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How To Use This Manual . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-1
OilView Disclaimer. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-3
Electrostatic Discharge or Other Harsh Environments. . . . . . . . . . . . . . . . 1-3
On-Line Help System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-4
OilView System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
Trivector Laboratory Data Import . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
License Configurations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-5
OilView Software Menu Structure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-8
Drop down menus . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-9
Toolbar. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-10
Database Tree . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-11
Change Marks. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-13
Right Mouse Click Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-14
Setup Menus. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-28
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System . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-30
Translations . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-34
Severity Codes . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-35
File Locations. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-36
Licenses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-37
DB Level Names . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-38
Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-39
Lab Labels . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-40
Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-41
E-mail. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-42
Text Shortcuts. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1-43
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Reference Database . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-1
Assign Reference. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-2
Assign Reference Special Functions. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-3
Reference Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Adding a Reference Oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-13
Database Queries. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-15
Measurement Point Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
General Information. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-17
Schedule . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-21
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. . . . . . . . . . . . . . . . . . 2-33
Alarms . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-38
Current Alarms. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-40
&KDSWHU 2LO9LHZ5HSRUWLQJ
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
YL
&KDSWHU ,PSRUWLQJ'DWD)URPWKH/DERUDWRU\
Import Lab E-mail . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-1
Laboratory Imports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-3
Database Export . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-4
Statistics Export. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4-6
&KDSWHU 2LO9LHZ$QDO\]HU0RGHOVDQG
Software Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-3
Verify . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-14
Calibrate . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-16
Test Data Plot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-20
Calibration Settings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Test Time Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-21
Calibration Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-22
Diagnostics. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-23
OilView AnalyzerInitial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
System Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-24
Sensor Curing . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-27
An Example Testing Session . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-28
Analyzer Model Test Differences . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-32
Dilution Of Viscous Samples (OilView Analyzer) . . . . . . . . . . . . . . . . . . . . . 5-34
Synthetic Oils. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-35
OilView Analyzer Usage Tips. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5-36
&KDSWHU 'LJLWDO9LVFRPHWHU0RGHO'9DQG0RGHO'9
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
YLL
Plot ASTM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Using the Digital Viscometer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-14
Viscosity. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-16
&KDSWHU 7KH2LO9LHZ3DUWLFOH&RXQWHU0RGHO3&
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-20
Diluent Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Settings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-21
Sample Preparation . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-22
Dilution of Model 51PC Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-25
Dilution Ratios . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-27
Sensor Cleaning . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7-33
Supplemental OilView Particle Counter Procedures . . . . . . . . . . . . . . . . . . . 7-36
&KDSWHU 7KH2LO9LHZ)HUURXV:HDU0RQLWRU0RGHO):
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-1
Standard Equipment . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-2
Software Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-3
Cables And Connections . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-5
Calibrating the Ferrous Wear Monitor . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Empty/Clean Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Standard Calibration. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
Taking Calibration Readings. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .
8-8
8-8
8-9
8-9
Testing Samples With the Ferrous Wear Monitor . . . . . . . . . . . . . . . . . . . . . . 8-11

Screening. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
Diagnostics and Raw Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8-12
YLLL
&KDSWHU :HDU'HEULV$QDO\VLV
Sample . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-5
Sample/Atlas. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-9
Atlas Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-11
Analyst tab . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-12
The OilView Analyzers And Wear. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9-14
Using the Model 51WD Wear Debris Patch Maker . . . . . . . . . . . . . . . . . . 9-18
Using the Model 51SM Shop Microscope . . . . . . . . . . . . . . . . . . . . . . . . . . 9-22
&KDSWHU 7KH0RGHO7ULYHFWRU$QDO\]HU
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-1
Instrument Overview . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-2
Initial Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-3
Test Procedure . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-12
Volumetric Dilution For Test 2 and Test 3. . . . . . . . . . . . . . . . . . . . . . . . .10-24
Dilution By Weight For Test 2 and Test 3. . . . . . . . . . . . . . . . . . . . . . . . . .10-25
Making WDA Filter Patches. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-26
Reference Oil Tests . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-28
Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-32
Plots . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-35
Test 2 Plot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-35
Test 3 ISO Plot. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-37
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
Test 2 Calibration & Verification . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-53
Preparation for Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-54
Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-55
Verification. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-58
Test 3 Calibration . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .10-60
Test 3 Particle Counter Calibration Overview . . . . . . . . . . . . . . . . . . . . . .10-60
L[
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 . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-83
Test 3 Resolution . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-86
Diagnostics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-90
&KDSWHU /DERUDWRU\,QIRUPDWLRQ0DQDJHPHQW6\VWHP/,06

Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-1
Assign Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-3
Assign Samples tab. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-5
Batch Types. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-9
Batch Information . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-10
Result Options . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-13
Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-15
Assign Contacts . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-17
Data Export. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-18
Manual Entry . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-20
Serial Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-21
LIMS Management Reports . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11-22
&KDSWHU 2LOYLHZ/LWH
Introduction . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-1
Setup. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Databases. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-2
Adding a Sample and Running a Test. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-3
Reporting . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-4
Alarm Sets . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-5
Reference Oils . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-6
Data . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 12-7
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Where To Use the OilView Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-2
Collecting Oil Samples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-5
Sampling Hints . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .A-7
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Applying the OilView Analyzer . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-2
Plot Examples . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-5
Test Results . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-9
OilLife Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-10
Chemical Index. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-11
Contaminant Index . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-12
Ferromagnetic Index (Fe) . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-13
Large Contaminant Indicator . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-14
Dielectric Number . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .B-14
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Understanding the Frequency Units Data Plot . . . . . . . . . . . . . . . . . . . . . . .C-1
Original Frequency Units Data Plot Examples . . . . . . . . . . . . . . . . . . . . . . .C-2
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Communications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-1
OilView Instrument Directory Setup . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .D-4
Setting up OilView File Locations for Terminal Server or Citrix AMS Machinery
Manager ClientsD-6
Setting up OilView File Locations for Workstation A using AMS Machinery Manager
Local Client AD-7
Setting up OilView File Locations for Workstation B using AMS Machinery Manager
Local Client BD-8
Setting up OilView for Terminal Server or Citrix . . . . . . . . . . . . . . . . . . . . .D-9
Setting up OilView Local Client . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
Summary . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . D-10
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This manual describes the operation of OilView instrumentation and software 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 OilView 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 applicable to the other instruments as well.
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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.

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These conventions are used throughout this manual to call attention to the adjacent text:
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The Note paragraph indicates special comments or instructions.
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The Caution paragraph alerts you to actions that could have an effect on the
equipment or the collected data.
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The Warning paragraph warns you of actions that could cause serious
injury or death.

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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 comprehensive 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.
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In unusually harsh operating environments, operation of this product may require
reset and/or restart of the function in progress. This user recoverable 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.

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OilView and the AMS Machinery Manager software uses an HTML Help program
to provide you with context sensitive Help as you navigate through the programs.
Pressing F1 on the keyboard launches a special CSI version of Microsoft Explorer.
Explorer displays the same information as is found in the AMS Suite: Machinery
Health Manager program 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 information.

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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
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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 configuration 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 AMS Machinery Manager installations and does not require a license.
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The Minilab Instruments and Data Edit/Entry configuration is used to operate any
of the CSI OilView products including any or all of the following:
5200 Trivector Analyzer
OilView Analyzer (Models 5100, 5100-1, and 5100-2)
Digital Viscometer (Models 51DV or 52DV)
Particle Counter (Model 51PC)
Ferrous Wear Monitor (Model 51FW)
These instruments are designed for use in industrial maintenance departments.
They are all portable, bench-top operated devices operated off of 110 to 230 V A/
C power.
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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 AMS Machinery Manager, 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

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The following table shows which tabs are activated by the three license categories.
The Trivector Lab Import does not require a license.
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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.

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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.
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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.

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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

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The OilView database is a part of the hierarchical database system used in all modules of the AMS Machinery Manager system as shown in the following illustration.

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.

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Although other types of data may be visible on the database tree, OilView will only display oil points.
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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.

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The right mouse button can be used to perform the following functions from
within the database tree:
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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, measurement
point, and oil sample under all Areas.
Schedule Schedule sampling for every point in the database. See scheduling,
chapter 2.
Clear Marks - clears all of the change marks for each piece of equipment, measurement point, and oil sample under all Areas.
Print/Preview
Point Labels Create sample bottle labels for the entire database.
Sample Summary Sample summary report for entire database.

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Parameter Exception A report similar to the parameter exception report created

using the softwares 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.
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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.
re-calculate

chapter 2.
Print/Preview
using the AMS Machinery Manager reporting module. This report has been customized for oil data giving more detailed information.
year.
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The customer details are described in the Laboratory Information Management

System (LIMS) on page 11-1.

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Add Equipment - allows you to add a new piece of equipment to the current area.
Edit Area - allows you to change the ID and/or the name of the clicked on area.
Delete Area - allows you to delete an area provided there is only oil points under
the area. If there are any other technology points under the area then the only way
to delete the area is using the database utility program.
re-calculate
Alarm Details This options shows the severity of all technologies as show below.
Set Report Language This options sets the languages for reporting for all points.
Clear Marks - clears all of the change marks for each piece of equipment, measurement point, and oil sample under the selected Area.
re-calculate
chapter 2.

Print/Preview
using the AMS Machinery Manager reporting module. This report has been customized for oil data giving more detailed information.
year.

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This screen shows the severity contribution from all technologies.

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You can set the following preferences:

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 AMS Machinery Manager programs. The
default is 0, which means that automatic repaint is disabled.
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The icons on the database tree are only available if you have purchased RBMview Full.
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This box displays the different technologies. Those technologies with check marks
in the boxes beside them will be the ones with active Alarm Tree Filters. You can
turn on the 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.
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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.

Delete Equipment - allows you to delete a piece of equipment provided there are
only oil points under the equipment. If there are any other technology points
under the equipment then the only way to delete the equipment 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.
chapter 2.
Print/Preview
Sample Labels Print Sample labels.
year.

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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.
re-calculate
Clear Marks - clears all of the change marks for every oil sample under the selected
piece measurement point.

chapter 2.
Print/Preview
year.

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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.

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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
year.
Sample Labels create a sample label.
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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.

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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.
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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.

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The Setup menus includes functions to specify operating characteristics of the OilView hardware and software.
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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.

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.

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You will observe that there are several other general purpose laboratory instruments in the list. These instruments can be connected to the LIMS system for automatic data import. You are limited first off to the number of comm ports available
on your computer (up to a maximum of 8) and secondly to the number of LIMS
instrument link licenses you have purchased.

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.
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Comm 1 is the serial port number 1 (or letter A) on the computer;

Comm 2 is the serial port number 2 (or letter B) on the computer.
The Port numbers refer to the ports on the Model 5100-1 or Model
5100-2. See System Setup on page 5-24 for OilView Analyzer port
assignments.
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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.
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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 OilView software. They are tools that you may need to use when communicating with CSIs customer support

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These options are for use only when working with CSIs Customer Support and you
are resolving a problem.
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Diagnostics Enable Minilab instrument diagnostics. These features are used for
diagnosing problems in conjunction with CSI customer support.

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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.
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This function is used to change the security level in the OilView software located on
the current computer.
Read Only - When this box is checked, the software is in the Read Only user
mode. The user is allowed to download data into the OilView database, and the
ability to view and print plots and reports. However, changing information and/or
data in the OilView database is not permitted.
Advanced User - This option places the software in the Advanced user mode and
allows the administrator of the OilView software to set up or edit areas and equipment, measurement points, and other technical information. When this option is
selected, the grayed out primary tabs that are not available to the read only user
are now accessible.
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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.
6HWXS0HQXV

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, Contamination and Chemistry) alarm severities.
Disable RBMview connection (restart after change) On slow networks 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).
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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 troubleshooting session.

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This function clears the existing log file and begins writing new data.
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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 compatible 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.
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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.
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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.

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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.

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When renaming the severity codes with this option, the actual levels
are not changed, only the name associated with the particular severity
code.
Severity is ranked from 0 = Normal to a value between 1 - 100 as shown above.
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This window shows the hard drive location of the calibration files for the instruments that make up the OilView MiniLab system. The displayed default locations
are set up during the original software installation. However, this window can be
used to change the file locations if desired.

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.
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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.

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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.
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This file location is used to store setup configuration information such as which
RS232 ports are being used by the various instruments. It is important to set this
location to your local drive in a multi-user network installation as this information
is specific to a particular PC.
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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.

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The Database Level Names options enable you to globally substitute other descriptive names used in the hierarchical database structure and the reference oil database.
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CSI recommends that you do not use a keyword to replace another keyword. For
example, Equipment should not be substituted for Area.

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.

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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 bottles.

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Select the required fields to be printed on the sample label.

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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.
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Select a default label size.
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The lab labels identify the sample and are used during the testing phase in the laboratory.

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The test matrix lists the tests to be performed based on the Point Setup.
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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.
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Select a default label size.

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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.

Report Colors - This sliding color level is used to tone down the colors on trend
plots or on printed reports.
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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 standard 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.

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The LIMS enables the automatic faxing of reports. this is enabled by setting up a
fax printer.
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When typing an observation or action message, you can use shortcuts that automatically enter phrases into your message. This is done by first setting up the shortcuts.
You do this by selecting the Text Shortcuts secondary tab at the bottom of the
screen. Next, click on the first box under the Shortcut column and type in your
shortcut letter, number, symbol or combination of letter, number, and symbol. The
shortcut can be from one to six characters long.
Now, when typing in an observation or action, type the / key, then the shortcut
character or characters, and then press the Enter key. The observation or action
text associated with that shortcut appears in the observation or action dialog area.
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Many of the minilab measurements result from comparing new or reference oil
tests with similar tests on used oil samples. The OilView Analyzer, Digital Viscometer, and Particle Counter all use Reference Oil test data. The OilView 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 reference 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. Therefore, there is no assurance that a reference sample
taken after the fact from a new oil drum can be applied to a test oil that originated
from a previous drumeven though the oil is of the same type and from the same
supplier.

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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 Measurement Point or Sample highlighted
on the User Database tree in the display on the left.

To change the assigned reference oil sample, first find the sample or measurement
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 reference 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 reference
sample and either a user measurement point or sample are both highlighted 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.
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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.
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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.

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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.
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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.
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Another feature available by right-mouse clicking at the top level of the reference
DB tree on the Assign Ref tab is to expand and collapse the entire tree.
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The last feature available by right-mouse clicking at the top level of the reference
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.
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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.

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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.

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The Oil Type tab is only available when viewing the oil designator (e.g., measurement point) level of the Reference Oil Database (Advanced user mode). Check off
the one base stock field that describes the reference oil. If synthetic is selected as
the base stock, then select the type of synthetic oil base stock from the lower list.
This lower list is grayed out unless synthetic is checked in the upper list.

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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.

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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.

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The upper selection of this section is only available when viewing the oil designator
(e.g., measurement point) level of the Reference Oil Database (Advanced user
mode). It is used to identify the relative additive concentration for mineral oil base
oils tested using the Model 5100, 5100-1, 5100-2, or 5200. This information is used
by the OilView software in calculation of estimated water contamination.
The lower section is only available when viewing the reference oil sample level at
the Reference Oil Database and is used to identify the default settings used when
testing samples on the Model 51PC. Typical default settings are 50 ml/min flow
rate, 25 ml flush volume, and 5 ml test volume.

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This plot shows the reference value relative to all samples that use this reference.
This is used for verifying that the reference value is appropriate for the samples that
it is being applied to. This feature can also be used to set a reference value by either
dragging the 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 automatically net all reference parameters using the Set/Save
All button. This feature can also be used for establishing reference values when no
reference oils is available.

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This displays the data used to create the histogram plot and is used to identify these
data points that appear to be incorrectly assigned.

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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.

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Any data also may be entered manually by typing it into the Sample
Info/Data Spreadsheet. For example, Digital Viscometer reference
data such as the viscosities at 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 appropriate oil description and paste.

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This option requires a license to the LIMS module.

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.

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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.
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This menu option generates a list of samples that are due based on the current date
and Look Ahead date. The Start button will generate the list.
The list of points due for sampling can be manually edited. Sample bottle labels
and a report listing all the samples can also be printed.

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The Point Info tab (measurement point information) includes the minimum
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.

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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 numbering points so that the ID designator will be meaningful.
For example you may use DR1 for an oil sample taken from the drain port or
OP3 for the third oil sample in line taken from the oil line leading away from the
oil lubricated machinery or OC1 for an oil sample taken from the oil compartment (e.g., oil sump).

Description - This field of up to 28 alphanumeric characters describes the current

point and should be as descriptive and unique as possible.
Lab Unit ID - This field can be used to enter an alphanumeric identification 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 Recommended Cleanliness
Levels on page 7-19 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 parameters 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 currently 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 profiles, 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 equipment 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.

Alarm Limit Set - Click on this field to assign an alarm limit set to the current measurement point (from the pop-up window containing a list of predefined sets).
The Alarm Limit (AL) Set is the list of alarms for the measurement point. If you
have selected the CSI Default Analysis Parameter set, the Alarm Limit set will automatically be generated when you select an Equipment Type. See Alarms on page
2-38 for more information.

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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.

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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.
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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.

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The Trend Info and Sample Info display filter can be used to prevent particular
analysis parameters from being displayed. The analysis parameters with a checked
box will display in the report. Unchecked analysis parameters will not be displayed.

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 display back on.

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You can use these fields to document reference information that may be useful in
detailed oil analysis and root cause diagnosis.

Oil Pressure - Indicate the system oil pressure as:

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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.
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Category - Select either filtered or not filtered category.

Actual - If known, enter the actual filter specification in terms of micron size and
beta ratio.
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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.
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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.

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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.

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Type - Indicate how corrosive the external environment is.

Lube System - Specify whether the system is opened or closed.
External Temperature - Indicate the ambient temperature:
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Humidity - Indicate the ambient, relative humidity:

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Particulate - Indicate if the area contains abrasives that may be problematic.
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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.

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Gears - Enter the composition of any gears.

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

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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.

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The analysis parameter (AP) sets that are available for the database are represented
as icons at the bottom of the database tree. To expand and view the sets, click the
plus box beside the folder AP Sets and AL Sets.

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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.

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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.
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This option automatically sets the Ref and Point alarm type for each reference
parameter in all the AL Sets.
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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.
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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 baseline.
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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.

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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.

Use this option to edit the AP Set Description and to add/edit the AP Set ID code.
This ID is used to export AP Sets and then import them to the correct location
within a database. This is the same principal as the Area, Equipment, and Point ID.
The other options are explained under Alarms on page 2-38.
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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 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.
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.

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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.
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Current Views
The analysis parameter set current views include a table with eight columns. The
first column is the list of all the Analysis Parameters in the set. CSI strongly recommends that you use the CSI default Analysis Parameter set if at all possible to help
you manage the defined Alarm Limit (AL) sets for different equipment types.


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.
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Profile Setup is a list of all the parameters in the analysis parameter set. Editing of
this list will permanently change the analysis parameter set and is not recommended except when absolutely necessary. The Update Changes button must be
clicked in order to actually save the new parameters.

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.

Update Changes This writes any changes made to an AP Set back into the database.
Highlight Used Parameters The Drag and Drop feature enables the merging of
AP Sets. This may result in more than 96 parameters in which case it is presented.
This feature enables you to see which parameters in an AP Set actually have data.
Those parameters that do not have data can be removed (deleted) from the AP Set
making room for additional parameters that can be merged from another AP Set.
A Few Words about Drag and Drop. Drag and drop enables more than the
merging of two AP Sets. In addition, the AL Sets from the AP Set being dragged
and dropped are also added to the AL Sets of the target AP Sets. Also, an AL Set
may also be dragged and dropped or copied from one AP Set to another. In the
process all data is automatically updated. This can be a slow process and there is a
progress bar showing status of the merge operation.
The user can also drag one parameter on top of another thereby superseding one
with the other. This is essential to replace the Special Test parameters with actual
parameters or if a parameter has been incorrectly used.

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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.

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This shows the coverage weeks between an alert severity happening (i.e., severity of
1) where 0 implies normal. This can be referred to as Mean Time Between Alerts
(MTBA). Best results depend on alarm limits being correct and uniformly applied
to the statistics. The Recalculate option is useful in achieving this. Once this has
been done, it is also necessary to Update Statistics.
The MTB can be used to establish sampling intervals, which should be more 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.

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

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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.
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Edit AP Set description and AP Set ID code.

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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.
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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.

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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.

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The used AL Sets are highlighted. This is useful for reviewing only those AL Sets
that are used.
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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.
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This table shows the current alarms assigned to the Alarm Limits (AL) set. The
alarm threshold value fields can be edited, if required.

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.

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This column shows the AL Set baseline value.

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.

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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.

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.

Right mouse button click on a particular parameter to display a histogram over

time.
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This is an extremely useful statistical plot for setting alarm limits. The x-axis plots
the parameter values and the y-axis the percentage of samples for each parameter
value. The basic concept in establishing alarm limits is that a maintenance department can only handle a certain percentage of problems at any one time. Therefore, one typically assigns the extreme alarm limit at 95% (i.e. put only those
samples whose parameter values fall in the top 5% into this category). Similarly the
next alarm limit down is set at 90% (top 10%), then at 80% (top 20%) and the
lowest alarm limit at 70% (top 30%).
The vertical bars representing the alarm limit values can be dragged with the
mouse to the desired value. Once all the alarm limit positions have been set then
press the Save Changes button and the alarm limit value will be automatically
written back to the AL Set. Using this method one can easily and reliably set the
alarm limits for all the parameters.
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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.
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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.
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Sometimes the plot has several bumps that are difficult to interpret.
This is most often when a Reference baseline is being applied.

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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.
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To further diagnose obscure plots the raw data itself can be viewed here to find the
specific data that is causing inconsistent plots. Using this information you can then
usually correct the problem much as fixing an incorrect oil reference.
One way of minimizing these sorts of issues is to run the Point Configuration Summary report, which is designed to find incorrect oil reference and other Point
Setup issues.

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The scatter plot is used to see if there is a correlation between any two parameters.
Simply select the appropriate two parameters from the X and Y drop down lists and
then press the Plot button.
If the two parameters correlate well, they will fall on a relatively straight line unlike
the one shown here. The slope and intercept of the best fit line are shown on the
display together with the correlation coefficient. A correlation coefficient of 1 represents a perfect 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.
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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.

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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.
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The LIMS license is required in order to access the Alarm List tab. This tab is useful
for quickly checking and changing configuration information. Lines can be sorted
by clicking a caption at the top of the column. Additional sort criteria may be
entered in the text boxes at the top. Columns can be hidden and made visible by
clicking the buttons at the top. The Type ID, AL Set, RefID, TCLs, and Report
Group (Grp) can all be modified from this screen.

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Sequential items may be changed by selecting the desired value and dragging
down the list.

You may also select Ref oils from a drop down list on the Ref Oil Desc field.

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The Trend Info tab is used to view and edit historical data and alarm status for all
samples stored on a given point.
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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 filtered to include
only those which are part of the minilab or lab on the respective tabs.

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You can limit the number of parameters displayed using the Test and
Display Filter option on the Point Info tab.
The second column includes reference oil data or statistical data for the sample.
Click on the top of the second column to toggle through the options which include
Mean, Standard Deviation, Median, Point Baseline, and Oil Reference. The
number of samples included in the running statistical calculations selected on the
Point Info tab, Equip minor tab.
The remaining columns display sample data for the point with the most recent
sample on the left. The first two entries on these columns are the sample date,
sample number.
Alarming measurement status is reflected in the color shading behind the numerical values. The color corresponds to the severity criteria of the Setup Tab as well as
to the Trivector Plot. Many of the analysis parameters may not be suitable for
alarming and the alarm option for these can be toggled on and off using the alarm
flag which is part of the AP Sets tab.

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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.
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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 individual measurement values.
You can add or limit the number of trend plots displayed using the Plots? Yes/No
feature under AP Sets, Current Views. Similarly, only those parameters that have
the alarm flag turned on will show the horizontal alarm limit lines.
The number of samples show on a trend plot can be limited to either a fixed
number or for a given time limit. This is set up on the Setup System tab.

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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 reference value, local median,
mean and standard deviations and symbols to indicate what observation are applicable.

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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.
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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 categories. The plot reports oil condition in each category in a range from Normal to Alert to High Alert to
Fault to Extreme.
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.
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This automatically analyzes Minilab data and generates Observations and Actions.
It does not use laboratory or any non-minilab data.
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This button is used in conjunction with the LIMS.

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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.
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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.

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A trivector plot showing high wear but otherwise healthy oil would look like this.
A plot of good oil contaminated by a water leak would appear as so.
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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.
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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.
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This list of selectable observations serves as a sample record for non-trendable
information.

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The Notes tab allows you to add free form text to the sample data and sample diagnosis.

Sample Observation Notes Used to describe any additional information 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.
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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.

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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 Information, Equipment tab).

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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. 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.
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The standard plot displays the cumulative counts versus size. This plot displays the
actual counts versus size (dashed line) and total volume of the particles 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 configuration in order to calculate System Debris.
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The particle PPM is calculated by volume whereas the typical PPM is

PPM by weight. To convert PPM by volume to PPM by weight, you
must multiply by density. If one assumes that all the particles were the
same size then one would multiply the PPM by volume by 7 to get the
PPM by weight of all the particles in the oil sample. Because it is difficult t know what type of particles are being counted we report the
PPM by volume which is an accurate measure.

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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.

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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 produced by alternating a magnet sequence that alternately stands up and lays down ferrous particles. If there are no ferrous particles present then these two curves fall on top of
each other. The second part of the plot shows a decrease in dielectric as the ferrous
particles are swept off the grid. If there are no ferrous particles present, then the
curve becomes a continuation of the first part. If there are large particles present,
then spikes appear on these curves.

The shapes of these curves are used to determine the contamination and ferrous
indices as well as the presence of large ferrous and non-ferrous particles. The water
content is also estimated from these curves.

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The Viscosity Plot shows how viscosity changes with temperature for both the reference and used oil samples. This plot is used to determine what viscosity 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.

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

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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.
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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.
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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.

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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.
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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.
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This report shows the Area, Equipment, Point, Sample Date, Sample ID, and then
the Wear, Contamination, and Chemistry severities.

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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.
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This report is a customized version for oil analysis of the exception report created
by the AMS Machinery Manager reporting module. It details the Area, Equipment,
Point, Sample Date, and Sample ID together with the parameter in alarm, color
coded for severity, along with the actual alarm limits.
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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 inconsistencies 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 viscosity 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 reference oil has been assigned to the
point. You must update the Point baseline value before running this report. You
can do the update from the Database tree popup menu when you right click on the
point in the tree.

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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.
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This report shows the oil added per year for each point. It then summarizes the oil
used per year for each oil type.
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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.
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The Print Preview window is controlled with the following buttons:

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.

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Logon - Press this button to log onto your E-mail system. You must setup your Email 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.

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.

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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 Email the data file to you.
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.

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This tab is used to export data from the CSI AMS Machinery Manager database to
a file that can be imported into a spreadsheet or relational database. The data
exported will depend on the current position in the database tree. For example, to
export the entire database the database level would be selected. To export just one
sample, that sample would be selected.
Save As - The name of the file that will contain the exported data.
Export Format
CSI Generic (.zip) using the Lab Unit ID as the key for data import
Area, Equipment, Point (.zip) codes as keys for import. This option automatically creates the Area, Equipment or Point in the target database 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.
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When exporting sample data using the A/E/P option, the reference
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 database.

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This tab is used to export data for the Alarm Limit statistics option.

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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 information about
the suitability of the lubricant for continued use, and the condition 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 environmental impact of waste oil disposal by ensuring that
oils and filters are not replaced before their service lives have ended.

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 Laboratory for additional in-depth
testing, please provide a copy of the OilView 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 corrosive (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 combustion byproducts 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.

6RIWZDUH6HWXS
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This menu is used to test used oil samples with the Model 5100 and to test reference
oil samples. Select either the user database or the reference database tab; select or
create the sample point on the corresponding database tree; clean the sensor grid
and begin testing.
A principle difference when Model 5100 tests are done on the user database is the
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 5-16) or verify (see Verify on page 5-14) each
sensor that is going to be used that day.
6RIWZDUH6HWXS

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.

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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.

The Diluted Testing For All Parameters option is good for all oils in any viscosity
range (see Dilution Of Viscous Samples (OilView Analyzer) on page 5-34). The
dilution effectively allows all of the measurable wear particles to get to the sensor
during the 250 second test interval, while only a small portion of the particles have
enough time to get to the sensor without 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.
6RIWZDUH6HWXS

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The following table lists various oils that can and cannot be tested using the Model
5100-series OilView Analyzer.
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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 dielectric.
The Model 5100 sensor grid gasket can be either buna-n rubber, this is a red gasket;
or it can be ethylene propylene rubber, this is a black rubber gasket. The red
rubber is not 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 similar dielectric within +/- 0.2
dielectric units.
Most mineral and synthetic oils can be diluted with K1 kerosene (see Dilution Of
Viscous Samples (OilView Analyzer) on page 5-34). Some users prefer to use other
hydrocarbon solvents such as hexane or heptane.
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Consult your industrial hygiene department, be aware of flammability characteristics and skin contact restrictions for solvents and oils.
6RIWZDUH6HWXS

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This selection assures that the correct calibration is applied to the sensor being
used.
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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.
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The Long Test is a full-length test performed by the OilView Analyzer. This test will
take from 250 to 1200 seconds depending on the viscosity of the oil and the test
option. A long test consists of 500 cycles through a three-step measurement
sequence:
measure dielectric with electromagnet off,
measure dielectric with electomagnet north, and
measure dielectric with electromagnet south.

Altogether, a full test consists of 1500 dielectric measurements and two temperature measurements (at the beginning and end of each test). The OilView software
uses these raw data to calculate dielectric and index values.
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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 dielectric 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.
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The Start button begins a test sequence.

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The Cancel button aborts a test sequence in process.

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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.
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This is the date of the reference oil test.

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The viscosity value is obtained from the reference oil database and is used to determine the time period for either Enhanced Particle Sensitivity or Reduced Particle Sensitivity test options. If this value is missing or incorrect, it can be edited in
the reference oil database.
6RIWZDUH6HWXS

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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.
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Sometimes the results show Critical. The OilView analyzer measures dielectric
values between 1 and 16. Many fluids such as water and coolant have dielectric constants much higher than 16. Also, metal particles can short the capacitance of the
sensor grid causing the sensor to report a value exceeding 16. If the dielectric value
is greater than 16 at the end of an OilView Analyzer test, the display will report Critical. The Contaminant and Ferrous indexes will not be displayed for a Critical
sample because the extreme contamination has overwhelmed the sensitivity of the
sensor at the end of the test.
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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.

1RWH
Never dilute the reference oil. Chemical comparisons between the

reference and the used oil must both be measured on unmixed,
undiluted oils.
6RIWZDUH6HWXS

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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.
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 calibrate your
grids on Monday and they pass a Verification Test on Tuesday and Wednesday but
fail Thursday, you may want to set the calibration period to three days. The conditions at each 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 suggest a
strong action such as changing 500 gallons of oil, for example, run a verification test
to confirm the operation of the OilView Analyzer.

The procedure for performing verification is the same as that used for the Calibrate procedure which is described in the next section.
6RIWZDUH6HWXS

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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 reference and used oil samples being
tested.
You should calibrate each sensor once each day using two CSI supplied-calibration
fluids. See Oil Compatibility Chart on page 5-8 to determine whether a sensor
should be calibrated with Fluids A and B or with Fluids B and C. The software will
automatically prompt you for the correct fluid based on the configuration of the
Model 5100s Calibration Settings tab.

1RWH
In earlier versions of OilView software, Chemical and OilLife Indexes

were computed by comparing sensor outputs measured 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 frequency outputs.
Now by using absolute dielectric calibration, each measurement 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.
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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.
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6RIWZDUH6HWXS

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 standard 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.
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Repeat this process for each calibration fluid, following the instructions in the software.
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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 calibratinginadvertently selecting the wrong
grid color. You must select the grid color before doing anything else on this menu
tab.
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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.
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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 measurement. (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.)
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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.
6RIWZDUH6HWXS

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

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Three test options are available to the OilView Analyzer user. These settings remain
in effect constantly until they are changed.
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There are three test time options. CSI recommends using the enhanced particle
sensitivity option unless there is a reason not to.
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This is the oldest of the OilView Analyzer test options. CSI only recommends using
this test time option when testing viscous oils that would otherwise require longer
than 500 seconds to test.
6RIWZDUH6HWXS

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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 viscosity. Diluted test results are much
more sensitive than neat oil test results since dilution enables more particles to
settle onto the sensor.
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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.
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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-Phosphate
Ester types. Most people do not require Phosphate Ester type grids (which have a
black rubber seal material that the oil sensor plugs into). Select the grid type that
matches the sensor. While Phosphate Ester grids are always in the high range
requiring calibration with Fluids B and C, the non-phosphate ester grids may be
either: normal requiring fluids A and B, or high requiring fluids B and C. (See Oil
Compatibility Chart on page 5-8.)
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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.
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You may specify the out-of-date warning interval. This setting defaults to one day
(the CSI recommended calibration interval). This interval can usually be lengthened with experience.

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The diagnostics tab is only to be used under the direction of CSI Customer Support
when troubleshooting potential problems.
6RIWZDUH6HWXS

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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.
1RWH
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.
1RWH
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.

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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 downdamaging 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 OilView copyright
message on its LCD screen.
Access the OilView software program. The system is now ready for use. Configuring
the software is described in Software Setup on page 5-3 and a typical testing session is described in An Example Testing Session on page 5-28.
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The sensing grid should never be exposed directly to water.
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Because the OilView Analyzer is extremely sensitive to moisture, it

should be used indoors where humidity and temperature are relatively constant. For best results, the humidity should be low and the
temperature should be nearly constant.

1RWH
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.
1RWH
OilView initializes the serial port where the analyzer is defined. If the
computer mouse is connected to that port, the mouse will not work.
1RWH
If necessary, the fuse (next to the power connector) can be replaced

with a standard 2-amp fuse.

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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 displace 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.
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Never expose a new sensor to water or water contaminated oil before it is cured.
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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.
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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.
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Do not use phosphate ester oil or CSI-supplied Calibration Fluid C on normal

sensors that have the red rubber seal. These fluids are not compatible with the
seal.

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This section describes a typical oil testing session using the OilView Analyzer 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 Analyzer
Initial Setup on page 5-24).
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 5-24 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.

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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.


1RWH
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.

4. . . Plug the sensor into the OilView Analyzer. Take care to ensure that each of
the plugs on the sensor body is fully inserted in the jacks on the face plate of
the analyzer.


5. . . Make sure the correct sample point is selected so the correct reference will
be used. A typical test will take approximately eight minutes to complete.
After conducting the test, save the test results.

1RWH
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 5-17).
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The sensing grid should never be directly exposed to water.
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Prolonged exposure to salt water or acid may damage the sensor grid.
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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.

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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 conduct 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.

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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 5-21 for more information).
Dilution is generally not necessary with light lubricating oils such as commonly
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.
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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.

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.
1RWH
For information on diluting samples to be used with the OilView Particle Counter, see Dilution Of Viscous Samples (OilView Analyzer)
on page 5-34.
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Consult your industrial hygiene department, be aware of flammability characteristics and skin contact restrictions for solvents and oils.
6\QWKHWLF2LOV
The OilView Analyzer can be used to test most synthetic lubricants. Extra care
should be taken in cleaning the grid when changing between mineral oils and synthetic lubricants. See Oil Compatibility Chart on page 5-8 for additional information regarding testing synthetics with OilView instrumentation.
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Procedural consistency and proper techniques are the best way to achieve reliable
results from your OilView analyzer. The following list of procedures 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 OilView customers.
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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 thoroughly 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.
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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.
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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.
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Start-up support is a good way to get off on the right foot. Allow CSI Reliability Services (423-675-2110) to come to your plant to set up your initial databases and collect the first samples. In many cases, the results of this first round of tests detect
problems and achieve significant cost savings.

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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.
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.
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For safety reasons, the OilView Digital Viscometer should never be

applied to a highly flammable hydrocarbon liquid such as gasoline.

1RWH
The well must be cleaned of previously tested fluid before each new
measurement. Old fluid can be poured out of the unit by tilting it and
allowing the fluid to flow into a disposable receptacle. Take care to
ensure that the steel ball does not fall out of the well and be accidentally discarded. Alternatively, you may place a paper towel into the well
and allow it to absorb the old fluid, or use the syringe to remove the
fluid.

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Place the Digital Viscometer on a level surface. Plug the Digital Viscometers cable
into port 2 of the OilView Analyzer, and then connect the Model 5100 to the host
computer (see System Setup on page 5-24 for more information on cable connections). Allow both the OilView Analyzer and the Digital Viscometer to warm up
for an hour before using.
&DXWLRQ
Exercise care when inserting the Digital Viscometers 15-pin connector into the
OilView Analyzers port 2it is possible to force the connector upside down.

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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.

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

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All Digital Viscometers are shipped with a factory calibration file on diskette. Usually this calibration will be all you need to get started.
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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 reenter 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 selection of CSIsupplied 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 calibration procedure is described on the
next page.
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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 1-28). You are now read to begin the calibration procedure.
*. ISO 14, 32, 68, 100, 137, 220, 460, and 680

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Make sure your Digital Viscometer is plugged in and warmed up for

one hour prior to starting a calibration. When calibrating, start with
the highest viscosity oil and progress to the lowest viscosity oil.
Enter the Name, 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.
1RWH
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:
Auto-Calc - Check this box to instruct the program to automatically calculate 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.
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This function button starts the calibration for the highlighted oil entry.
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This function can be used to delete the highlighted calibration oil.

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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.

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This function aborts a calibration run in progress. Any new fluid data entered will
be lost after aborting and leaving the Calibration tab.
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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 recommends
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.
1RWH
When calibrating, start with the highest viscosity oil and progress to
the lowest viscosity oil.
After clicking on the Start button, a window will follow asking you to prepare the
viscosity standard for testing. Make sure that the sample well and steel ball are clean,
and place enough of the fluid into the well to fill it to the vertical rim as shown
below. Then, place the steel ball into the well (if it is not already there). Click the
OK button to begin the calibration procedure.

A progress bar will be displayed showing the test progress as the ball rotates. The
progress will display Finished at the end of the run. You may then save the results
by clicking on the Save button, or discard the results by clicking on the Cancel
button.
Remove the ball from the cup using the magnetic ball retriever. Then remove the
ball from the retriever to prevent the ball from becoming magnetized. Discard the
oil and clean the cup and ball bearing before the next test.
1RWH
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 reference oil is
chosen for a point or if the chosen reference oil doesnt include a 100C viscosity.
1RWH
CSI strongly recommends that the default reference be changed as

needed to match, as closely as possible, the viscosity index of the oil
being tested to the viscosity index of the calibration oil. The viscosity
index is printed on the labels of 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.

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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.
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 displayed.
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.

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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.

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This tab displays an ASTM plot of calibration oil viscosity versus temperature.

1RWH
The Settings, Diagnostics, and Raw Data tabs are normally grayed out
and not accessible. They may be used by CSI Customer Support to
help diagnose problems.

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Make sure that the correct machine and measurement point are being displayed
in the database information box on the database tree.
Test oils at room temperature, making sure that the sample and test procedure 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.

Whenever possible, assign a reference oil to the displayed point prior to running
the Digital Viscometer test. Best results will be achieved if you provide both the 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 calibration 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.
1RWH
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.
1RWH
If both the 40C and 100C values are not specified on the point, the
Digital Viscometer will use the viscosity/temperature profile from the
default calibration file.
As in the calibration procedure, make sure that the sample well and steel ball are
clean, and place enough of the fluid into the well to fill it to the vertical rim. Then,
place the steel ball into the well (if it is not already there). Click the Start button to
begin the test procedure.
After the test has completed, the window will display the calculated viscosity in cSt
at 40C and the percent viscosity change from the reference value.
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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 lubricant. 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 instruments. 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 crankcase oil should be changed if the viscosity
increase is greater than 30%. Viscosity limits for other applications vary widely.

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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 sensors for
lube condition, full integration with the OilView and AMS Machinery Manager
software product family, and industry recognized standard outputs. These outputs
are readily trended using the OilView software with automatic, knowledge-based
expert system interpretation and recommendations.
The Model 51PC Particle Counter includes:
Laser Particle Counter with color and dielectric sensors
OilView software
Communications and power cables
External universal power supply
CO2 cartridge
Plant air adapter
Sensor cleaning brush

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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.

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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 computers 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.
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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).
Make sure that all cables are connected properly (see OilView Particle
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 1-28).
5XQQLQJD7HVW

1RWH
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.

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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 7-22).
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.
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CSI highly recommends using an ultrasonic bath to prepare samples for the particle counter. If reducing sample preparation time is an important consideration, a vacuum chamber may also be used to speed up removal of entrained air.
See Sample Preparation on page 7-22 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 7-22.)
*. Hydraulic Fluid PowerFluid Sample ContainersQualifying and Controlling Cleaning Methods ISO 3722, International Organization for Standardization, Stockholm,
Sweden
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1RWH
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.

1RWH
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.
4. . . Ensure that the current sample point has been specified for the particle
counter (see Database Tree on page 1-11). Click on the Test tab at the
bottom of the window. Then in the Test Control area, verify the flow rate, test
volume, flush volume, diluent amount, and sample amount. (To change
these settings see Settings on page 7-21.)
5XQQLQJD7HVW

1RWH
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.

1RWH
Dilution is sometimes required to accomplish particle counter measurement. If viscosity gets too high, it causes a low-pressure 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 7-25 for more information on dilution.
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6. . . Make sure that a drain container is positioned beneath the drain tube.

7. . . Select Start from the 51PC Test tab. When the test begins, turn the drain/fill
valve knob when requested to do so.
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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 regulator.
Plant air pressure is too low. You may need to increase air pressure to 100 psi
or more.
The sensor is dirty and needs to be cleaned (see Sensor Cleaning on page
7-33).
2Q3RZHU8S
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.
5XQQLQJD7HVW

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Customers have the ability to change the flow rate on the Model 51PC particle
counter. However, CSI strongly discourages this and instead recommends 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.
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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 particles greater than 15 m.
The ISO Codes for X and Y represent a breakdown 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
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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.
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Lube Quality - This is a measure of fluid degradation as detected by the colorimetric

and dielectric sensors. This measurement correlates with the analyzer Chemical
index.

Dielectric Constant - A measure of the dielectric permittivity of the fluid (i.e., the
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.
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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 onlybefore 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).

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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: description 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.

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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.
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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 minutes 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.
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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
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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.
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An appropriate amount of the sample can be anywhere between one

to twenty grams of sample depending upon contamination.
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.
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The mixed solvent is proven to be effective on samples with up to

17% water content.
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Dilution may improve results and consistency when testing with the OilView 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 particle 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 calibration 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.)
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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 commercial 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 cleanliness, 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.

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The computer will automatically calculate the exact dilution ratio. However, 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.

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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).

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.


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.


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

5. . . Add an approximate amount of the diluent. For a 1:1 dilution ratio, add
about the same weight of diluent as the sample. For a 10:1 dilution ratio, add
ten times as much diluent as the sample.


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


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

8. . . Then enter the diluent weight and the sample weight in the cells in the Test
Control table.
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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 accurate calculation of particle counts
on diluted samples.

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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.)
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The laser windows in the Model 51PC are made of sapphire and
cannot normally be damaged with the bristles of the supplied wire
brush.


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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 continued 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 consuming after testing a
high viscosity lubricant. You may choose to dilute high viscosity lubricants with
clean kerosene to minimize flushing time between batches.
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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 lubricant that can be tested, since other synthetics will
not dissolve in kerosene.
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Do not test per fluorinated ethers (for example, Krytox or Fomblin) since there
is no solvent that chemically dissolves this PTFE-based synthetic material.
To prevent excessive flushing time, do not test used diesel engine oils that are black
from soot. Note that all of these types of samples are able to be tested on the OilView Analyzereven though they cannot be tested using the OilView Particle
Counter.

Finally, although it will not damage the particle counter, water/oil emulsions
cannot be adequately tested because the water droplets may give false particle
counts.
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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.
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If you intend to screen the sample as described, you should split the
oil sample so that the Model 5100 test does not contaminate the
Model 51PC sample.
If high contamination or ferrous wear is indicated with the OilView Analyzer, then
it will be extreme when tested with the OilView Particle Counter which has 100
times greater 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 probably not needed:
Obvious visual sediment in bottle,
Obvious visual indication of water or milky appearance.
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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 whatever 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 7-36.
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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 contamination requiring dilution, or
excessive viscosity requiring dilution.
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When the sensor does not come clean with multiple kerosene flushing, use the wire
brush supplied with the particle counter to clean the sensor (see Sensor Cleaning
on page 7-33). The wire brush is able to clean contamination from the sapphire
windows of the laser 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.
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Clean kerosene can be purchased from Fisher Scientific or other laboratory

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.

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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 ideally suited for
measuring viscous oils, such as gear lubes and greases, without dilution.
Also, because the Model 51FW does not depend on optical properties, it can easily
be used on opaque and/or soot loaded oils without any special preparation.

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The Model 51FW does not detect lube degradation. Sufficient quantities of non-ferrous particles can be detected and will generate a
non-ferrous particles message in the status area.
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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
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The cables provided with the Model 51FW are custom engineered and cannot
be substituted with a standard serial cable.

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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.
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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 computer.
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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.

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The Ferrous Wear Monitor Model 51FW can be connected to the computers
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.

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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 communications cable; freeing
port 2 for use with the Digital Viscometer.
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The Ferrous Wear Monitor uses a three-way power switch. Operation is shown in
the following illustration.
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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.

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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.
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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.)

1RWH
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 Message box
should read Initializing. After a moment, the status box will display Ready, and
the User Action box should display Place Sample on 51FW. In this case, place a
clean, empty sample bottle on the Model 51FW.
The Results area displays the results of the individual tests. The 51FW Message box
displays the current status of the analyzer. Choose save to store the empty bottle
result after three good readings.
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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.
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The 51FW Calibration Standard needs no special preparation to be measured
simply 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.
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Bad readings are commonly caused by slow placement of the sample

or movement of the sample before the measurement has been completed.
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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.
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An excessive range message indicates an inconsistency between the

three bottle placement readings. This is most commonly caused by
the standard being placed off-center from the red sensing area.
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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 fluctuations in the electromagnetic readings will be zeroed out when the 51FW is calibrated.
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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 compared against a gold standard at CSI. Any fluctuations
in the electromagnetic readings will be zeroed out when the 51FW is
calibrated.

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Testing lubricant samples with the Model 51FW is very similar to the calibration
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 particles falling out of the
sample, so it is not imperative to disperse the particles. 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.
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.
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Data taken from a regular Ferrous Wear Monitor test may not be
stored to a reference file.
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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.
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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.

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Ripples in the plot could indicate electromagnetic interference

resulting from the 51FWs being too close to another electronic
device.

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The Wear Debris Analysis (WDA) tab is used to assist in analysis and documentation of visual microscopic observations of wear debris and contamination extracted
from oil 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 mechanisms and
how the OilView analyzers and microscopes assess wear.
Although you do not have to capture images to do wear debris analysis, it is helpful
to use a CCD camera with video capture to bring live images into the image
window. The OilView 4.0 Software provides image capture capabilities using a video
camera and video frame grabber card. Various video cameras and frame grabbers
may be used, but the key to the software interface is that the video frame grabber
must provide an industry standard TWAIN software interface. That is to say, the
frame grabber manufacturer must supply a TWAIN driver dynamic link library
(.dll) along with the card. Note that the software can import JPEG image files
regardless of their source. The recommended camera and frame grabber card
specifications and requirements are listed in the following tables.

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The CSI Model 51CV Wear Debris Image Capture Kit includes a camera and video
frame grabber card. Refer to the camera and capture card manuals for installation
and setup instructions.

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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 pertinent to a specific image and others are pertinent to the oil sample which may have no images,
one image, or several images.

In effect wear debris analysis introduces another level below the sample level on the
User Database treethe image level.

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You will want to pay particular attention when you are recording information in the
WDA tab as to whether it is being applied to one specific image or to the sample.
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The Sample tab is used to analyze and document this analysis for each individual
image as well as the overall oil sample. These features on the screen pertain to the
image and to the sample.
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Sizes range from Fine <6u, to Small 6-14u, to Med 14-40u, to Large 40-100u,
to Huge >100u.
The photograph taken through the microscope is captured using the Capture
button. Otherwise, photographs are imported using the Add File button.
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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.

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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 represented in
this group.
Max Size - The maximum size particle in the group.
Aspect Ratio - The maximum to minimum dimensions ratio for a particle
(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 suggests 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.
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 automatically. 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.

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Before you can measure the size of particles in the captured image, you must calibrate the microscope capture system.
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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.
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To measure the particle density (particles per square millimeter), first press the
Measure button and then draw a rectangle around the region containing the particles. Next, press the Count (particles with mouse click) button. Now, you can visually count the particles, pointing the mouse cursor to each particle and clicking. this
automatically counts the 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.

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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.
The left photograph is functionally the same as it is on the Sample screen, except
that you cannot edit the caption, notes, or select through the wear debris analysis
grid.
The right photograph is one from the atlas. If no atlas image is present then you
may scroll through the tree on the lower right to select and view until you see one
that looks like the sample image.
The Show Analysis button displays the WDA matrix settings for the selected atlas
image.
Once you have found an image that has features you want ported over to the wear
debris analysis, select one of the five groups on the lower left and then select the <<<
button. This automatically replaces entries in that analysis group with those from
the atlas image.

Go back to the Sample tab to edit these entries to exactly fit your analysis of the
sample.

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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.

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The Analyst tab displays multiple sample images simultaneously for easier classification and diagnosis.

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Calibration
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 graticule (supplied
with the microscope or available from CSI), which has calibrated marking in
microns as shown above. Each small mark is 1 micron. Adjust the microscope magnification and zoom settings so that you see most of the graticale
You must now enter the magnification and zoom settings in the text boxes in the
software as well as the length in microns of the graticale you are going to measure
with the cursor. Press the Measurement button and drag the cursor between the
graticale lines that represent the distance to be measured. When you release the
mouse button the pixels /micron calibration factor is recorded. Now, save these settings by pressing the Save button.

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Wear is the (unwanted) removal of material from a surface. In lubricated
machinery, abnormal wear results from one or more of three general mechanisms:
abrasion, fatigue, or adhesion.
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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 contamination 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 particles 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.
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Fatigue wear is caused by cyclic loading of metal surfaces. This wear eventually
results in micro-cracks in the surface which causes separation of metal from the surface as the cracks spread. Metal surfaces exposed to cyclic loading often fail from
fatigue. The time to failure decreases with increasing load and increasing cyclic
load frequency. This implies that high loads from sharp surfaces can cause both
abrasive and fatigue wear in rolling elements. Common machine parts subject to
fatigue failure include gear teeth, roller element 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 particles are easily detected by the
OilView Analyzers, Ferrous Wear Monitor and Particle Counter.

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In many cases, fatigue wear will not have a solution other than planning to replace
the worn part. In the short term, corrosion influences and secondary abrasive wear
from fatigue wear particles should be minimized by changing the oil and filter. In
addition, vibration analysis should be performed on the machine to determine if
the system is being subjected to abnormally high levels of vibration. In terminal
cases, the use of a more viscous oil can sometimes delay catastrophic surface failure
at the cost of increased friction and higher operating temperatures.
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Adhesive wear is caused by metal to metal contact in the absence of an oxide or

lubricant film. The mechanism involves bonding at the atomic level between clean
opposing metal surfaces. Wear debris produced by adhesion is often referred to as
rubbing or sliding wear. The size of the wear particles produced is generally dependent on the roughness of the opposing surfaces. Finely finished metal surfaces produce very fine wear debris particles. Mild adhesive (rubbing or sliding) wear is
normal in many machine types.
Sliding wear particle sizes may decrease over time as opposing surfaces polish one
another. This is the case during break-in of newly aligned or machined bearing
surfaces. Abnormal adhesive wear is usually a result of an inadequate oil film, or
increased surface roughness. The OilView Analyzer sensor grids and Ferrous Wear
Monitor are only 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.
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When the OilView Analyzers or Ferrous Wear Monitor are used to screen for ferrous wear, the most important things to look for are increasing ferrous levels over
time and a large ferrous indication. Remember that the ferrous 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.

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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.
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To classify particles, see the CSI Wear Particle Atlas.

If the residue moves with the magnet, the material is ferromagnetic. If individual
particles can be resolved with the naked eye under a bright light, they are probably
40 microns or larger along their smallest dimension and are evidence of abnormal
wear of a ferrous 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.

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 conductive 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.
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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.
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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.

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Assemble the filter into the patch maker including all O-rings and screens
according to the diagram.
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All samples must be diluted before they are put into the patch maker. A very small
amount of actual sample is required. About 2 ml of sample should be used consistently, unless a sample is extremely clean or extremely dirty. Shake the sample thoroughly and then extract 2 ml using a clean pipette. Add this to a clean mixing bottle
or beaker, and then add 10 to 20 ml of solvent (lamp oil will suffice). The diluted
sample will filter and clean-up more easily as well.
Shake the diluted sample and then pour it into the patch maker chamber. Press the
vacuum pump foot pedal to run the pump and suck the sample through the patch.
Pour additional solvent into the chamber while vacuuming to wash the particles
through the plumbing and to clean the oil residue off of the filter patch. Continue
running the pump and suck air through the patch to help dry it.
Remove the filter patch(es) from the holder and allow them to dry. After they have
dried, glue them onto the backing in the filter storage container so they will stay flat
for microscopic viewing.
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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.

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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-ferrous 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.

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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 photograph. 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.
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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 solvent (while a permanent magnet
retains ferrous particles) and through-lens lighting can then be used to view the
remaining ferrous particles.
In addition to photomicrographs wear particle identification, CSIs Wear Particle
Atlas (included with the Model 51SM shop microscope) provides hints and recommendations on particle extraction and examination.
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Refer to the manual which came with your microscope for setup and operation
instructions.

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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 magnifiction. See the illustration below and the microscope manual for setup and operation.

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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.

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The front panel of the instrument is replicated in the software interface, and the
instrument can largely be operated from either interface aside from certain
mechanical operations.
The interface is divided into three tests. Test 1 measures the dielectric of the neat
oil, Test 2 the contamination and ferrous indices, and Test 3 the particle counts. In
addition, the diluted oil from the Test 2 chamber can be filtered through the patch
maker to create wear debris filter patches.
The front panel has a series of colored LEDs that are used to indicate the status of
each test. In general, a flashing LED indicates the next action that you should take.
The four push 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.

The vacuum control valve is used to direct the vacuum from the foot operated
vacuum pump to the appropriate chamber for cleaning or degassing. The LEDs
will indicate the position for this valve.
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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 instrument can be operated.
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Refer to the illustration of the rear view of the analyzer for all cable connections.
The 5200 communicates with a computer using a standard 9-pin, RS232 serial communications cable which is included.
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Before making any cable or power connections, turn off the power to the unit by
toggling the power switch on the rear panel to the off position.
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The 5xDV communications port is a 15-pin, high-density sub-D connector

which provides both power and serial communications. Use caution when
inserting the 15-pin cable into this port as it is possible to force the connector
upside down damaging the cable and the port connector. Always make sure
the power is off before connecting this cable.
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The power supply cable connector is keyed and labeled on the top
position.
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After verifying the cable connections, go to the Setup/Comm Ports software screen
and configure the ports as described in Chapter 1.
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The analyzer system includes an electronic scale which is used for accurately
weighing dilution ratios. The scale comes with its own DC power supply which is
unique and should not be used on any other instrument. The scale also uses batteries, but its power supply should be used to keep it out of power saver mode.
Connect the scale to its port on the back of the 5200 using a 9-pin, RS232 cable.
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The null modem communications adapter must be connected inline with the cable to the electronic scale.

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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 dilution ratio calculations. If necessary, use the
following procedure to re-calibrate 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
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Underload error. Check to make sure weighing tray is properly

installed.

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.
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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.
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The vacuum pump is not explosion-proof. It must not be used in the

presence of flammable liquids or gases. Adequate ventilation of its
exhaust is required.
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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 bubbles. If the vacuum still remains from a previous test, then
the vacuum relief valve may be manually pressed to quickly release any leftover
vacuum.

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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.

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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 Initializing message for approximately
25 seconds while the data is being read.
If any errors occur during the initialization, then check the power to the analyzer
and verify the communications cable connection to the computer is correct before
re-trying in the software. The software will periodically re-try while the 5200 Test tab
is active until the calibration data has been successfully read.
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Any communications errors must be resolved before using the instrument.

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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:
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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 solvent if the oil and solvent mixture becomes either milky or layered indicating 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.
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When collecting used oil samples, collect approximately 2/3 of a sample bottle of
oil. This will be sufficient for running the digital viscometer test and all 5200 tests.
Do not fill the bottle to the top. Full bottles are not easily mixed by hand shaking. If
you need more oil for other tests, consider collecting a second sample bottle.
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Use the OilView Digital Viscometer to measure the viscosity of the undiluted oil
sample. You may want to test viscosity on all samples in the batch before beginning
5200 tests. Always run the viscosity test on the undiluted oil before the 5200 tests.
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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.
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Both Toluene and Isopropyl Alcohol have flash points below room
temperature. They require an explosion proof vacuum pump.

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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.
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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.
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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.
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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.

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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.
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If testing a new reference oil sample, refer to the section on reference

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.
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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 evacuating 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.
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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.

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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.
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Use this test to count particles and determine particle size distributions in eight different size ranges. This is a laser optical particle counter. Air bubbles 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 additional 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 contamination 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, representative 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 procedures for saving diluent counts.
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The following table summarizes the water masking solvent options:

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Both Toluene and Isopropyl Alcohol have flash points below room
temperature. They require an explosion proof vacuum pump.
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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 sensors. 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 backflush clean diluent.
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Dowanol DPnB is a clear colorless solvent produced by the Dow Chemical Company. It is soluble in hydrocarbon oils as well as water, which explains how it works
as a water mask solvent for lubrication oils. For the purpose of water masking,
handle the Dowanol as if it were kerosene. However Dowanol has a higher flash
point 212 F than kerosene 148 F which makes it safer to use. This solvent is one of
a series of glycol ether solvents made by Dow Chemical, and was chosen because of
its relatively low toxicity as based on the MSDS. The user should follow all precautions as stated on the MSDS as well as following all applicable regulations. Use this
URL for DOWANOL DPnB technical information:
http://www.dow.com/dowanol/nam/products/dpnb.htm
The sharp-eyed observer may have noted that there are two CAS numbers for Dowanol DPnB. Inquiries to Dow Chemical gave the following response, Actually,
both registry numbers can be used to describe DOWANOL DPnB. The registry
number 35884-42-5 describes the mixture of all 4 structural isomers, whereas
29911-28-2 describes the secondary, secondary 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.
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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.
1RWH
Test 3 itself is not cleaned because the initial 10 ml of the diluted

sample is used to flush the laser detector. Additional cleaning should
be performed at the end of the day by manually squirting a syringe
full of solvent into the Test 3 input port. Manual cleaning should also
be used after testing a very dirty sample or between dissimilar fluid
batches.
14. . Remove and discard the used syringe. The syringe has been contaminated
on both the inside and outside and will contaminate the next sample if reused.
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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.

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The scale checkbox must be checked for the scale to be activated.

If an empty bottle has not been previously weighed, you will be prompted to place
an empty bottle on the scale. Once the empty bottle is on the scale, press the button
on the front panel next to the scale icon to automatically record the weight of the
empty bottle. (Do not use the buttons on the scale.) If you must re-weigh an empty
bottle, double click on the empty bottle icon to set the empty bottle weight to zero.
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 halffilled 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
automatically calculated from the recorded weights.
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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 Microscopic examination including Energy Dispersive X-ray elemental analysis.
,QVWUXPHQW2YHUYLHZ

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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 contamination 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.

1RWH
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.
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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 disabled 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.
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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 measurement 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 disabled 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 retest. 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 reference 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.
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This screen shows the details of the measurements from each of the three tests.
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.
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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.
Chemical Index The chemical index is a measure of the change in dielectric of
the used oil sample relative to the reference oil. This indicates a chemical change
in the oil, water in the oil, or a mixture of different oil types. The chemical index is
scaled such that a 0.10 dielectric change produces a chemical index value of 10
which is an alarm status for most oils. A reference oil with known dielectric must be
assigned in order to calculate the chemical index.

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

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The Test 2 plot shows a time resolved plot of dielectric as particles settle on the
detector grid. The first part of the plot shows two curves that are produced by alternating a magnet sequence that alternately stands up and lays down ferrous particles. If there are no ferrous particles present then these two curves fall on top of
each other. The second part of the plot shows a decrease in dielectric as the ferrous
particles are swept off the grid. If there are no ferrous particles present, then the
curve becomes a continuation of the first part. If there are large particles present,
then spikes appear on these curves.
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The shapes of these curves are used to determine the contamination and ferrous
indices as well as the presence of large ferrous and non-ferrous particles. The water
content is also estimated from these curves.

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The ISO 4406 plot is a representation of size distribution and concentration for particles in oil. The graph has two lines. One line is for the sample data, and the other
is for the target cleanliness level (as set on the Point Information, Equipment tab).
Cumulative counts are displayed on the left vertical axis whereas ISO codes are displayed on the right vertical axis.
The size axis displays either the old or new particle sizes based upon the current
ISO 11171 display mode.

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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.
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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 profile. So this category is the
one that actually determines the NAS value.
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The 5200 is factory calibrated so it is ready to use out of the box. The calibration
procedure uses known fluids with known chemistry and contaminant 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 calibration data and historical
calibration log data are stored in a calibration database. 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.
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The 5200 Calibrate tab contains the screens for Calibration and Verification 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 instrument is
within calibration limits. Verification is first used immediately after a calibration to
check the accuracy and repeatability of the calibration. Verification 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.

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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 verification, then do not use the New button.
Simply re-calibrate with the failing fluid as described under Test 1 Calibration
below.
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Each calibration screen contains a Restore Latest button which is used to restore
the most recently saved calibration data for that test. This function may be used to
restore the latest calibration data after viewing an older, historical calibration. Also,
if the user starts a re-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.
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Each calibration screen also contains a Save Changes button which saves changes
to the hardware and to the calibration database. This button is initially grayed out
and becomes active after changes have been made to the data. In order to save
time, the user should wait until all fluid samples for a particular test have been
tested before clicking the Save button. If you forget to save the changes, the software will prompt you to save when you try to switch tabs.
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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.
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The software reads the 5200 hardware during initialization to get the current 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.
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The historical calibration data table lists all past and present calibrations that have
been saved in the calibration database. The calibrations are sorted in the table by
serial number, test type, and date. This table serves as a log of all calibration activity
for the unit. Also, if it ever becomes necessary to restore a previous calibration, then
this is the place to do it.
The current calibration database path name is displayed above the table. The
button may be used to browse for and switch calibration databases. However, normally only the default A5200cal.mdb calibration database should be used.
Read Test(s) This command button is used to restore previous calibrations. First
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 calibration 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.
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The dielectric sensor 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 calibration fluids A, B, and C.

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.

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Never use the wrong syringe with the wrong calibration fluid bottle.
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An initial test is required to record a clean sensor value. Perform the following
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.
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During re-calibration, the calculated dielectric will not always be available or accurate because it is derived from the calibration itself. The
frequency value, however, should stay relatively the same for the clean
sensor, and the software uses the stored clean frequency to determine
when the sensor is sufficiently clean.

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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

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As you cycle through the Freq 1-3 tests, the software will display 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 frequency. 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.
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If this is the first calibration fluid of a new calibration then the dielectric calculation will not be available, only the clean frequency will be
displayed.
Repeat steps 2 to 15 for the remaining calibration fluids. The software will average
the results each time and then plot the average on the graph.
As each fluid is tested, the software will display the Fit % Error for each fluid. The
plot is a best-fit line through all points. Therefore the percent error is a calculation
of the deviation of each fluid point (Avg F) from the best-fit line. If the software
pops up a warning message that the error is outside the limits, then you will need
to repeat one or more fluid calibrations. Start with the fluid which has the most variation between its Freq 1 to 3 values.

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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.

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Verification is performed immediately after calibration to verify that the calibration

data is good and repeatable. Verification should also be performed 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.

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 calibration fluids A, B and C.

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.

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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.
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An initial test is required to record a clean sensor value. Perform the following
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.
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During re-calibration, the calculated dielectric will not always be available or accurate because it is derived from the calibration itself. The
frequency value, however, should stay relatively the same for the clean
sensor.

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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
11. . The software will highlight the Freq 3 cell for the third test using the same

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As you cycle through the Freq 1-3 tests, the software will display 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 redo 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 . 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.
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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 outside the limits, then you will need
to repeat one or more fluid calibrations. Start with the fluid which has the most variation between its Freq 1 to 3 values.

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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.

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Verification is performed immediately after calibration to verify that the calibration

data is good and repeatable. Verification should also be performed 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.

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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.

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The factory default calibration is based upon the ISO 4402 calibration standard.
The full ISO 11171 standard adds some tests which are to be performed 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 instrument 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 calibration, 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.
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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.
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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 information on this special calibration service.
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The majority of particle sizes being counted are not visible to the naked eye. Thus
the user must take proper precautions to make sure extraneous contamination
does not get into the containers or calibration samples:
All calibrations must be performed in a dust-free environment.
Sample bottles and lids should be certified clean or cleaned in accordance
with ISO 3722. Keep the bottles tightly sealed until ready for use.
The syringes must be kept sealed in the original factory packaging until
ready to use. Do not handle the outside of the syringe or lay the syringe
down on a contaminated surface prior to use.
If dust has accumulated on the outside of the calibration fluid bottles during
storage, then clean it off with a lint-free cloth before use.

Never re-use bottles or syringes, or recycle calibration fluids. Any contamination tends to accumulate from prior use.
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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-suspended 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.
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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.
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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.
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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.
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The volume calibration is used to enter the dimensions of the syringe, and to verify
the sample volume and count repeatability with flow.
First use a metric ruler to measure the dimensions of the syringe as illustrated on
the display. These dimensions are necessary to get the correct flow rate and volume
through the particle counter. Enter the dimensions in the three boxes as shown.
Next, a standard fluid must be used to run a volume verification test. The fluid
should have between 2000 and 8000 particles/ml at the smallest size of interest.
The ISO 11171 standard uses a concentration of Ultrafine Test Dust (UFTD). Concentrations between 0.5 and 1.0 mg/l will work. However, either ACFTD, MTD, or
UFTD may be used to verify volume accuracy. Select the appropriate fluid from the
drop-down list in the software. Enter the manufacturer and lot number in the
boxes below the fluid type.
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Finally, have a stopwatch ready and run the volume verification test as follows:
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 coefficient 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 several seconds
as the data is written back to the hardware.

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The Test 3 sizing calibration is performed as part of the factory standard calibration. The purpose of this calibration is to establish calibration curve data which correlates sensor output signal levels to particle sizes. The sizing calibration needs to be
repeated following repair or readjustment of the particle counter, or at least on an
annual basis.
The 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 settings to try to match the standard sizes more closely and produce the correct particle counts. The three samples multiplied by eight channel settings produces a calibration curve of 24 points. This curve is then used to compute
final channel settings for the particle sizes of interest.

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).
start the test.
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 displayed 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 settings 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.

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The Test 3 verification is performed as part of the factory standard calibration. The
purpose of verification is to verify particle counting accuracy using size channel
voltage settings calculated from the calibration data curve. Verification should be
performed whenever the accuracy of the particle counter is in question or after
repair or adjustments have been made to instrument.
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 channels 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 manufacturer, lot number, and
dust concentration in the boxes provided. The software determines the standard
particle sizes and counts, based upon the fluid type and dust concentration, and displays them in the table. The software also calculates the channel voltages for the
particle sizes from the calibration 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.
start the test.
position. The software will update the sample counts, AvgCnt, %Err, CoV%,
and Rng% in the table. See the descriptions below for these calculations.
test.
The following results are displayed in the verification data table:
StdCnt Standard particle counts per ml for each particle size for the calibration
fluid concentration.
AvgCnt Average of all valid sample particle counts per ml for each particle size.
%Err Percent error of average count versus standard count. The software checks
to make sure the percent error is within limits.
CoV% Coefficient of Variation percentage is the percent standard deviation
between the three samples. The software will display an error if the variation is not
within limits.
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Sample n Each syringe sample is counted as three sub-samples. The detailed subsample 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 verification 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 seconds as the data is
written back to the hardware.

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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 standard 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.

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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.
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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.
start the test.
position. The software will update the sample counts, AvgCnt, and %Range
in the table.
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.
versus particle size. A Diluent / Clean Fluid data report is also 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.

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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 concentration limit of the
sensor. The general equation for calculating the volume of concentrate (V1 ml) to
use for the dilutions is as follows:

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


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 concentration 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).
start the test.
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.
10. . Repeat Steps 4 to 9 above until all samples have been 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. The
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.

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, substituting 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 coincidence 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.

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The Test 3 Flow Rate Limits test establishes the flow rate limits of the instrument.
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. Alternatively, the user may use the software to run this test on-site.
ISO 11171 calibration standard. ISO Ultrafine Test Dust (UFTD) fluid is used to
establish the upper and lower flow rate limits. Identical samples are prepared and
tested at flow rates ranging from 10 ml/min up to 80 ml/min in 10 ml/min increments.
7HVW)ORZ5DWH/LPLWV

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 dropdown list. Then enter the manufacturer, lot number, and dust concentration 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.
start the test.
position. The software will update the sample counts, Avg/ml, 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:
Avg/ml Average counts per ml of the three sub-samples.
Rng% Percent range of the sub-sample count data within a given sample. The

%Err The percent error of the average counts versus the average counts at the
working flow rate of 50 ml/min.
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.
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The Test 3 Resolution test measures the ability of the instrument to distinguish
between particles of different sizes. This is largely governed by the optics and electronic design. This test is not part of the factory standard calibration procedure, but
may be ordered as a special calibration service. Alternatively, the user may use the
software to run this test on-site.
ISO 11171 calibration standard. This test requires the use of a certified suspension
of 10 micron latex spheres at a concentration that is approximately 25% of the concentration limit of the sensor. A super clean dilution fluid will also be used for
flushing the sensor.

During the test, the software uses the calibration curve data to set the channel
voltage 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 software 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 voltages as described above. The voltage settings
and equivalent sizes will be displayed.
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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.
start the test.
position. The software will update the sample counts, Avg/ml, 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. The
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 seconds as the data is
written back to the hardware.
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The 5200 Diagnostics tab is used mainly by CSI Customer Support to help troubleshoot 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.

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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 manually 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.
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Keeping track of oil samples as they are processed can be difficult. Normally, only a
subset of machines in an oil analysis program are sampled at one time. The oil analysis technician must search the database for the machines and sampling points
before each test is 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 appropriate recipients.

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, analysis, and diagnostic comments are automatically stored in the proper location 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.
Begin by selecting the LIMS sub-Tab of the left-hand database tree.

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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 appropriate
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.
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.
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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 automatically 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.

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

Finally, click on the LIMS button at the top of the screen to return to the
LIMS window.

Find Sample ID Find a sample.
Add Area Add an area to the database.
Edit Customer Edit customer details.
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The options available in this dialog box will be the same whether or not the Display
Customer Level option is enabled.

Find Equipment Find a particular piece of equipment.
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Find Sample ID Find a sample.

Add Equipment Add equipment level to the database.
Edit Area Edit area details.
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Add Point Add a point to the database.

Edit Equipment Edit equipment details.
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Add Sample Add a sample to the database.

Edit Point Edit point details.
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Edit Sample Edit sample details.
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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 samples at once as we will discuss in the next section.
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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 instruments 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.

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.

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.
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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.

Depending on which of the flags are set on the options specified for reporting, you
can then generate a variety of reports for printing and automatic E-mailing. You
can also export the data for importing at a remote site using the report results
menu option shown below.

Before any reports can be generated, each Area and/or Equipment level in your
database must have at least one customer assigned to it. Each customer has an
address that is printed on the report, and a profile specifying the kinds of reports
that customer requires. These details are described later in this section of the
manual.

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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 customer 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.

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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.
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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.

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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 Email 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.

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.)
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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 convenient to place the reports in
a directory that the contact can access. To use this method, check the Directory
box instead of the E-mail box. The directory is specified in the Contact Subdirectory text box.
Each customer is required to have a unique sub-directory that is used as a working
directory by the software.

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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. Multiple 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.

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.
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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 customer assigned at the area level, but
there can be many contacts at either the area or equipment level.
For those customers that require the sample data to be sent directly to them, the
Data Export section must be completed. This information is completely independent of the contacts assigned to either the Customer, Area, or Equipment levels.
At the customer level you must specify the sub-directory into which temporary
information is stored prior to the data being sent. Each customer must have their
own unique sub-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 email option then the data remains in the sub-directory and can be accessed directly
from a WAN. The data format defaults to the Area, Equipment, Point (AEP)
format. The alternative uses the Unit ID format.
The data export setup only applies to the Area level. You must specify the customers
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 general, the
local lab database level structure may be different from the customers at the top
(Area) level. If this is the case, then the next field Cust Area ID must be filled in
with the customers ID.
To automatically E-mail the data to the customer, the E-mail checkbox must be
checked and an E-mail address entered. For the export process as a whole to be activated, the export flag must be checked.

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 automatically 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 customer area ID are not used with Unit ID
method.

At each Area level of the database you must enter the database name to which the
data is being sent (In general this will be different from the current database.) as
well as the 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.
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For those instruments in the lab that do not have RS232 serial communication
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 displayed for data entry are setup in
the AP Set. This log sheet can be printed out and filled in as test are performed.

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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.

Once the instruments are connected through the RS232 port, then their data will
be automatically loaded into the LIMS as the tests are run. Samples must be identified by their Lab ID in the testing device. The Batch Info screen will automatically
display the status of these tests.
Certain problems may be corrected without having to re-run a test. For example,
an invalid Lab ID could be edited and re-processed.
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Contact Statistics and Lab Statistic reports are available from the drop down menu
and will process samples based on the tree location.

From the drop down menu, select either Contact Statistics or Lab Statistics.

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.
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If you select Lab Statistics from the drop down menu, this report gives statistics on
the severity of the samples and the turn-around times.
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The OilviewLite software package is designed to operate the new Model 5200
Trivector Analyzer, Model 52DV Digital Viscometer, and the Model 51FW Ferrous
Wear Monitor. This software is completely independent of AMS Machinery Manager and has a simple Microsoft Access database for storing the sample data. This
data can be exported into either the CSI generic file (for import into OilView when
you upgrade to the full-featured system), or into a comma separated value (csv) file
for import into spreadsheets such as Excel.

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.
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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.
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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.

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To add a new sample, press the Add New Sample button above the sample list. You
then assign an Alarm Set and Reference Oil to the sample. The next step is to select
the test to be run (Models 5200, 52DV, 51FW) and proceed as described elsewhere
in this manual for each instrument.
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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.

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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.
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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.

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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.
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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 5-6.)
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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. Viscosity is measured with a viscometer such as the
Model 51DV Digital Viscometer.
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Oils used in steam turbines and water pumps are prone to contamination with
water. In these oils, the OilView Analyzer will detect water concentrations below 100
ppm. In addition, the OilView Analyzer will indicate when free water (droplets)
are present in the oil. Avoiding free water is important because water droplets can
disrupt hydrodynamic and elastohydrodynamic 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.
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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.
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Many industrial lubrication applications, such as fans, electric motors, and compressors, have oil-lubricated bearings with relatively small oil capacities. Lubricating
oil in many of these applications has a relatively long service 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.
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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 accompanied by subsequent laser particle counter tests.
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Mineral and synthetic oils used in compressors can be tested for moisture contamination, oil breakdown, and mechanical wear. It is normally important to degas the
used oil samples taken from refrigerant compressors prior to testing them regardless of what instrumentation is being used. Most often it is normal for the used lubricant to contain significant amounts of refrigerant such as ammonia, CFC, or
R134A. The ammonia in particular has a significant effect on the OilView Analyzer
sensor since ammonia has a high dielectric just like water.
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A special test option can be selected (see Oil Compatibility Chart on page 5-8) to
test transformer oils using the OilView Analyzer. This screening test evaluates the oil
quality and moisture contamination for electrical insulating oils commonly used in
transformers and oil filled circuit breakers (OCBs). The OilView screening test
does not replace the need for dissolved gas analysis to detect partial discharge in
high voltage transformers.
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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.
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The key factor in any oil and machine condition monitoring program is consistency in collecting samples. Any oil monitoring program will probably fail if careful
attention is not paid to your sampling technique. Therefore, you must always
sample from the same 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 particulate contaminants will have been
removed by the filter. Keep in mind that the oil compartment or sump will act as a
sedimentation filter.
The manner of collection should always involve a gradual, uniform flow of oil into
a clean bottle. Care should always be taken not to take the dregs or the initial spurt
of oil when filling from a drain or pressurized line.
Oil should be sampled either just after a machine has been shutdown or (if safe)
while the machine is still running. The when of sampling is most critical in the
cases of lubrication systems with relatively low operating viscosities.
Because the OilView tests are relatively inexpensive and under your direct control
and interpretation, do not hesitate to tailor unconventional sampling techniques
to your specific needs. Just remember to apply common sense in correlating your
sampling technique and test results to your application.
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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 container is used, remember to shake it vigorously before transferring the oil to a plastic bottle.
The OilView Analyzer and its accessories are designed to work with
room-temperature oils.
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Follow standard practice procedures for health and safety as established by your safety department when collecting oil samples or handling new and used lube oils, hydraulic fluid, and transformer oils.
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For those new to this form of condition monitoring, a few hints about sampling
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 important 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 concerned 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. Conversely, 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 receptacle on the suction pump clean.
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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 identify the
oil type, the machine from the which the oil was taken, and the date on
which the sample was taken. If a sample is diluted prior to testing, the label
should reflect that fact. A sample taken from an unknown source has little
value. Mislabeling of samples may lead to unnecessary maintenance actions.
Over time, some contaminants will agglomerate and cling to the bottle walls,
moisture may evaporate, and small ferromagnetic particles may be chemically altered to a non-magnetic form which will not be detected by ferrographic means. Therefore, tests should be conducted within a reasonable
time frame.
All OilView tests should be conducted with the oil at room temperature and with
the sample vigorously shaken just before the test.
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For clean, fresh oils, all OilView Analyzer index values should be at or near zero.
Increasing values indicate increasing levels of degradation or contamination.
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.
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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 properties of the oil while the X
axis represents 500 test magnetic oscillations during the test.*
1RWH
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 recommendations in a text format.
*. For more technical information on this subject, refer to Portable Oil Analyzer for Predictive and Proactive Maintenance, by Kirkpatrick, J. F., Nov. 1992 (available as an Industry Report from CSI).
%
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.

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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.
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The figure below is an OilView Analyzer plot of a used pump oil containing ferrous
debris. Note the divergence of the two upper magnetic lines from the lower nonmagnetic or base line. This indicates ferromagnetic particles in the oil.
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The figure below was taken with a fresh turbine oil containing 0.13% water. Note
that all three lines overlay indicating no significant ferromagnetic content. However, all lines have a steep upward slope, rising more than half a point in 500 seconds. This indicates a 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.
)UHVKWXUELQHRLOFRQWDLQLQJZDWHU
The figure below is a data plot from a test sample contaminated with large copper
particles. Note the shape of this plot as compared to the two previous plots; the presence of upward spikes with all three magnet lines running together.
2LOFRQWDPLQDWHGZLWKODUJHQRQIHUURXVFRQGXFWLYHSDUWLFOHV
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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 magnetoff line and the magnet-on lines, ferrous debris is probably present.
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More information can be obtained from oil testing when test results are trended
over time. Lubricant degradation is rarely linear over time. Typically, a petroleumbased 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.
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The OilLife Index reports on the overall condition of the lubricant, considering
both lube degradation and system contamination.
When the OilLife index is near zero, the lubricant is in good shape. An increase in
the OilLife index indicates performance of the lubricant is getting worse. Oil degradation, such as oxidation, affects both the OilLife and Chemical index. Oil contamination, such as water in mineral oil, affects both the OilLife and Contaminant
indexes.
Because of the way in which the OilLife index is computed from OilView Analyzer
raw data, it has greater sensitivity than either the Chemical or Contaminant
indexes. This can be valuable when testing very clean oils such as transformer,
hydraulic, and new lubricants.
1RWH
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.
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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 5-14.
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.
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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.
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This index is a measure of the level of oil-insoluble contaminants in the oil as
opposed to changes in the bulk oil chemistry. Some common contaminants
include water, glycol 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 laboratory 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, conductive metal particles may be present.
The following conditions will cause an increase in the contaminant index:
the presence of insoluble water in the oil. Very high values will be seen if corrosive compounds (such as salts) are present in the water,
the presence of conductive metal particles in the oil. If the particles are large
and highly conductive, very sharp upward spikes will be seen,
the presence of dirt, grit, or polar hydrocarbons in the oil.
This index will be influenced by a reference. If a reference has been made, the 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 analysis. Consequently,
small, near-zero values may be seen when a reference has been used that will not be
present if the same test is made without a reference.
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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 conductive), 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 produces 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 complementary rather than redundant.
A full analytical ferrographic examination of the sample by an oil lab is recommended if this index gives a high positive reading. For more information see The
OilView Analyzers And Wear on page 9-14.
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There are four text outputs for the qualitative assessment reported as Large Contaminant Indicator.
No Large Indications - indicates that the analyzer did not detect excessively large
metal particles or water droplets.
Large Ferrous - indicates that large iron particles, probably much larger than 60
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.
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Any Large Contaminant Indication other than No Large Indications may indicate a serious problem.
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This field reports the permittivity or dielectric constant, which, like boiling point,
melting point, viscosity, and refractive index, is a fundamental property of a material. Simply put, dielectric constant measures the resistive, or nonconductive properties of the oil. Contaminants (liquids or solids) settling 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.
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This Appendix has outlined the primary differences in the original frequency units
test method and the new dielectric units test method. The dielectric units method
is recommended and the original frequency units method is no longer supported.
Older data that has been stored in the user database is viewable.
8QGHUVWDQGLQJWKH)UHTXHQF\8QLWV'DWD3ORW
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 contaminants 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.
*. 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).
&
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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.
&OHDQRLOSORW
&
The figure below is an OilView Analyzer plot of a used pump oil containing ferrous
debris. Note the divergence of the two lower magnetic lines from the upper nonmagnetic or base line. This indicates ferromagnetic particles in the oil. Also note
the jagged appearance of the magnetic lines relative to the base line. This indicates
relatively large ferromagnetic debris being attracted to the sensing grid.
2LOZLWKIHUURXVZHDUGHEULV
&
The figure below was taken with a fresh turbine oil containing 0.13% water. Note
that all three lines overlay indicating no significant ferromagnetic content. However, all lines have a steep downward slope, dropping more than five percent in 500
seconds. This indicates a significant non-ferromagnetic contaminant content. In
this case there was also at least one small droplet of free water as indicated by the
small spike which occurred at about 260 seconds into the test.
)UHVKWXUELQHRLOFRQWDLQLQJZDWHU
&
The figure below is a data plot from a test sample contaminated with large copper
particles. Note the shape of this plot as compared to the two previous plots; the presence of downward spikes with all three magnet lines running together.
2LOFRQWDPLQDWHGZLWKODUJHQRQIHUURXVFRQGXFWLYHSDUWLFOHV
&
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 magnetoff line and the magnet-on lines, ferrous debris is probably present.
&ULWLFDORLOVDPSOHZLWKIUHHZDWHUGURSOHWVDQGODUJHPHWDOFKLSV
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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 instruments using Thin Path, as time delays over the
WAN make this totally unreliable. Furthermore, the wear debris image capture can
only work with a direct connection between the PC image capture card and video
camera attached to the microscope.
'
The other issue with a WAN installation is the slowness of the MS Access databases.
One way to overcome this issue is to use terminal server or Citrix in which case AMS
Machinery Manager is running over a LAN (between The AMS Machinery Manager server and the AMS Machinery Manager client installed on the computer running Terminal Server or Citrix) and only display information and mouse and
keyboard entries are transmitted over the WAN with no data access being sent. This
works well for analyzing data using the OilView software as hardware connections
are not required for this process.
The most convenient setup for running the minilab instruments is to install an
AMS Machinery Manager client directly on the PC workstation to which the
minilab instruments are connected. This overcomes the RS232 communication
issues. In order to limit the slowness of the MS Access databases, OilView has features to disable the slowest of these, namely the RBMview connection (see below).
Furthermore, to avoid confusion between the two types of installations there are
several setup options that need to be set as described below.
'
The basic mode of operation is therefore to use the AMS Machinery Manager
Local Client on each workstation to run the minilab instruments and capture the
data. Analysis features will be disabled in this case. The user then swaps to terminal
server or Citrix to run the other version of OilView which allows analysis but disables access to the minilab instruments.
'
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This directory appears under the Custdata directory and is used to store calibration
and setup information for the minilab instruments. There must be a separate directory for each set of instruments connect to a particular PC workstation. If we
assume that we have two workstations A and B using minilab instruments then we
require the following directory structure, containing the files listed below.
The only exception to this is the 5200 which uses a common calibration file,
a5200cal.mdb. This is so because the 5200 hardware has a readable serial number
that is used to identify the correct calibration data in the a5200cal.mdb database.
Furthermore, this database is only accessed when the 5200 is being calibrated;
under normal operation the calibration data is read directly from the hardware.
\Custdata\Instrmnt\
a52caldm.def
a52calHW.def
a5200cal.mdb
example.zip
olv5200.cfg
olvcfg.cfg
parms.mdb
Wdatlas.mdb
\Custdata\Instrmnt\A\
anDemoR0.cfg
anDemoR1.cfg
anDemoT0.cfg
anDemoT1.cfg
dvcal_d.def
'
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.
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All instances of OilView running under terminal server or Citrix use the same
Instrmnt directory.
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'
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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.
'
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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.
6XPPDU\
The AMS Machinery Manager local based client will be used for data collection
only and the RBMview communications will be disabled.
The AMS Machinery Manager terminal server or Citrix client will be used for data
analysis. RBMview communications will be enabled.
'
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The NAS 1638 standard ends at 12. CSI has extended this table to better serve
industrial applications.
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Numerics
5200 Back-Flushing Procedures 10-20
A
abrasive wear 9-14
accessories, ports 1-28, 5-24
additives B-9, B-12
adhesive wear 9-15
Alarm Details 1-19
Alarms
Alarm Analysis 2-49
Alarm Limit (AL) sets 2-38
Baseline Adjusted Plot 2-44
CSI Default Alarm 2-38
Current Alarms 2-40
Default Alarm Sets 2-39
Histogram Plot 2-43
Raw Data 2-46
Raw Data Plot 2-45
Scatter Plot 2-47
Standard Alarm 2-48
Statistics 2-41
An Example testing Session
Analyzer Model Test Differences 5-32
Typical Test Procedure 5-29
Analysis Parameter Sets
Add User Alarm 2-31
Current Views 2-33
Edit AP Desc 2-32
Profile Setup 2-34
Report Group Setup 2-36
Set Default Alarm Type 2-31
Statistics 2-37
Update Alarm Baseline 2-31

Update Statistics 2-31
applications-OilView Analyzer A-2
assign contacts 11-17
ASTM plot 6-13
B
batch information 11-10
bearings A-3
babbit A-3
roller element A-3
sleeve A-3
C
Calibrating the Digital Viscometer
Calibration Procedure 6-7
Existing Digital Viscometer Users 6-6
new user of the Digital Viscometer 6-6
Plot ASTM 6-13
Verify 6-12
Calibration
5200 Diagnostics 10-90
calibration
ferrous wear monitor 8-8 to 8-10
change marks 1-13
chemical index B-11
CO2 cartridge 7-5
color measurement
particle counter 7-19
combustion by-products 5-2
communication ports 5-24, 7-2
contacts 11-15
contaminant index B-12
,
contaminants B-5, C-2

large B-14
minimum B-2
corrosion B-11
Customer Details 1-16
D
Data Export 11-18
Database Export 4-4
database tree
change marks 1-13
expand entire tree 2-4
Right Mouse Click Functions 1-14
definition
contacts 11-18
customers 11-18
diesel A-2
digital viscometer
calibration 6-6 to 6-13
connections 6-3 to 6-5
Digital Viscometer Setup 6-3
Alternate OilView Analyzer Port 6-4
Using the Digital Viscometer 6-3
Using the Digital Viscometer With a
Computer 6-5
dilution 5-34
particle counter 7-11, 7-25
Dilution Of Viscous Samples 5-34
dilution ratio 7-27
dilution samples
dilution ratios 7-27
Disclaimers
electrostatic discharge 1-3
harsh environments 1-3
results 1-3
double cleaning
sensor grids 5-36
drain plug A-7
,
E
E-mail 1-42
Import Lab 4-1
Laboratory Information Management
System 1-42
engines A-2
enhanced particle sensitivity 5-34
F
fatigue wear 9-14
ferromagnetic B-5, B-6, C-2, C-3
ferromagnetic index B-13
ferrous wear 9-15
Ferrous Wear Monitor 8-1
Cables And Connections 8-5
calibrating 8-8
Empty/Clean Calibration 8-8
Software Setup 8-3
Standard Calibration 8-9
Standard Equipment 8-2
Taking Calibration Readings 8-9
Testing Samples 8-11
ferrous wear monitor
calibration 8-8 to 8-10
filter 9-14, A-5, A-8
free water A-2, B-7, C-4
frequency units test method
data plot C-1 to C-6
fuel A-4
fuse 5-26
G
gear A-2
H
hardware setup
ferrous wear monitor 8-5 to 8-7
oilview analyzer 5-24
particle counter 7-2 to 7-3

humidity 5-25
I
If Duplicate File Name 11-14
Import Lab E-mail 4-1
ISO Code 7-15
K
kerosene 7-38
L
labels
lab label 1-40
sample bottle label 1-39
Laboratory Imports 4-3
Laboratory Information Management System
11-1
assign customers 11-17
Assign Samples 11-3
Batch information 11-10
contact address book 11-15
Manual Entry 11-20
Result Options 11-13
Serial Communications 11-21
left mouse button function
Drag and Drop 2-4
Drag and Drop Sample 1-26
License Configurations 1-5
lighting, microscope 9-23
M
Measurement Point Information
Alarm Limit Set 2-19
Analysis Parameter Set 2-18
Description 2-18
Equipment Type 2-19
External Working Environment 2-26

Filter 2-23
General 2-17
Internal Process Material 2-25
Internal Working Environment 2-23
Lab Unit ID 2-18
Lubrication System, Units 2-18
Oil Capacity 2-24
Oil Wetted Bearing Parts (P1) 2-27
Oil Wetted Parts (P2) 2-28
Oil Wetted Parts (P3) 2-29
Point ID 2-17
Report Group 2-18
Report Language 2-18
Schedule 2-21
Target Cleanliness 2-18
Test and Disply Filter 2-22
Usage Units 2-18, 2-24
microscope 9-16 to 9-23
model 51SM 9-22
N
NAS 7-18
nitration 5-2
O
oil
bearing A-3
collecting samples A-5 to A-8
crankcase A-2
gears A-2
hydraulic A-3
pump A-2
turbine A-2
Oil Tests
reference 10-28
OilLife index B-10
OilView Analyzer
,
usage tips 5-36

OilView Analyzer - Initial Setup 5-24
sensor curing 5-27
system setup 5-24
OilView Analyzer Usage Tips 5-36
Double-Clean the Grid 5-36
Verify Calibration 5-36
OilView Particle Counter Setup 7-2
OilviewLite 12-1
Adding a Sample and Running a Test 12-3
Alarm Sets 12-5
Data 12-7
Databases 12-2
Reference Oils 12-6
Reporting 12-4
Setup 12-2
On-Line
help 1-4
tutorial 1-4
Overview
Calibration 10-42
oxidation 5-2, A-2
P
particle counter
sample dilution 7-25
sensor cleaning 7-33, 7-38
setup 7-2
phosphate ester 5-27
plant air adapter 7-6
plot B-4 to B-8
lines B-5
Plot Cal 6-11
plots
trivector 3-5
pressure regulator 7-5
pumps A-2
,
R
Ref Samples used in Database 2-4
reference
file B-12
Reference Oil
adding 2-13
Reports 3-18
Result Options 11-13
right mouse button function
Area Icon 1-17
Database Icon 1-14
Equipment Icon 1-21
Measurement Point Icon 1-23
Sample Icon 1-25
RS232 port 5-24, 5-28, 7-2
Running a Test 7-5
Alternative Testing Method 7-14
Particle Counter Test Procedure 7-7
Problems 7-13
S
sample 1-39
sample bottle 5-29, A-7, A-8
label A-8
Sample Information
5100 Data Plot 3-15
5200 Plot 3-16
Data tab 3-10
ISO 4406 plot 3-11
NAS Count 3-12
Notes 3-9
Observations 3-8
TriVector Plot 3-5
Viscosity Plot 3-17
Sample Preparation 7-22
Schedule 2-21
sensor curing 5-27
sensor grid
cleaning 5-18
curing 5-27
double cleaning 5-36
phosphate ester 5-27
using 5-29 to 5-32
setup, operating characteristics 1-28 to 1-39
shop microscope 9-22
Software Menu Structure 1-8
Software Setup 5-3
Calibrate Tab 5-16
Calibration Information 5-22
Calibration Settings 5-21
Diagnostics 5-23
Test 5-3
Test Data Plot tab 5-20
Test Time Options 5-21
verification testing 5-14
specific gravity 6-8
spectroscopy 9-14
Statistics Export 4-6
Summary Report Options 3-22
Alarm Setup Exception Report 3-25
Oil Usage Report 3-26
Parameter Exception Report 3-23
Point Configuration Summary Report 3-24
Sample Summary Report 3-22
Schedule Summary Report 3-26
sump A-7
Superseding References 2-3
Supplemental OilView Particle Counter
Procedures 7-36
Batching Similar Oil Samples 7-37
Flush Till Clean 7-36
Intelligent Software 7-38
Kerosene 7-38
Sample Types 7-36
Screening Samples 7-37
sensor cleaning 7-38
synthetic lubricants 5-35, 5-36, 7-36
T
tare weight 7-28 to 7-32
test 5-28 to 5-32
results B-9 to B-14
Test esults 7-15
test options
high viscosity oils 5-35
Test Results 7-15
Diluent Test 7-21
ISO 4406 Cleanliness Code Levels 7-16
ISO Recommended Cleanliness Levels 7-19
NAS Code 7-18
Settings 7-21
Test ISO Plot and Test NAS Plot 7-20
Tests
Reference Oil 10-28
Text Shortcuts 1-43
Toolbar 1-10
Trend Information 3-1
Data, Minilab Data, and Lab Data Tabs 3-1
Detailed Parameter Plots 3-4
Wear, Contamination, and Chemical Plots
3-3
Trivector Analyzer 10-1
Dilution By Weight For Test 2 and Test 3
10-25
Initial Setup 10-3
Instrument Overview 10-2
Making WDA Filter Patches 10-26
Plots 10-35
Test 2 Plot 10-35
Test 3 ISO Plot 10-37
Test 3 NAS Plot 10-40
Results 10-32
Test 2 Wear / Contamination 10-33
Test 3 Contamination 10-33
Test 1 Calibration & Verification 10-46
Calibration 10-48
Initial Clean Check 10-47
Verification 10-51
,
Test 2 Calibration & Verification 10-53

Calibration 10-55
Preparation for Calibration 10-54
Verification 10-58
Test 3 Calibration 10-60
Test 3 Coincidence Error Limit Test 10-78
Test 3 Diluent/Clean Fluid Calibration
10-75
Test 3 Particle Counter Calibration
Overview 10-60
Test 3 Sizing Calibration 10-69
Test 3 Verification 10-72
Test Procedure 10-12
Volumetric Dilution For Test 2 and Test 3
10-24
trivector plot 3-5
turbines A-2
U
ultrasonic bath 7-7, 7-22
Using the Digital Viscometer 6-14
V
vacuum chamber 7-22
verification test
OilView Analyzer 5-14
viscometer 5-34
Viscosity 6-16
viscosity
adhesive wear 9-15
dilution 5-34
fuel dilution A-2
viscosity index 6-8
viscosity index value 6-7
W
water 9-18, A-2
contaminant index B-12
,
corrosion index B-11

droplets B-14
example plot B-7, B-8, C-4, C-6
hydraulic oil 5-2
sampling location A-7
WDA Filter Patch 10-26
wear 9-14 to 9-18
Wear Debris Analysis 9-1
Analyst tab 9-12
Atlas Setup 9-11
Model 51SM Microscope 9-22
Model 52LM Lab Microscope 9-23
Model 52ZM Stereoscopic Zoom
Microscope 9-24
OilView Analyzers And Wear 9-14
Sample 9-5
Sample/Atlas 9-9
Using the Model 51WD Wear Debris Patch
Maker 9-18
Video Camera 9-2
Video Frame Grabber 9-2
wear particles 5-2, B-13

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Reference Info . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2-4

Plot ASTM. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6-13

Testing Samples With the Ferrous Wear Monitor . . . . . . . . . . . . . . . . . . . . . . 8-11

Test 3 Preliminary Instrument Check . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10-66

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The Note paragraph indicates special comments or instructions.

Open Database Switches to another database.

Help accesses the online help system.

Open Database switches databases.

Parameter Exception A report similar to the parameter exception report created

Add Area Add a new area to the database.

The customer details are described in the Laboratory Information Management

This screen shows the severity contribution from all technologies.

You can set the following preferences:

If the sample is dropped on a point, then the sample will be added to

Comm 1 is the serial port number 1 (or letter A) on the computer;

Lab Options Reserved for the CSI Trivector lab.

All Data plot all data on trend plots.

These file locations should be adequate unless multiple users at a site

Select the required fields to be printed on the sample label.

Select a default label size.

Select a default label size.

The Laboratory Information Management System (LIMS) requires an internet

Add Ref Sample Add a reference sample

This option requires a license to the LIMS module.

Select the Cust ID (Customer Identification) or Cust Desc (Customer Description)

Description - This field of up to 28 alphanumeric characters describes the current

When specifying a new piece of equipment, you will probably want to

Printing of sample labels for due samples is done on the Q (Database

Criticality - is the relative impact of a failure of this equipment on overall plant

Oil Pressure - Indicate the system oil pressure as:

Oil Temperature - The measured temperature of the oil.

Category - Select either filtered or not filtered category.

Estimate - Enter the approximate oil capacity of the system.

Type - Indicate how corrosive the external environment is.

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Humidity - Indicate the ambient, relative humidity:

Particulate - Indicate if the area contains abrasives that may be problematic.

Bearings - Indicate if bearings are used in the system.

Gears - Enter the composition of any gears.

Turbine Blades - Enter the composition of any turbine blades.

Add User Alarm Add a new alarm limit (AL) set.

Edit AP Set description and AP Set ID code.

This column shows the AL Set baseline value.

Right mouse button click on a particular parameter to display a histogram over

Set/Save All - automatically sets all alarm limits.

This button is used in conjunction with the LIMS.

A plot of good oil contaminated by a water leak would appear as so.

Selecting an observation automatically adds one or more items to the Actions

The particle PPM is calculated by volume whereas the typical PPM is

You can zoom in on the preview window by double-clicking the left

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The Start button begins a test sequence.

The Cancel button aborts a test sequence in process.

This is the date of the reference oil test.

Never dilute the reference oil. Chemical comparisons between the

In earlier versions of OilView software, Chemical and OilLife Indexes

The sensing grid should never be exposed directly to water.

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