Oil View

Reference Manual
OilView for RBMware
In-Shop Oil Analysis and Laboratory

Information Management System
CSI Part # 97381 Rev. 7

Copyright CSIs Reference Manuals
2003 by Computational Systems, Incorporated. This document was written, illustrated, and produced
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Disclaimer
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ii
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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 CSIs 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 CSIs 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
Chapter 2 OilView Database Options

Reference Database 2-1
Assign Reference 2-2
Assign Reference Special Functions 2-3
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
Chapter 3 OilView Reporting

Trend Information 3-1
Sample Information 3-5
TriVector Plot Data 3-5
Observations 3-8
Notes 3-9
Data 3-10
ISO Count 3-11
NAS Count 3-12
5100 Data Plot 3-15
5200 Plot 3-16
Viscosity Plot 3-17
Reports 3-18
Summary Report Options 3-22
Print Preview 3-28
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
Chapter 5 OilView Analyzer Models 5100, 5100-1, and 5100-2

Software Setup 5-3
Test 5-3
Verify 5-13
Calibrate 5-15
Test Data Plot 5-19
Calibration Settings 5-20
Test Time Options 5-20
Calibration Information 5-21
Diagnostics 5-22
OilView AnalyzerInitial Setup 5-23
System Setup 5-23
Sensor Curing 5-26
An Example Testing Session 5-27
Analyzer Model Test Differences 5-32
Dilution Of Viscous Samples (OilView Analyzer) 5-33
Synthetic Oils 5-34
OilView Analyzer Usage Tips 5-35
Chapter 6 Digital Viscometer Model 51DV and Model 52DV

Digital Viscometer Setup 6-3
Using the Digital Viscometer With the OilView Analyzer 6-3
Alternate OilView Analyzer Port 6-4
Using the Digital Viscometer With a Computer 6-5
Calibrating the Digital Viscometer 6-6
Existing Digital Viscometer Users 6-6
New Digital Viscometer Users 6-6
Calibration Procedure 6-7
Verify 6-12
vii
Plot ASTM 6-13
Using the Digital Viscometer 6-14
Viscosity 6-16
Chapter 7 The OilView Particle Counter - Model 51PC

OilView Particle Counter Setup 7-2
Particle Counter Component Locations 7-4
Running a Test 7-5
Particle Counter Test Procedure 7-7
Problems 7-13
Alternative Testing Method 7-14
Test Results 7-15
Test ISO Plot and Test NAS Plot 7-19
Diluent Test 7-20
Settings 7-20
Sample Preparation 7-21
Dilution of Model 51PC Samples 7-24
Dilution Ratios 7-26
Sensor Cleaning 7-32
Supplemental OilView Particle Counter Procedures 7-34
Chapter 8 The OilView Ferrous Wear Monitor - Model 51FW

Introduction 8-1
Standard Equipment 8-2
Software Setup 8-3
Cables And Connections 8-5
Calibrating the Ferrous Wear Monitor 8-8
Empty/Clean Calibration 8-8
Standard Calibration 8-9
Taking Calibration Readings 8-9
Testing Samples With the Ferrous Wear Monitor 8-11
Screening 8-12
Diagnostics and Raw Data 8-12
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
Chapter 10 The Model 5200 Trivector Analyzer

Introduction 10-1
Instrument Overview 10-2
Initial Setup 10-4
Test Procedure 10-13
Volumetric Dilution For Test 2 and Test 3 10-25
Dilution By Weight For Test 2 and Test 3 10-26
Making WDA Filter Patches 10-27
Reference Oil Tests 10-30
Results 10-33
Plots 10-36
Test 2 Plot 10-36
Test 3 ISO Plot 10-38
Test 3 NAS Plot 10-40
Calibration Overview 10-42
Calibrate Overall Tab 10-44
Test 1 Calibration & Verification 10-46
Initial Clean Check 10-47
Calibration 10-48
Verification 10-51
Preparation for Calibration 10-54
Calibration 10-55
Verification 10-58
Test 3 Calibration 10-60
Test 3 Particle Counter Calibration Overview 10-60
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 11 Laboratory Information Management System (LIMS)

Introduction 11-1
Assign Samples 11-3
Assign Samples tab 11-6
Batch Types 11-10
Batch Information 11-11
Result Options 11-14
Contacts 11-16
Assign Contacts 11-18
Data Export 11-19
Manual Entry 11-21
Serial Communications 11-22
LIMS Management Reports 11-23
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
Appendix A Using the OilView Analyzer

Where To Use the OilView Analyzer A-1
Collecting Oil Samples A-4
Sampling Hints A-6
Appendix B Understanding the OilView Analyzer Data

Applying the OilView Analyzer B-1
Plot Examples B-4
Test Results B-7
OilLife Index B-8
Chemical Index B-9
Contaminant Index B-10
Ferromagnetic Index (Fe) B-11
Large Contaminant Indicator B-12
Dielectric Number B-12
Appendix C The Original Frequency Units Data Plot

Understanding the Frequency Units Data Plot C-1
Original Frequency Units Data Plot Examples C-2
Appendix D WAN Setup for OilView

Communications D-1
OilView Instrument Directory Setup D-4
Setting up OilView File Locations for Terminal Server or
Citrix RBMware Clients D-6
Setting up OilView File Locations for Workstation A
using RBMware Local Client A D-7
Setting up OilView File Locations for Workstation B
using RBMware Local Client B D-8
Setting up OilView for Terminal Server or Citrix D-9
Setting up OilView Local Client D-10
Summary D-10
xi
Appendix E Extended NAS Table
Index
xii
Chapter 1
Introduction
How To Use This Manual

This manual describes the operation of OilView instrumentation and soft-
ware that includes:
the OilView software program,
OilviewLite software program,
the Model 5200 Trivector Analyzer,
the Model 5100-1 and 5100-2 OilView Analyzer,
the Model 51SM LM and ZM Microscopes,
the Model 51CV Camera and Video Card,
the Model 51FW Ferrous Wear Monitor,
the Model 51DV and 52DV Digital Viscometer, and
the Model 51PC Particle Counter
the Model 51WD Wear Debris Patch Maker.
Any one or combination of these in-shop oil analysis tools can be operated
through the OilView software program. The combination of multiple Oil-
View instruments at a single workstation is referred to in this manual as a
mini-lab.
The central element of a mini-lab is the OilView Analyzer. Most of this
manual assumes that the OilView Analyzer is being used in conjunction
with the other instrumentation, such as the Shop Microscope, Ferrous Wear
Monitor, etc. For instance, sampling techniques and reference oils are
described in the chapter covering the OilView Analyzer and are also appli-
cable to the other instruments as well.
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.
Electrostatic Discharge or Other Harsh Environments

In unusually harsh operating environments, operation of this product may
require reset and/or restart of the function in progress. This user recover-
able condition should be readily apparent to the user and will not result in
product damage or loss of stored data Such a condition is intended and
normal. Any questions regarding proper operation of this product should
be directed to Computational Systems, Inc.
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 users 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.
On-Line Help System 1-5

OilView System
The OilView system includes oil analysis software used in conjunction with
an oil laboratory, a minilab, or both. This manual describes the operation
of the OilView software, lab communications devices, and OilView
minilab instruments.
There are three license/configurations of the OilView system. Depending
on which software license you purchased, you may have one or more of the
following configurations enabled.
Minilab instruments
Laboratory Information Management System (LIMS) and Data I/O
Wear Debris Analysis
Trivector Laboratory Data Import

The Trivector Laboratory Data Import configuration is used by the CSI lab
customer who only wants to view CSI lab data without the possibility of
adding, editing, or performing further analysis on the data. This configura-
tion allows you to automatically import data from the CSI Trivector lab,
and view the data in tabular and graphical reports. This option is available
with all RBMware installations and does not require a license.
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 CSIs 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
OilView System 1-7

The following table shows which tabs are activated by the three license cat-
egories. The Trivector Lab Import does not require a license.
Activated categories
OilView Users
Software Manual Trivector Minilab LIMS &
Tabs Chapter WDA
Lab Import Instruments Data I/O
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
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.

Drop down menus
The File drop down menu includes the following functions:
Open Database Switches to another database.

Create Database Create a new RBM database.
Create Oil Reference Database Create a new oil reference database.
Print Prints the report (if available) for the current data view.
Printer Setup Sets up the printer for printing reports.
Set Oil Reference Database Selects the active oil reference database.
Compact WDA & LIMS Databases There are MS Access database that
can become very large with use. Compacting them reduces their size and
makes the data access more efficient.
Sort DB Structure This sorts the main RBM database tree alphabetically
based on the sort code at each level.
Exit Exits the OilView program.
The Help drop-down menu includes the following functions:

Help accesses the online help system.
Tutorial runs the online tutorial.
Print Certification Test prints the OilView certification test.
About displays the current software version number and build date.
1-10 Introduction
Toolbar
The toolbar icons are as follows (from left to right):
Open Database switches databases.

Print Prints the currently selected report.
Print Preview Previews the currently selected report.
Help Opens the on-line help system.
Save Grid Save grids to a CSV file for importing into spreadsheets
Report List Selects a report for printing.
Graphics Save Saves the graphics from a data plot to RBMView
RBMView Opens RBMView

Database Tree
The OilView database is a part of the hierarchical database system used in
all modules of the RBMWare system as shown in the following illustration.
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.
Clicking on the + symbol to the left of a Database branch allows you to

expand it. Similarly, clicking on the - collapses the branch. The color of the
Oil Sample icon in the database tree indicates the samples alarm status. A
red icon indicates that at least one of the parameters in the associated
sample is in an extreme alarm state.
Severity The level of severity at each branch of the DB tree reflects the
highest severity below that branch.
Customer Level The RBM database can have an additional customer
level that groups areas under a particular customer. The feature is activated
under setup.

The Reference database has a similar structure to the User database.
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:
Click On the Database Icon
Add Customer Allows addition of a customer level. Areas can be

dragged and dropped for one customer to another. Initially all areas fall
under the Unknown Customer.
Find Sample # A search facility to find a specific sample.
Recalculate Alarms Should one change alarm limits then you have the
ability to re-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.
Click on the Customer Icon
Add Area Add a new area to the database.

Edit Customer Edit customer details. Detailed customer information can
be edited in the LIMS Module.
Delete Customer Delete a customer from the database.
in the database.
1-16 Introduction
uling, chapter 2.
Print/Preview
the sample data.
for one year.

Customer Details
The customer details are described in the Laboratory Information Man-

agement System (LIMS) on page 11-1.
Click On the Area Icon
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.
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.
measurement point, and oil sample under the selected Area.
in the database.
uling, chapter 2.
Print/Preview
the sample data.
for one year.

Alarm Details
11
This screen shows the severity contribution from all technologies.
Alarm Display Options
12
You can set the following preferences:
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
users 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.
Alarm Tree Filters
13

This box displays the different technologies. Those technologies with check
marks in the boxes beside them will be the ones with active Alarm Tree Fil-
ters. You can turn on the filters for an entire technology category by
checking in the box beside the category head of a technology. For example,
you can check Periodic Vibration and it will turn on all the analysis types
under that Technology category. Or you can check those individual analysis
types you want filtered.
By default, the tree will show the status for all technologies that the user has
purchased. However, applications may set a filter to limit the number of
technologies for which status is displayed. For example, OilView may
choose to set a filter to only display Oil Technology statuses.
You can also click on the box beside Use these filters for all programs to
turn on the filters for all the technologies. Doing so changes the dialog box
heading to Global Alarm Tree Filters.
Click On the Equipment Icon
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.
in the database.
uling, chapter 2.
Print/Preview
Sample Labels Print Sample labels.
the sample data.
for one year.

Click On the Measurement Point Icon
15
Add Sample - allows you to add a new sample to the current measurement
point.
Edit Point allows you to edit the clicked on measurement point.
Delete Point - deletes the clicked on measurement point.
Copy Point - allows you to copy the current measurement point so that it
can be pasted (duplicated) into another piece of equipment.
in the database.
Clear Marks - clears all of the change marks for every oil sample under the
selected piece measurement point.
1-24 Introduction
in the database.
uling, chapter 2.
Print/Preview
the sample data.
for one year.

The Add Sample option pops up a form in which you enter the sample data
and number. You also have the opportunity to record the observations that
have been recorded when the sample was collected.
16
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

the sample data.
for one year.
Sample Labels create a sample label.
Drag and Drop Sample

Sample data can be dragged to another point or another point or another
sample. First, click and hold the left mouse button on the sample. Next,
move the highlight data to another point or sample. Finally, release the
mouse button.
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.
Copy for Ref DB

This enables one to copy an oil sample from the User database into the Oil
Reference database. Select the sample, then right click on the mouse, and
then go to the Ref(erence) Database where you will be able to paste it into
the correct location.
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
Setup Menus 1-29

The PC Comm Ports area grid has space for 8 RS232 comm port selections.
The comm ports available on your computer are in white while the rest are
greyed out. For each available comm port use the drop down list box to
select the appropriate piece of equipment to be connected. For example, if
the OilView Analyzer (5100 or 5200) is connected to the Comm 1 port on
the computer, select the OilView Analyzer from the list as shown below.
You will observe that there are several other general purpose laboratory
instruments in the list. These instruments can be connected to the LIMS
system for automatic data import. You are limited first off to the number of
comm ports available on your computer (up to a maximum of 8) and sec-
ondly to the number of LIMS instrument link licenses you have purchased.
19
The OilView Analyzer Type area is used to specify which Model 5100 or
5200 is to be used with this software. Click the appropriate box beside the
Model 5100 version or 5200 you will be using. You cannot connect both a
5100 and a 5200 simultaneously to your 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 computers Comm Port Status to see if the
ports are available. If a ports status is unavailable, then either it is not
configured in the operating system or some other application program is
using it.
Setup Menus 1-31

System
This window allows the system administrator to set the security status of
data editing and data entry within the OilView software.
The remaining functions are not used in the normal operation of the Oil-
View software. They are tools that you may need to use when communi-
cating with CSIs customer support
20
Error Tracing
These options are for use only when working with CSIs 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 CSIs 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.
Setup Menus 1-33

Let lab alarm levels override user alarms on import By default when
importing lab data the lab severity is stored with the user severity, which is
calculated based on alarm limits. This option disables the calculation of
user severity based on stored alarm limits and instead sets the user severity
equal to the severity imported from the lab. This is essential if the alarm
limits have not been correctly set up.
Let user alarms override lab alarms at overall level When importing
data the user set alarms are used to override the overall (Wear, Contamina-
tion and Chemistry) alarm severities.
Disable RBMview connection (restart after change) On slow net-
works and if not using RBMview for reporting, then this option disables the
connection (see Appendix D). You have to restart OilView for this to take
effect.
Disable auto problem creation in RBMview When diagnosing a
sample in Sample Info, the observations and actions are automatically
sent to RBMview. This option disables auto sending and requires the user
to manually post the diagnosis to RBMview if required.
Disconnect Actions from Observations There are times when the
actions associated with observation may not be appropriate. This option
disables the relationship. The user must then manually add the required
actions for the selected observations.
Print WDA Analyst diagnosis grid The WDA analyst report will
append the WDA matrix grid if this option is selected.
Client Prompt for Computer Name at Startup This is a special setting
for use in a WAN Thin Path setup. It is used to identify the correct registry
setting for the minilab instrument calibration files.
Skip edit on Sample Add The sample will be added without displaying
the edit sample screen.
Reset Factory Defaults This option resets all of the fields on this window
to the factory defaults the next time the software is started (overriding any
changes you have made).
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.
Clear Log File

This function clears the existing log file and begins writing new data.
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.
Setup Menus 1-35

Translations
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.
Severity is ranked from 0 = Normal to a value between 1 - 100 as shown

above.
Setup Menus 1-37

File Locations
This window shows the hard drive location of the calibration files for the
instruments that make up the OilView MiniLab system. The displayed
default locations are set up during the original software installation. How-
ever, this window can be used to change the file locations if desired.
23
You may type in the file location manually, or you may use the browse
button (on the right side of the field next to the appropriate instrument) to
search through the hard drive 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 CSIs 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
Setup Menus 1-39

DB Level Names
The Database Level Names options enable you to globally substitute other
descriptive names used in the hierarchical database structure and the refer-
ence oil database.
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.
Setup Menus 1-41

Lab Labels
The lab labels identify the sample and are used during the testing phase in
the laboratory.
27
Label Fields
The test matrix lists the tests to be performed based on the Point Setup.
Label printer
Select the appropriate printer. Labels can either be printed form sheets or
single labels depending on the printer selected. This enables printing labels
on a specific printer rather than the system default printer.
Default Labels
Select a default label size.
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.
Setup Menus 1-43

E-mail
29
The Laboratory Information Management System (LIMS) requires an

internet connection for E-mailing data and reports. Additionally, the Data
I/O section also requires an internet connection to download data directly
using E-mail.
For these two options to work you need to establish a direct link to the
internet using the Simple Mail Transfer Protocol (SMTP) to send E-mail
and the Post Office Protocol (POP3) to receive E-mail. These are fairly stan-
dard internet protocols. If your internet service provider does not support
these protocols then you will have to E-mail data and reports manually (i.e.
not directly from OilView).
Your internet service provider will provide you with a User Name, User e-
mail address, Password, SMTP host name and POP3 host name. Enter
these in the appropriate fields and then test the connections using the Test
SMTP and Test POP3 button. If these connections do not work you will
have to contact your internet service provider for help.
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.
Setup Menus 1-45

1-46 Introduction
Chapter 2
OilView Database Options
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 Analyzers Chemical Index readings are given relative to a
reference sample. So are the Particle Counters 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
drumeven 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.
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.
2-2 OilView Database Options

To change the assigned reference oil sample, first find the sample or mea-
surement point needing the change applied to it from the User Database.
Click on this sample or measurement point to bring it into focus. Assigning
a reference to the measurement point will automatically apply this refer-
ence to future samples created on this point. However, this will not affect
the reference assigned to any previously stored samples.
Next click on the appropriate reference sample. At this point a single refer-
ence sample and either a user measurement point or sample are both high-
lighted with focus.
Finally click on the Set Reference button. The assignment pointer is now
in place.
To change it or view it, simply click on samples and points from the User
Database. Focus will automatically move to assigned references.
To void a reference use the Clear Reference button.
Assign Reference Special Functions

The same reference oil may be assigned to multiple samples and points in
the user database when the oil is used in more than one piece of equipment.
If the oil supplier or oil type for one piece of equipment is changed, then
the new oil can be assigned as a reference to that one point as described
above.
Superseding References at the Point Level

Sometimes, however, an oil supplier is replaced and the user may wish to
re-assign references for all pieces of equipment which had previously used
an old supplier. In this case, the historical data samples must keep the old
reference oil. However, all new samples added to the point should use the
new reference oil. Instead of manually assigning the new reference oil to
each point, the software allows the old reference oil to be superseded by the
new reference oil on every point in the current user database where the old
oil was assigned.
After adding the new reference oil and saving its data, the user simply uses
the mouse to drag the new reference oil sample and drop it onto the old
reference oil sample in the Assign Ref, center Ref DB tree.
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.
Superseding References at the Point and Sample Levels

A somewhat different situation arises when the user has merged old oil
databases and has duplicate reference samples. In this case, the user wishes
to supersede not only the references assigned at the point level for future
samples, but also the references assigned at the sample level. This allows
only one of the duplicate references to be assigned and the other duplicate
references may be deleted. In order to perform this operation, the user
must first right-mouse click at the top level of the reference database tree on
the Assign Ref tab, and then choose the Enable Global Supersede and Lock
DB menu item. After this, dragging and dropping a reference oil sample
will assign the dragged reference oil to all samples and points where the old
reference was previously assigned. After completing the global supersede
function, the user must right-mouse click at the top level again to Enable
Default Supersede and Unlock DB.
Expand Entire Tree

Another feature available by right-mouse clicking at the top level of the ref-
erence DB tree on the Assign Ref tab is to expand and collapse the entire
tree.
Show Ref Samples used by this Database

The last feature available by right-mouse clicking at the top level of the ref-
erence DB tree on the Assign Ref tab is to Show Ref Samples used by this
Database. Once the tree has been expanded, then all reference samples
used by the current database will be highlighted in green when choosing
this option.

Reference Info
Reference Info Tabs
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.

Oil Type
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.

Purpose
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.

Stat Plot
Stat Plot: Histogaph
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
Stat Plot: 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.

Adding a Reference Oil
To add an oil to the reference database first select the Ref DB (Reference
Database) tab and then add the Supplier, Brand and Oil Description to the
database. This is the same as adding Area, Equipment and Point. At the Oil
description level (equivalent to Point) use the Ref Info Tab (equivalent to
Point Info) to enter the required information as described above. This is
much easier than entering and editing this information at the Assign Ref
tab, although it is still useful when in the User DB and assigning references.
The next step is to add a sample and run the necessary tests. Lab data can
be imported in a similar way to the user database. Most of the functionality
available for the user database is also available for the Reference database.
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 40C and 100C,
and the specific gravity are easily entered this way.
Add Ref Sample Add a reference sample

Edit Oil Description Edit the reference oil sample.
Delete Oil Description Delete the reference oil and all its data.
Paste Ref Sample from User DB After copying a user sample, you can
use this option to paste it into the oil reference database. Select the appro-
priate oil description and paste.

Database Queries
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
Select the Cust ID (Customer Identification) or Cust Desc (Customer

Description) from the drop down menus. You may also select various
reporting conditions as show and a start and an end date. Press the Start
button to run the query.
The results of a query are shown as a list similar to the LIMS (Laboratory
Information Management System) Batch Info display. You have full access
to all the reporting options for the list as detailed in the LIMS module.
Generate Schedule
12
This menu option generates a list of samples that are due based on the 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.

Measurement Point Information
The Point Info tab (measurement point information) includes the min-
imum information that must be completed when a measurement point is
created (Advanced user mode). The tabs fields are only available when
a point within the user database is highlighted.
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).

Description - This field of up to 28 alphanumeric characters describes the
current point and should be as descriptive and unique as possible.
Lab Unit ID - This field can be used to enter an alphanumeric identifica-
tion when using an oil lab other than the CSI Trivector Laboratory. This
identification must be unique throughout all of your databases.
Report Language - The language used to translate the test on the Sample
Trend and Minilab reports. The diagnostic must be written in the selected
language. (It is not translated.) The other test is translated on the Setup -
Translation tab.
Report Group - This field selects the report group (1 - 8) that determines
the layout of the sample report. These groups are described under Analysis
Parameter Sets.
Usage Units Has been moved from the Internal tab. These units are used
to specify the amount the unit (measurement point) has been in operation
(for example the number of hours, days, distance it has been running). This
unit of measure applies to both the quantity of usage for the unit as well as
the quantity of usage for the oil in the unit. This should not be confused with
the units below that refer to the quantity of oil in the unit.
Target Cleanliness - is the ISO cleanliness code, 2 micron/5 micron/15
micron, that this equipment should be operating at. See ISO Recom-
mended Cleanliness Levels on page 7-18 for an ISO Cleanliness table.
Lubrication System, Capacity Has been moved from the Internal tab.
This is the oil capacity of the system and will be used to calculate oil usage
and System Debris.
Lubrication System, Units Has been moved from the Internal tab.
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.
Analysis Parameter Set - is the listing of all of the measurement param-
eters for which you intend to collect data. Click on this field to assign an
analysis parameter set (from the displayed list of predefined sets) to the cur-
rently highlighted measurement point.

CSI strongly recommends that you use the CSI Default Analysis Parameter
(AP) set for oil if possible. You can then add additional custom parameters
to the default set, if necessary (see Add AP Set on page 2-30). AP sets can
have up to 96 parameters, and by selecting a comprehensive analysis
parameter set that includes all of the parameters in all of your testing pro-
files, you will find it easier to manage Alarm Limit (AL) sets. CSI supplies
default AL sets matched to the AP set. See Analysis Parameter Sets on
page 2-30 for more information.
Equipment Type - Clicking on the button on the right side of this field
brings up a tree list of equipment types. Once you have selected the equip-
ment type you must then select the corresponding Alarm Limit (AL) Set. If
this relevant AL Set does not exist you must go to the AP and AL Set branch
of the database tree and add the required AL Set.
14

Alarm Limit Set - Click on this field to assign an alarm limit set to the cur-
rent measurement point (from the pop-up window containing a list of pre-
defined sets).
The Alarm Limit (AL) Set is the list of alarms for the measurement point. If
you have selected the CSI Default Analysis Parameter set, the Alarm Limit
set will automatically be generated when you select an Equipment Type.
See Alarms on page 2-40 for more information.
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.

Schedule
15
Setup sampling schedule by right mouse click on appropriate date. You

should setup the schedule for at least one year in advance, although you can
setup for as far in the future as you want.
Note
Printing of sample labels for due samples is done on the Q
(Database Queries) tab.
Criticality - is the relative impact of a failure of this equipment on overall

plant operation. This function enables you to specify one of five levels of
criticalness for this piece of equipment.

Test and Display Filter
The Trend Info and Sample Info display filter can be used to prevent par-
ticular analysis parameters from being displayed. The analysis parameters
with a checked box will display in the report. Unchecked analysis parame-
ters will not be displayed.
16
Criticality - is the relative impact of a failure of this equipment on overall

plant operation. This function enables you to specify one of five levels of
criticalness for this piece of equipment.
Many of the more than 90 parameters in the Analysis Parameter set are
used for reference and are not important in every report. By using this filter,
you can limit the number of parameters displayed to those of greatest
interest. If at any time you want to view the data, simply check the box or
clear the check.
The filter is organized by measurement device. This way you can turn off
the display of blank information when you are not conducting particular
tests on a point. Later, if you begin collecting these data, simply turn the dis-
play back on.

Internal Working Environment
You can use these fields to document reference information that may be
useful in detailed oil analysis and root cause diagnosis.
17
Oil Pressure - Indicate the system oil pressure as:
low <500 psig

medium <2000 psig
high >2000 psig
Oil Temperature - The measured temperature of the oil.

Separator - The type of water/oil separator that the piece of equipment
uses.
Oil Change - describes the basis that is used to decide when to do an oil
change.
Coolant - Indicate whether coolant is used and if so, what type.

Filter
Category - Select either filtered or not filtered category.
Actual - If known, enter the actual filter specification in terms of micron
size and beta ratio.
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.

Internal Process Material
18
General - If it is possible for process contamination of the oil, identify if

this can cause the oil to become chemically neutral, acidic, caustic, or
unknown.
Gas - If the processed material is a gas, enter the kind.
Liquid - If the processed material is a liquid, enter the kind.
Solid - If the processed material is a solid, enter the kind.
Transformer - If the piece of equipment is a transformer, indicate the rated
features.

External Working Environment
19
Type - Indicate how corrosive the external environment is.

Lube System - Specify whether the system is opened or closed.
External Temperature - Indicate the ambient temperature:
hot greater than 140 F (60 C)

temperate 40 F (5 C) to 140 F (60 C)
cold less than 40 F (5 C)
Humidity - Indicate the ambient, relative humidity:
dry less than 40%

moderate 40% to 80%
very humid 80% to 95%
wet 100%
Particulate - Indicate if the area contains abrasives that may be problem-

atic.

Oil Wetted Bearing Parts (P1)
20
Bearings - Indicate if bearings are used in the system.

Speed - Enter the speed range of the piece of equipment.
Sleeve (Conformal) - Indicate what type of conformal sleeves (if any) are
used.
Roller Cage - If a roller cage is in the bearing, indicate its material.
Other - Select any other elements that may be present in the oil system.

Oil Wetted Parts (P2)
21
Gears - Enter the composition of any gears.

Seals - Enter the composition of any seals.
Cylinders/Pistons/Rings - Enter the composition of any of these compo-
nents.
Shafts/Slides/Cams - Enter the composition of any of these components.

Oil Wetted Parts (P3)
22
Turbine Blades - Enter the composition of any turbine blades.

Oil Pump - Enter the composition of an oil pump.
Other Parts - Enter the composition of any other parts as required.

Analysis Parameter Sets
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
AP Sets and AL Sets (Folder icon)
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

Delete Unused Alarms
This option removes all un-used AL Sets from the database. This not only
frees up space in the database for new AL Sets (there is a limit of 512), it also
makes it a lot easier to view the statistics for each AL Set as the only AL Sets
available are those that are actually used. CSI therefore recommends that
you use this option to clear-out all the un-used AL Sets.
Set Default Alarm Type

This option automatically sets the Ref and Point alarm type for each refer-
ence parameter in all the AL Sets.
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.
Update Alarm Baseline

Once the statistics have been exported, you must them update the AL Set
baseline. This is necessary if you have set an alarm to use the AL Set base-
line.
Add User Alarm

To add a new user alarm to an individual analysis parameter set, right
mouse click on an individual AP Set icon from the list under a folder icon.
Then pop-up menu. You can then edit the current view and profile setup as
required for the new set.

CSI Default Oil AP Set (AP Set icon)
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.
Other selections in this menu box include:

Add User Alarm Add a new alarm limit (AL) set.
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 cur-
rently being used. If they are the user cannot delete the AP Set.
Add CSI Default Alarm Add a selected default AL Set from a list of
default AL Sets.
Generate Default Alarm Sets Generate a complete set of CSI default
AL Sets.
Show Used AL Sets The used AL Sets are highlighted. This is useful for
reviewing only those AL Sets that are used.

Additional Drag and Drop feature
You can supercede an AP Set with another by dragging and dropping onto
another AP Set. Parameters will be added to the target AP Set so that data
is not lost. All points using the old AP Set will be converted to the New AP
Set.

AP Sets Secondary Tabs and Information Window
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.

The Plot column is used to mark, with a Yes, for those parameters for
which a trend plot will appear on the Trend Info tab. If you mark No then
the plot will not appear, although the data will be stored and easily viewed
at a later time.
The Alarm column is used to mark those parameters for which there are
alarm limit values. Many of the analysis parameter values are for reference
or human interpretation and should not be subjected to alarms, so you can
turn alarming off by simply marking No as desired. You will notice that
all of the oil lab parameters begin with default No for alarm indications.
The reason is that the lab should give an overall interpretation of their
results which overrides individual alarms.
The Manual column is used to mark those parameters that appear on the
manual data entry form in the LIMS module.
The Digits column shows the number of display digits for each parameter
and may be set from 0 to 4.
The Import Units column is used to specify the units for the import of lab
data.

Profile Setup
Profile Setup is a list of all the parameters in the analysis parameter set.
Editing of this list will permanently change the analysis parameter set and
is not recommended except when absolutely necessary. The Update
Changes button must be clicked in order to actually save the new parame-
ters.
The grayed out Tests in the AP Set box is for information only. It shows
which tests or instruments are included in the parameters from the analysis
parameter set.
27
Update Changes This writes any changes made to an AP Set back into
the database.
Highlight Used Parameters The Drag and Drop feature enables the
merging of AP Sets. This may result in more than 96 parameters in which
case it is presented. This feature enables you to see which parameters in an
AP Set actually have data. Those parameters that do not have data can be
removed (deleted) from the AP Set making room for additional parameters
that can be merged from another AP Set.

A Few Words about Drag and Drop. Drag and drop enables more than
the merging of two AP Sets. In addition, the AL Sets from the AP Set being
dragged and dropped are also added to the AL Sets of the target AP Sets.
Also, an AL Set may also be dragged and dropped or copied from one AP
Set to another. In the process all data is automatically updated. This can be
a slow process and there is a progress bar showing status of the merge oper-
ation.
The user can also drag one parameter on top of another thereby super-
seding one with the other. This is essential to replace the Special Test
parameters with actual parameters or if a parameter has been incorrectly
used.

Report Group Setup
This screen is used to setup the parameters and trend plots that appear on
the Sample Trend report. The Table column is used to mark those
parameters that appear in the table on the report and the Plot column is
used to mark those parameters for which a trend plot is provided. There is
a maximum of 6 trend plots and 70 parameters on a report. The different
groups enable you to define different combinations of parameters and plots
for different types of equipment. For example, you could have one group
for engines and another for gearboxes. The specific group used is defined
at the Point level.
28

Statistics
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 MTBAs will
give an indication of the most frequent type of problems. This is very useful
management type information.

Alarms
To view the Alarm Limit (AL) sets within an analysis parameter set, click
the checkbox beside the analysis parameter name.
30
Add User Alarm Set

To add a new alarm set, use a right mouse click on the folder icon and select
Add Alarm Set from the pop-up menu. You can then edit the current values
as required for the new set.
Edit AP Set Desc.

Edit AP Set description and AP Set ID code.
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.
Add CSI Default Alarm

Add a selected default AL Set from a list of default AL Sets. To add a new
alarm set, use a right mouse click on the folder icon and select Add CSI
Default Alarm Set from the pop-up menu. This will give you a drop-down
list of the available default AL Sets from which you can select one. You can
then edit the current values as required for the new set.

Generate Default Alarm Sets
Generate a complete set of CSI default AL Sets. This function (also
accessed with a right mouse click on the folder icon) will create ALL the
default alarm sets for each of the equipment categories listed in the Point
Setup. CSI recommends that you do not use this function but rather only
create those you require using the previous option.
31
Show Used AL Sets

The used AL Sets are highlighted. This is useful for reviewing only those
AL Sets that are used.
Additional Drag and Drop feature (not shown on menu)

You can supersede an AP Set with another by dragging and dropping onto
another AP Set. Parameters will be added to the target AP Set so that data
is not lost. All points using the old AP Set will be converted to the New AP
Set.
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.

Table of Combinations
Base Type Delta Type Alarm Type
Zero Value Up
ABS Value
Oil Ref. Value Up
AL Base Percent Down
Pnt Base Up and Down
Ref or Pnt
Disabled
AL Base
This column shows the AL Set baseline value.
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.

This table shows the average, minimum, maximum, count and standard
deviation of the set of samples to which this AL Set has been assigned in the
database. This information is useful for establishing alarm limits.
34
The annual average values for each parameter as calculated based on a

simple average, or on the 80%, 90%, 95%, or 98% percentile values. This
information is used to establish whether the oil analysis program is having
a beneficial impact on the equipment, and is based on a steady decline in
contamination and wear.
Alarms 2-45
Right mouse button click on a particular parameter to display a histogram
over time.
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.

There should be at least 100 samples in the statistics before one can reliably
use this method to set the alarm limits. The more samples the better.
Remember to update the statistics at regular intervals to ensure you are
using the latest samples collected.
Baseline Adjusted Plot
35
Set/Save All - automatically sets all alarm limits.

Set Alarm Limits - automatically sets alarm limits for selected parameters.
Save Changes - save manual changes by dragging vertical alarm limit
lines, and then pressing the Save Changes button.
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.

Raw Data
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.

Alarm Templates
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.

Alarm Analysis
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, TCLs, 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.

43
You may also select Ref oils from a drop down list on the Ref Oil Desc field.
Alarms 2-55
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
All Data, Minilab Data, and Lab Data Tabs

These three data tabs display stored data in a table format. The first column
of the table lists the analysis parameters within the AP Set. This list is fil-
tered to include only those which are part of the minilab or lab on the
respective tabs.
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.
3-2 OilView Reporting

Any of the values or blank spaces on the data tabs can be edited by typing
in the desired value. However this alone will not update the overall
Trivector status (wear, contamination, and chemical status). After typing in
or editing data, you should right-mouse-click on the appropriate sample on
the tree and select Recalculate Alarms. This must be repeated for each
separate sample that is edited.
Wear, Contamination, and Chemical Plots

The three plot tabs display data in trend graphs with separate tabs for wear,
contamination and chemistry related parameters. The horizontal lines on
the trend plots represent alarm levels. The vertical bars represent indi-
vidual measurement values.
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.
Detailed Parameter Plots

Right Mouse click on a parameter description in the grid or on a trend plot
and you will get a detailed trend plot for that parameter. You can select
what additional information to display on this plot by using the check
boxes. These include showing the alarm levels as illustrated below, the ref-
erence value, local median, mean and standard deviations and symbols to
indicate what observation are applicable.
47

Sample Information
The Sample Info tab is used to view graphs, observations, and notes for
individual oil samples. This tab can be used with either the User Database
or the Reference Database.
TriVector Plot Data

The TriVector plot combines multiple test results into one graph. It consists
of three mutually perpendicular axis extending from a common origin. The
results of an oil test are categorized to fit into one of three evaluation areas:
wear, contamination, or chemistry. Each axis represents one of these cate-
gories. The plot reports oil condition in each category in a range from
Normal to Alert to High Alert to Fault to Extreme.
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.

Analyze
This automatically analyzes Minilab data and generates Observations and
Actions. It does not use laboratory or any non-minilab data.
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

A trivector plot showing high wear but otherwise healthy oil would look
like this.
50
A plot of good oil contaminated by a water leak would appear as so.
51

Observations Block
The Observations block provides the opportunity to annotate the sample
with noteworthy observations. To add an observation, use a right mouse
click on the intended row and select the appropriate observation from the
pull-down list.
Selecting an observation automatically adds one or more items to the
Actions block. If any of these is not what you want reported you may delete
any item.
The fields under Observations and Actions can only be filled using the pull-
down lists. You cannot type any entries into these fields.
Sample diagnosis is your text description of the status and recommendation
for this sample.
Observations
This list of selectable observations serves as a sample record for non-
trendable information.
52

Notes
The Notes tab allows you to add free form text to the sample data and
sample diagnosis.
53
Sample Observation Notes Used to describe any additional informa-

tion concerning the sample when it was collected.
Sample Diagnosis The actual sample diagnostic message.
Wear Debris Diagnosis Description of the wear debris as entered in the
WDA module. This note is appended to the Sample Diagnosis on reports.
Lab Diagnosis The sample diagnosis that is imported. This message is
also entered into the Sample Diagnosis note but, unlike it, cannot be edited.
This ensures that a copy of the lab diagnosis is always preserved.

Data
The Data tab shows all the parameter data for the selected sample divided
into Wear, Contamination and Chemistry. This grid is similar to the Grid
on the Trend Info Tab enabling data entry and edit.
54

ISO Count
The ISO 4406 plot is a representation of size distribution and concentration
for particles in oil. Each 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).
55

NAS Count
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. 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.
Number of particles per 100 ml

NAS
range
1638
Class
5 to 15 15 to 25 25 to 50 50 to 100 > 100
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

56

PPM Plot
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.

5100 Data Plot
The 5100 Data Plot shows the time resolved dielectric measurement graph
for new and reference oil test data. For a detailed explanation of how to
understand these plots, see Appendix B.
58

5200 Plot
The 5200 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.
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.

Viscosity Plot
The Viscosity Plot shows how viscosity changes with temperature for both
the reference and used oil samples. This plot is used to determine what vis-
cosity the oil has at the operating temperature. This is done by moving the
mouse across the plot and measuring of the viscosity at any temperature
between 0 and 100 C. This can be done for either the reference oil or the
current oil sample.
60

Reports
This option, accessed by clicking on the Print Preview button, is used to
preview reports generated by the OilView program.
Sample Trend Report
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.

Note
You can zoom in on the preview window by double-clicking
the left mouse button. To move the zoomed image within the
window, click the left mouse button (and hold) and drag the
mouse. You can zoom out by double-clicking the right mouse
button.
Standard Sample Report
62
This report is used to give more detailed sample information including

alarm limits and diagnostics comments for each sample. It is typically used
for reporting on historical examples.
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.

Sample Reports
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
The range of summary reports is controlled by the position on the database

tree, e.g., Database, Customer, Area Equipment, and Point and by the
above selections.
Sample Summary Report
66
This report shows the Area, Equipment, Point, Sample Date, Sample ID,
and then the Wear, Contamination, and Chemistry severities.

If the sample has observations and actions assigned to it, the report will also
show the category into which they fall. For example, Inspection Day,
Clean, Oil, Flush, Mechanical, Sampling, and Other. This information
helps create a clear idea of the typical problems occurring in the plant.
Parameter Exception Report
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.

Alarm Setup Exception Report
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.

Schedule Summary Report
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.

Chapter 4
Importing Data From the Laboratory
Import Lab E-mail
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.
4-2 Importing Data From the Laboratory

Laboratory Imports
This tab is used to import lab data from oil laboratories including the CSI
Trivector Lab. Before using this function, you must have already obtained
the file to be imported the internet, an E-mail, a floppy disk, etc. The CSI
Trivector Lab will E-mail the data file to you.
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 computers 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.

A/E/P with Cust (.zip). This option includes the customer level in the
export.
DB Structure. This option exports only the database structure down
to the point level without any sample information. This is useful for
duplicating database structures.
AP & AL Sets. this option exports AP and AL Set data. You must first
assign AP and AL Set IDs because they are used to identify the AP
and AL Sets when importing.
Note
When exporting sample data using the A/E/P option, the ref-
erence oil and AP &AL Set IDs 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 IDs.
Filters - Date and/or Change Marks

Date Filter - Check the Enabled box to limit the export to data that
falls on or within the selectable Start Date and End Date.
Change Mark - Only exports sample for which the change mark has
been set.
Misc Area/Equip/Point
DB Name The name of the RBM database into which the data is to
be imported.
RBM DB Target Data will be imported into the RBM user database.
REF DB Target Data will be imported into the Oil Reference data-
base.
4-5
Statistics Export
This tab is used to export data for the Alarm Limit statistics option.
76

Chapter 5
OilView Analyzer Models 5100, 5100-1, and 5100-2
77
CSIs OilView Analyzer is a multifunctional predictive maintenance tool

for immediate, on-site evaluation of in-service lubricating oils. It is an easy
to use, quick, and accurate tool for use by maintenance departments and
service shops.
The OilView Analyzer tests in-service lubricating oils, providing informa-
tion about the suitability of the lubricant for continued use, and the condi-
tion of the lubricated metal surfaces. Predictive maintenance programs
based on in-service oil analysis can reduce unexpected downtime, conserve
oil, and reduce maintenance and replacement costs when applied to a wide
range of lubricated machinery. In-service testing also reduces the environ-
mental impact of waste oil disposal by ensuring that oils and filters are not
replaced before their service lives have ended.
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.
The OilView Analyzer will test for the following conditions:

The presence of moisture in the oil down to concentrations as low as
100 parts per million (ppm) for fresh water in hydraulic oil and even
lower for salt water or acids. The OilView Analyzer reacts to the cor-
rosive (conductive) potential of the contaminant as opposed to its
mere presence.
The presence of abnormal ferromagnetic (iron, steel) wear particles
in the oil. Concentrations of only a few micrograms of ferrous metals
per milliliter of oil can be detected. The OilView Analyzer is
extremely sensitive to recent, abnormal wear in steel and iron gears,
cams, and rolling element bearings. The OilView Analyzer will also
detect recent abrasive wear in journal bearings.
Changes in the oil chemistry associated with thermal degradation
such as oxidation and nitration.
The OilView Analyzer is also sensitive to the presence of insoluble com-
bustion by-products in crankcase oils, including carbon soot and emulsion
sludge.
When used as a screening tool for the preceding conditions, The OilView
Analyzer provides you with immediate and nearly cost-free results.
5-2 OilView Analyzer Models 5100, 5100-1, and 5100-2

Software Setup
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.
Software Setup 5-3

Now you are ready to choose from the following test options and begin a
test on either port of the Model 5100-2, or on the left port of the Model 5100
or Model 5100-1. The following table outlines four different selectable test
sequences used with the OilView Analyzer. In order to get meaningful
trend information, you should select one option and then use it consistently.
Test Sequences and Test Options for the OilView Analyzer.
Model 5100 test options
Testing for Testing for

Undiluted Diluted testing Comments
Model 5100 oil wear and
testing for all for all
test sequence chemistry contamination
parameters parameters
only only
double clean 40 sec 40 sec 40 sec 40 sec avoid cross

sensor grid contamination
short test for n/a 10 sec 10 sec n/a fingerprint
dielectric and oil and
oil chemistry measure
chemistry
save data n/a 10 sec 10 sec n/a
open sample n/a 30 sec n/a 30 sec drops viscosity
and add to <20 cSt
solvent
full test 250 to 1200 250 sec n/a 250 sec measures
sec contaminants
and ferrous
save data 10 sec 10 sec n/a 10 sec
view wear 60 sec 60 sec n/a 60 sec see ferrous,
debris non-ferrous,
and water
total time 360 to 1310 410 sec 60 sec. 340 sec
sec

Testing Profiles for Minilab.
5100
Test
Neat Diluted 51FW 51PC 5xDV 51SM
Short time*
Full Full
Test
Test Test
Test time* 9 <1 5 <1 2 2 <1
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.
Software Setup 5-5

The Diluted Testing For All Parameters option is good for all oils in any vis-
cosity range (see Dilution Of Viscous Samples (OilView Analyzer) on
page 5-33). The dilution effectively allows all of the measurable wear parti-
cles to get to the sensor during the 250 second test interval, while only a
small portion of the particles have enough time to get to the sensor without
dilutioneven though the test interval is much longer.
The Testing For Oil Chemistry Only option has the shortest total test time.
This option results in only the Chemical Index and Dielectric Constant
tests and is used when abnormal wear and moisture contamination are not
of interest. This option is commonly used to decide if an oil change is
needed for engine crankcase oils, and it is useful when testing reference oils
to verify correct oil identity. Keep in mind that viscosity measurement is
especially important in addition to the Chemical Index measurement in
determining the need for oil changes in fuel injected engines.
The Testing For Wear And Contamination Only option is convenient when
the reference oil test is not available and when chemical deterioration of the
oil is unlikely. This method is commonly used when testing greases and can
also be used when testing high gear oils.

Oil Compatibility Chart
The following table lists various oils that can and cannot be tested using the
Model 5100-series OilView Analyzer.
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
Software Setup 5-7

Note
If kerosene does not dissolve a specific type of oil then consider
using another solvent. However, make sure that the solvent has
a dielectric value of less than 16. Most alcohols, for example,
have a dielectric value of greater= than 16.
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.

Click To Change Grid Color
This selection assures that the correct calibration is applied to the sensor
being used.
79
Available For Test Seconds To Go

This box informs you of the status of tests. Available for test indicates that
there is not a test in progress. xxx seconds to go indicates the amount of
time remaining until the test will be completed on a test port. (This status
updates once every few seconds.) At the end of the Model 5100-1 or Model
5100-2 test interval, the status will show Reading test data.
It normally takes three or four seconds to read all of the raw data from the
OilView Analyzer, and during this interval other software operations will
be delayed. Otherwise, you are free to move about the software and use
other functions while a Model 5100-1 or Model 5100-2 test is running in the
background.
Software Setup 5-9

Long Test
The Long Test is a full-length test performed by the OilView Analyzer. This
test will take from 250 to 1200 seconds depending on the viscosity of the oil
and the test option. A long test consists of 500 cycles through a three-step
measurement sequence:
measure dielectric with electromagnet off,
measure dielectric with electomagnet north, and
measure dielectric with electromagnet south.
Altogether, a full test consists of 1500 dielectric measurements and two tem-
perature measurements (at the beginning and end of each test). The Oil-
View software uses these raw data to calculate dielectric and index values.
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.

Date
This is the date of the reference oil test.
Viscosity
The viscosity value is obtained from the reference oil database and is used
to determine the time period for either Enhanced Particle Sensitivity or
Reduced Particle Sensitivity test options. If this value is missing or incor-
rect, it can be edited in the reference oil database.
Displayed Test Results

Immediately following a 5100 test, the results are automatically extracted
from the analyzer and displayed in the test results block. The two ports are
independent, so one port might have results displayed while the other port
is either idle or still running a test. The displayed results will remain until
the data is either saved or cancelled.
If you want to see a data plot before saving these results, click on the Test
Data Plot. (This will not affect the buffered data.) The red flag on the 5100
tab is your reminder that you need to come back to the Test tab to choose
between the save or cancel option.
Use the Sample Info tab to view the data plot after the results are stored.
Keep in mind that results are saved to the sample that was highlighted at
the start of the test, which may not be the same as the sample highlighted
at the end of the test. By the time the test is over and the results are saved,
you may already be on an entirely different point. The point and sample
information for a data set are displayed with the data.
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.
Software Setup 5-11

Is This a Diluted Sample?
A Long Test performed on a sample with short test data will bring up the
message Is this a diluted sample? This prompt is included for the frequent
case where you have run a Short Test to get Dielectric and Chemical Index
measurements in preparation for a diluted sample test. After clicking on
Yes, the analyzer will begin a 250 second test.
Diluted sample tests are intended to measure Contaminant, Ferrous, and
Large Contaminant. The Chemical and Dielectric measurements are
retained from previously stored Short Test of unmixed oil, prior to dilution.
When the long test results are saved, the results of the long and short test
are automatically merged.
Note
Never dilute the reference oil. Chemical comparisons between
the reference and the used oil must both be measured on
unmixed, undiluted oils.

Verify
Verification testing quickly confirms whether a sensors calibration is still
within a recommended range. It is used for two reasons: to provide you
with information to decide whether to extend the time period that a
sensors calibration remains valid, and to double-check test results before
taking a strong action based on the advice of the OilView Analyzer.
80
The first applicationdeciding the length of time a sensor grids calibration

will remain valid before a warning message informs you that the calibration
has expiredwill depend on environmental factors. For example, if you cal-
ibrate your grids on Monday and they pass a Verification Test on Tuesday
and Wednesday but fail Thursday, you may want to set the calibration
period to three days. The conditions at each users site will determine the
number of days selected. (Ambient temperature and relative humidity
changes will be the largest factors in grid calibration changes.)
If, at any time, you run a test and the results seem unreasonable or they sug-
gest a strong action such as changing 500 gallons of oil, for example, run a
verification test to confirm the operation of the OilView Analyzer.
Software Setup 5-13

The procedure for performing verification is the same as that used for the
Calibrate procedure which is described in the next section.

Calibrate
The Calibrate Tab and Verify Tab for the OilView Analyzer are similar in
operation and function. They both use CSI-supplied calibration fluids
having a known dielectric to establish the basis for comparison to all refer-
ence and used oil samples being tested.
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 5100s Calibration Settings tab.
Software Setup 5-15

Note
In earlier versions of OilView software, Chemical and OilLife
Indexes were computed by comparing sensor outputs mea-
sured on new and used oil samples. This frequency method is
replaced beginning with Version 3.2 of the OilView Software
by true dielectric measurement instead of relative sensor fre-
quency outputs.
Now by using absolute dielectric calibration, each measure-

ment is not just relative to another oil tested on the same sensor
under the same conditions, it is comparable to oils tested on
different sensors under different conditions.
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.
Cleaning the sensor grid.

After the grid is wiped clean, apply a few drops of the next oil to be used
onto the surface of the grid and wipe it clean and dry. This procedure is
intended to wet out the surface of the sensor with the next oil, completely
removing any trace of the previous oil. Make this double cleaning a stan-
dard practice as it prevents cross contamination of samples and is very
important to reliable data collection.
Plug the first grid to be calibrated into your OilView Analyzer, if you have
a Model 5100-2, make sure the sensor is plugged into the left port. Using
the CSI-supplied bottle of calibration fluid, open the flip-top and add
enough fluid to reach the first diameter change in the gasket.
82
Cross-section of sensor grid.
Software Setup 5-17

Note
Repeat this process for each calibration fluid, following the
instructions in the software.
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 calibratinginadvert-
ently selecting the wrong grid color. You must select the grid color before
doing anything else on this menu tab.
Start and Cancel

These selections are similar to regular Model 5100 testing except that the
Calibration fluid is poured into the sensor rather than screwing a bottle
onto the sensor. This prevents contamination caused by reuse of the CSI-
supplied calibration fluids.
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.)
Starting new calibration

Since you may be calibrating or verifying multiple sensor grids, the
sequence is repetitive. At the beginning or end of the sequence the dialog
box will state that you are starting a new calibration or verification. At this
point you should verify grid color and dielectric values for calibration fluids
listed on the Calibration Settings tab.

Continue.. cancel
Continue through the sequence, following the instructions in the dialog
box. You will be asked to clean the sensor grid and then fill the sensor well
with two calibration fluids sequentially. Calibration Fluids A and B are used
for normal oils and Fluids B and C are used for higher dielectric oils.
While you are testing calibration oils, other tabs will be grayed out because
they are not available for use. These will return to normal appearance after
calibration or verification is completed.
Frequency for calibration fluids is too close.

This warning indicates a common problem. You may have forgotten to
switch fluids or the grid may not have been cleaned properly.
Test Data Plot

This tab is used to view the OilView Analyzer data plots corresponding to
the left and right test ports before the data has been saved. Use the 5100
Data Plot on the Sample Info tab to view plots after the data has been
saved.
Software Setup 5-19

Calibration Settings
83
Test Information
Three test options are available to the OilView Analyzer user. These set-
tings remain in effect constantly until they are changed.
Test Time Options

There are three test time options. CSI recommends using the enhanced
particle sensitivity option unless there is a reason not to.
Regular 500 Second Test

This is the oldest of the OilView Analyzer test options. CSI only recom-
mends using this test time option when testing viscous oils that would oth-
erwise require longer than 500 seconds to test.

Enhanced Particle Sensitivity
This is the CSI recommended test option. This option enables viscosity-
based test times ranging from 250 seconds to 1200 seconds. When you
follow the suggested procedures and dilute any samples over 48 cSt, the test
time for diluted samples is 250 seconds regardless of the undiluted vis-
cosity. Diluted test results are much more sensitive than neat oil test results
since dilution enables more particles to settle onto the sensor.
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.)
Calibration Fluid Dielectric

The dielectric constant (also called permittivity) for the calibration Fluids
A, B, and C are copied from the CSI-supplied bottle and entered into these
fields. If you are not using any high dielectric oils, there is no need to enter
any value in for Fluid C.
Calibration Out Of Date Warning

You may specify the out-of-date warning interval. This setting defaults to
one day (the CSI recommended calibration interval). This interval can usu-
ally be lengthened with experience.
Software Setup 5-21

Diagnostics
The diagnostics tab is only to be used under the direction of CSI Customer
Support when troubleshooting potential problems.

OilView AnalyzerInitial Setup
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 Analyzers 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.

Caution!
Port 2 is a 15-pin, high-density Sub-D port intended to provide both
power and serial communication to either the Digital Viscometer or the
Ferrous Wear Monitor. Use caution when inserting the 15-pin cable
into Port 2 as it is possible to force the connector upside downdam-
aging the cable and the port connector.
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
The OilView Analyzer should be turned on before use,
allowed to warm up for a few minutes, and should not be
turned off until after all tests have been stored to the database
system. Before analyzing oils, the OilView Analyzer should be
operated through one entire Full Test sequence to preheat the
electromagnet.
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.

Sensor Curing
When the OilView Analyzer is first unpacked, it will be necessary to cure
the sensing grid. As delivered, the grid may contain air in the interstitial
space between fibres in the substrate. It is necessary to cure the grid by
allowing a clean oil to stand in the sensor for a few hours. The oil will dis-
place the air pockets and the sensor is then ready for use. If this is not done,
the first few calibrations taken with the sensor will be offset by the low
dielectric constant of the air relative to oil.
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 gridthe 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.

An Example Testing Session
This section describes a typical oil testing session using the OilView Ana-
lyzer system and assumes the following conditions have been met:
the OilView software has been loaded onto your computer, and
the sensor grid has been cured and calibrated (see OilView Ana-
lyzerInitial Setup on page 5-23).
Before beginning the test:

1 Connect one end of the supplied 9-pin interface cable into the
communications port 1 on the right-hand side of the OilView
Analyzer (see System Setup on page 5-23 for port location).
Connect the other end of the cable to the computers COM1 or
COM2 serial communication (RS232) port.
2 After connecting the interface cable, plug one end of the supplied
power cable into the OilView Analyzer and the other end into a 110/
220 volt outlet.
3 Turn the OilView Analyzer on. The analyzer should sound a three-
tone output and display the OilView copyright message on its LCD
screen.

Typical Test Procedure
To test an oil sample with the OilView Analyzer system:
1 Inspect the sensor. If necessary, wipe grid clean (see Step 7).
2 Vigorously shake the sample bottle after making sure that the cap is
screwed on tightly. This must be done to ensure that the contaminants
are evenly dispersed in the sample. The bottle should be shaken 15
seconds or until no sediment can be seen on the bottom of the bottle
after it has been inverted. In extreme cases, it may be necessary to stir
the sediment from the bottom of the bottle using a clean plastic or
glass rod before shaking.
86

Note
This procedure describes shaking the sample bottle and then
screwing on the sensor. Some users prefer to shake the sample
after the sensor has been screwed onto the bottle. Either
method is acceptable as long as the sample is vigorously
shaken just before the test.
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.

88
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.

Note
The test is time dependentstart the test as soon as the sensor
is plugged into the OilView Analyzer. Do not allow the sample
to stand on the analyzer for an extended period of time before
starting the test. If necessary, shake the bottle again before
starting the test.
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.

Analyzer Model Test Differences
Model 5100
When testing with the Model 5100, do not attempt to use the computer for
any other task while the test is runningdata may become corrupted or lost.
Model 5100-1 or 5100-2 OilView Analyzer

When testing with either the Model 5100-1 or 5100-2, the computer initiates
the tests and reads the data after a test has been completed. You can con-
duct other tests, or exit the program to run another software package. Prior
to starting a test, be sure the intended sample point appears on the database
tree. This point will automatically be recalled when the test data are read
from the analyzer. The OilView software will keep track of both sample
points when simultaneous tests are run.

Dilution Of Viscous Samples (OilView Analyzer)
The OilView Analyzers contamination and ferrous indexes are dependent
on magnetic and gravitational forces moving contaminants and debris
through the oil onto the sensing grid. When an oil is very thick (viscous),
this process is very slow. Consequently, viscous oils such as gear oils should
be diluted or cut with a petroleum solvent such as kerosene or diesel fuel
before testing. Dilution is the recommended method for testing thick oils
(see table below). However, if dilution is not practical, then thicker oils can
be tested for longer test durations using enhanced particle sensitivity (see
Test Time Options on page 5-20 for more information).
Dilution is generally not necessary with light lubricating oils such as com-
monly used multigrade motor oils (SAE 5W-30), light turbine oils, and light
hydraulic fluids. When dilution is used, comparisons and trending should
be based on a constant dilution ratio. When the OilView Analyzer is being
used as a screening tool, a second undiluted sample should be taken in the
event the oil is to be sent to an oil lab. Also note that chemical indexes
should only be recorded from an undiluted oil. The following table gives
recommended dilution ratios.
Sample Viscosity/(ISO NUM) @ Kerosene

40 degrees C (to be added)
<48 cSt (ISO < 48) None

>48 cSt (ISO > 48) Dilute 1:1
The viscosity of the undiluted sample should be determined with the

optional Model 51DV Digital Viscometer. If this test shows a viscosity of
less than 48 centistokes (cSt), dilution is not necessary. If the viscosity is
greater than 48 cSt, the oil should be diluted by adding kerosene to the oil
sample. This can be done by filling the sample bottle slightly over 1/3 full
with oil, adding an equal amount of kerosene, and leaving the rest empty
to allow for easy mixing when shaking the sample.
When an oil is diluted prior to a test, it is wise to record that fact in the test
comment line.
Dilution Of Viscous Samples (OilView Analyzer) 5-33

The recommended procedure for testing high viscosity oils is:
1 Perform a Short Test to measure the chemical index on an undiluted
sample,
2 store test results (chemical information) on the sample,
3 open sample bottle, add solvent, replace grid, shake, and run full test
on diluted sample,
4 store test results (contaminant, ferrous, and large contaminant
information) on same sample as step 2 above.
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.

OilView Analyzer Usage Tips
Procedural consistency and proper techniques are the best way to achieve
reliable results from your OilView analyzer. The following list of proce-
dures has been shown over time to provide the most reliable Chemical and
OilLife Index measurements and to improve the general repeatability of
measurements. These are best practices being used effectively by Oil-
View customers.
Double-Clean the Grid

Clean the grid two times to prevent cross contamination. CSI recommends
that in addition to wiping the grid after a test, you should apply a small
amount of the next oil to be tested onto the surface of the grid, and thor-
oughly wipe it a second time. Then return the sensor to the analyzer and
test the sample. This procedure is intended to wet out the surface of the
sensor with the next oil, completely removing any trace of the previous oil
or solvent.
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.
OilView Analyzer Usage Tips 5-35

Chapter 6
Digital Viscometer Model 51DV and Model 52DV
CSIs Model 51DV and 52DV Digital Viscometer (referred to in this

manual as the Model 5xDV) can be used to rapidly measure the viscosity
of lubricants and other fluids that have a 40C viscosity of from 20 cSt to
680 cSt.
89
The Digital Viscometer package includes the following:

Digital Viscometer with communications cable
OilView software
9/16 in steel ball bearing
10 cc syringe
ball retrieval magnet.
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.
6-2 Digital Viscometer Model 51DV and Model 52DV

Digital Viscometer Setup
Using the Digital Viscometer With the OilView Analyzer

Place the Digital Viscometer on a level surface. Plug the Digital Viscom-
eters cable into port 2 of the OilView Analyzer, and then connect the
Model 5100 to the host computer (see System Setup on page 5-23 for
more information on cable connections). Allow both the OilView Analyzer
and the Digital Viscometer to warm up for an hour before using.
90
Caution!
Exercise care when inserting the Digital Viscometers 15-pin connector
into the OilView Analyzers port 2it is possible to force the connector
upside down.

Alternate OilView Analyzer Port
Using the optional viscometer power supply, the digital viscometer can be
connected to port 3 or 4 of the OilView Analyzer as shown below. This
frees port 2 for use with the Model 51FW ferrous wear monitor.
91

Using the Digital Viscometer With a Computer
An optional power supply package allows the Digital Viscometer to be used
with a computer without using the OilView Analyzer as shown below.
92

Calibrating the Digital Viscometer
All Digital Viscometers are shipped with a factory calibration file on dis-
kette. Usually this calibration will be all you need to get started.
Existing Digital Viscometer Users

If you have already used CSIs Digital Viscometer with an earlier version
of OilView Software, you may or may not need to recalibrate your unit. If
your current Model 5xDV test options with the previous software are set as
Single Power (recommended) Default, then you can start with your
existing DVCAL_H.DEF file. Find this file in your previous CSI program
directory and copy it into the Model 5xDV directory as selected in the
Setup tabs File Locations. Then when you exit and re-enter the OilView
software and select the 5xDV tab, the program will ask you if you wish to
convert the older DVCAL_H.DEF file to the new format. Answer Yes.
You then may recalibrate with your own laboratory-tested oils* or a selec-
tion of CSI-supplied calibration oils (recommended). If you are supplying
your own oils, you will need to know their 40C and 100C viscosities and
the viscosity index as provided by an oil analysis laboratory. The calibra-
tion procedure is described on the next page.
New Digital Viscometer Users

If you are a new user of the Digital Viscometer, you have two additional
steps before you begin the calibration process. First, you must copy a file
from a disk that was provided with the Digital Viscometer to your hard
drive. Copy the DVCAL_H.DEF file into the Instruments subdirectory.
Second, you must tell the OilView software that you are adding a Digital
Viscometer (see Setup Menus on page 1-29). You are now read to begin
the calibration procedure.
*. ISO 14, 32, 68, 100, 137, 220, 460, and 680

Calibration Procedure
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, 40C and 100C 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.

Calibration Oil Description - Enter a unique name or title to identify the
fluid being used for calibration.
Viscosity @ 40C- Enter the viscosity of the fluid at 40C as provided by
the vendor or taken from actual oil analysis data provided by CSIs Fluid
Analysis Laboratory.
Viscosity @ 100C - Enter the viscosity of the fluid at 100C as provided
by the vendor or taken from actual oil analysis data provided by CSIs
Fluid Analysis Laboratory.
Specific Gravity - Enter the specific gravity value as obtained from the
fluid data sheet. Specific gravity can be converted from API gravity with the
following formula:
94
Auto-Calc - Check this box to instruct the program to automatically calcu-

late the specific gravity for non-synthetic oils based on the 40C viscosity
and temperature.
Viscosity Index - is an empirical number indicating the rate of change of
an oil within a given temperature range. A low viscosity index indicates
large change, and a high viscosity index indicates a relatively small change.
As you remove unsaturates from the oil during the refining process, you
increase the thermal stability as well as the viscosity index.
If two oils had the same viscosity at room temperature, as the temperature
increased the high viscosity index oil would thin out less and have a higher
viscosity at elevated temperature.
Start Calibration
This function button starts the calibration for the highlighted oil entry.
Delete Calibration
This function can be used to delete the highlighted calibration oil.

Default Calibration
The Default Calibration function can be used to identify the highlighted oil
(with an asterisk) as the typical viscosity/temperature profile that will be
used to compute the 40C viscosity value when tests are performed on
unknown oils or when the 100C value has not been entered.
Cancel Calibration
This function aborts a calibration run in progress. Any new fluid data
entered will be lost after aborting and leaving the Calibration tab.
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.

After clicking on the Start button, a window will follow asking you to pre-
pare the viscosity standard for testing. Make sure that the sample well and
steel ball are clean, and place enough of the fluid into the well to fill it to the
vertical rim as shown below. Then, place the steel ball into the well (if it is
not already there). Click the OK button to begin the calibration procedure.
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.

Highlight one of the oils in the calibration table and choose the Default (*)
button to select it as the default reference. This default will be used if no ref-
erence oil is chosen for a point or if the chosen reference oil doesnt include
a 100C 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.

Limit lines are plotted for the upper and lower viscosity ranges. These lines
represent 5% linear approximations of those parts of the calibration
curve. Normally, the points should fall between these limits. If a point is
outside of the limits, than a bad calibration may be indicated for that oil, or
one of the nearby oils, and a recalibration may be required.
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

Plot ASTM
This tab displays an ASTM plot of calibration oil viscosity versus tempera-
ture.
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.

Using the Digital Viscometer
Make sure that the correct machine and measurement point are being dis-
played in the database information box on the database tree.
Test oils at room temperature, making sure that the sample and test proce-
dure are the same every time. For the Model 51DV, always use new oil if a
second test of the oil is necessary. Do not retest with the same oil. For the
Model 52DV, the same oil may be retested without removing it from the
cup.
99
Whenever possible, assign a reference oil to the displayed point prior to

running the Digital Viscometer test. Best results will be achieved if you pro-
vide both the 40C and the 100C viscosity data for this reference (see
Assign Reference on page 2-2 and Data Available on page 2-5).

These 40C and 100C values will allow the Digital Viscometer to give the
most accurate measurements. There are three cases where the default cali-
bration in the calibration file will be used:
if the 40C viscosity is defined on the reference on the point, but the
100 C viscosity is not,
if neither the 40C nor 100C viscosity is defined on the reference on
the point,
if a default reference is not defined on the point.
To select the default calibration, select the 5xDV Calibrate tab, highlight
the desired oil, and then click the Default Calibration button to place the
asterisk (*) next to the default calibration.
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 40C and 100C 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 40C and the percent viscosity change from the reference
value.
Using the Digital Viscometer 6-15

Viscosity
Viscosity determination is important for several reasons (viscosity can be
measured with the OilView Digital Viscometer; see Chapter 6). The first
and most important reason is to detect misapplication of lubricant such as
when a 32 cSt oil is accidentally used in a 68 cSt application. Viscosity is
the only practical way to find this misapplication of perfectly good lubri-
cant. Chemically the misapplied oil may be identical to the correct oil so
no other testing method will detect a problem. Viscosity swings of 50% to
100% are common with misapplication.
Secondly, rapid decreases in viscosity may occur as a result of fuel dilution
of the oil and shearing of viscosity index-improving polymers. Decreases in
the viscosity of engine crankcase oils can result in engine failure. A check
for fuel dilution should be ordered from a lab if the viscosity decreases by
10% or more.
Viscosity determination also gives you a numerical value for trending and
for use with viscosity-based test time options on the Model 5100 and the
Model 51PC particle counter. And finally, viscosity testing can confirm a
suspected problem that has been highlighted with one of the other instru-
ments. For example, if the OilView Analyzer gave a high Chemical Index
due to oxidation in the oil, an increase in viscosity would be expected.
A change in an oil viscosity over 15% may indicate a problem. Changes
below that level are within the variability of the instrument and human
error. Increases in viscosity occur with oxidation and increasing levels of
insoluble materials, such as soot or lacquers. A gradual increase in viscosity
of engine crankcase oils is normal. As a conservative rule of thumb, a crank-
case oil should be changed if the viscosity increase is greater than 30%. Vis-
cosity limits for other applications vary widely.

Chapter 7
The OilView Particle Counter - Model 51PC
The CSI Model 51PC Particle Counter is a laser-based optical particle

counter enabling direct particle measurements and size distribution from 2
microns upwards. The particle counter is an essential tool for monitoring
clean oil systems such as turbines, hydraulics, high-speed compressors, or
where life extension of equipment is an important consideration.
The particle counter features ISO and NAS cleanliness outputs, in-line sen-
sors for lube condition, full integration with the OilView and RBMware
software product family, and industry recognized standard outputs. These
outputs are readily trended using the OilView software with automatic,
knowledge-based expert system interpretation and recommendations.
The Model 51PC Particle Counter includes:
Laser Particle Counter with color and dielectric sensors
OilView software
Communications and power cables
External universal power supply
CO2 cartridge
Plant air adapter
Sensor cleaning brush
7-1
OilView Particle Counter Setup
Connect the provided interface cable to the 9-pin connector located on the
right side of the particle counter and connect the other end of the interface
cable into port 3 or 4 on the OilView Analyzer. Alternatively, the particle
counters interface cable can be plugged directly into the computer's
COM1 or COM2 serial communication (RS232) port.
Connect the power supplys output cable into the power connector located
on the right side of the particle counter. Plug the power supplys AC cable
into a standard 110/220 VAC outlet.
100
7-2 The OilView Particle Counter - Model 51PC

Computer Connection
The Model 51PC can also be connected directly to the computers COM
port via the 9-pin communications cable. Plug the one end of the cable into
the Model 51PCs Communication port and the other end into the com-
puters COM port.
Connect the power supplys output cable into the power connector located
on the right side of the particle counter. Plug the power supplys AC cable
into a standard 110/220 VAC outlet.
101
OilView Particle Counter Setup 7-3

Particle Counter Component Locations
102
103

Running a Test
Before starting the testing procedure:
Attach a CO2 cartridge or plant air to the pressure regulator and turn
the pressure regulator knob to the HI position (reading > 2 kgf/
cm2).
104
Make sure that all cables are connected properly (see OilView Par-
ticle Counter Setup on page 7-2), then turn on the Particle Counters
power switch.
Ensure that the communication port configuration is properly set up
(see Setup Menus on page 1-29).
Running a Test 7-5

Note
When using plant air, the plant air adapter must be used
between the plant air hose and the regulator. If plant air is used,
instrument air (air that passes through a filter and a dryer)
should be used. Unfiltered air may add contaminants to the
sample.
105

Particle Counter Test Procedure
1 Place the sample fluid in a clean sample bottle. For maximum
accuracy, use a certified super-clean sample bottle in accordance with
ISO 3722*. Thoroughly shake the sample bottle to break up any
clumps. Ultrasonically agitate the sample to remove any air bubbles.
Air bubbles in the test fluid can be counted as particles and should be
removed before the test by ultrasonic agitation or by vacuum
(see Sample Preparation on page 7-21).
If there is a problem with cross-contamination or frequent sensor fouling
due to highly contaminated or unknown sample testing,
dilute every sample 1:1.
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.)
*. Hydraulic Fluid PowerFluid Sample ContainersQualifying and Control-

ling Cleaning Methods ISO 3722, International Organization for Standardiza-
tion, Stockholm, Sweden
Running a Test 7-7

Note
Be sure not to pour the sample directly into the sample cup.
The sample bottle should contain enough of the test fluid to
equal the flush volume plus three test volumes. In addition, an
extra amount should be included to ensure that the tube does
not draw air when the fluid reaches the bottom of the bottle.
106

Note
The OilView software will notify you if it has been more than
24 hours since the last flush cycle.
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.)
Running a Test 7-9

108
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.

Note
Dilution is sometimes required to accomplish particle counter
measurement. If viscosity gets too high, it causes a low-pres-
sure error message. CSI recommends that you dilute samples
over 90 cSt before running a particle counter test. Dilution is
also required if the sample is badly contaminated with solid
particles. See Dilution of Model 51PC Samples on page 7-24
for more information on dilution.
Recommended Particle Counter Settings For Diluted Sample .
Flow Rate Flush Volume Test Volume Minimum Total

ml/min ml ml Sample Volume
50 25 5 50 ml
6 Make sure that a drain container is positioned beneath the drain tube.
109
Running a Test 7-11

7 Select Start from the 51PC Test tab. When the test begins, turn the
drain/fill valve knob when requested to do so.
110

Problems
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.
Running a Test 7-13

Alternative Testing Method
Customers have the ability to change the flow rate on the Model 51PC par-
ticle counter. However, CSI strongly discourages this and instead recom-
mends using dilution whenever possible to maintain the flow rate at 50 ml/
minute.
Since the Model 51PC is calibrated at 50 ml/minute, changing the flow rate
invalidates the calibration. Results will be repeatable but not accurate.
Accuracy is only achieved at a flow rate of 50 ml/minute.
However, since repeatability can be achieved at other flow rates besides 50
ml/minute, trending of data is possible for customers who, for whatever
reason, are unable to dilute their sample.
The following table suggests particle counter settings that change the flow
rate.
Particle Counter Settings For Undiluted Sample (not recommended).
Fluid Flow Rate Flush Volume Test Volume Minimum Total

Viscosity ml/minute ml ml Sample Volume
1-90 cSt 50 25 5 50 ml
91-160 cSt 20 25 5 50 ml
160-300 cSt 10 25 5 50 ml

Test Results
111
Point - Displays the database point for the sample.

Sample - indicates the sample ID and the date of the currently displayed
sample.
Lube Contamination - reports the contamination level of the fluid under
test in particle counts per milliliter of sample for several size ranges.
ISO Code - The ISO 4406 standard consists of a two-digit code X/Y,
where X is the level of particles greater than 5 m and Y is the level of par-
ticles greater than 15 m. The ISO Codes for X and Y represent a break-
down of particle counts from 0.01 to 2,500,000 particles per milliliter as
shown in the table on the following page. The extended ISO Code consists
of a third digit prefix which is the code level for particles greater than 2 m.
The Model 51PC reports the extended three-digit ISO Code.
. Hydraulic Fluid PowerFluidsMethod for Coding Level of Contamination
by Solid Particles, ISO 4406, International Organization for Standardization,
Stockholm, Sweden
Test Results 7-15

ISO 4406 Cleanliness Code Levels
Particle Count Range (per

ml)
Minimum Maximum
ISO Code
(Included) (Excluded)
1 0.01 0.02
2 0.02 0.04
3 0.04 0.08
4 0.08 0.16
5 0.16 0.32
6 0.32 0.64
7 0.64 1.3
8 1.3 2.5
9 2.5 5.0
10 5.0 10
11 10 20
12 20 40
13 40 80
14 80 160
15 160 320
16 320 640
17 640 1300
18 1300 2500
19 2500 5000
20 5000 10000
21 10000 20000
22 20000 40000
23 40000 80000
24 80000 160000
25 160000 320000
26 320000 640000
27 640000 1300000
28 1300000 2500000

NAS Code - reports the NAS cleanliness code. NAS 1638 was developed
by the Aerospace Industries Association of America, and is similar to ISO
4406 in that it classifies cleanliness according to pre-defined particle counts
of certain particle sizes. The following table shows the particle sizes, counts,
and corresponding 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.
Number of particles per 100 mL

NAS
range
1638
Class 5 to 15 15 to 25 25 to 50 50 to 100 > 100
00 125 22 4 1 0
0 250 44 8 2 0
1 500 88 16 3 1
2 1000 178 32 6 1
3 2000 356 63 11 2
4 4000 712 126 22 4
5 8000 1425 253 45 8
6 16000 2800 506 90 16
7 32000 5700 1012 180 32
8 64000 11400 2000 360 64
9 128000 22800 4100 720 128
10 256000 45600 8100 1440 256
11 512000 91200 16200 2800 512
12 1000000 182000 32400 5800 1024
Lube Quality - This is a measure of fluid degradation as detected by the

colorimetric and dielectric sensors. This measurement correlates with the
analyzer Chemical index.
Test Results 7-17

Dielectric Constant - A measure of the dielectric permittivity of the fluid
(i.e., the insulating quality). This will increase as the lubricant becomes
degraded by oxidation or acidity.
Dielectric Index - Reports the change in dielectric constant as an index
relative to the reference oil; for which 0.0 is good and 10.00 or more
(depending on the alarm setting) is deteriorated lube oil.
Color - A measure of the fluid color. In general, color changes from amber
to reddish brown as oil is degraded. Clear to amber oil has a color value of
zero. The value increases as the red/brown color darkens.
Light Absorbance - A measure of the total optical absorbance of the oil
over a range of optical wavelengths. Directly related to total contamination
and degradation of the oil.
ISO Recommended Cleanliness Levels
Fluid classification
Component type
ISO code
Servo valves 17/14/11

Vane and piston pumps/motors 19/16/13
Directional and pressure control valves 19/16/13
Gear pumps/motors 20/17/14
Flow control valves and cylinders 21/18/15
Aircraft test stands 16/13/10
Injection molding 19/16/13
Metal working 20/17/14 - 19/16/13
Mobile equipment 21/18/15 - 19/16/13
New unused oil 21/18/15

Test ISO Plot and Test NAS Plot
The Test ISO and Test NAS plots are graphs of the test data before it has
been stored to the sample in the database. These plots are for viewing only
before performing the Save function. After the particle counter data has
been saved, the plot can be viewed from the Sample Info tab (see Sample
Information on page 3-5).
112
Test Results 7-19

Diluent Test
The Diluent Test tab is used when testing the contamination of particle
counter diluents. These results are used when you test diluted samples. The
OilView software automatically subtracts the counts associated with diluent
so that accurate counts for the oil sample can be computed.
To run a diluted sample test, complete the fields for diluent data: descrip-
tion and lot number. Verify the flow rate, flush volume, and test volume (50,
25, 5 recommended). Start the test and follow the Test Status instructions.
The results are reported in the Test Results fields.
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.

Sample Preparation
The OilView Particle Counter uses advanced laser technology to count
individual particles down to 2 micrometers in size as they pass through the
laser window. These measurements are naturally sensitive to settling of the
particles in the sample bottle and are adversely affected by air bubbles or
water droplets in the oil. Each of these points is addressed separately below.
It is important for particles to be evenly distributed in the sample just prior
to testing on the OilView Particle Counter. A very good way to do this
without entrapping air bubbles in the sample is to use an ultrasonic bath.
After thoroughly shaking the sample, tightly seal the caps on sample bottles
and place them in an ultrasonic bath. Leave the samples in for 30 to 60
seconds for samples with viscosities less than 100 cSt, and two to three min-
utes for higher viscosities. The agitating motion of the ultrasonic bath has
the ability to maintain suspension of particles while dissipating entrapped
gas bubbles.
A vacuum chamber, available from companies such as Fisher Scientific**,
can be used in conjunction with an ultrasonic bath to speed up the removal
of entrained air. After initially removing the majority of air from the sample
with an ultrasonic bath, loosen the caps to the sample bottles and place
them in a vacuum chamber for a few minutes to remove the remaining
small air bubbles.
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).

Water present in the test fluid will not mix well and may cause false counts.
(Use the OilView Analyzer to measure water content.) In the case of water
contaminated oil samples, a mixed solvent may be used to eliminate water
emulsion, the key interference of particle count analysis. This procedure is
only applicable to samples that are completely soluble in the mixed solvent.
If, after adding the mixed solvent, the sample is hazy or has layers, the
sample was not completely soluble.
The mixed solvent is prepared by mixing one part commercial grade (99%
or better) 2-propanol with three parts of toluene. Filter the mixed solvent
through 0.8 micron filter paper.
The procedure for using the mixed solvent is as follows:
1 Flush the Model 51PC particle counter with the mixed solvent.
2 Run a particle counter test on the mixed solvent and store the results
as the diluent.
3 Weigh, to the nearest 0.1 gram, an appropriate amount of the sample
in a tared sample bottle. Record and tare the weight.
Note
An appropriate amount of the sample can be anywhere
between one to twenty grams of sample depending upon con-
tamination.
4 Add approximately 50 grams of the mixed solvent to the tared

sample bottle. Record the mixed solvent weight to the nearest 0.1
gram.
5 Shake the sample and mixed solvent vigorously for at least thirty
seconds.
6 Degas the sample solution in the ultrasonic bath and optional vacuum
chamber.
7 Perform a particle count following the particle counter diluent test
procedure and save the results.
Note
The mixed solvent is proven to be effective on samples with up
to 17% water content.

Sample bottle in an ultrasonic bath.

Dilution of Model 51PC Samples
Dilution may improve results and consistency when testing with the Oil-
View Particle Counter in two primary circumstances: when the viscosity is
high, and when the sample is badly contaminated with solid particles. In
either case, dilution can be performed as described below to improve par-
ticle counter results. However, the lube quality measurements (colormetric
and dielectric) will be voided by this action since the sample fluid will be a
solution of diluent and oil and not pure oil.
When the sample viscosity is greater than 90 cSt, dilution will reduce the
viscosity and enable the sample to be tested at 50 ml/min (the sensor cali-
bration flow rate). It is most common for the dilution level to be 1:1 (i.e., 1
part diluent to 1 part oil).
When the sample contamination level is excessively high, dilution will
allow more accurate counting of individual particles without coincidence.
(Coincidence means that two particles blocked the laser beam at the same
point in time, causing a missed count or a larger particle to be counted.)
Recommended Dilution Ratios.
Dilution ratio for excess contamination: 10:1

Dilution ratio for dark samples: 10:1
Dilution ratio for high viscosity: 1:1
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 fluidthis 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.

For very clean systems, you will want to purchase laboratory reagent grade
kerosene, or you may even opt for superclean diluent which is certified
to meet specified particle count levels. In any case you will need to test a
representative sample of the diluent to be used, verify acceptable cleanli-
ness, and store the results as diluent reference.
The OilView software will store this diluent particle count data in a special
file called diluent.def. This file is able to be accessed from any OilView
database in the given subdirectory. These data allow the OilView software
to automatically compensate for the particle count contribution from the
diluent when diluted samples are tested.
If the same diluted samples are to be tested on the OilView Analyzer as well
as the Particle Counter, you should proceed as follows:
1. Place a small amount of undiluted oil sample onto the Model 5100
sensor. Do not screw the bottle onto the grid as the sample will be
contaminated and particle count data will be compromised.
2 Run the Short test on the OilView Analyzer and store the data,
3. Dilute the sample and remove gas,
4. Run the Particle Counter test on the diluted sample and then store the
data,
5. Run the Full test on the OilView Analyzer, then store the data.

Dilution Ratios
The computer will automatically calculate the exact dilution ratio. How-
ever, you will need to type in the amount of diluent and the amount of
sample. Amounts can be measured either by weight (CSI recommended
method) or by volume so long as the same measure is used for both diluent
and sample.
Procedures for both methods are described on the following pages.

Measuring by Weight
To measure amounts by weight, use a scale to measure tare weight of the
sample, then measure the tare weight of the diluent added to the sample.
1 Turn on the power to the scale, and verify that the scale reads zero
(0.0).
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

116
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

4 Select the tare option again to make the bottle and sample equal 0.0
gram.
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.

119
6 Write the weight of the diluent on the label along with the weight of
the sample.
120 7

7 When testing diluted samples using the OilView Particle Counter,
check the Diluted Sample box under Test Control.
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.

Sensor Cleaning
The internal particle counter sensor does not have to be cleaned very often;
however, inadequate pressure problems or laser calibration failure after
flushing indicates that the sensor needs to be cleaned.
The included cleaning brush may be inserted slowly into the sample pick-
up tube with a rotating motion until it stops (approximately one inch of the
brush handle remaining below the sample tube; see illustration on next
page).
Flush completely with approximately 200 ml of kerosene or similar light
mineral oil for final cleaning. Check particle counts for repeatability and
reasonableness to determine effectiveness and completeness of sensor
cleaning. (The software performs some basic checks during the Flush Only
test.)
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.

122
Sensor Cleaning 7-33

Supplemental OilView Particle Counter Procedures
Flush Till Clean
At the start and finish of each OilView Particle Counter testing day as well
as between sample batches, you will be prompted to flush the sensor with
kerosene until an acceptable particle count is achieved. (A batch is defined
as a collection of used oil samples of the same type, for example the same
reference oil.)
Use the sensor flushing option to automatically select 100 ml/min flow rate,
35 ml flush, and 5 ml test. The particle counter will reinstate the previously
set flow, flush, and test values after flushing. The software will suggest con-
tinued flushing and cleaning until ISO 18/17/15 or better is achieved during
flushing.
Some oil types require more flushing than others. This is normally because
of the time and flow volume of kerosene required to completely remove the
film of lubricant left on the sensor window and is particularly time con-
suming after testing a high viscosity lubricant. You may choose to dilute
high viscosity lubricants with clean kerosene to minimize flushing time
between batches.
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.

To prevent excessive flushing time, do not test used diesel engine oils that
are black from soot. Note that all of these types of samples are able to be
tested on the OilView Analyzereven though they cannot be tested using
the OilView Particle Counter.
Finally, although it will not damage the particle counter, water/oil emul-
sions cannot be adequately tested because the water droplets may give false
particle counts.
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.
If high contamination or ferrous wear is indicated with the OilView Ana-

lyzer, then it will be extreme when tested with the OilView Particle Counter
which has 100 times greater sensitivity. If the OilView Analyzer gives any
marginal, bad, or extreme readings, then it is not necessary to test the
sample with the OilView Particle Counter.
In addition to using the OilView Analyzer to screen obviously bad samples
before introducing them to the particle counter, look at the sample in the
bottle. If the following visual conditions exist, a laser particle count is prob-
ably not needed:
Obvious visual sediment in bottle,
Obvious visual indication of water or milky appearance.
Supplemental OilView Particle Counter Procedures 7-35

Batching Similar Oil Samples
Prior to beginning a test with the OilView Particle Counter, the software
will check to see if the last reference oil is the same as the present default
reference oil. If it is the same, or if the last test was the flush sequence, the
test will proceed as normal (50 ml/min flow, 25 ml flush, 5 ml test; or what-
ever flow rate, flush and test volumes were stored with the reference oil).
If the last test indicated a different reference oil (i.e., a different date/time
for reference oil test) then you will be prompted to stop and flush and clean
the sensor with kerosene or other suitable solvent before testing this
sample. The flushing sequence is the same as described in the section
Flush Till Clean on page 7-34.
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.
. Fisher Scientific (1-800-766-7000) Odorless kerosene, Fisher No. K10-4.

Chapter 8
The OilView Ferrous Wear Monitor - Model 51FW
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
Users 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.
8-2 The OilView Ferrous Wear Monitor - Model 51FW

Software Setup
The OilView software must be informed that you will be using a Model
51FW. Click the Setup tab on the main menu and check the appropriate
checkbox to specify the port where the Model 51FW is connected. When
finished, click on the Save Changes button.
Model 51FW connected to Port 2 of the Model 5100.
Software Setup 8-3

Model 51FW connected to Comm 1 on the computer.

Cables And Connections
There are two ways to connect the Ferrous Wear Monitor depending on
whether it is to be connected to an OilView Analyzer or directly to a com-
puter.
124
Connection to OilView Analyzer Port

The Ferrous Wear Monitor Model 51FW can be connected to port 2 on the
OilView Analyzer Model 5100-1 or 5100-2 via the supplied 15-pin to 15-pin
cable. Plug one end of the cable into the Model 51FWs Communication
port and the other end into the Model 5100s port 2. This cable also supplies
power to the Ferrous Wear Monitor.
125

Computer Connection
The Ferrous Wear Monitor Model 51FW can be connected to the com-
puters COM port via the 15-pin to 9-pin communications cable. Plug the
15-pin end into the Model 51FWs Communication port and the 9-pin end
into the computers COM port. Power is supplied to the Model 51FW via
a wall-mounted power supply (+12, +5, and Ground). The cable from this
power supply is plugged into the Power Supply jack on the Model 51FW.
126

Alternate OilView Analyzer Port
Using the power supply, the Ferrous Wear Monitor can be connected to
port 3 or 4 of the OilView Analyzer with the 15-pin to 9-pin communica-
tions cable; freeing port 2 for use with the Digital Viscometer.
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.

Calibrating the Ferrous Wear Monitor
Before testing any samples, the Ferrous Wear Monitor Model 51FW must
be calibrated (with the provided calibration standard) using the following
procedure. Calibration is quick and should be performed on a daily basis.
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

Note
The 51FW uses an optical sensor in the black ring on top to
sense bottle placement. Some empty bottles may not be
sensed; therefore, you may need to add tape around the
bottom of the bottle.
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.
Taking Calibration Readings

The 51FW Calibration Standard needs no special preparation to be mea-
suredsimply place the standard in the center of the ring located on the top
panel of the Ferrous Wear Monitor. The sample bottle must be placed in the
cap-up position.
When the sample is placed, the status box will display either Good
Reading or Bad Reading. If a good reading has been taken, the Results
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.
Calibrating the Ferrous Wear Monitor 8-9

Note
Bad readings are commonly caused by slow placement of the
sample or movement of the sample before the measurement
has been completed.
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.

Testing Samples With the Ferrous Wear Monitor
Testing lubricant samples with the Model 51FW is very similar to the cali-
bration procedure. First, decide if you want to agitate the oil sample to get
an even dispersion of particles. The Model 51FW does not depend on par-
ticles falling out of the sample, so it is not imperative to disperse the parti-
cles. For maximum sensitivity, CSI recommends testing samples unshaken
in the cap-up position. Consistent results can usually be obtained by filling
the sample bottles to the same level (constant volume) and by allowing the
sample to settle for at least four hours.
Select the 51FW tab to display the Model 51FW test window.
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.

You will be asked to place and remove the sample until the software records
three good readings. When the third good reading is recorded, you must
remove the sample and click the Save button to store the results.
After pressing a key, the OilView software will average the three readings
and display the result.
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.
Diagnostics and Raw Data

The 51FW Diagnostics and Raw Data tabs display information which is
mainly useful to CSI Customer Support for trouble-shooting problems.
These tabs are normally grayed out, but may be enabled through the main
Setup / System / Diagnostics check box.
The 51FW Raw Data plot is sometimes useful to see why bad readings are
occurring. A good raw data plot for the calibration standard is shown
below. The raw data plot shows 40 measurements that were taken before,
during, and after bottle placement. The plot should be relatively flat before
and after bottle placement and show a steep rise in the middle as the bottle
is placed. A more gradual upward slope in the middle indicates the bottle
was placed too slowly. Bumps in the plot that occur before or after bottle
placement usually indicate slow bottle placement or bottle movement
(including bouncing or sliding) after placement.

Note
Ripples in the plot could indicate electromagnetic interference
resulting from the 51FWs being too close to another electronic
device.
131

Chapter 9
Wear Debris Analysis
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
Recommended Specifications Minimum System Requirements
1/3" Color CCD Camera

470 TV lines horizontal resolution Power Supply
768 (H) x 494 (V) effective pixels Video Cable Assembly
525 line/60 Hz 2:1 interlace scanning sys- C-Mount Adapter Ring
tem
NTSC or PAL video output
Small size for mounting on microscope
Video Frame Grabber
Recommended Specifications Minimum System Requirements

Composite NTSC, PAL, or S-Video input Intel Pentium computer or greater
24/16/15 bit RGB video digitizing 8 MB RAM (ideally 16 MB or more)
640 x 480 NTSC (768 x 576 PAL) digitiz- MS Windows NT or Windows 95 or later
ing resolution
30 frames/sec, 60 fields/sec TWAIN Video Capture Software Inter-
face
Full bandwidth PCI bus mastering read
and write (up to 132 MB/sec)
One available PCI 32-bit bus master
expansion slot
Interpolated scaling in X and Y directions
Digital control of offset, gain, brightness,

contrast, hue, and saturation
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.
9-2 Wear Debris Analysis

Wear debris analysis is performed on an oil sample and may include one or
more photomicrograph images. Some of the actions within this tab are per-
tinent to a specific image and others are pertinent to the oil sample which
may have no images, one image, or several images.
9-3
In effect wear debris analysis introduces another level below the sample
level on the User Database treethe image level.
132

You will want to pay particular attention when you are recording informa-
tion in the WDA tab as to whether it is being applied to one specific image
or to the sample.
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.
Feature Image Sample
Photograph with tool bar X

Image Caption X
Image Note X
Wear Debris Analysis Sample Diagnosis X
Analysis Grid with 5 Groups X
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.

Notes added to the wear debris analysis Sample Diagnosis field are copied
to the sample record under the Sample Info tab. These notes apply to any
or all images for a given sample.
The wear debris analysis grid includes five pages. Each page represents an
analysis of a different group of particles. To do this analysis you can select
one item from each column for each group which most closely describes
the group.
There are ten categories of analysis for each group of particles:
Concentration - A relative comparison of the concentration or
amount of particles in the group.
Average Size - The average size in microns for the particles repre-
sented in this group.
Max Size - The maximum size particle in the group.
Aspect Ratio - The maximum to minimum dimensions ratio for a par-
ticle (e.g., length to width).
Shape - The three dimensional shape of the particles.
Texture - The surface texture of the particles.
Composition - The physical composition of the particles.
Classification - The wear mechanism classification of the particles.
Severity - The overall severity of wear condition based on this group
of particles.
Concentration, average size, maximum size, and severity are all trendable
parameters that are in the CSI Default Analysis Parameter Set. CSI sug-
gests that you do not apply alarms to any of these except the severity level.
The others are used only for reference during analysis.
You can use the Assist button to automatically add selected categories to the
wear debris analysis Sample Diagnosis note after the items are selected. You
are free to edit this note field. These automatic entries are provided for your
convenience.
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.
Measuring Image Size and Particle Density
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.

Counting Particles
To measure the particle density (particles per square millimeter), first press
the Measure button and then draw a rectangle around the region con-
taining the particles. Next, press the Count (particles with mouse click)
button. Now, you can visually count the particles, pointing the mouse
cursor to each particle and clicking. this automatically counts the particles.
Or you can count the particles and manually enter the number to get the
particle diversity.
When finished, this information can be used to fill in the WDA matrix.
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
The left photograph is functionally the same as it is on the Sample screen,

except that you cannot edit the caption, notes, or select through the wear
debris analysis grid.
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.

Atlas Setup
The Atlas tab is much like the Sample tab except that it is used to add or
edit the wear debris analysis Atlas. You must be an advanced user to edit
the atlas.
The tree on the upper left is used to select the image to be viewed, and the
note field below the tree contains information relevant to this image.
The wear debris analysis grid below the image represents the most obvious
group of 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

Calibration
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.
Severe Abrasive Wear

Severe abrasive wear is the removal of surface material through the cutting
action of relatively harder particles against a relatively softer surface.
Grinding, sanding, and polishing processes are all examples of intentional
abrasive wear.
Abrasive wear occurs in lubricated systems primarily through contamina-
tion of the oil by solids. Wear particles resulting from abrasive wear of steel
are work-hardened and themselves act as abrasives. The size of wear parti-
cles produced by abrasion typically increases with the severity of the wear.
Abrasive wear of metals produces particles with clean, conductive surfaces.
Severe abrasive wear of ferrous surfaces will be detected by the OilView
Analyzer, Ferrous Wear Monitor and Particle Counter.
The solution to any abrasive wear problem is to first change the oil and
filter, and then identify and eliminate the source of the abrasive particles.
Note that abrasive wear may continue after an oil change for a short period
of time if abrasive particles have been embedded in soft bearing materials.
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 components useful service life.

Fatigue wear can be accelerated through surface corrosion and inadequate
lubricant film thickness. In general, the size of fatigue wear particles
increase with increasing rates of wear. The particles produced are often too
large to be detected with atomic spectroscopy. These relatively large parti-
cles are easily detected by the OilView Analyzers, Ferrous Wear Monitor
and Particle Counter.
In many cases, fatigue wear will not have a solution other than planning to
replace the worn part. In the short term, corrosion influences and sec-
ondary abrasive wear from fatigue wear particles should be minimized by
changing the oil and filter. In addition, vibration analysis should be per-
formed on the machine to determine if the system is being subjected to
abnormally high levels of vibration. In terminal cases, the use of a more vis-
cous oil can sometimes delay catastrophic surface failure at the cost of
increased friction and higher operating temperatures.
Adhesive Wear
Adhesive wear is caused by metal to metal contact in the absence of an
oxide or lubricant film. The mechanism involves bonding at the atomic
level between clean opposing metal surfaces. Wear debris produced by
adhesion is often referred to as rubbing or sliding wear. The size of the wear
particles produced is generally dependent on the roughness of the opposing
surfaces. Finely finished metal surfaces produce very fine wear debris 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 m.
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 CSIs 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 analyzers 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

Allow the oil to drain into the bottle and remove the bottle from the grid.
Place the grid back on the analyzer and attach the microscope. Initiate an
OilView Analyzer test to cycle the analyzers electromagnet. You can then
observe ferrous particles as they are rotated through three distinct angular
positions each second.
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.
Using the Model 51WD Wear Debris Patch Maker

The Model 51WD Wear Debris Patch Maker is a complete, standalone
system, including vacuum pump and waster container, for preparing wear
debris filter patches. See the diagrams below for setting up the system and
assembling the patch holder.
The patch maker offers these features:
Separation of large particles from smaller particles using stacked
filter patches.
Magnetic separation of ferrous particles from non-ferrous particles
on separate patches.
Easy clean-up and disposal of waste oil.

Preparation
Select the pore size(s) for the filter patch(es) based upon the estimated or
measured particle size range. Standard filter patch pore sizes are 3 micron
and 8 micron. Other pore sizes ranging from 0.8 micron to 30 micron are
readily available and may be used. A few tests will quickly reveal what pore
sizes tend to plug and which ones yield meaningful specimens. The goal is
to produce wear debris analysis patches with particles distributed so they
can be easily viewed with a microscope.
Assemble the filter into the patch maker including all O-rings and screens
according to the diagram.
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.
Dual Filter Sizes

You can separate large particles from smaller particles using stacked filter
patches. For example, if the sample is highly contaminated you may choose
to use a 30 micron filter above a 10 micron filter. Keep in mind that the
small pore size filter is most often the one that is plugged from excess con-
tamination.
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

142
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.
Model 51SM using oblique lighting.
Model 51SM using through-lens lighting.

Through-lens lighting can be used when viewing particles where the oil film
has been removed; however, oblique lighting is best when viewing particles
in an oil film. (An oil film clouds the image when using through-lens
lighting.)
Keep in mind that the process of removing the oil film with solvents will
also remove most of the non-ferrous particles. Therefore, oblique lighting
can be used first to view both ferrous and non-ferrous wear debris with an
oil film present. Then, if desired, the oil film can be washed away with sol-
vent (while a permanent magnet retains ferrous particles) and through-lens
lighting can then be used to view the remaining ferrous particles.
In addition to photomicrographs wear particle identification, CSIs Wear
Particle Atlas (included with the Model 51SM shop microscope) provides
hints and recommendations on particle extraction and examination.
Model 52LM Lab Microscope

Refer to the manual which came with your microscope for setup and oper-
ation instructions.
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

Chapter 10
The Model 5200 Trivector Analyzer
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.
10-2 The Model 5200 Trivector Analyzer

The vacuum control valve is used to direct the vacuum from the foot oper-
ated vacuum pump to the appropriate chamber for cleaning or degassing.
The LEDs will indicate the position for this valve.
Front view of the Model 5200.

Initial Setup
The 5200 must be connected to a computer for starting and controlling the
test sequences and for collecting the test results. Also, the analyzer comes
complete with a waste container system including a vacuum pump. The
communications cables and plumbing must be connected before the instru-
ment can be operated.
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.

Electronic Scale
The analyzer system includes an electronic scale which is used for accu-
rately weighing dilution ratios. The scale comes with its own DC power
supply which is unique and should not be used on any other instrument.
The scale also uses batteries, but its power supply should be used to keep it
out of power saver mode.
Connect the scale to its port on the back of the 5200 using a 9-pin, RS232
cable.
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.

4. Press and hold the CAL/MODE key until +200.0 appears on the
display.
5. Gently place the 200 gram calibration weight onto the center of the
tray top.
6. The + sign will disappear. Wait about 10 seconds for the unit to
complete internal calibration. Do not move the weight or touch the
scale during this time.
7. When internal calibration is complete, the unit will beep, the display
will blink, and the + sign will re-appear with the correct weight
displayed.
8. Remove the calibration weight and press the TARE/PRINT key
briefly to reset the scale to zero.
Scale Error Codes The following error codes may be displayed during
scale operation. Error codes in left column, meaning in right.
Error Code and Meaning
L Underload error. Check to make sure weighing tray is prop-
erly installed.
H Overload error. Excessive weight or force may have been
applied to the scale. It is critical to not exceed the maximum
load capacity of 600 grams for this scale. If exceeded, damage
to the scale may occur.
E-02 Usually detected during calibration, as a result of vibrations,
air drafts, or unstable environment. Make sure the 0.0 g
weight display is stable before pressing the CAL/MODE key.
E-10 Turn unit off and back on to clear stored Memory value.
E-30 Electronic malfunction. Return unit for evaluation.
E-54 Indicates the electronics are out of factory set parameters.
Most commonly caused by objects being dropped onto the
weighing tray or from the scale itself being dropped. The unit
must be returned for repair.
Triangle (in upper left corner of display) Sensor out of spec. May be due
to rough handling or spillage of liquids into the scale. Return
for repair.

Scale Configuration The scale is factory configured to communicate
with the 5200 and software. Normally these configuration parameters are
stored even when power is removed from the unit. If the software has
trouble reading the scale, first check the cable connections and null modem
adapter. If necessary, the scales communication setup parameters may be
verified/changed as follows:
1. Start with the scale turned off. Briefly press the ON/MEMORY key
and then immediately and briefly press the TARE/PRINT key while
all LCD segments are displayed.
2. After a moment, a 1 should appear as the left segment value on the
left side of the display. There are actually three positions, left, center,
and right, which are displayed during configuration. By briefly and
repeatedly pressing the CAL/MODE key, the user moves from the
left position to the right position and then back to the left position.
3. Different configuration parameters are selectable by changing the left
and center position values. As each position is displayed, it may be
incremented to select a different parameter by briefly pressing the
TARE/PRINT key. The parameter selections and settings for the
5200 communications are shown in the table below.
4. Increment the left segment value using the TARE/PRINT key until
it reaches a 5 as shown in the table. If the 5 is skipped, continue
pressing the TARE/PRINT key until the segment value cycles back
to the 5.
5. Press the CAL/MODE key to move to the center segment. Again
increment with the TARE/PRINT key to get to the next value shown
in the table. Press the CAL/MODE key again to move to the right
segment.
6. The value displayed for the right segment will be the current setting
for that parameter. If it does not match the table value, then use the
TARE/PRINT key to increment until it is correct.
7. When the right segment value is correct, press and hold the CAL/
MODE key until the small arrow appears to the right of the value.
8. Press the CAL/MODE key briefly to return to the left segment, then
repeat Steps 4 through 8 until all table settings have been verified/set.

9. When finished, press and hold the TARE/PRINT key until the scale
resets. All of the new settings will then be saved for each time the
scale is powered up.
Electronic Scale Configuration Parameters for 5200 Communications

Segment Position Values
Parameter Left Center Right Value
Baud Rate 5 1 7 9600
Parity 5 2 2 space
Handshake 5 4 1 software
Waste Container System

The waste container system provides a means for automatically removing
waste oils and cleaning the 5200 after each test. The vacuum pump is used
to vacuum the waste from the Test 1 and Test 2 sensors. It also provides
vacuum degassing of air bubbles from the syringe for Test 3. The vacuum
line is not connected to the Test 3 sample port. This port may be flushed by
manually squirting a syringe full of solvent into the sample port. Test 3 uses
a direct drain line into the waste container. Refer to the assembly diagrams
below for setting up the waste system.
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.

Vacuum Relief Valve
Once a vacuum has been applied to the system, the pump will hold this
vacuum until the system has been fully vented, even after the pump stops
running. The vacuum is released slowly from the flasks as air enters one of
the 5200s test ports. This release usually takes several seconds. In some
cases, the vacuum may need to be released more quickly, depending upon
the next operation to be performed by the user. For example, a vacuum
should not be applied to Test 1 during its test as this may introduce air bub-
bles. If the vacuum still remains from a previous test, then the vacuum relief
valve may be manually pressed to quickly release any leftover vacuum.

Note
The vacuum pump will not restart when the system is already
holding a vacuum. If the foot pedal is pressed, and the pump
does not run, then the system is already under vacuum, and
additional vacuum from the pump should not be required until
the vacuum is released.
146

147
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.

Rear view of analyzer.
Side view.

Test Procedure
The 5200 Trivector Analyzer has a simple 1-2-3 step operation yielding
automatic chemistry, contamination, and wear measurements in about 5
minutes. When appropriate, a fourth step is added to extract particulate
debris on filter patch(es) for detailed microscopic wear debris analysis. The
steps below outline the testing sequence:
Front view of the Model 5200.

Test 1, chemistry. Fill 10 ml syringe with neat, undiluted oil. Insert
syringe tip and inject into hole at bottom, run test, and then flush/clean with
solvent.
Test 2, wear and contamination. Pour 1:1 diluted sample: solvent to top
of taper in chamber, run test, and then flush/clean with solvent.
Test 3, particle count contamination. Fill 30 ml syringe with diluted
sample (1:1 to 1:99). Use optional water mask solvent. Degas to remove air
and then run test.
Verify that the oils quickly dissolve into a clear liquid when mixed with the
cleaning and diluting solvent you select. You must choose a different sol-
vent if the oil and solvent mixture becomes either milky or layered indi-
cating oil and solvent are immiscible.
WDA Patches Typically use 3 and/or 8 micron patches as needed to view
wear debris from Test 2. Two patches may be stacked with the larger pore
size patch on top.
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.

Table 10 - 1. Oil and Solvent Solubility: Y=Yes, N=No
Original
Ultra Original
Lamp Oil
Oil Class Dielectric Pure Lam Oil + Toluene Hexane Fluid A Fluid B Fluid C
or
Lamp Oil Fluid B
Kerosene
Mineral 2.1 - 2.4 Y Y Y Y Y Y Y N Most

Oil industrial
lubricants
PAO 2.1 - 2.4 Y Y Y Y Y Y Y N Synthetic
Hydro-
carbon
Diester 3.4 - 4.3 Y Y Y Y Y Y Y Y Diester
POE + 4.6 - 4.8 Y Y Y Y Y Y Y Y Polyol
PAG Ester +
Poly-
alkylene
Glycol
PAG 6.6 - 7.3 N N N Y Y N N N Poly-
alkylene
Glycol
PhE 6.0 - 7.1 ? N Y Y Y N Y Y Phosphate
Ester
Warning!
Both Toluene and Isopropyl Alcohol have flash points
below room temperature. They require an explosion
proof vacuum pump.
Software Test Setup

The software provides instructions and the hardware flashes appropriate
LEDs to automatically lead the user through the test sequence. However,
before pressing the Start button to begin testing, check the following:
1 Select the correct sample on the database tree. If the sample is not
there, then add the sample to the correct Area, Equipment, and Point.

2 Normally all three 5200 tests are run by default. If some tests are not
required for a particular sample, then un-check the test-enable boxes
next to the test icons for the non-required tests.
3 When diluting by weight using the scale, make sure the scale-enable
checkbox is checked. Also, select the additional dilution for Test 3 as
needed.You will be directed to the scale at the appropriate time
during the test.
4 Press the Start button in the software. This will initiate the testing
sequence. Now simply follow the instructions and the flashing LED.
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.

6 Flush Test 1. Remove and discard the syringe. Use the foot pedal to
run the vacuum pump to evacuate the oil from the Test 1 chamber.
You may push thick oils out of the sensor using a syringe filled with
solvent.
7 Clean Test 1. Pour lamp oil or other solvent into the chamber to flush
out the oil. Do this for 5 to 10 seconds, and then, without pouring any
additional solvent, just vacuum air through the chamber to dry it.
8 Perform a clean check. Press the Test 1 button next to the flashing
yellow LED, and the software will take a reading. If not sufficiently
clean, you may try vacuuming more air and pressing the button
again. If this fails, then clean by flushing with more solvent and
vacuuming air, then repeat the clean check.
9 When the chamber is sufficiently clean, you will be directed to the
next test to clean, or to wait for Test 2 to complete.
Test 2, Wear and Contamination

Use this test to detect water and metal debris that settle out of the oil onto
the sensor at the bottom of the chamber. The patented, time-resolved
dielectric measurement is sensitive to water, iron, and other metal particles
in the oil. All oil samples are diluted approximately 1:1 with solvent (see
Table 1) before filling the Test 2 chamber with approximately 20 ml of
diluted oil. Dilution reduces the viscosity of industrial oils having a viscosity
range of 32 to 680 cSt down to a very low range of 10 to 20 cSt. This allows
the particles to settle during the test time. Dilution also makes cleaning easy
and cross-contamination unlikely.
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.

After completing any required, undiluted oil tests (for example, viscosity
and Test 1 chemistry tests), follow these Test 2 procedures:
1 Determine which dilution method will be used, either the volumetric
or weighing method as described later. If weighing, then enable the
scale and the software will guide you through the process. Otherwise,
disable the scale and enter the volumes into the software.
2 Dilute the sample approximately 1:1 in its original sample bottle,
using the appropriate solvent (see Solvent Selection information
above).
3 Replace the lid on the sample bottle and shake vigorously until the
Test 2 LED flashes green indicating the sample may be added.
4 Open the bottle and pour the diluted oil sample into the Test 2
chamber up to the top of the tapered cone this takes approximately
20 ml. The sensor will automatically detect the fluid, start the test by
itself, and stop flashing the LED.
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.

7 If you wish to prepare filter patches, make them at this time, following
the procedure outlined later in this chapter for making WDA filter
patches.
8 Clean Test 2. Pour lamp oil or other solvent into the chamber to flush
out the sample. Do this for 5 to 10 seconds, and then, without pouring
any additional solvent, just vacuum air through the chamber to dry it.
Use a cotton-tipped swab to gently wipe the surface of the grid to dry
off most of the solvent.
Caution!
Never touch the Test 2 sensor grid with a hard object! Doing so may
permanently damage the sensor.
9 Perform a clean check. Press the Test 2 button next to the flashing
yellow LED, and the software will take a reading. If not sufficiently
clean, you may try further drying and press the button again. If this
fails, then clean by flushing with more solvent and vacuuming air,
then repeat the clean check.
Manual Clean Check

Tests 1 and 2 include a manual clean check button (the C button on the
display next to the test icon) that may be used before starting a test to make
sure the sensor has been left clean. This will perform a short test and display
the dielectric value of the clean sensor. A dry sensor will have a dielectric
close to 1.00. However, a slightly wet sensor could read 1.20 or higher. The
software will display a message indicating the pass/fail status.
Test 3, Particle Counts

Use this test to count particles and determine particle size distributions in
eight different size ranges. This is a laser optical particle counter. Air bub-
bles and water droplets can cause false counts. Air bubbles are eliminated
in the vacuum degassing step. Water droplets are eliminated using water-
masking solvent (method protected by US Patent 6,064,480 issued to CSI;
see Table 2, Particle Counting Water Masking Options below).

All samples are diluted for this test from 1:1 to 1:99 (sample: solvent). Most
mineral oil samples are diluted 1:1, just like for Test 2, so there is no addi-
tional dilution after Test 2. However, second and even third dilutions are
performed for three reasons:
1) If the oil has a milky or cloudy visual appearance due to water con-
tamination then water-masking solvent is added to turn the solution
clear before particle counting,
2) If the oil has high particulate contamination then it may require high
dilution ratios to keep from exceeding the count rates for the laser
sensor. If you can see particles in the oil, then the sample will
require extra dilution; and
3) If the oil is extremely dark in color then additional dilution may be
required.
The OilView software accounts for dilution ratios and back-calculates to
report the particle counts for an undiluted sample. In order to do this, rep-
resentative particle counts for both the standard diluent and the water-
masking solvent (when used) must be saved ahead of time. See the Test 3
Diluent/Clean Fluid Calibration section later in this chapter for the proce-
dures for saving diluent counts.
The following table summarizes the water masking solvent options:
Table 10 - 2. Patented Particle Counting Water Masking Options
Solvents
DOWANOL DPnB Toluene Isopropyl Alcohol

Ratio (Diluted
Water Masking (*Fp 205F) Available (Fp 50F) Available (Fp 54F) Available
sample to masking Application
Solvent Mixture from chemical from chemical from chemical
fluid)**
supply supply supply
Mask 1 100% Add until clear Particle count with

water-in-oil
Mask 2 75% 25% 1:2 Particle count with
water-in-oil
Mask 3 25% 75% 1:2 Particle counting
diluent for water-
glycol hydraulics
*Fp = Flash point

**These solvent blends are added to the already diluted 1:1 sample from Test 2.

Warning!
Both Toluene and Isopropyl Alcohol have flash points
below room temperature. They require an explosion
proof vacuum pump.
5200 Back-Flushing Procedures

Current 5200 Analyzers have back-flush capabilities for Tests 1 and 3. This
is to aid in cleaning large debris that becomes lodged in either of these sen-
sors. The newer model can be identified by a third fitting on the right side
panel behind the Test 3 drain fitting. During normal operation, this extra
fitting must remain capped.
Test 1 Back-Flushing Procedure
1 Remove the stopper from Flask #1 and insert the end of the tubing
into a container of clean diluent.
2 Turn the vacuum control knob to the Test 1 position.
3 Insert a syringe tip into the bottom of the Test 1 chamber.
4 Pull the syringe plunger up to back-flush clean diluent.
5 Replace the stopper and drain tubing in Flask #1 when finished.
Test 3 Back-Flushing Procedure

1 Remove the cap from the Test 3 back-flush fitting.
2 Move the Test 3 drain line from the normal drain fitting to the back-
flush fitting.
3 Place the cap on the normal drain fitting.
4 Place the end of the Test 3 drain tubing into a container of clean
diluent.
5 Insert a syringe into the Test 3 sample port, and pull the plunger up
to back-flush clean diluent.

Dowanol Statement
Dowanol DPnB is a clear colorless solvent produced by the Dow Chem-
ical Company. It is soluble in hydrocarbon oils as well as water, which
explains how it works as a water mask solvent for lubrication oils. For the
purpose of water masking, handle the Dowanol as if it were kerosene.
However Dowanol has a higher flash point 212 F than kerosene 148 F
which makes it safer to use. This solvent is one of a series of glycol ether
solvents made by Dow Chemical, and was chosen because of its relatively
low toxicity as based on the MSDS. The user should follow all precautions
as stated on the MSDS as well as following all applicable regulations. Use
this URL for DOWANOL DPnB technical information:
http://www.dow.com/dowanol/nam/products/dpnb.htm
The sharp-eyed observer may have noted that there are two CAS numbers
for Dowanol DPnB. Inquiries to Dow Chemical gave the following
response, Actually, both registry numbers can be used to describe DOW-
ANOL DPnB. The registry number 35884-42-5 describes the mixture of all
4 structural isomers, whereas 29911-28-2 describes the secondary, sec-
ondary isomer, which is the major isomer in our product, though we dont
routinely measure and cannot control isomer content. The way to ensure
that you are getting DOWANOL material is to use the Aldrich product
code 48,423-7.
Follow these steps to obtain Test 3 particle counts on the sample:

1 Visually inspect the undiluted sample to decide if additional dilution
(beyond 1:1 needed for Test 2) is needed. If diluting for high
contamination or dark oils, then use the same solvent as for Test 2
(refer to the Oil and Solvent Solubility Table). If diluting because the
sample is cloudy or milky from water contamination then use the
water-masking solvent. You must make this decision before starting
the test. If necessary, select the Additional Dilution checkbox on
the display next to the last bottle icon. Double-click the last bottle
icon to toggle the selection between the standard diluent and masking
solution for additional dilution. The bottle icon will display half blue
when the water masking solvent has been selected.

2 When using the scale, the software will prompt you for re-weighing
after filling Test 2 if additional dilution has been selected. If not using
the scale, you must type in the relative volumes to give the correct
dilution ratios.
3 Shake the diluted oil sample to thoroughly mix the solvent and re-
suspend the particles.
4 Open a new syringe package and extract 30 ml of diluted sample
from the bottle.
5 Fully extend the syringe plunger to create an air gap, until the plunger
hits the built-in stop.
6 Insert the syringe spacer to hold the plunger out, and place the tip of
the syringe into the degassing port (located on the left side at the top
of the Test 3 column).
7 Turn the valve on the 5200 to the degas position pointing up.
8 Use the foot pedal to run the vacuum pump so that any air bubbles
in the oil can be removed from the syringe. This will take from 15
seconds up to a minute depending upon the viscosity of the dilution.
For thicker dilutions, you will be able to see a wave of bubbles rise to
the top.
9 Push the Test 3 button once next to the flashing yellow LED to tell the
software that degassing is complete. After a second, the LED will start
flashing green.
10 Remove the syringe from the vacuum port and remove the spacer.
With the tip of the syringe pointing up, slowly push in the plunger to
remove the air pocket and return the plunger to about 30 ml.
11 Insert the tip of the syringe into the Test 3 test port and clip the body
in place.
12 Press the Test 3 button next to the flashing green LED. The LED
should stop flashing, and the stepper motor arm will come down and
drive the syringe plunger at a constant rate. The first 10 ml pushed
through the syringe is flush volume, the next 15 ml are counted as the
fluid goes through the laser sensor, and approximately 5 ml are left in
the syringe at the end and can be discarded.

13 At the end of the test, the Test 3 LED will change from green to red
indicating that the data has been automatically saved to the database.
The motor will reverse and return the arm to the top, home position.
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.

Volumetric Dilution For Test 2 and Test 3
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.

Dilution By Weight For Test 2 and Test 3
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.

Making WDA Filter Patches
The wear debris filter patch maker is connected between the Test 2
chamber and the drain. Therefore, as the diluted oil sample is drained from
the Test 2 chamber, it passes through the filter patch maker. To create a filter
patch you must open the filter patch maker and insert a filter patch before
cleaning the chamber using the vacuum pump.
Refer to the illustrations below to see how the filter patches are assembled
into the patch maker. You may use either one or two filter patches at a time.
Select the pore size (0.8 to 30.0 micron) for the filter patch based on
the size distribution and total contamination results from Test 3. A
few tests will quickly reveal what pore sizes tend to plug and which
ones yield meaningful specimens. The goal is to produce WDA
patches with particles distributed so they can be easily viewed with a
microscope. This is also a good way to see if the high particle counts
from Test 3 were caused by water.
You can separate large particles from smaller particles using stacked
filter patches. For example, if the sample is highly contaminated you
may choose to use a 30 micron filter above a 10 micron filter. Keep
in mind that the small pore size filter is most often the one that is
plugged from excess contamination.
If you wish to view ferrous and non-ferrous particles on separate
patches, then use the sheathed magnet to extract ferrous particles
from the Test 2 chamber before ever flushing the diluted sample
through the filter patch(es). After removing the ferrous particles, you
can flush the remaining particles to create the non-ferrous patch(es).
Remove the non-ferrous patch(es) and insert new patch(es) for the
ferrous particles. Then remove the magnet from the sheath, and rinse
the ferrous particles off of the sheath into the empty Test 2 chamber
with solvent. Flushing this time will create the ferrous patches.

If you are unsure of the composition of the debris, you can send the
filter patch to the CSI Trivector Lab for Scanning Electron Micro-
scopic examination including Energy Dispersive X-ray elemental
analysis.
148

149

Reference Oil Tests
When testing new reference oils in the reference oil database for the 5200,
only the Test 1 dielectric is absolutely required in order to calculate the
Chemical Index. However, as an additional option for more accurate con-
tamination and estimated water results, two different Test 2 contamination
tests may be run on the reference oil. The first of these additional tests is
run just like the diluted, used oil test. The second Test 2 option involves
adding water to the reference oil to characterize its time-resolved dielectric
response to water. If this latter test is not run on the reference oil, then the
default water calculation will use the reference additive level information to
estimate the water content in used samples.
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

Reference Test 1 and 2, Standard
When the Ref DB tab is selected for the reference database, the 5200 Test
screen is slightly different than usual. First, Test 3 Particle Counts are dis-
abled since they are not required for a 5200 reference oil. Next, the user
will notice the Ref DB Water Test checkbox near the bottom of the
screen. Leave this box unchecked in order to run the standard Test 1 and 2
on the reference oil. Refer to the Test 1 and 2 procedures earlier in this
chapter to run these tests. Test 1 will measure and save the reference oils
absolute dielectric value. Test 2 will measure and save the sensor grids
response to the diluted reference oil, where the dielectric inherently varies
slightly over the length of the test. A small trivector symbol will be added
beside the sample bottle in the Ref DB tree to indicate the standard Test 2
data has been saved for the reference oil.
Reference Test 2 with Water

After running the standard Test 1 and 2 on the reference oil, the optional
water test may be run. Each oil has its own additive package, or lack
thereof, which affects how the oil keeps water in solution. The purpose of
the reference water test is to measure how the time-resolved dielectric
changes when there is a known amount of water in the oil. This measure-
ment is made by running Test 2. The software then calculates and saves a
water factor based upon the change in dielectric per 1% water. This water
factor for the reference oil is then applied to the Test 2, used-oil results to
calculate the percentage water.
First check the Ref DB Water Test checkbox and notice that another box
appears for entering water Drops/50 ml. Also, Test 1 and Test 3 are dis-
abled when running the reference water test. Note that the same sample
should be selected in the reference database where the standard Test 1 and
2 data have already been saved. Follow these steps to prepare the sample
and run the test:
1. Pour 50 ml of the clean, water-free reference oil into a new sample
bottle.
2. Using a pipette or syringe, carefully add a single drop of water to the
oil.
3. Enter the number of water drops per 50 ml of oil into the text box in
the software.

4. Connect the clean stirring paddle to the variable speed electric drill,
attach and position the drill in a lab stand, and insert the paddle into
the oil sample.
5. Stir on high (2000 rpm) for two minutes.
6. Immediately dilute the sample with an equal volume of the standard
diluent for this oil type, for example kerosene or lamp oil, and shake
well to mix.
7. Run Test 2 as described previously. No further dilution is required.
Also, since the dilution has been performed one-to-one by volume,
the scale should be disabled, and the default values of 10.0 and 20.0
should be used for undiluted and diluted weights. Continue shaking
the sample until right before it is added to the Test 2 chamber.
8. At the end of the test, the software will use the change in dielectric to
compute a water factor. If the change in dielectric is too low or too
high, then the software will prompt to increase or decrease the
amount of water and re-test. If this is the case, start with a new,
undiluted sample and follow the instructions for number of drops of
water and volume, then repeat Steps 3 through 8. Note that, if
requested to use one drop per 100 ml of oil, then enter 0.5 drops
per 50 ml in the software for Step 3.
9. If the software does not prompt to re-test the oil, then the data is okay.
A small water drop symbol will be added beside the sample bottle in the
Ref DB tree to indicate the Test 2 water data has been saved for the refer-
ence oil. Both the standard Test 2 and the Test 2 water plots will be available
on either the 5200 / Plots / Test 2 tab or under the Sample Info / 5200 plot
tab. An option button near the top left of these graphs is used to choose
which plots to view. The newly calculated water factor will be listed under
Sample Info / Data near the bottom of the Contamination column. Finally,
the equivalent water contamination index is shown under 5200 / Results by
checking the Ref DB Water Test box under the Test 2 results.

Results
This screen shows the details of the measurements from each of the three
tests.
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 2 Wear / Contamination

The Test 2 sensor measures dielectric properties of contaminants in the oil.
The Test 2 sensor uses gravity and an electromagnetic field to concentrate
and move particles on the surface of the sensor grid during the test. See the
Test 2 Plot example later to better illustrate the following indices.
Contamination Index This index is based upon the change in apparent
dielectric resulting from non-ferrous contaminants settling onto the sensor
grid over the test time. Water has the largest affect on the contamination
index, but other non-ferrous metals affect it as well. The contamination
index is calculated by scaling the total dielectric change during the test.
Non-Ferrous Index This index is the same as the Contamination Index.
Ferrous 1 Index This index is a measure of the delta dielectric resulting
from the ferrous particles standing up and lying down on the sensor grid.
An internal electromagnet changes states during the first part of Test 2 to
produce this effect.
Ferrous 2 Index During the second part of Test 2, a different electromag-
netic field sequence is used to sweep the settled iron outside of the sensing
area. The resulting change in dielectric is scaled to give the Ferrous 2 Index.
Large Ferrous As the particles settle onto the grid and the electromagnet
changes states, large ferrous particles or ferrous chains of particles will
sometimes cause abrupt spikes in the data plot. The Large Ferrous indicator
is a count of these spikes.
Large Non-Ferrous Spikes which occur while the ferrous particles are
standing up are treated as Large Non-Ferrous indicators.
Water Droplets As water droplets settle onto the sensing grid, they cause
abrupt changes in dielectric too. However, these changes last for at least a
few test cycles, and are thus distinguishable from other contaminant spikes.

Estimated % Water As mentioned before, water has the largest effect on
the contaminant index. Water will settle onto the sensor grid differently for
different oil types and additive levels. Water also affects the Test 1 Chemical
Index.
Test 3 Contamination
Test 3 uses a laser-based particle counter to simultaneously count and size
particles in eight different size ranges as the fluid is forced through the
sensor at a constant flow rate.
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 m, etc.) or the newer ISO 11171
sizes (i.e. 4, 6, 14 m(c), etc.). The size display mode is selectable under
Setup / System by checking or un-checking the Display ISO 11171 counts
box. A micron (m) is one millionth of a meter. There are 25.4 m per
thousandth of an inch (per mil). The m(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 m / >5 m / >15 m. For the newer 1999 standard, the
three ISO codes are for >4 m(c) / >6 m(c) / >14 m(c). The ISO codes
for >5 m and >15 m should be almost equivalent to the >6 m(c) and
>14 m(c) codes. The >4 m(c) ISO code could be one or more higher
than the >2 m 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

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.
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

ISO 4406 Cleanliness Code Levels
Particle Count Range (per ml)

Up to and
ISO Code More than
including
1 0.01 0.02
2 0.02 0.04
3 0.04 0.08
4 0.08 0.16
5 0.16 0.32
6 0.32 0.64
7 0.64 1.3
8 1.3 2.5
9 2.5 5.0
10 5.0 10
11 10 20
12 20 40
13 40 80
14 80 160
15 160 320
16 320 640
17 640 1300
18 1300 2500
19 2500 5000
20 5000 10000
21 10000 20000
22 20000 40000
23 40000 80000
24 80000 160000
25 160000 320000
26 320000 640000
27 640000 1300000
28 1300000 2500000
>28 2500000
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.
Number of particles per 100 ml

NAS
range
1638
Class
5 to 15 15 to 25 25 to 50 50 to 100 > 100
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

155
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 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.
Verification Versus Calibration

The 5200 Calibrate tab contains the screens for Calibration and Verifica-
tion of each of the three tests. There is also an Overall tab which contains
overall hardware information and a summary list of historical calibrations.
Verification is a very important feature and is used to ensure that the instru-
ment is within calibration limits. Verification is first used immediately after
a calibration to check the accuracy and repeatability of the calibration. Ver-
ification is also used on a periodic basis to make sure the calibration is still
valid. In general, verification is quicker than calibration, and it does not
change any stored calibration factors; it only verifies them.

The calibration and verification for each test are described in detail in the
following sections.
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.
Calibration Overview 10-43

Calibrate Overall Tab
The 5200 Calibrate, Overall tab shows current hardware information plus
historical calibrations for all tests. This tab also allows previous calibration
data to be restored for individual tests or for all tests.
Current Hardware Info

The software reads the 5200 hardware during initialization to get the cur-
rent hardware information which includes the following items. The test
operator is the only item which should be changed by the user.
Model Model number of unit; should be 5200.
Serial Number Should match serial number label on unit.
Rev Hardware revision level from label.
PC Sensor Particle counter sensor type.
Operator Use this field to enter the default test operators name or initials
for the calibration log.
Firmware Version Current hardware firmware versions.
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.

Read Final Cal This command button is used to restore all of the latest
calibration data for the highlighted serial number in the table. This function
may be used after viewing older data to restore the latest calibration data
for all tests.
Save Final Cal Clicking this button saves the current units latest calibra-
tion data for all tests into a serialized calibration database. This calibration
database is then sent with the unit if the unit is to be moved to a different
computer.
Calibrate Overall Tab 10-45

Test 1 Calibration & Verification
The dielectric sensor has been calibrated at CSI prior to shipping. How-
ever, you must regularly verify that the sensor is still in calibration and if
not, you must re-calibrate using the CSI supplied calibration fluids A, B,
and C.
156
Preparation for Calibration

Verify that the information in the calibration table matches what is given on
the calibration fluid bottles. If any values need to be changed, then click on
them in the calibration table and correct them. Double-check the dielectric
values.

Calibration should always start with a clean sensor and clean syringes and
bottles. Dedicate and label four, clean 10ml syringes, one for each of the
three calibration fluids and one for the cleaning solvent. Also prepare and
label four, clean 100ml sample bottles for the fluids. Pour approximately 75
ml of each calibration fluid and cleaning solvent into the appropriately
labeled bottles.
Caution!
Never use the wrong syringe with the wrong calibration fluid bottle.
Initial Clean Check

An initial test is required to record a clean sensor value. Perform the fol-
lowing steps:
1 Turn the valve on the instrument so the arrow points to the LED at
the right of the valve, Test 1 position.
2 Draw up 10ml of solvent into the solvent syringe, place the tip of the
syringe into the hole at the bottom of the Test 1 chamber, and squirt
the solvent into the sensor.
3 Remove the syringe and use the foot pedal to run the vacuum until
all of the fluid runs through the tubing to the waste container.
4 Press the C Clean Check button on the screen next to the Test 1
icon. After about five seconds, the dielectric (if available) and
frequency value will be displayed.
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.

Calibration
The response of the sensor to the three calibration fluids must be measured
to establish the calibration curve, which should be a straight line. Repeat
the following steps for each calibration fluid:
1 Clean the sensor by flushing with solvent and vacuum the solvent out
of the sensor. Then always perform the initial clean check using the
Clean Check button. If necessary, continue cleaning with solvent
and/or vacuuming to flush fluid out of the sensor. Keep in mind that
the cleaner and more consistent the cleanliness level between each
different fluid tested, then the more reliable your next test will be.
2 Prep the sensor by drawing up10ml of the calibration fluid, using its
dedicated syringe, from the sample bottle. Insert the syringe tip into
the hole at the bottom of the Test 1 chamber, and squirt the fluid into
the sensor. Remove the syringe and run the vacuum to flush this
initial sample out of the sensor. DO NOT chase this with solvent.
3 Highlight the Freq 1 cell in the calibration table for the fluid to be
tested.
4 Click the Start Calibration button. The software will prompt you to
squirt 10ml into the Test 1 sensor.
5 Draw up 10ml using the correct syringe and calibration fluid. With
the syringe tip pointing upward, push the plunger in enough to
express any air bubbles in the tip of the syringe.
6 Now place the tip of the syringe into the hole at the bottom of the Test
1 chamber and slowly squirt the oil into the sensor. Any air bubbles
introduced into the line will cause a false reduced dielectric reading.
Leave the syringe in the chamber until after the reading.
7 Press the Test 1 button beside the flashing LED on the instruments
Front Panel.
8 The test will finish in about 5 seconds and display the frequency.
9 Remove the syringe and vacuum the sample out of the sensor.
10 The software will highlight the Freq 2 cell for the second test using
the same calibration fluid. Repeat steps 4-9 above.
11 The software will highlight the Freq 3 cell for the third test using the
same calibration fluid. Repeat steps 4-9 above.

Note
As you cycle through the Freq 1-3 tests, the software will dis-
play the average of the test data frequencies in the Avg F box.
If the frequency for one of the tests is extremely out of line with
the other two, the software will ask if you want to re-test the fre-
quency. You can re-do this single calibration fluid test following
Steps 4-9.
12 If the software determines that the three tests of the same fluid are
consistent, then follow the software's prompt and clean the sensor by
proceeding with Step 13.
13 Using the solvent syringe, squirt 10ml of solvent into the Test 1
chamber.
14 Follow this with some additional solvent (~ 10-20ml), using the squirt
bottle while running the vacuum pump. Make sure you continue to
run the pump after all fluid has been pulled out of the sensor. This will
flush any remaining neat oil from the sensor and at the same time
help wash any oil from the walls of the sensor. It will also help dry the
walls of the sensor.
15 Push the button beside the flashing Test 1 LED. The software will
check whether the Test 1 sensor is clean. You may need to use more
solvent or you may just need to pull more air through the sensor for
drying purposes. Repeat this step until the sensor passes Clean test.
Note
If this is the first calibration fluid of a new calibration then the
dielectric calculation will not be available, only the clean fre-
quency will be displayed.
Repeat steps 2 to 15 for the remaining calibration fluids. The software will
average the results each time and then plot the average on the graph.

As each fluid is tested, the software will display the Fit % Error for each
fluid. The plot is a best-fit line through all points. Therefore the percent
error is a calculation of the deviation of each fluid point (Avg F) from the
best-fit line. If the software pops up a warning message that the error is out-
side the limits, then you will need to repeat one or more fluid calibrations.
Start with the fluid which has the most variation between its Freq 1 to 3
values.
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.

Verification
157
Verification is performed immediately after calibration to verify that the

calibration data is good and repeatable. Verification should also be per-
formed periodically, preferably using at least two calibration fluids to verify
the sensor is still calibrated.
Go to the 5200/Calibrate/Test 1/Verification screen. For each fluid to be
verified, perform the following steps:
1 If this is a periodic verification, check the fluid information and
dielectric on the calibration bottle against the table and make
corrections as needed.
2 Repeat Calibration Steps 1 to 9, with the only difference being that
you will highlight a fluid row in the Verification table, and click the
Start Verification button to start the test.

3 For verification, the software will compute the fluids Verification
Dielectric and % Error using the calibration curve. The software will
put up a warning message if the % Error is outside of acceptable
limits.
4 If the % Error of the verification fluid is outside of tolerance, first
cancel the test and vacuum the sample from the sensor without using
any solvent to flush. Add another syringe full of the verification fluid
to the sensor and repeat the test. If the verification still fails, then go
back and repeat the calibration procedure for this one fluid.
5 Clean the sensor as usual with solvent when prompted by the flashing
yellow LED (see Calibration Steps 13 through 15).
Once all necessary calibration fluids have been successfully verified, save
the data by selecting the Save Changes button.

Test 2 Calibration & Verification
The Test 2 sensor is also a dielectric sensor and has been calibrated at CSI
prior to shipping. However, you must regularly verify that the sensor is still
in calibration and if not you must re-calibrate using the CSI supplied cali-
bration fluids A, B and C.
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.

Preparation for Calibration
Verify that the information in the calibration table matches what is given on
the calibration fluid bottles. If any values need to be changed, then click on
them in the calibration table and correct them. Double-check the dielectric
values.
Initial Clean Check

An initial test is required to record a clean sensor value. Perform the fol-
lowing steps:
1 Turn the valve on the instrument counter-clockwise so the arrow
points to the filter port LED at the left, Test 2 position.
2 Use the squirt bottle to squirt clean solvent into the Test 2 chamber,
cleaning the walls and grid surface while using the foot pedal to run
the vacuum. Continue vacuuming air across the sensor for up to 30
seconds after the fluid has drained. Wipe gently with a cotton-tipped
swab to dry the surface of the sensor grid.
4 Press the C Clean Check button on the screen next to the Test 2
icon. After about ten seconds, the dielectric (if available) and
frequency value will be displayed.
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.

Calibration
The response of the sensor to the three calibration fluids must be measured
to establish the calibration curve, which should be a straight line. Repeat
the following steps for each calibration fluid:
1 Clean the sensor by flushing with solvent and vacuum the solvent out
of the sensor. Perform the initial clean check using the Clean Check
button. If necessary, continue cleaning with solvent and/or
vacuuming/drying to flush fluid off of the sensor. Keep in mind that
the cleaner and more consistent the cleanliness level between each
different fluid tested, then the more reliable your next test will be.
2 Use the flip top calibration fluid bottle and squirt about 5ml (about
half an inch deep on the sensor) of the fluid onto the sensor at the
bottom of the Test 2 chamber opening. Try not to get the fluid onto
the sides of the chamber as this will need to be cleaned when
changing to a different fluid.
3 Flush this initial preparation of the fluid out, but do not chase it with
the solvent. Use a clean cotton-tipped swab and gently wipe the
surface with what is left of the vacuumed calibration fluid.
4 Highlight the Freq 1 cell in the calibration table for the fluid to be
tested.
5 Click the Start Calibration button. The software will prompt you to
squirt 5ml of the calibration fluid into the Test 2 sensor.
6 Squirt an additional 5ml of the calibration fluid onto the grid.
7 Press the Test 2 button beside the flashing LED on the instruments
Front Panel.
8 The test will finish in about 10 seconds and display the frequency.
9 Vacuum the fluid sample out of the sensor, again do not chase it with
the solvent.
10 The software will highlight the Freq 2 cell for the second test using
the same calibration fluid. Repeat steps 4-9 above.
11 The software will highlight the Freq 3 cell for the third test using the
same calibration fluid. Repeat steps 4-9 above.

Note
As you cycle through the Freq 1-3 tests, the software will dis-
play the average of the test data frequencies in the Avg F box.
If the frequency for one of the tests is extremely out of line with
the other two, the software will ask if you want to re-test that
frequency. You can re-do this single calibration fluid test fol-
lowing Steps 4-9.
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.

As each fluid is tested, the software will display the Fit % Error for each
fluid. The plot is a best-fit line through all points. Therefore the percent
error is a calculation of the deviation of each fluid point (Avg F) from the
best-fit line. If the software pops up a warning message that the error is out-
side the limits, then you will need to repeat one or more fluid calibrations.
Start with the fluid which has the most variation between its Freq 1 to 3
values.
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.

Verification
159
Verification is performed immediately after calibration to verify that the

calibration data is good and repeatable. Verification should also be per-
formed periodically, preferably using at least two calibration fluids to verify
the sensor is still calibrated.
Go to the 5200/Calibrate/Test 2/Verification screen. For each fluid to be
verified, perform the following steps:
1 If this is a periodic verification, check the fluid information and
dielectric on the calibration bottle against the table and make
corrections as needed.
2 Repeat Calibration Steps 1 to 9, with the only difference being that
you will highlight a fluid row in the Verification table, and click the
Start Verification button to start the test.

3 For verification, the software will compute the fluids Verification
Dielectric and % Error using the calibration curve. The software will
put up a warning message if the % Error is outside of acceptable
limits.
4 If the % Error of the verification fluid is outside of tolerance, first
cancel the test and vacuum the sample from the sensor without using
any solvent to flush. Add another 5ml of the verification fluid to the
sensor and repeat the test. If the verification still fails, then go back
and repeat the calibration procedure for this one fluid.
5 Clean the sensor as usual with solvent when prompted by the flashing
yellow LED (see Calibration Steps 13 through 15).
Once all necessary calibration fluids have been successfully verified, save
the data by selecting the Save Changes button.

Test 3 Calibration
Test 3 Particle Counter Calibration Overview

The 5200 Particle Counter has been calibrated by CSI prior to shipping.
You can re-calibrate the particle counter yourself using calibration fluid
available from CSI. The recommended interval for calibration is at least
once per year, or more frequently if the Verification test indicates a need to
do so.
160

Particle Counter Calibration Standards
The factory default calibration is based upon the ISO 4402 calibration stan-
dard. The full ISO 11171 standard adds some tests which are to be per-
formed once per unit. These are the Coincidence Error Limits, Flow Rate
Limits, and Resolution tests. These are labor and fluid intensive tests which
CSI has deemed to be more to prove the design capabilities of the instru-
ment rather than to test individual unit functionality. Thus, these tests have
been run on representative 5200 units to come up with unit specifications.
These additional tests are not included as part of the factory standard cali-
bration, but can be ordered separately.
The 5200 Particle Counter calibration software supports both the older
ISO 4402 standard and the newer ISO 11171 standard for calibration of
automatic particle counters.
The actual sizing calibration and verification parts of the two standards are
very similar procedurally. The procedures differ by the fact that they use
different calibration fluids and measure different size ranges. The older ISO
4402 uses AC Fine Test Dust (ACFTD) as a calibration fluid whereas the
newer ISO 11171 uses NIST Medium Test Dust (MTD) and Ultrafine Test
Dust (UFTD). When ISO 11171 was created, the standards committee
decided that the original ISO 4402 ACFTD particle sizes were measured
incorrectly. Thus, the new ISO 11171 particle sizes are not the same as the
older ISO 4402 sizes. The table below shows the relationship between the
old and new particle sizes.

ACFTD size (ISO 4402:1991), m *NIST (ISO 11171) size, m(c)
0.8 4
1 4.2
2 4.6
4.3 6
5 6.4
10.25 10
15 13.6
15.5 14
23.4 20
25 21.2
40 31.7
50 38
52 - 55 40
70 - 75 48
100 54
*Note that the newer ISO 11171 particle sizes are always designated as
m(c).
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 m / >15 m.
Industry extended this standard to a three-part code of >2 m / >5 m /
>15 m.
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 m(c) /
>6 m(c) / >14 m(c).

Note that the new >6 m(c) and >14 m(c) ISO codes line up fairly closely
with the older >5 m and >15 m codes. Thus, target cleanliness level
(TCL) codes should stay about the same for these sizes. However, the older
>2 m code does not really match the newer >4 m(c) code. If a 2m TCL
has been assigned to a machine previously, then it will need to be adjusted
upward under the new coding system for higher expected contamination
levels at the smaller particle size.
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.
General Sample Preparation

These procedures apply to all calibration tests, and are listed here so they
do not have to be duplicated in the following sections.

Proper sample preparation is very important in order to get homogenous
samples and good, repeatable results. Particles must always be re-sus-
pended in the fluids before sampling. Always shake the large, calibration
standard fluid bottles for one minute before pouring them into the smaller,
sample bottles. Also, always vigorously shake the sample bottle before
drawing a sample with the syringe. A mechanical shaker may be used if
available.
Syringe Sampling and Degassing

After shaking the sample, follow these steps to draw the sample and run
each test:
1. Insert a clean syringe into the sample bottle and draw the fluid into
the syringe to the last marking or slightly over. Ignore any air bubbles
in the syringe at this point.
2. Remove the syringe from the sample bottle and completely extend
the plunger, pulling air into the syringe, until the plunger reaches the
built-in stop.
3. Insert the brass spacer around the syringe plunger in preparation for
degassing.
4. Insert the syringe tip into the luer fitting, degas port on the top of the
tower for a snug fit.
5. Turn the 5200 vacuum control valve to the degas position, and
operate the vacuum pump by depressing the foot pedal. A wave of
air bubbles will begin to rise in the syringe. Try to not pull too much
of the fluid into the luer fitting. Once you create a vacuum, you may
release the vacuum pump pedal and the vacuum will be maintained.
Therefore, air bubbles will continue to be pulled from the sample in
the syringe.
6. After the wave of air bubbles has moved to the top of the syringe
(usually no longer than 30 seconds), remove the syringe from the
degas fitting. The bubbles on the surface should mostly disappear as
the vacuum is released.

7. Remove the brass, plunger spacer from the syringe, then tilt the
syringe upward so the air pocket is directly under the tip. Slowly rock
the plunger and push it forward to expel the air pocket and most of
the remaining air bubbles. The plunger should return to almost the
original fluid volume. It will be a little less since some air volume was
removed.
8. Press the Test 3 button next to the flashing yellow LED once to let the
software know that degassing is complete.
9. Insert the tip of the syringe into the Test 3 sample input port and push
the syringe body back into the retainer clip. Any air bubbles which
were left near the syringe tip should rise to the top of the syringe and
will not be counted. Push the Test 3 button again, and the flashing
green LED should turn solid green, and the motor arm will begin
moving downward.
10. Wait for the motor to continue pushing the sample into the sensor.
About five ml of sample will be left in the syringe at the end and can
be discarded by manually squirting it on through the sensor.
11. The software will read the particle counts from the instrument and
then return the plunger arm to the top, home position.

Test 3 Preliminary Instrument Check
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:

1. Pour approximately 75 ml of super clean fluid into a clean sample
bottle.
2. Use a clean syringe to draw up 30 ml of fluid and manually squirt the
entire contents into the Test 3 sample input port. This serves to flush
the sensor.
3. Use a new, clean syringe and draw up another 30 ml of clean fluid.
Squirt all but the last 5 ml into the Test 3 sample port and do not
remove the syringe from the port.
4. Click the Start button next to the noise level table in the software.
The software will begin cycling through the eight size channels,
incrementing the channel voltage settings (Pot, mV in the table),
and taking noise count readings at each setting.
5. When all channels read zero noise counts, the software will take
several repeated readings to make sure there is no more noise. The
noise level is then recorded as the previous Max, mV voltage
setting which had noise counts. This voltage level is then used to
calculate the minimum channel setting for the volume calibration test
below.
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:
Test 3 Preliminary Instrument Check 10-67

1. Vigorously shake the standard fluid as described previously and pour
approximately 40 ml into a clean sample bottle.
2. Click the Verify button in the software to start the test. The software
will set the smallest channel size voltage to 1.5 times the noise level.
3. Shake the sample bottle and use a clean syringe to draw up 30 ml,
then degas the sample (see Syringe Sampling and Degassing).
4. Insert the syringe into the sample port and push the Test 3 button
twice to start the test.
5. Use the stopwatch and time from when the syringe plunger starts
moving at 30 ml until it stops at 5 ml. The time should be between
29.5 and 30.5 seconds.
At the end of the test, the subcounts for the sample will be displayed in the
table. The software will compute the average counts per ml and the coeffi-
cient of volume variation, COV%, for the subsamples counted in the
syringe. The average counts per ml should be at least 2000. The COV%
must be 3% or less for the test to pass.
The software will also prompt for the remaining volume in the syringe. If
the syringe dimensions were entered correctly, then the remaining volume
should be between 4.5 and 5.5 ml.
Click the Save button to save all results. The save operation will take sev-
eral seconds as the data is written back to the hardware.

Test 3 Sizing Calibration
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 sensors 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.

The sizing calibration is located in the software under the 5200 / Calibrate
/ Test 3 / Calibration screen. If performing a new calibration, first click the
New button to erase the previous calibration data. Next select the fluid type
from the drop-down list. Then enter the manufacturer, lot number, and
dust concentration in the boxes provided.
Follow these steps to perform the calibration:
1. Vigorously shake the calibration standard fluid bottle as described
previously and pour approximately 40 ml into each of three, clean
sample bottles.
2. Click on the table header for Sample 1 to select it as the sample to be
tested.
3. Click the Start button in the software to start the test.
4. Thoroughly shake the sample bottle, use a clean syringe to draw up
30 ml, then degas the sample (see Syringe Sampling and Degassing).
6. Wait for the test to complete and for the motor arm to return to the
home position. The software will update the sample counts, AvgCnt,
%Diff, and Rng% in the table, and compute new channel voltage
settings, PotCal, based upon the data. See the descriptions below for
these calculations.
7. The software will automatically select and highlight the next sample
to be tested. Alternatively, the user may re-select any sample to re-run
that samples test with a new sample.
8. Repeat Steps 3 to 6 above until all samples have been tested.
Each syringe sample is counted as three sub-samples. The detailed sub-
sample count data may be displayed by double-clicking on the sample
header in the table. The average of these three sub-sample counts is dis-
played in the table in the sample column and also in the AvgCnt column.

The Rng%, percent range, data for each particle size is calculated from the
three sub-samples as the difference between the minimum and maximum
sub-counts, divided by the average, and multiplied by 100%. The ISO
11171 standard specifies maximum range limits based upon the average
number of particles counted. There must be at least 100 counts per ml for
the range to be considered. The software uses these limits to display
warning messages.
The %Diff column of the table displays the percent difference between the
average count and the standard count for each particle size for the last
sample that was tested. This is an indication of how close the channel set-
tings are to the standard sizes, but is not a pass/fail criteria.
As each sample is tested, the software updates the Counts plot of average
counts versus channel setting. When finished, this plot should be a smooth
curve of all 24 data points. If the curve is jagged, then one or more samples
did not test consistently, and that sample should be re-tested. A Settings plot
is also available which shows channel settings versus particle size. Finally,
a sizing calibration data report is available for printing.
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.

Test 3 Verification
163
The Test 3 verification is performed as part of the factory standard calibra-

tion. The purpose of verification is to verify particle counting accuracy
using size channel voltage settings calculated from the calibration data
curve. Verification should be performed whenever the accuracy of the par-
ticle counter is in question or after repair or adjustments have been made
to instrument.
The unit is verified 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, the newer NIST Medium Test
Dust (MTD), or Ultrafine Test Dust (UFTD). ISO 11171 calls for the use of
1.00 mg/l ISO UFTD to verify the accuracy of counts of at least six chan-
nels up to 15 m(c). CSIs factory standard calibration uses ACFTD in
order to verify larger particle sizes which are not contained in the UFTD.

The verification test is run from the 5200 / Calibrate / Test 3 / Verification
screen. First click the New button to erase the previous verification data.
Next select the fluid type from the drop-down list. Then enter the manufac-
turer, lot number, and dust concentration in the boxes provided. The soft-
ware determines the standard particle sizes and counts, based upon the
fluid type and dust concentration, and displays them in the table. The soft-
ware also calculates the channel voltages for the particle sizes from the cal-
ibration data curve.
First prepare three identical samples of the verification fluid. Make sure the
calibration fluid bottle is well shaken before pouring 40 ml into each of
three clean sample bottles. Cap each bottle with a clean lid.
Follow these steps to perform the verification:
1. Click on the table header for Sample 1 to select it as the sample to be
tested.
%Err, CoV%, and Rng% in the table. See the descriptions below for
these calculations.
that samples test.
The following results are displayed in the verification data table:
StdCnt Standard particle counts per ml for each particle size for the cal-
ibration fluid concentration.
AvgCnt Average of all valid sample particle counts per ml for each par-
ticle size.
%Err Percent error of average count versus standard count. The software
checks to make sure the percent error is within limits.
Test 3 Verification 10-73

CoV% Coefficient of Variation percentage is the percent standard devia-
tion between the three samples. The software will display an error if the
variation is not within limits.
Sample n Each syringe sample is counted as three sub-samples. The
detailed sub-sample count data may be displayed by double-clicking on the
sample header in the table. The average counts per ml of these three sub-
sample counts is displayed in the table in the sample column.
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.
As each sample is tested, the software updates the table and plots average
counts versus particle size. The plot should be a smooth curve. A verifica-
tion data report is also available.
After the three samples have been successfully verified, click the Save
Changes button to save all results. The save operation will take several sec-
onds as the data is written back to the hardware.

Test 3 Diluent/Clean Fluid Calibration
164
After the Test 3 laser sensor has been calibrated and its calibration verified,
it is necessary to verify the sensors 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 users diluent test.
The user needs to regularly test and store counts for the diluent used to
dilute samples. This allows the software to subtract the diluent counts from
the diluted sample results and report the counts per milliliter of the original
undiluted sample. The 5200 / Calibrate / Test 3 / Diluent / Clean Fluid
screen allows a standard diluent and an optional water masking diluent to
be tested and stored for diluted sample calculations.

Note
Clean fluid tests are very sensitive to any contamination. Thus,
the procedures below must be followed as closely as possible
to get accurate, repeatable results.
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.

4. Thoroughly shake one of the 40 ml sample bottles, use a clean
syringe to draw up 30 ml, then degas the sample (see Syringe
Sampling and Degassing). Note that a thin solvent, such as kerosene,
will degas very quickly, and not many bubbles will be present.
and %Range in the table.
that samples test.
The %Range indicates how much the three samples vary with respect to
the average count. The software ignores this value for counts which are too
low to give good statistics.
counts versus particle size. A Diluent / Clean Fluid data report is also avail-
able.
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.

Test 3 Coincidence Error Limit Test
165
The Test 3 Coincidence Error Limit test establishes what concentration of

particles causes the sensor to start undercounting particles. The error is a
result of the physical dimensions of the sensing volume as well as the fluids
particle size distribution, including particles too small to be counted. If
there are too many particles in the sample, then some particles may overlap
each other in the sensing volume and be counted as a single bigger particle
instead of multiple smaller particles. CSI specifies a coincidence error limit
for the instrument based upon the design of the sensor. Thus, this test is not
part of the factory standard calibration procedure, but may be ordered as a
special calibration service. Alternatively, the user may use the software
along with the proper calibration fluids to run this test.
The procedure described here and implemented in the software is based
upon the ISO 11171 calibration standard. Multiple dilutions of ISO
Ultrafine Test Dust (UFTD) fluid are used to establish the error limit.

Sixteen dilutions of UFTD must be prepared for the series of tests. These
dilutions are 0%, 10%, 20%, 30%, , to 150% of the theoretical concentra-
tion limit of the sensor. The general equation for calculating the volume of
concentrate (V1 ml) to use for the dilutions is as follows:
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 m(c) in 1 mg/l of ISO UFTD
is 6,750. Using a default dust concentration of 2.5 mg/l gives 2.5 times
6,750, or 16,875 particles/ml as a theoretical concentration limit for the
sensor. This value should be in the right ballpark for the test. The dilution
volumes will come out even if a beginning concentrate is chosen which is
an even multiple of the theoretical concentration limit of the sensor. For
example, if 2.5 mg/l of UFTD is the theoretical concentration limit of the
sensor, then an initial 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

Add 76 ml of super clean dilution fluid to the 4 ml of concentrate for the
10% dilution. The 0% dilution is simply 80 ml of super clean fluid. The 20%,
30%, 40%, , 150% dilutions would use 8 ml, 12 ml, 16 ml, , 60 ml,
respectively, of concentrated 5.0 mg/l UFTD. Using these numbers
requires a total of 480 ml of UFTD plus 800 ml of super clean dilution fluid.
The test is run from the 5200 / Calibrate / Test 3 / Coincidence screen. First
click the New button to erase any previous coincidence test data. Next
select the fluid type from the drop-down list. This normally will be the
UFTD fluid. Then enter the manufacturer, lot number, and dust concentra-
tion in the boxes provided. The default UFTD concentration is 2.5 mg/l for
100% of the concentration limit of the sensor. Only one particle size
channel is used for the test. Its threshold voltage setting is automatically set
to 1.5 times the noise level of the instrument to count the smallest particles.
Follow these steps to perform the test:
1. Pour 40 ml of super clean dilution fluid into a clean sample bottle for
initial flush.
2. Use a clean 30 ml syringe and draw up the clean dilution fluid until
the plunger stops. Insert the syringe into the Test 3 sample input port
and manually squirt the contents into the sensor as quickly as possible
to flush.
3. Click on the table header for 0% to select it as the first sample to be
tested.
5. Thoroughly shake the selected sample bottle and use a clean syringe
to draw up a pre-test sample volume of about 35 ml. Manually squirt
this volume through the sensor.
6. Thoroughly shake the sample bottle again and use another clean
syringe to draw up 30 ml, then degas the sample (see Syringe
Sampling and Degassing).
home position. The software will update the sample counts, Avg/ml,
Rng%, Xt/ml, and Err% in the table. See the descriptions below for
these calculations.

9. The software will automatically select and highlight the next higher
concentrated dilution to be tested.
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.
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.
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.

Test 3 Flow Rate Limits
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.
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.

First prepare nine identical samples of 1.00 mg/l of ISO UFTD fluid. Make
sure the UFTD fluid bottle is well shaken before pouring 40 ml into each
of the nine clean sample bottles. Cap each bottle with a clean lid.
Run the test from the 5200 / Calibrate / Test 3 / Flow Rate screen. First click
the New button to erase the previous data. Next select the fluid type from
the drop-down list. Then enter the manufacturer, lot number, and dust con-
centration in the boxes provided. The software will automatically set the
channel size voltage to the smallest calibration particle size. As each sample
is tested, the software will also set the flow rate for that sample.
Follow these steps to run the test:
1. Use a clean syringe and draw out of the first sample bottle until the
plunger stops. Insert the syringe into the Test 3 sample input port and
manually squirt the contents into the sensor as quickly as possible as
an initial flush.
2. Click on the table header for the 10 ml/min flow rate to select it as the
first sample to be tested.
Rng%, and %Err in the table. See the descriptions below for these
calculations.
7. The software will automatically select and highlight the flow rate to
be tested. Alternatively, the user may re-select any flow rate to re-run
that samples test.
8. Repeat Steps 3 to 7 above until the samples have been tested at all
flow rates.
The following results are displayed in the data table:

Test 3 Flow Rate Limits 10-83

Avg/ml Average counts per ml of the three sub-samples.
Rng% Percent range of the sub-sample count data within a given sample.
sample.
%Err The percent error of the average counts versus the average counts
at the working flow rate of 50 ml/min.
counts versus flow rate. The plot should be a smooth curve. After all flow
rates have been tested, the software examines the data above and below the
working flow rate. The upper and lower flow rate limits are calculated to be
where the average counts differ by + or - 5% from the working flow rate
counts. These limits are plotted with vertical bars. The particle counter
should always be operated within these flow rate limits. A flow rate limits
data report is available.
After all flow rates have been successfully 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.

Test 3 Resolution
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.
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.

During the test, the software uses the calibration curve data to set the
channel voltage settings for five channels to center around the 10 micron
sphere size. The software also converts the cumulative counts from the
hardware into differential counts for each size range to the left and right of
the sphere size. Because latex spheres do not always respond the same as
test dust, the test must be repeated until the channel settings are centered
around the actual sphere size. The channel settings as computed by the soft-
ware and shown in the data table are as follows:
0.72 times the sphere voltage setting,
0.9 times the sphere diameter,
1.0 times the sphere diameter,
1.1 times the sphere diameter, and
1.32 times the sphere voltage setting.
Run the test from the 5200 / Calibrate / Test 3 / Resolution screen. First
click the New button to erase the previous data. The fluid type should be
10u spheres. Enter the manufacturer, lot number, certified sphere size, and
sphere size standard deviation, in microns, in the boxes provided. When
the test is started, the software will automatically set the channel size volt-
ages as described above. The voltage settings and equivalent sizes will be
displayed.
Follow these steps to run the first part of the test:

1. Shake and pour 40 ml of super clean dilution fluid into a clean sample
bottle. Use a clean syringe and draw up the fluid until the plunger
stops. Insert the syringe into the Test 3 sample input port and
manually squirt the contents into the sensor as quickly as possible as
an initial flush.

Rng%, StdDev, m, and Resolution % in the table. See the
descriptions below for these calculations.
6. The software will also internally calculate the percent difference
between left and right side counts to see if the channel settings are
centered around the sphere diameter. If the counts are not centered,
an error message will pop up along with a recommendation to re-
adjust the apparent sphere diameter. Use the data along with the plot
to see which diameter corresponds to the peak count. Enter this new
diameter and repeat Steps 2 to 6 if necessary. If less than 3%
differences cannot be obtained, then use the settings which give the
least difference and continue on.
7. After centering the settings for the sphere size, verify that the
calculated left and right percent resolutions are less than or equal to
10% in order to pass the resolution test. If this fails, check cleanliness
measures, sample preparation procedures, and the certified latex
itself.
The following results are displayed in the data table:

Avg/ml Average counts per ml of the three sub-samples.
Rng% Percent range of the sub-sample count data within a given sample.
sample.
StdDev Apparent standard deviation in microns of left and right side
counts.
Resolution % Left and right side resolution percentages, a measure of the
standard deviation as a percentage of the sphere diameter.
After testing the spheres with the final channel settings, click the Save
Changes button to save all results. The save operation will take several sec-
onds as the data is written back to the hardware.

Diagnostics
The 5200 Diagnostics tab is used mainly by CSI Customer Support to help
trouble-shoot hardware/software problems over the phone. However, the
default test settings are also stored under the Diagnostics tab. Some of these
settings may be changed by the customer. For example, one setting is used
to enable or disable the scale every time the software is entered.
By default, the Diagnostics tab is disabled and grayed out. It may be
enabled by going to the main Setup function and then choosing the System
minor tab. The Diagnostics enable checkbox is in the Test Modes frame.
From the 5200 / Diagnostics tab, select the Diag Settings tab, toward the
left center of the window, to get to the default settings.
170

Only the settings described below should be changed by the user:
Neat Oil Test 1, Neat Test Enable checkbox This is the default enable/
disable for Test 1 each time the software is started.
Wear Test 2, Wear Test Enable checkbox This is the default enable/
disable for Test 2 each time the software is started.
Wear Test 2, Manual Start Dielectric This is the neat oil, threshold
dielectric value, above which the software will prompt for Test 2 to be man-
ually primed and started.
Particle Counter Test 3, Particle Counter Test Enable checkbox - This
is the default enable/disable for Test 3 each time the software is started.
Particle Counter Test 3, Additional Diluent Type This is the default
setting for selecting either no additional Test 3 dilution, the standard
diluent, or the masking diluent.
Dilution/Scale, enable scale checkbox This is the default setting to
enable/disable the scale each time the software is started.
Dilution/Scale, Sample Volume, mL When the scale is disabled, this
is the default relative volume of undiluted oil.
Dilution/Scale, Sample+Diluent 1, mL When the scale is disabled, this
is the default relative volume for the Test 2 diluted sample.
Dilution/Scale, Sample+Dil 1 +Dil 2, mL When the scale is disabled,
this is the default relative volume for the Test 3 diluted sample.
Save After changing the settings, press the Save button to save the new
settings to the hardware. This will take several seconds.
Defaults Pressing this button restores the CSI factory default settings.
Read File This will read the settings from a configuration backup file.
Diagnostics 10-89
Chapter 11
Laboratory Information Management System (LIMS)
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 activitiestests, analyses, and reportsis 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
Begin by selecting the LIMS sub-Tab of the left-hand database tree.
11-2 Laboratory Information Management System (LIMS)

Assign Samples
The first step is to organize the samples to be tested into groups or batches
according to similar oils, test profiles, customers, or whatever is most appro-
priate for your particular situation. Typical batches range in size from 20 to
40 samples (the maximum batch size is 99), and there can be multiple
batches for a given day.
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
Assign Samples 11-3

The next step is to log the samples into the batch. This process involves
identifying the Point in your database using the right-hand database tree.
Once the relevant point has been highlighted, use the Add button to auto-
matically add a new sample into your database, and also to add it to the
batch list. Continue this process for all of the samples in the batch. You can
also Add an existing sample to the batch by selecting the sample in your
database tree and then pressing the Add button.
If you are using the barcode system and the sample bottle has the PDFHD
barcode then you can use this to automatically log samples into the batch.
First press the Barcode button and then use the barcode reader to read the
barcode.
You now have a batch list that is easily identified by year, month, day, and
batch number for easy reference. Each sample in the batch has a unique
Lab# that is used for automatically importing data from non-Minilab
instruments using the RS232 interface, which will be discussed later. This
lab number is also shown on reports and can be used to easily find a sample
in any batch.
175

Batches can also be deleted using the menu options. When a batch is
deleted, the samples and their data are not deleted from your database, they
are only removed from the batch list.
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.)
Assign Samples 11-5

Assign Samples tab
From the user database tree, you can use the Assign Samples tab to add
Customers, Area, Equipment and Points. This avoids the necessity of either
using Dbase or moving back to the user DB in OilView, both of which are
time consuming.
Database Level
177
Find CAEP (Ctrl F) Find a particular customer, area, equipment or

point.
Find Equipment Find a particular piece of equipment.
Find Sample ID (Ctrl S) Find a sample.
Add Area / Add Customer Add an area or customer to the database.
To have the Add Customer option, you must first enable the Display Cus-
tomer Level.
To do so, click on Setup button at the top of the OilView screen. The
main viewing window changes.
Next, click on the Systems secondary tab at the bottom of the screen.
Now, locate the LIMS category and click to place a check mark in
the box beside the Display Customer Level selection.
Finally, click on the LIMS button at the top of the screen to return to
the LIMS window.
If not enable, Add Area will be the option appearing in the dialog box.

Customer Level
For this option to be visible, the Display Customer Level must be
enabled. If not enabled, you will not see this dialog box. To have the Cus-
tomer Level option, you must first enable the Display Customer Level.
To do so, click on Setup button at the top of the OilView screen. The
main viewing window changes.
Next, click on the Systems secondary tab at the bottom of the screen.
Now, locate the LIMS category and click to place a check mark in
the box beside the Display Customer Level selection.
Finally, click on the LIMS button at the top of the screen to return to
the LIMS window.
178

point.
Find Sample ID Find a sample.
Add Area Add an area to the database.
Edit Customer Edit customer details.
Assign Samples 11-7

Area Level
The options available in this dialog box will be the same whether or not the
Display Customer Level option is enabled.
179

point.
Find Equipment Find a particular piece of equipment.
Find Sample ID Find a sample.
Add Equipment Add equipment level to the database.
Edit Area Edit area details.
Equipment Level
180

Add Point Add a point to the database.
Edit Equipment Edit equipment details.
Point Level
181
Add Sample Add a sample to the database.

Edit Point Edit point details.
Sample Level
182
Edit Sample Edit sample details.
Assign Samples 11-9

Batch Types
The LIMS database tree has two types of batches. The top-most batch
folder are for those samples that you have logged in. Below this batch is
another batch folder entitled Imported Batches.
This batch type is automatically created when you import sample data
using the Data I/O option. This is extremely useful in that it groups
together in batches all samples that are imported at any one time so that
you can easily find the individual samples without having to search through
the user databases. It also enables you to generate reports for all the sam-
ples at once as we will discuss in the next section.

Batch Information
This is the display that will be used most frequently. It shows the progress
of each sample as activities are completed. As each test is run, that instru-
ments checkbox is automatically marked.
To run CSI Minilab instruments, select the sample on the tree and then
click the instrument tab, such as 5200. This makes it very convenient for
CSI Minilab users to test a series of samples without having to find the
sample in their database tree. The Wear, Contamination, and Chemistry
status of each sample is automatically displayed for each samplemaking it
easy to identify problem samples.
183

The Diag column is filled in when a diagnostic message is entered. Then
the RVWD column checkbox is checked when the Reviewed button is
clicked on the Sample Info tab. You may also finish a sample by right
clicking on a sample in Trend Info and selecting Finish from the menu. This
is used to confirm that the sample diagnosis is complete. The REPT and
Exp checkboxes are automatically marked when the reports are printed
and the data has been exported.
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.

The RVWD, REPT, Exp, Imp, and Diag flags can be cleared using the
menu option shown below. These flags are used to control which samples
are reported on.
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.

Result Options
The Result Options tab serves two purposes: to establish the conditions
under which reports can be generated, and to override the normal
reporting process.
The General Options region is used to set the conditions for generating
reports based on the flags that are set as each sample is processed. For each
of the flags shown, you can specify Ignore, Checked, or Unchecked.
Reports will be generated only for those samples in the batch that match
these conditions. The actual reports that are generated depend on the cus-
tomer report profile for each sample. The filename defaults to the date
format that is chronologically listed in the computers directory. For data
export, this file is appended to it. For report export, this file is overwritten.
187

The section Report Override Options is used to generate ad hoc reports
that will ignore or override the specific setup for each customer assigned to
the sample. The options here are the same as those in the customer report
profile that will be described in the next section.
If Duplicate File Name

Each day data and reports are temporarily exported into each contacts sub-
directory where they are assembled. A temporary file with the days date is
created to store this information. The section If Duplicate File Name is
used to specify the action to be taken if a report or data for the contact is
generated more than once per day. By default new reports and data are
appended to the existing file. These files can also be manually renamed or
automatically renamed.

Contacts
This tab is used to create a contact address book and reporting profile for
each contact. The Add New, Delete, and Update buttons are used to
manage this list. The E-mail address can be used to automatically E-mail
reports to contacts. These emailed reports can be viewed and printed using
CSIs free report viewer program, which is available on the CSI web site
http://www.compsys.com, or with a PDF viewer.
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.

The Fax reports operate in the same manner. You must setup a fax printer
to enable automatic faxing of reports. (See E-mail/Fax tab in ten Setup tab.)
The check boxes are used to specify which form the reports are to be sent.
To automatically E-mail a report directly to a contact, check the E-mail
(Report Viewer) box. In a network environment, it may be more conve-
nient to place the reports in a directory that the contact can access. To use
this method, check the Directory box instead of the E-mail box. The
directory is specified in the Contact Sub-directory text box.
Each customer is required to have a unique sub-directory that is used as a
working directory by the software.
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.

Data Export
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.
Assign Contacts 11-19

The AEP export specifies the Area, Equipment, and Point IDs for each
sample in the export file. This is the most versatile method as it will auto-
matically create the area, equipment, and point levels in the target database
if they do not exist. The unit ID method requires that the Lab Unit ID in
the target database point setup be specified. Customer DB name and cus-
tomer area ID are not used with Unit ID method.
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.

Manual Entry
For those instruments in the lab that do not have RS232 serial communica-
tion capability or CSI communication drivers, you must enter their results
manually into the system. This tab has been provided to make this easy in
terms of the batch of samples. Each sample is identified by the unique Lab
# assigned to it when the sample was logged in. The actual parameters dis-
played for data entry are setup in the AP Set. This log sheet can be printed
out and filled in as test are performed.
191
Manual Entry 11-21

Serial Communications
The CSI Minilab instruments are automatically linked to the LIMS system.
Other instruments such as a spectrometer or FTIR instrument can be
linked directly into the LIMS system via a RS232 communication link.
Each of these instruments require a special driver that is connected to the
RS232 port in the Setup Module. Contact CSI for specific information on
your lab instruments.
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.

LIMS Management Reports
Contact Statistics and Lab Statistic reports are available from the drop
down menu and will process samples based on the tree location.
193
From the drop down menu, select either Contact Statistics or Lab Statistics.
194
Then click on the Report Preview icon button.

You will then be prompted to select the month and a start and end date to
include in the statistics.

Then the preview of Contact Statistics report appears.
Contact Statistics report

If you select Lab Statistics from the drop down menu, this report gives sta-
tistics on the severity of the samples and the turn-around times.
Lab Statistics report

Chapter 12
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
Adding a Sample and Running a Test 12-3

Reporting
OilviewLite has a single report that can either be sent directly to the printer
or previewed using the Print and Preview buttons on the toolbar. The
report is for the selected (highlighted) sample and shows the results for each
parameter along with the reference oil data and alarm limit values.
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
Alarm Sets 12-5

Reference Oils
Each reference oil requires such information as dielectric, and viscosity at
40C and 100C. This information is acquired by sending a clean, unused oil
sample to a laboratory for analysis. This information must then be entered
manually for each reference oil. To add a new reference oil, use the Add
Reference Oil menu option under the Setup Menu option. Reference oils
can be deleted from the Edit menu.
To connect a reference set to a sample, first select the sample with a mouse
click, select the required reference set, and then make a right-button mouse
click.The message box shown below will prompt you to either click OK if
this is correct or Cancel and select a different reference oil.
The selected reference oil for each sample is displayed at the top of the
screen.
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
Using the OilView Analyzer
Where To Use the OilView Analyzer

The OilView Analyzer detects degraded lubricating oil or abnormal wear
in lubricated machinery. However, many lubricating oil applications are
unique with respect to both oil properties and the machinery in which they
are used. The following paragraphs discuss appropriate OilView Analyzer
applications. (See also Testing Profiles for Minilab. on page 5-5.)
Engine Crankcase Oils

The OilView Analyzer can be used to test crankcase (motor) oils used in
reciprocating engines. It is an excellent tool for monitoring oil condition in
diesel, gas, and gasoline engines. It has a special value with respect to diesel
engines where soot makes any visual determination of oil quality or debris
content difficult.
The OilView Analyzer is sensitive to oxidationa common mode of oil
failure in modern engines. It is sensitive to soot loading in diesels, and will
also detect abnormal wear of ferrous parts. The OilView Analyzer is very
sensitive to the presence of either coolant or water in the oil. Oils taken
from engines fueled with liquid hydrocarbons (diesel or gasoline) should
also be screened for viscosity reduction resulting from fuel dilution. Vis-
cosity is measured with a viscometer such as the Model 51DV Digital Vis-
cometer.
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.
Bearing Lubricating Oils

Many industrial lubrication applications, such as fans, electric motors, and
compressors, have oil-lubricated bearings with relatively small oil capaci-
ties. Lubricating oil in many of these applications has a relatively long ser-
vice life and oil analysis is often not applied for reasons of cost. However,
OilView Analyzer testing permits inexpensive monitoring of these oils for
contaminants and bearing condition.
Typically, roller element bearings produce easily detectable ferrous debris
when failing. This debris is often detectable before any other symptoms of
abnormal wear can be seen. Sleeve bearing failure may also be detected if
a ferrous shaft is experiencing abnormal wear. Remember that the OilView
Analyzer will only detect gross abnormal wear of babbitt (nonferrous)
bearing surfaces. Detection of pending failure of babbitt bearings requires
supplemental laboratory testing, or testing with the OilView Particle
Counter - Model 51PC.
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.
Electrical Insulating Oils

A special test option can be selected (see Oil Compatibility Chart on page
5-7) to test transformer oils using the OilView Analyzer. This screening test
evaluates the oil quality and moisture contamination for electrical insu-
lating oils commonly used in transformers and oil filled circuit breakers
(OCBs). The OilView screening test does not replace the need for dissolved
gas analysis to detect partial discharge in high voltage transformers.
Fuel Testing
The OilView Analyzer can be used to test fuel oils such as #2 diesel for
watera 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.
Where To Use the OilView Analyzer A-3

Collecting Oil Samples
The key factor in any oil and machine condition monitoring program is
consistency in collecting samples. Any oil monitoring program will prob-
ably fail if careful attention is not paid to your sampling technique. There-
fore, you must always sample from the same location, in the same manner,
and under the same machine conditions.
The location from which the oil is sampled should always be from the same
plug, valve, or port. In general, oil should be sampled from a location
where the oil is well agitated or flowing. Samples should normally be taken
from the return line to the oil compartment upstream of any filter. If the oil
is sampled on the downstream (outlet side) of a filter, wear debris and par-
ticulate contaminants will have been removed by the filter. Keep in mind
that the oil compartment or sump will act as a sedimentation filter.
The manner of collection should always involve a gradual, uniform flow of
oil into a clean bottle. Care should always be taken not to take the dregs or
the initial spurt of oil when filling from a drain or pressurized line.
Oil should be sampled either just after a machine has been shutdown or (if
safe) while the machine is still running. The when of sampling is most crit-
ical in the cases of lubrication systems with relatively low operating viscos-
ities.
Because the OilView tests are relatively inexpensive and under your direct
control and interpretation, do not hesitate to tailor unconventional sam-
pling techniques to your specific needs. Just remember to apply common
sense in correlating your sampling technique and test results to your appli-
cation.
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.
Never handle very hot oil with a plastic bottle, as the

bottle may melt or deform. Use an intermediate, clean
metal container to cool the oil, if necessary. If a metal con-
tainer is used, remember to shake it vigorously before transfer-
ring the oil to a plastic bottle.
The OilView Analyzer and its accessories are designed to work

with room-temperature oils.
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.

Sampling Hints
For those new to this form of condition monitoring, a few hints about sam-
pling techniques:
Do not take the cap off the sample bottle until you are ready to
sample. As soon as the sample is taken, replace the cap. This will
help to keep dust, moisture, and dirt out of the sample. Do not fill the
bottle completely to the top. A partially full bottle allows the contents
to be more easily agitated by shaking prior to testing, and also allows
for easier dilution, if required. For consistent Fe indexes, it is impor-
tant to fill the sample bottle to the same level each time.
When using the OilView Particle Counter, fill the bottle completely
to the top (since approximately 40 ml of oil will be consumed for
each particle counter test), perform the particle counter test first and
then the OilView Analyzer test. Because the Model 51PC is typically
used on hydraulic or other ultra clean systems with low viscosity
oils, the small air space left in the sample bottle should still be enough
to adequately mix the sample when shaken.
When drawing oil through a drain plug or valve, do not collect oil
during the initial spurt or rush. It may contain metal from the plug
threads and it will certainly contain debris that has collected over
time around the plug or valve opening. Similarly, dont take the
dregs if the oil is being completely drained. However, if you are con-
cerned about water, sample from the initial rushjust remember that
the oil sample will not be representative of the bulk of the oil and the
data should not be used for trending purposes. A second sample
should be taken to determine the bulk oil condition.
When using a suction pump to draw oil up from a sump through a
fill pipe, dipstick tube, or other orifice, do not let the tube contact the
bottom of the sump or scrape dirt from the access orifice. Con-
versely, if you are concerned about free water as opposed to debris,
sample near the floor. Always change or clean your sampling tube
between samples. Also, remember to keep the sample bottle recep-
tacle on the suction pump clean.
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.

A-8
Appendix B
Understanding the OilView Analyzer Data
Applying the OilView Analyzer

For clean, fresh oils, all OilView Analyzer index values should be at or near
zero. Increasing values indicate increasing levels of degradation or contam-
ination. These values should be trended over time using a trend plot and
the Tabular History feature of the OilView software.
Look for increasing values over time. A sharp upward increase in an index
value is a strong indication of a new or worsening lubrication problem. Do
not be hesitant to use CSIs Fluid Analysis Laboratory Service if you are
having any problem in interpreting an OilView result.
The following table gives the known minimum contaminant levels that the
OilView Analyzer can detect. If these sensitivities are not adequate for your
application, you may find that CSIs OilView Particle Counter must also be
used.
B-1
OilView Analyzer Model 5100 Detection Limits
Property Indexes Lubricant Type Minimum Detectable Limit
Lube Degradation
Oxidation OL, LC Most Lubricants <<10% by FTIR (OL, Chl)
Soot OL, Chl Heavy duty diesel 0.4% by TGA
Lube System Contamination
Water OL, Hydraulic <0.005% (OL and Cont)

Cont, LC 0.06% (LC-Droplets)
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)
Glycol OL, Chl Heavy Duty Diesel <0.2%
Mechanical Wear
Iron Fe, Cont, All 1 ppm >5 (Fe)

LC <50 ppm >5 (Cont)
<1 ppm >40 (LC-Ferrous)
Copper Cont, LC All 50 ppm >5 (Cont)

<1 ppm >40 (LC-Nonfer)
Tin Cont, LC All 50 ppm >5 (Cont)
<1ppm >40 (LC-Nonfer)
Lead Cont All 50 ppm >5 (Cont; Instead of affecting the

contaminate index, it may cause a chemical
index response due to chemical oxidation of the
lead particles. The process of oxidation makes
them electrically nonconductive.)
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).

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.
Clean oil plot.
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.
Oil with ferrous wear debris.
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.
Fresh turbine oil containing 0.13% water.
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.
Oil contaminated with large, nonferrous conductive particles.

These spikes are caused by the large copper particles settling on the grid.
In an extreme case involving free water or large metal chips, you may see
a sudden upward jump of the plot with no return to a lower value. This will
be accompanied by the display of the word Critical on the results screen.
Shake the bottle and repeat the test. If the pattern is repeated, you have a
serious lubrication problem involving either severe wear or free water in
the oil. In this case, Fe and large Fe values cannot be reported. However, if
the plot reveals a divergence of the magnet-off line and the magnet-on lines,
ferrous debris is probably present.
Critical oil sample with free water droplets or

large metal chips that have electrically shorted the grid.
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.
Test Results B-7

OilLife Index
The OilLife Index reports on the overall condition of the lubricant, consid-
ering both lube degradation and system contamination.
When the OilLife index is near zero, the lubricant is in good shape. An
increase in the OilLife index indicates performance of the lubricant is get-
ting worse. Oil degradation, such as oxidation, affects both the OilLife and
Chemical index. Oil contamination, such as water in mineral oil, affects
both the OilLife and Contaminant indexes.
Because of the way in which the OilLife index is computed from OilView
Analyzer raw data, it has greater sensitivity than either the Chemical or
Contaminant indexes. This can be valuable when testing very clean oils
such as transformer, hydraulic, and new lubricants.
Note
The OilLife, Chemical and Contaminant Indexes are a direct
measure of the difference in dielectric permittivity between
new and used oils when the measurements are made at the end
of the respective tests. A 0.10 increase in ending dielectric
yields an index of 10.0.
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. SeeVerify 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.
Test Results B-9

Contaminant Index
This index is a measure of the level of oil-insoluble contaminants in the oil
as opposed to changes in the bulk oil chemistry. Some common contami-
nants include water, glycol coolants, metallic wear debris, and road dust.
This index may also increase if solid additives have been added to the oil.
This index should normally read near zero. Any positive increase in this
value over time indicates increasing levels of contaminants and a labora-
tory oil test is recommended. The graphics plot on the results screen will
slope more sharply up with increasing levels of contaminants. If the plot
shows that the magnet on and magnet off lines overlay but are rough
and jagged, it is an indication of relatively large semi-conductive bodies
such as water droplets. If the plot shows very sharp upward spikes, conduc-
tive metal particles may be present.
The following conditions will cause an increase in the contaminant index:
the presence of insoluble water in the oil. Very high values will be
seen if corrosive compounds (such as salts) are present in the water,
the presence of conductive metal particles in the oil. If the particles
are large and highly conductive, very sharp upward spikes will be
seen,
the presence of dirt, grit, or polar hydrocarbons in the oil.
This index will be influenced by a reference. If a reference has been made,
the contamination value will be given with reference to the reference oil. If
a reference is not used, an allowance for noise will be included in the anal-
ysis. Consequently, small, near-zero values may be seen when a reference
has been used that will not be present if the same test is made without a ref-
erence.
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 spectrometrythe 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.
Test Results B-11

Large Contaminant Indicator
There are four text outputs for the qualitative assessment reported as
Large Contaminant Indicator.
No Large Indications - indicates that the analyzer did not detect exces-
sively large metal particles or water droplets.
Large Ferrous - indicates that large iron particles, probably much larger
than 60 m were detected. The magnet north/south plots should show
upward spikes for tests reporting Large Ferrous or LF.
Large Non-Ferrous - indicates that large (usually much larger than 60 m)
non-ferrous particles, such as copper, aluminum, tin, lead, or chrome, were
detected. The magnet off plots should show upward spikes for tests
reporting Large Non-Ferrous or NF.
Droplets - indicates that water droplets or similar fluid droplets were
detected. All three plots (magnet off/north/south) should show spikes or
sharp changes in slope for tests reporting Droplets or D.
Note
Any Large Contaminant Indication other than No Large 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
The Original Frequency Units Data Plot
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.
Understanding the Frequency Units Data Plot

The OilView Data Plot displays 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 a percent change in electrical
properties of the oil measured by the OilView Analyzer that falls as con-
taminants enter the sensing grids oscillating electric and magnetic fields.
The X axis represents 500 test magnetic oscillations during the test.*
If a reference file is available for the current data, the top 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.
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.
Clean oil plot.
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.
Oil with ferrous wear debris.
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.
Fresh turbine oil containing 0.13% water.
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.
Oil contaminated with large, nonferrous conductive particles.
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
WAN Setup for OilView
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-2 WAN Setup for OilView

The basic mode of operation is therefore to use the RBMware Local Client
on each workstation to run the minilab instruments and capture the data.
Analysis features will be disabled in this case. The user then swaps to ter-
minal server or Citrix to run the other version of OilView which allows
analysis but disables access to the minilab instruments.
D-3
OilView Instrument Directory Setup
This directory appears under the Custdata directory and is used to store 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

dvcal_d.def
dvcal_demo.def
dvcal_dm.def
dvcal_h.def
olv51dv.cfg
olv51fw.cfg
olv51pc.cfg
olv5100.cfg
olvcfg.cfg
olvwda.cfg
WDACalLM.jpg
WDACalZM.jpg
\Custdata\Instrmnt\B\
anDemoR0.cfg
anDemoR1.cfg
anDemoT0.cfg
anDemoT1.cfg
dvcal_d.def
dvcal_demo.def
dvcal_dm.def
dvcal_h.def
olv51dv.cfg
olv51fw.cfg
olv51pc.cfg
olv5100.cfg
olvcfg.cfg

olvwda.cfg
WDACalLM.jpg
WDACalZM.jpg
After creating these directories and placing the correct calibration files in
each directory, the OilView file location setup must be changed. These
locations are stored in the local PC registry, as they are user independent
and specific to the PC, and therefore the user requires administrative
rights to change them.
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\

Setting up OilView File Locations for Workstation A using RBMware Local
Client A
Example
\\FPServer\RBMnet\RBMSuite\Custdata\Instrmnt\A\

Setting up OilView File Locations for Workstation B using RBMware Local
Client B
Example
\\FPServer\RBMnet\RBMSuite\Custdata\Instrmnt\A\

Setting up OilView for Terminal Server or Citrix
Check the Data Analysis Mode as shown below. This will disable access
to the minilab instruments. Wear Debris is enabled, but image capture is
disabled.

Setting up OilView Local Client
Check the Data Collection Mode and Disable RBMview connection as
shown below. You must restart OilView for the second option to take effect.
This will disable access to the analysis options in OilView but will enable
the minilab instruments and image capture.
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.

Appendix E
Extended NAS Table
The NAS 1638 standard ends at 12. CSI has extended this table to better
serve industrial applications.
NAS Number of particles per 100 ml. range

1638
Class 5 to 15 15 to 25 25 to 50 50 to 100 >100
13 2048000 364800 64800 11520 2048

14 4096000 729600 129600 23040 4096
15 8192000 1459200 259200 46080 8192
16 16384000 2918400 518400 92160 16384
17 32768000 5836800 1036800 184320 32768
18 65536000 11673600 2073600 368640 65536
E-1
E-2 Extended NAS Table
Index
Numerics Update Alarm Baseline 2-31

5200 Back-Flushing Procedures 10-21 Update Statistics 2-31
applications-OilView Analyzer A-1
A assign contacts 11-18
ASTM plot 6-13
abrasive wear 9-14
accessories, ports 1-29, 5-23
additives B-7, B-10 B
adhesive wear 9-15 batch information 11-11
Alarm Details 1-20 bearings A-2
Alarms babbit A-2
Alarm Analysis 2-52 roller element A-2
Alarm Limit (AL) sets 2-40 sleeve A-2
Baseline Adjusted Plot 2-47
CSI Default Alarm 2-40 C
Current Alarms 2-42 Calibrating the Digital Viscometer
Default Alarm Sets 2-41 Calibration Procedure 6-7
Histogram Plot 2-46 Existing Digital Viscometer Users 6-6
Raw Data 2-49 new user of the Digital Viscometer 6-6
Raw Data Plot 2-48 Plot ASTM 6-13
Scatter Plot 2-50 Verify 6-12
Standard Alarm 2-51 Calibration
Statistics 2-44 5200 Diagnostics 10-88
An Example testing Session calibration
Analyzer Model Test Differences 5-32 ferrous wear monitor 8-8 to 8-10
Typical Test Procedure 5-28 change marks 1-14
Analysis Parameter Sets chemical index B-9
Add User Alarm 2-31 CO2 cartridge 7-5
Current Views 2-34 color measurement
Edit AP Desc 2-32 particle counter 7-18
Profile Setup 2-36 combustion by-products 5-2
Report Group Setup 2-38 communication ports 5-23, 7-2
Set Default Alarm Type 2-31 contacts 11-16
Statistics 2-39 contaminant index B-10
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
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
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

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Reference Manual

OilView for RBMware

In-Shop Oil Analysis and Laboratory

CSI Part # 97381 Rev. 7

Chapter 2 OilView Database Options

Chapter 3 OilView Reporting

Chapter 5 OilView Analyzer Models 5100, 5100-1, and 5100-2

Chapter 6 Digital Viscometer Model 51DV and Model 52DV

Chapter 7 The OilView Particle Counter - Model 51PC

Chapter 8 The OilView Ferrous Wear Monitor - Model 51FW

Chapter 10 The Model 5200 Trivector Analyzer

Chapter 11 Laboratory Information Management System (LIMS)

Appendix A Using the OilView Analyzer

Appendix B Understanding the OilView Analyzer Data

Appendix C The Original Frequency Units Data Plot

Appendix D WAN Setup for OilView

How To Use This Manual

Electrostatic Discharge or Other Harsh Environments

On-Line Help System 1-5

Trivector Laboratory Data Import

OilView System 1-7

OilView Software Menu Structure 1-9

The File drop down menu includes the following functions:

Open Database Switches to another database.

The Help drop-down menu includes the following functions:

The toolbar icons are as follows (from left to right):

Open Database switches databases.

OilView Software Menu Structure 1-11

Clicking on the + symbol to the left of a Database branch allows you to

OilView Software Menu Structure 1-13

Click On the Database Icon

Add Customer Allows addition of a customer level. Areas can be

OilView Software Menu Structure 1-15

Click on the Customer Icon

Add Area Add a new area to the database.

OilView Software Menu Structure 1-17

The customer details are described in the Laboratory Information Man-

Click On the Area Icon

OilView Software Menu Structure 1-19

This screen shows the severity contribution from all technologies.

Alarm Display Options

You can set the following preferences:

Alarm Tree Filters

OilView Software Menu Structure 1-21

Click On the Equipment Icon

OilView Software Menu Structure 1-23

Click On the Measurement Point Icon

OilView Software Menu Structure 1-25

OilView Software Menu Structure 1-27

Drag and Drop Sample

Copy for Ref DB

Setup Menus 1-29

Setup Menus 1-31

Setup Menus 1-33

Clear Log File

Setup Menus 1-35

Severity is ranked from 0 = Normal to a value between 1 - 100 as shown

Setup Menus 1-37

Setup Menus 1-39

Setup Menus 1-41

Setup Menus 1-43

The Laboratory Information Management System (LIMS) requires an

Setup Menus 1-45

OilView Database Options