all three magnet lines run-
ning together.
B-6
Test Results
More information can be obtained from oil testing when test results are
trended over time. Lubricant degradation is rarely linear over time. Typi-
cally, 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.
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.
B-8
Chemical Index
An increase in this index indicates that the oil is increasingly able to support
electrical conduction due to the presence of polar molecules and/or ions.
These conditions typically will lead to increased wear and corrosion.
The most common causes of an increase in this index include:
• thermally accelerated oxidation and nitration,
• soot loading,
• the formation of acids from combustion blowby in engines, and
• increased moisture content.
This index should be trended over time. Normally, it will be zero. If it is
non-zero, the oil is becoming corrosive and frequent testing is in order. If
the value continues to rise, it is probable that the oil additive package is
exhausted or a contaminant is entering the system. Before condemning the
oil, be sure to check that the oil was being compared to the proper reference
oil. If desired, perform a Verification Test to make sure that the OilView
Analyzer sensor has not been damaged. See“Verify” on page 5-13.
If, after verification, a second test gives the same results as the first, consider
changing the oil or sending a sample to an oil lab.
The following conditions will cause an increase in the chemical index:
• corrosive products of high-temperature oil oxidation and nitration,
• acids formed from combustion by-products such as sulfuric acid in
diesel engines,
• presence of dispersed water or coolant,
• high levels of very fine, suspended particles such as soot, dust, road
salt, or fine wear debris.
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
Ferromagnetic Index (Fe)
The ferromagnetic index is sensitive to conductive, ferromagnetic particles.
It increases linearly with both particle size and concentration. The index is
primarily sensitive to recent, severe wear of oil-wetted steel and iron parts,
because the surfaces of such particles are likely to be conductive. It is an
indicator of the condition of the lubricated system. In general, higher index
values correspond to higher wear rates.
This index should be near zero. Any positive value indicates ferromagnetic
debris. Higher values indicate increasing concentrations and/or particle
size. The graphic analog to this reading is the divergence of the “magnetic”
lines on the plot from the base “nonmagnetic” line. In the event that an oil
contains ferrous debris, the magnetic lines on the plot will diverge from the
base line. If the particles are large and have just been formed (highly con-
ductive), the magnetic lines will be rough and jagged and may have sharp
upward spikes.
It should be noted that many severe wear particles will not be detected by
atomic spectrometry—the standard laboratory analysis for metals in oil. The
atomic spectrometers used for oil analysis are not sensitive to particles
much larger than 5 to 10 microns in diameter. Severe wear typically pro-
duces larger particles. Consequently, even if you are having a spectrometric
metals analysis performed by a lab, you should also conduct an OilView
Analyzer test. Atomic spectrometry and OilView Analyzer testing are com-
plementary rather than redundant.
A full analytical ferrographic examination of the sample by an oil lab is rec-
ommended if this index gives a high positive reading. For more information
see “The OilView Analyzers And Wear” on page 9-14.
Note
Any Large Contaminant Indication other than “No Large Indi-
cations” 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 prop-
erty of a material. Simply put, dielectric constant measures the resistive, or
nonconductive properties of the oil. Contaminants (liquids or solids) set-
tling onto the surface of the sensor grid cause a change in dielectric constant
at the oil/grid interface. When oils are oxidized or the water concentration
increases, it is reflected in the dielectric number.
B-12
Appendix C
This Appendix has outlined the primary differences in the original fre-
quency units test method and the new dielectric units test method. The
dielectric units method is recommended and the original frequency units
method is no longer supported. Older data that has been stored in the user
database is viewable.
203
*. 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 Analyzer 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 parti-
cles in the oil. Also note the jagged appearance of the magnetic lines rela-
tive 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 con-
tent. 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
seconds 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 pre-
vious plots; the presence of downward 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 downward jump of the plot with no return to a higher 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 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 environment 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 instru-
ments using Thin Path, as time delays over the WAN make this totally unre-
liable. 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 RBMware is running over a LAN (between The RBM-
ware server and the RBMware client installed on the computer running
Terminal Server or Citrix) and only display information and mouse and
keyboard entries are transmitted over the WAN with no data access being
sent. This works well for analyzing data using the OilView software as hard-
ware connections are not required for this process.
The most convenient setup for running the minilab instruments is to install
an RBMware 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 connec-
tion (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-3
OilView Instrument Directory Setup
This directory appears under the Custdata directory and is used to store cal-
ibration 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, con-
taining 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
…\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
Setting up OilView File Locations for Terminal Server or Citrix RBMware Cli-
ents
All instances of OilView running under terminal server or Citrix use the
same Instrmnt directory.
Example
\\FPServer\RBMnet\RBMSuite\Custdata\Instrmnt\
Example
\\FPServer\RBMnet\RBMSuite\Custdata\Instrmnt\A\
Example
\\FPServer\RBMnet\RBMSuite\Custdata\Instrmnt\A\
Summary
The RBMware local based client will be used for data collection only and
the RBMview communications will be disabled.
The RBMware terminal server or Citrix client will be used for data anal-
ysis. RBMview communications will be enabled.
The NAS 1638 standard ends at 12. CSI has extended this table to better
serve industrial applications.
E-1
E-2 Extended NAS Table
Index
I-1
contaminants B-4, C-2 E
large B-12 E-mail 1-44
minimum B-1 Import Lab 4-1
corrosion B-9 Laboratory Information Management
Customer Details 1-18 System 1-44
engines A-1
D enhanced particle sensitivity 5-33
Data Export 11-19
Database Export 4-4 F
database tree fatigue wear 9-14
change marks 1-14 ferromagnetic B-4, C-2, C-3
expand entire tree 2-4 ferromagnetic index B-11
Right Mouse Click Functions 1-15 ferrous wear 9-16
definition Ferrous Wear Monitor 8-1
contacts 11-19 Cables And Connections 8-5
customers 11-19 calibrating 8-8
diesel A-1 Empty/Clean Calibration 8-8
digital viscometer Software Setup 8-3
calibration 6-6 to 6-13 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 calibration 8-8 to 8-10
Computer 6-5 filter 9-14, A-4, A-7
dilution 5-33 free water A-2, B-5, C-4
particle counter 7-11, 7-24 frequency units test method
Dilution Of Viscous Samples 5-33 data plot C-1 to C-6
dilution ratio 7-26 fuel A-3
dilution samples fuse 5-25
dilution ratios 7-26
Disclaimers G
electrostatic discharge 1-4
gear A-2
harsh environments 1-4
results 1-4
double cleaning H
sensor grids 5-35 hardware setup
drain plug A-6 ferrous wear monitor 8-5 to 8-7
oilview analyzer 5-23
I-2
particle counter 7-2 to 7-3 External Working Environment 2-26
humidity 5-24 Filter 2-24
General 2-17
I Internal Process Material 2-25
If Duplicate File Name 11-15 Internal Working Environment 2-23
Import Lab E-mail 4-1 Lab Unit ID 2-18
ISO Code 7-15 Lubrication System, Units 2-18
Oil Capacity 2-24
Oil Wetted Bearing Parts (P1) 2-27
K Oil Wetted Parts (P2) 2-28
kerosene 7-36 Oil Wetted Parts (P3) 2-29
Point ID 2-17
L Report Group 2-18
labels Report Language 2-18
lab label 1-42 Schedule 2-21
sample bottle label 1-41 Target Cleanliness 2-18
Laboratory Imports 4-3 Test and Disply Filter 2-22
Laboratory Information Management Usage Units 2-18, 2-24
System 11-1 microscope 9-16 to 9-23
assign customers 11-18 model 51SM 9-22
Assign Samples 11-3
Batch information 11-11 N
contact address book 11-16 NAS 7-17
Manual Entry 11-21 nitration 5-2
Result Options 11-14
Serial Communications 11-22
left mouse button function O
Drag and Drop 2-4 oil
Drag and Drop Sample 1-28 bearing A-2
License Configurations 1-6 collecting samples A-4 to A-7
lighting, microscope 9-23 crankcase A-1
gears A-2
hydraulic A-2
M pump A-2
Measurement Point Information turbine A-2
Alarm Limit Set 2-20 Oil Tests
Analysis Parameter Set 2-18 reference 10-30
Description 2-18 OilLife index B-8
Equipment Type 2-19 OilView Analyzer
I-3
usage tips 5-35 R
OilView Analyzer - Initial Setup 5-23 Ref Samples used in Database 2-4
sensor curing 5-26 reference
system setup 5-23 file B-10
OilView Analyzer Usage Tips 5-35 Reference Oil
Double-Clean the Grid 5-35 adding 2-13
Verify Calibration 5-35 Reports 3-18
OilView Particle Counter Setup 7-2 Result Options 11-14
OilviewLite 12-1 right mouse button function
Adding a Sample and Running a Test Area Icon 1-18
12-3 Database Icon 1-15
Alarm Sets 12-5 Equipment Icon 1-22
Data 12-7 Measurement Point Icon 1-24
Databases 12-2 Sample Icon 1-27
Reference Oils 12-6 RS232 port 5-23, 5-27, 7-2
Reporting 12-4 Running a Test 7-5
Setup 12-2 Alternative Testing Method 7-14
On-Line Particle Counter Test Procedure 7-7
help 1-5 Problems 7-13
tutorial 1-5
Overview S
Calibration 10-42
sample 1-41
oxidation 5-2, A-1
sample bottle 5-28, A-6, A-7
label A-7
P Sample Information
particle counter 5100 Data Plot 3-15
sample dilution 7-24 5200 Plot 3-16
sensor cleaning 7-32, 7-36 Data tab 3-10
setup 7-2 ISO 4406 plot 3-11
phosphate ester 5-26 NAS Count 3-12
plant air adapter 7-6 Notes 3-9
plot B-3 to B-6 Observations 3-8
lines B-3 TriVector Plot 3-5
Plot Cal 6-11 Viscosity Plot 3-17
plots Sample Preparation 7-21
trivector 3-5 Schedule 2-21
pressure regulator 7-5 sensor curing 5-26
pumps A-2 sensor grid
I-4
cleaning 5-17 synthetic lubricants 5-34, 5-35, 7-34
curing 5-26
double cleaning 5-35 T
phosphate ester 5-26 tare weight 7-27 to 7-31
using 5-28 to 5-31 test 5-27 to 5-31
setup, operating characteristics 1-29 to 1-41 results B-7 to B-12
shop microscope 9-22 Test esults 7-15
Software Menu Structure 1-9 test options
Software Setup 5-3 high viscosity oils 5-34
Calibrate Tab 5-15 Test Results 7-15
Calibration Information 5-21 Diluent Test 7-20
Calibration Settings 5-20 ISO 4406 Cleanliness Code Levels 7-16
Diagnostics 5-22 ISO Recommended Cleanliness Levels
Test 5-3 7-18
Test Data Plot tab 5-19 NAS Code 7-17
Test Time Options 5-20 Settings 7-20
verification testing 5-13 Test ISO Plot and Test NAS Plot 7-19
specific gravity 6-8 Tests
spectroscopy 9-15 Reference Oil 10-30
Statistics Export 4-6 Text Shortcuts 1-45
Summary Report Options 3-22 Toolbar 1-11
Alarm Setup Exception Report 3-25 Trend Information 3-1
Oil Usage Report 3-26 Data, Minilab Data, and Lab Data Tabs
Parameter Exception Report 3-23 3-1
Point Configuration Summary Report Detailed Parameter Plots 3-4
3-24 Wear, Contamination, and Chemical
Sample Summary Report 3-22 Plots 3-3
Schedule Summary Report 3-27 Trivector Analyzer 10-1
sump A-6 Dilution By Weight For Test 2 and Test
Superseding References 2-3 3 10-26
Supplemental OilView Particle Counter Initial Setup 10-4
Procedures 7-34 Instrument Overview 10-2
Batching Similar Oil Samples 7-36 Making WDA Filter Patches 10-27
Flush Till Clean 7-34 Plots 10-36
Intelligent Software 7-36 Test 2 Plot 10-36
Kerosene 7-36 Test 3 ISO Plot 10-38
Sample Types 7-34 Test 3 NAS Plot 10-40
Screening Samples 7-35 Results 10-33
sensor cleaning 7-36 Test 2 – Wear / Contamination 10-34
I-5
Test 3 – Contamination 10-35 viscosity index value 6-7
Test 1 Calibration & Verification 10-46
Calibration 10-48
Initial Clean Check 10-47 W
Verification 10-51 water 9-18, A-1
Test 2 Calibration & Verification 10-53 contaminant index B-10
Calibration 10-55 corrosion index B-9
Preparation for Calibration 10-54 droplets B-12
Verification 10-58 example plot B-5, B-6, C-4, C-6
Test 3 Calibration 10-60 hydraulic oil 5-2
Test 3 Coincidence Error Limit Test sampling location A-6
10-78 WDA Filter Patch 10-27
Test 3 Diluent/Clean Fluid Calibration wear 9-14 to 9-18
10-75 Wear Debris Analysis 9-1
Test 3 Particle Counter Calibration Analyst tab 9-12
Overview 10-60 Atlas Setup 9-11
Test 3 Sizing Calibration 10-69 Model 51SM Microscope 9-22
Test 3 Verification 10-72 Model 52LM Lab Microscope 9-23
Test Procedure 10-13 Model 52ZM Stereoscopic Zoom
Volumetric Dilution For Test 2 and Test Microscope 9-24
3 10-25 OilView Analyzers And Wear 9-14
trivector plot 3-5 Sample 9-5
turbines A-2 Sample/Atlas 9-9
Using the Model 51WD Wear Debris
U Patch Maker 9-18
ultrasonic bath 7-7, 7-21 Video Camera 9-2
Using the Digital Viscometer 6-14 Video Frame Grabber 9-2
wear particles 5-2, B-11
V
vacuum chamber 7-21
verification test
OilView Analyzer 5-13
viscometer 5-33
Viscosity 6-16
viscosity
adhesive wear 9-15
dilution 5-33
fuel dilution A-1
viscosity index 6-8
I-6